Roller Compactors and Granulators WP 200 Pharma

Technical Data
Examples of Granules
Roller Compactors and Granulators
WP 200 Pharma
Antibiotics
Riboflavin
Natrium Bicarbonate
Spice extract
Lactose
Flavours
Throughput, continuous operation
10 to 250 kg/hr
Granule size
variable
Maximum compacting pressure
18.4 kN/cm of roller width
Installed power
approx. 29 kVA
Weight
approx. 2,000 kg (complete unit, excluding
control cabinet)
Material of construction
1.4571 (complete), 316 Ti
Material of construction: Rollers
1.4122
Material of construction: Product touching seals
FDA approved materials
Applications
For many years pharmaceutical corporations all over the world have been using roller compactors made by
Alexanderwerk to produce granules, and to further process tablets or capsules, Life-Science products, flavours,
instant powders, or intense sweeteners.
www.fabermoldenhauer.de
Machine control separate from the machine (not shown).
Alexanderwerk AG Kippdorfstraße 6 –24 42857 Remscheid/Germany
P +49 (0)2191 79 50 F +49 (0)2191 79 53 50 [email protected] www.alexanderwerk.com
No liability will be accepted for errors or omissions. Subject to change (246-9011)
Pharma Roller Compactor and
Granulator WP 200 Pharma
The WP 200 Pharma is the obvious choice of
compactor and granulator for production. With a
throughput of up to 400 kg/hr (Lactose), the WP 200 Pharma is ideal for situations of frequent product
changes, special products, small batches, or for
compacting and granulating of a mono product in
continuous operation. The WP 200 Pharma comes with
the Combi-Vent-Feeder® System patented by
Alexanderwerk, as standard. This unique design of the
feed system facilitates the highly efficient operation of
this unit. Due to the dedicated venting of the gas flow,
larger quantities of material can be fed into the roller
gap. The process equipment is completely separated
from the drive equipment. As an option, the WP 200
Pharma is available in a “Through the Wall“ design.
With this special design, the access to the process
equipment can be separated from the access to the
drive equipment. For ultimate containment applications, the WP 200 Pharma can be fitted with an
Isolator. The machine‘s design meets all the requirements of the pharmaceutical industry:
•spatial separation of process and drive equipment
•Combi-Vent-Feeder® System
•two-stage rotor fine granulation in D design
•patented Suction-Cooling-System®
•cGMP design
•completely made of stainless steel
•all non-metallic materials according to FDA standards
•may be fitted with Isolator
•automated PLC
•optional: WIP (Wash In Place)
•optional: Through the Wall design
•optional: 21 CFR Part 11
•optional: PAT
•design according to URS
Quality parameters can be easily scaled to larger or
smaller production units. Quality parameters determined by means of the WP 120 Pharma pilot plant and
small-batch machine made by Alexanderwerk can be
easily scaled to the WP 200 Pharma and vice versa.
The operator panel is designed as a touch panel.
Granulation with Roller Compactors
made by Alexanderwerk
Compaction
The basic process principle of roller compaction is
simple. However, only the use of latest control technology facilitates the efficient production of a highquality granule.
The quality of the final granule is mainly determined
by the quality of the flake. A constant compacting
pressure and constant roller gap are required. The
control equipment made by Alexanderwerk will
compensate any physical fluctuations in the material
(such as local inhomogenities). As a result, the process
parameters (throughput, flake density, compacting
pressure, speed or similar) can be precisely adjusted at
highly repetitive accuracy.
With roller compactors made by Alexanderwerk,
there is a clear, modular separation between the process steps of feed and compaction. The feed screw 3
alone is designed to feed the powder to the rollers
4 – intentionally, this process does not aim at a precompaction by the feed screw system.
Patented Combi-Vent-Feeder® System to boost
Efficiency.
The Combi-Vent-Feeder® System patented by
Alexanderwerk offers an additional “chamber“next to
the material hopper (which does not contain any
material). Air, displaced from the material during compaction, can freely escape through this second chamber.
