Pharmaceuticals


Overs are out


A Kason vibratory screener ensures correct particle size when spray drying and screening of foods, pharmaceuticals and nutraceuticals


S


ummit Custom Spray Drying produces spray dried flavours, fragrances, cosmetics, nutraceuticals, and pharmaceutical grade materials. The GMP-compliant, FDA-registered facility, a wholly owned subsidiary of SummitReheis (www. summitreheis.com), produces powdered solid particles from solutions, slurries and emulsions, and employs a Kason vibratory screener to ensure that particle sizes meet tight tolerances. “When fully operational, three spray dryers will produce several hundred different spray dried powders for diverse customers,” says Kevin Kimmick, Summit Custom Spray Drying director of process technologies. “Runs can be small as pilot studies, to as large as 68,100 kg at the production level for a major firm.” “Our expertise in spray drying and equipment selection, as well as the specialised knowledge of our experienced staff, qualifies us to serve these sensitive industries,” he says. “To eliminate any possibility of contamination, we will not accept hazardous or toxic materials such as herbicides or pesticides. And we have specifically designed our equipment to be easily and thoroughly cleaned.”


TESTING DETERMINES PROCESS CONDITIONS


Mr. Kimmick has 23 years of experience and is highly skilled in spray drying. “Although spray drying is based on scientific principles, our test


28 March 2014 Solids and Bulk Handling


procedures enable us to determine and control optimum conditions according to


numerous variables,” he says.


Before accepting an order for a new material, the company performs laboratory and pilot plant testing using raw materials and formulae supplied by the customer. “This allows us to determine whether or not we can effectively spray dry the material,” he explains. “It also helps us to develop a cost estimate for the process. If the results of the tests are favourable, we then transition directly into production.”


SPRAY DRYER SEPARATES SOLIDS FROM LIQUIDS


A typical order begins with delivery of bulk quantities of raw materials by the customer. “Solids are stored in a warehouse in the original containers in which they were delivered. Liquids are stored in either drums, totes, or in separate holding tanks before being introduced into a mixing tank,” he says. “If the mixture needs to be emulsified, it will either be pumped through a high-pressure homogeniser (up to 35 kg sq c), or transferred to a homogeniser tank that has a fixed rotor-stator. The completed emulsion, solution or slurry is then transferred to a holding tank with


www.solidsandbulk.co.uk


Repose piles show cranberry powder, copper solution for vitamins and chlorophyll powder – several of the powders produced by Summit Custom Spray Drying.


Downstream of the spray dryer, a Kason screener removes oversize particles. Because of the


company’s expertise in spray drying, “overs”


(spout at right) comprise a small percentage of the total batch.


continuous mixing. From there, a feed pump metres the solution or emulsion into the spray drying chamber, where the solids and liquids are separated.”


“All the action happens in the vicinity of the atomiser, whether it is a centrifugal wheel or a nozzle,” Mr. Kimmick continues. “Selecting the proper equipment and determining the optimum settings and adjustments are the keys to successful spray drying. For example, various sizes and configurations of the spray nozzle can be selected to control particle size and density. When choosing process temperatures, you need to strike a fine balance between overheating the spray particles and having them stick on the wall of the dryer.”


CIRCULAR VIBRATORY SCREENER REMOVES OVERSIZE PARTICLES


Once the materials have been separated and dried in the spray dryer, they are conveyed to a rotary airlock. The particles pass through a rare earth magnet and are then fed into a Kason Vibroscreen circular vibratory screener to remove agglomerates, flakes, lumps and any sheets or layers that may have formed on the side walls of the spray dryer.


The screening chamber is suspended on >>>


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52