Granulation
The Glatt Group is recognized as an expert in the development, processing, and refinement of solids, including powders.
Particular expertise has been established in fluid bed systems, which are designed for the uniform processing, drying, or coating of powders and granulates. Systems for tablet coating and pellet production are also offered.
Over time, the service portfolio has been significantly expanded. Customers are now supported throughout the entire value chain, from primary particle production, granulation, coating, and pelletizing to formulation development, clinical studies, product and process development, and even the construction of complete manufacturing facilities.
Through close collaboration with subsidiaries and partner companies, an extensive product and service portfolio is made available, all from a single source and always tailored to meet individual customer requirements.
High Sheer Granulation Section
For the efficient production of particularly dense granules within especially short process times, high-shear granulators equipped with patented Z-rotors are considered the optimal solution.
The portfolio is designed to cover a wide range of applications, from laboratory and pilot plants to granulators suitable for large-scale production. Working volumes start from a few hundred millilitres at the laboratory scale and extend to capacities exceeding 20 hectolitres in large-scale operations.
Efficient solutions for the production of compact granules are made available, ensuring flexibility and reliability throughout the entire process.
Production Plants
We offer high-performance industrial systems for wet granulation. Our modular system concepts permit multiple processing options. Just as you need it.
The vertical granulator, equipped with patented Z-form rotor wings, has been developed for particularly fast wet granulation, delivering high granulate density and optimal particle stability. This unique technology is complemented by easy handling and user-friendly operation.
A modular construction has been designed to allow individual configuration and adaptation to specific process requirements. The granulator is fitted with the innovative and compact Q-Drive motor, which provides consistently high torque across all speeds. This ensures high product quality, improved efficiency, and reduced maintenance requirements.
The system is suitable for batch sizes ranging from 25 to 2,400 litres.
High-Shear Granulation and Fluidized Bed Drying in a Single Process.
For the first time, high-shear granulation and fluid bed drying have been combined into a continuous batch process through the revolutionary, patent-pending TwinPro® system.
This groundbreaking integration of two previously separate processes into a single system has made it possible for a complete machine unit to be eliminated. As a result, investment costs in both system and building technology are significantly reduced, while maximum process efficiency is achieved.
An efficient wet granulator has been developed for fast granulation processes, producing particularly dense granulate with a uniform structure. Flexible connection options are provided for the chopper to meet various process requirements.
High process safety is ensured through the clear separation of technical and GMP (Good Manufacturing Practice) areas. The working vessel is designed to be lowered, allowing for easy handling, as well as simple filling, cleaning, and inspection.
The system is suitable for batch sizes ranging from 25 to 1,200 litres.
Lab and Pilot Systems
New formulations can be explored, and various processing options in wet granulation can be tested using the multi-functional lab and pilot systems for high-shear granulation. These systems have been successfully proven in process development and have consistently enabled reliable scale-up from laboratory to production levels.
The modular design and flexible configuration are specifically engineered to allow rapid and efficient adaptation to changing process requirements.
A vertical granulator has been designed for the rapid preparation of granules with a compact and stable structure. Maximum volume flexibility is provided through the use of exchangeable product containers, allowing batch sizes from 2.5 to 50 litres, and even as low as 0.1 litres when an adapter is used.
The system is characterized by easy handling and intuitive control, ensuring smooth operation. Additionally, the granulator is available in a version that is certified as 12-bar shock pressure-proof for enhanced safety.
A process module for high-shear granulation is provided for the rapid production of compact granulates. Temperature-controlled vessels are available as options in sizes of 5 litres, 10 litres, and 15 litres. Smaller batch sizes, starting from 0.1 litres, can also be accommodated using an adapter.
Designed for maximum efficiency with minimal product volumes, this high-shear granulator features flexible, temperature-controlled working vessels for precise mixing and granulation of powders. Equipped with an integrated touch panel and a GMP-compliant design, it ensures quick installation and user-friendly operation.
The vessels can be fitted with powder funnels and a variety of spray nozzles to accommodate different processing requirements. Its compact size makes it ideal as a tabletop unit, supporting product volumes from 0.1 to 4.5 litres.
Spray Agglomeration
Fluid Bed Spray Agglomeration: Improving Powder Performance
Fluid bed spray agglomeration is a shaping process that enhances the properties of powders. In this process, fine particles are fluidized and sprayed with a binder liquid, forming agglomerates with improved flowability and solubility. It is widely used for making detergents, beverage powders, instant products, and as a precursor for tableting.
As the binder dries, the particles form porous, dust-free granules that are easy to handle, dose, and process. The agglomerate size, porosity, and bulk density can be precisely adjusted to meet specific product requirements.
Glatt’s fluid bed spray agglomeration delivers excellent results, producing powders that are:
- Porous with large surface areas
- Easily wettable and compressible
- Highly soluble
The process offers a flexible solution to achieve high-quality, flowable powders for various industries.
Spray Granulation
Spray Granulation: From Liquids to Free-Flowing Granules
Spray granulation is a continuous process where liquid starting materials such as solutions, suspensions, or melts are sprayed into a fluid bed or spouted bed system and dried to form dense, free-flowing granules. Compared to agglomerates, spray granules are harder, more uniform, and have improved solubility.
As the liquid is sprayed and dried, small particles form and grow layer by layer into solid granules. This layered build-up results in durable particles with controlled size, typically ranging from 50 micrometres to 5 millimetres. The process also allows for automatic separation of fully formed granules via air classification.
Spray granulation is ideal for converting liquids into dry, stable products in industries such as chemicals, pharmaceuticals, food, animal feed, and detergents. It’s especially suitable for sensitive substances like enzymes, proteins, and microorganisms.
Key Benefits of Glatt’s Spray Granulation Process:
- Produces dense, abrasion-resistant, and free-flowing granules
- Enables easy dosing, transport, and storage
- Allows precise control of particle size, moisture, and bulk density
- Minimizes hygroscopic behaviour, reducing moisture uptake
Glatt’s advanced spray granulation systems help customers achieve reliable, scalable results with consistent product quality.