As a result of this configuration, the material can be fed
to the screw, and thus to the rollers, more uniformly,
there is less back pressure building up in the feed section, and the process, as such, runs smoother, faster and
more uniformly.
1
2
3
4
Additionally, the Combi-Vent-Feeder® System can do
more undersize or fines (e. g. side seal leakages) can be
continuously recycled into the additional hopper chamber, blending with raw material to form a consistent
feed quality.
5
6
Another option available is the vacuum station for the
screw feeder. A vacuum is applied on the screw housing
to force the return-flow air into a defined path. Thus,
the processing of very light or heavily fluidizing materials
is made possible.
Granulation
Granules are characterised by defined particle sizes, i. e.
the size of the particles varies between fixed upper and
lower limits (oversize, undersize). After feeding into the
compacting unit, the course flakes are generally larger
than the upper tolerance limit of the finished product.
Only defined size reduction in the granulation unit will
produce the finished granule.
Downstream further processing of the granule, such as
in tableting machines, requires a tight tolerance and for
this reason the granulation unit of the WP 200 Pharma
is of a two-stage diagonal design. The first stage is pregranulation, and the second stage is designed as a fine
granulator.
The process equipment of the WP 200 Pharma can be completely
dismantled without any special tools.
1
2
7
3
8
1
Material feed
2
Feed hopper in Combi-Vent-Feeder® design
3
Feed screw system
4
Compacting unit: Roller Unit
Feed hopper in Combi-Vent-Feeder® design as standard.
5
Pre-crushing
6
Sampling
7
Two-stage granulating unit
1 Vent for displaced air and feed hopper for undersize and
oversize at the same time
8
Granule outlet
2 Material feed hopper
3 Socket for level probe
Modular Design
From the consumer’s point of view, porosity is the most
critical requirement of pharmaceutical products. From
the user‘s point of view, flexibility is a decisive characteristic of a pharmaceutical machine, specifically in a time
of ever tighter markets.
The WP 200 Pharma meets both requirements – defined
porosity of the final product, and flexible use of the machine. Due to its consistent modular design, the WP 200
Pharma can be dismantled practically
without special tools.
Rollers 4 (protective shroud removed) and flake crusher 5 .
Cantilever bearing design of rollers for easy replacement or
cleaning.
Numerous special or customized designs available
upon request.
Two-stage granulating unit in
diagonal design 7
(protective shroud removed).
The granulator screens are
exchangeable, and the
particle size of the final
granule is determined by the
mesh size and screen design.
Pharma Roller Compactor and
Granulator WP 200 Pharma
The WP 200 Pharma is the obvious choice of
compactor and granulator for production. With a
throughput of up to 400 kg/hr (Lactose), the WP 200 Pharma is ideal for situations of frequent product
changes, special products, small batches, or for
compacting and granulating of a mono product in
continuous operation. The WP 200 Pharma comes with
the Combi-Vent-Feeder® System patented by
Alexanderwerk, as standard. This unique design of the
feed system facilitates the highly efficient operation of
this unit. Due to the dedicated venting of the gas flow,
larger quantities of material can be fed into the roller
gap. The process equipment is completely separated
from the drive equipment. As an option, the WP 200
Pharma is available in a “Through the Wall“ design.
With this special design, the access to the process
equipment can be separated from the access to the
drive equipment. For ultimate containment applications, the WP 200 Pharma can be fitted with an
Isolator. The machine‘s design meets all the requirements of the pharmaceutical industry:
•spatial separation of process and drive equipment
•Combi-Vent-Feeder® System
•two-stage rotor fine granulation in D design
•patented Suction-Cooling-System®
•cGMP design
•completely made of stainless steel
•all non-metallic materials according to FDA standards
•may be fitted with Isolator
•automated PLC
•optional: WIP (Wash In Place)
•optional: Through the Wall design
•optional: 21 CFR Part 11
•optional: PAT
•design according to URS
Quality parameters can be easily scaled to larger or
smaller production units. Quality parameters determined by means of the WP 120 Pharma pilot plant and
small-batch machine made by Alexanderwerk can be
easily scaled to the WP 200 Pharma and vice versa.
