IPC. Your expert partner for granules and pellets. - Glatt

IPC.
Your expert partner
for granules and
pellets.
IPC (International Process
Center GmbH) is a member
of the world-wide Glatt
Group and specialises in
contract manufacturing
of pellets and granules of
all types. Our modern
production equipment and
our expertise are avail-
able to customers in the
food/feed, pharmaceutical
and chemical industries.
Qualified, highly motivated
staff provide a wide range
of top-quality services at
our sites in Dresden and
Weimar.
Technology that's
ahead of the rest.
IPC is able to make use of
the decades of experience
and expertise offered by
the Glatt Group, one of the
world's leading plant
manufacturers in the field
of fluidised bed technology.
Through the practical
application of the latest
developments, IPC is able
to offer the most up-to-
date process technology at
all times.
IPC.
There are lots of good
reasons to use our services:
Access to the techno­
logies of the future.
As a customer of IPC, you
can test all sorts of differ-
ent process technologies in
the development of new
products and transfer the
results directly to achieve
the best manufacturing
process. Highly qualified
staff and ultra-modern
laboratories provide you
with support in process
development.
Faster market
launches.
IPC's experience allows you
to modify your products and
processes faster. Because of
the close connection with
plant construction, specific
process technology require-
ments can be realised
immediately, guaranteeing
our customers that their
market launches will be well
ahead of the competition!
Transfer of process
expertise.
A precise knowledge of
process technology reduc-
es costs and risks in the
later development of an
independent production.
Operator training at IPC
ensures a smooth transfer
of knowledge.
Production around
the clock.
Our uninterrupted 3-shift
operation offers you
maximum flexibility in
production.
Avoiding bottlenecks.
Use the services offered
by IPC to cover peaks
in demand so that you only
need to design your own
production capacities for
normal requirement levels.
1

Drying.
Our fluidised bed systems
are ideal for the rapid dry-
ing of temperature-sensitive
products. These materials
are fluidised in the pretreat-
ed, warm flow of air. The
ideal heat exchange and the
associated vaporization
conditions in the fluidised
2
Do you already know
what you want?
Are you looking for the
best solution?
IPC can offer you
tailor­made processes for
tailor­made products:
bed produce much shorter
drying times than other
processes, guaranteeing
optimum protection of the
product with a uniform
temperature distribution.
Temperature and humidity
are measured online.
Wet granulation.
Many areas require dust-
free yet mechanically stable
products. Granulates from
our wet mixers are character-
ised by their free flowing
structures, since the prod-
uct is mechanically com-
pacted during the process.
After equalization in the wet
sieve, the product is then
sucked directly into the flu-
idised bed for drying.
Principles of drying Dried granules
Wet granulation in the vertical granulator
Vertical Granulator VG 100

Fluidised bed
granulation.
Fine powders can cause
major problems in process-
ing, not only because of the
dust emitted, but also by
their poor flowability and
low solubility. Top spray
agglomeration with solvents
or binder liquids creates a
porous granule structure
Porous fluidised bed
granule
which dramatically improves
flow behaviour, suitability
for further processing and
the dispersion qualities of
the products.
Principles of granulating and top spray coating
Fluidised bed granulation and top spray coating in the GPCG 500/800
Top Spray Coating.
The coating of sensitive
products can considerably
improve shelf life and open
up new areas of applica-
tion. It can also prevent
individual substances react-
ing with each other and
stop oxidation reactions. In
addition, the dispersion
characteristics of the prod-
ucts can also be modified.
Coated granule
Suitable film materials are
finely atomised via noz-
zles to form a film on the
surface of the product that
completely encloses it. The
process is particularly
suitable for coating with
waxes and hot melts.
3

Bottom Spray Coating.
For high-quality films for
the controlled release
of ingredients, the film
solution is sprayed onto
the product via a nozzle in
the bottom of the contain-
er. The product continually
passes through a Wurster
column positioned around
the nozzle, guarantee-
ing even encapsulation of
every particle. The fine
atomisation of the coating
solution and the particular
layout of the nozzle means
that even the finest parti-
cles of around 50 µm can be
enclosed, in contrast to Top
Spray Coating.
4
Principles of bottom spray coating
Bottom spray coater product
container
Bottom spray coating in the GVW 32"
Pellet with various coatings

Pelletisation.
Compact particles are
created by wet granulation,
extrusion and subsequent
spheronisation. Subsequent
drying and possible coat-
ing of the pellets is carried
out efficiently in the
fluidised bed.
Vertical Granulator
Principles of pellet manufacture
Material container for
fluidised bed drying
Wet granulation in the vertical granulator VG 800
Extruder
Spheroniser
Emptying of the spheroniser
5

Sieving and milling
technology.
Various sieving technologies
are available for screening
of the end product as well
as sizing of the granule
structure.
Classifier sieve
6
Mixing.
All kinds of additives
can be blended in the
container mixer with
different batch sizes, up
to 1300 l/batch.
Charging the mill
Dust-free charging of a container
Milling.
The raw materials can be
milled to various grain sizes
using impact pulverizers.

IPC.
Staying ahead
through service.
Process development.
IPC offers you tailor-made
processes for tailor-made
products – and not only on
a production scale. You can
also test the processes
using laboratory/pilot equip-
ment of different sizes. A
GMP facility at Glatt, in
Binzen, is available for
pharmaceutical and food
products whereas manufacturing
processes for
chemical products are
developed in a separate
laboratory. The processes
can then be transferred
easily to production after
scale-up.
Laboratory tests
Process optimisation.
Trials in our own technical
facilities allow processes to
be optimised and guarantee
the best possible start to
production.
In­process control.
Our own laboratories carry
out quality monitoring including
continuous in-process
control in accordance with
the agreements reached.
Preliminary tests in our
laboratories and analyses
round off the perfect quality
assurance system.
Retained sample
Process
documentation.
A detailed process documentation
of all batches
including storage of retained
samples guarantees traceability
and means that the
agreed quality parameters
can be monitored.
Charging the Bag-in-Box
Making up.
The end product can be
made up in various containers:
Big-Bags, sacks,
barrels, cartons, cans or
bottles. Naturally, IPC can
also carry out labeling if
required.
Finished goods store
Storage.
The buffer store for raw
and finished products means
we can react flexibly to
your logistics. A separate
coldroom is available for
sensitive products.
Logistics.
If required, IPC can also
take over complete purchase
of raw materials, dispatch
and environmentally
correct disposal of waste.
7

8
IPC plants
Plant type Batch size Suitable for Processing of solvents
Fluidised bed granulator/ up to 400 kg Food/Pharma Yes
Top spray coater
up to 700 kg Food/Feed No
up to 1200 kg Food/Feed No
up to 700 kg Fine Chemicals Yes
Bottom spray coater up to 300 kg Food/Pharma Yes
up to 600 kg Food/Feed/Fine Chemicals No
Wet granulator 600 l Food/Feed No
600 l Fine Chemicals Yes
Extruder dep. on product Food/Feed No
Spheroniser up to 400 kg/h Food/Feed No
Classifier sieves dep. on product Food/Feed/Pharma/Fine Chemicals No
Sizing sieves - dep. on product Food/Feed/Pharma/Fine Chemicals No
for dried and moist products
Universal mill dep. on product Food/Feed No
dep. on product Fine Chemicals No
Container mixer 1300l/Charge Food/Feed/Pharma/Fine Chemicals No
Filling in bottles, cans, sacks, Food/Feed/Pharma/Fine Chemicals –
Big-bags, barrels