The operator panel is designed as a touch panel.
Granulation with Roller Compactors
made by Alexanderwerk
Compaction
The basic process principle of roller compaction is
simple. However, only the use of latest control technology facilitates the efficient production of a highquality granule.
The quality of the final granule is mainly determined
by the quality of the flake. A constant compacting
pressure and constant roller gap are required. The
control equipment made by Alexanderwerk will
compensate any physical fluctuations in the material
(such as local inhomogenities). As a result, the process
parameters (throughput, flake density, compacting
pressure, speed or similar) can be precisely adjusted at
highly repetitive accuracy.
With roller compactors made by Alexanderwerk,
there is a clear, modular separation between the process steps of feed and compaction. The feed screw 3
alone is designed to feed the powder to the rollers
4 – intentionally, this process does not aim at a precompaction by the feed screw system.
Patented Combi-Vent-Feeder® System to boost
Efficiency.
The Combi-Vent-Feeder® System patented by
Alexanderwerk offers an additional “chamber“next to
the material hopper (which does not contain any
material). Air, displaced from the material during compaction, can freely escape through this second chamber.
As a result of this configuration, the material can be fed
to the screw, and thus to the rollers, more uniformly,
there is less back pressure building up in the feed section, and the process, as such, runs smoother, faster and
more uniformly.
1
2
3
4
Additionally, the Combi-Vent-Feeder® System can do
more undersize or fines (e. g. side seal leakages) can be
continuously recycled into the additional hopper chamber, blending with raw material to form a consistent
feed quality.
5
6
Another option available is the vacuum station for the
screw feeder. A vacuum is applied on the screw housing
to force the return-flow air into a defined path. Thus,
the processing of very light or heavily fluidizing materials
is made possible.
Granulation
Granules are characterised by defined particle sizes, i. e.
the size of the particles varies between fixed upper and
lower limits (oversize, undersize). After feeding into the
compacting unit, the course flakes are generally larger
than the upper tolerance limit of the finished product.
Only defined size reduction in the granulation unit will
produce the finished granule.
Downstream further processing of the granule, such as
in tableting machines, requires a tight tolerance and for
this reason the granulation unit of the WP 200 Pharma
is of a two-stage diagonal design. The first stage is pregranulation, and the second stage is designed as a fine
granulator.
The process equipment of the WP 200 Pharma can be completely
dismantled without any special tools.
1
2
7
3
8
1
Material feed
2
Feed hopper in Combi-Vent-Feeder® design
3
Feed screw system
4
Compacting unit: Roller Unit
Feed hopper in Combi-Vent-Feeder® design as standard.
5
Pre-crushing
6
Sampling
7
Two-stage granulating unit
1 Vent for displaced air and feed hopper for undersize and
oversize at the same time
8
Granule outlet
2 Material feed hopper
3 Socket for level probe
Modular Design
From the consumer’s point of view, porosity is the most
critical requirement of pharmaceutical products. From
the user‘s point of view, flexibility is a decisive characteristic of a pharmaceutical machine, specifically in a time
of ever tighter markets.
The WP 200 Pharma meets both requirements – defined
porosity of the final product, and flexible use of the machine. Due to its consistent modular design, the WP 200
Pharma can be dismantled practically
without special tools.
Rollers 4 (protective shroud removed) and flake crusher 5 .
Cantilever bearing design of rollers for easy replacement or
cleaning.
Numerous special or customized designs available
upon request.
Two-stage granulating unit in
diagonal design 7
(protective shroud removed).
The granulator screens are
exchangeable, and the
particle size of the final
granule is determined by the
mesh size and screen design.
Pharma Roller Compactor and
Granulator WP 200 Pharma
The WP 200 Pharma is the obvious choice of
compactor and granulator for production. With a
throughput of up to 400 kg/hr (Lactose), the WP 200 Pharma is ideal for situations of frequent product
changes, special products, small batches, or for
compacting and granulating of a mono product in
continuous operation. The WP 200 Pharma comes with
the Combi-Vent-Feeder® System patented by
Alexanderwerk, as standard. This unique design of the
feed system facilitates the highly efficient operation of
this unit. Due to the dedicated venting of the gas flow,
larger quantities of material can be fed into the roller
gap. The process equipment is completely separated
from the drive equipment. As an option, the WP 200
Pharma is available in a “Through the Wall“ design.
With this special design, the access to the process
equipment can be separated from the access to the
drive equipment. For ultimate containment applications, the WP 200 Pharma can be fitted with an
Isolator. The machine‘s design meets all the requirements of the pharmaceutical industry:
•spatial separation of process and drive equipment
•Combi-Vent-Feeder® System
•two-stage rotor fine granulation in D design
•patented Suction-Cooling-System®
•cGMP design
•completely made of stainless steel
•all non-metallic materials according to FDA standards
•may be fitted with Isolator
•automated PLC
•optional: WIP (Wash In Place)
•optional: Through the Wall design
•optional: 21 CFR Part 11
•optional: PAT
•design according to URS
Quality parameters can be easily scaled to larger or
smaller production units. Quality parameters determined by means of the WP 120 Pharma pilot plant and
small-batch machine made by Alexanderwerk can be
easily scaled to the WP 200 Pharma and vice versa.
The operator panel is designed as a touch panel.
Granulation with Roller Compactors
made by Alexanderwerk
Compaction
The basic process principle of roller compaction is
simple. However, only the use of latest control technology facilitates the efficient production of a highquality granule.
The quality of the final granule is mainly determined
by the quality of the flake. A constant compacting
pressure and constant roller gap are required. The
control equipment made by Alexanderwerk will
compensate any physical fluctuations in the material
(such as local inhomogenities). As a result, the process
parameters (throughput, flake density, compacting
pressure, speed or similar) can be precisely adjusted at
highly repetitive accuracy.
With roller compactors made by Alexanderwerk,
there is a clear, modular separation between the process steps of feed and compaction. The feed screw 3
alone is designed to feed the powder to the rollers
4 – intentionally, this process does not aim at a precompaction by the feed screw system.
Patented Combi-Vent-Feeder® System to boost
Efficiency.
The Combi-Vent-Feeder® System patented by
Alexanderwerk offers an additional “chamber“next to
the material hopper (which does not contain any
material). Air, displaced from the material during compaction, can freely escape through this second chamber.
As a result of this configuration, the material can be fed
to the screw, and thus to the rollers, more uniformly,
there is less back pressure building up in the feed section, and the process, as such, runs smoother, faster and
more uniformly.
1
2
3
4
Additionally, the Combi-Vent-Feeder® System can do
more undersize or fines (e. g. side seal leakages) can be
continuously recycled into the additional hopper chamber, blending with raw material to form a consistent
feed quality.
5
6
Another option available is the vacuum station for the
screw feeder. A vacuum is applied on the screw housing
to force the return-flow air into a defined path. Thus,
the processing of very light or heavily fluidizing materials
is made possible.
Granulation
Granules are characterised by defined particle sizes, i. e.
the size of the particles varies between fixed upper and
lower limits (oversize, undersize). After feeding into the
compacting unit, the course flakes are generally larger
than the upper tolerance limit of the finished product.
Only defined size reduction in the granulation unit will
produce the finished granule.
Downstream further processing of the granule, such as
in tableting machines, requires a tight tolerance and for
this reason the granulation unit of the WP 200 Pharma
is of a two-stage diagonal design. The first stage is pregranulation, and the second stage is designed as a fine
granulator.
The process equipment of the WP 200 Pharma can be completely
dismantled without any special tools.
1
2
7
3
8
1
Material feed
2
Feed hopper in Combi-Vent-Feeder® design
3
Feed screw system
4
Compacting unit: Roller Unit
Feed hopper in Combi-Vent-Feeder® design as standard.
5
Pre-crushing
6
Sampling
7
Two-stage granulating unit
1 Vent for displaced air and feed hopper for undersize and
oversize at the same time
8
Granule outlet
2 Material feed hopper
3 Socket for level probe
Modular Design
From the consumer’s point of view, porosity is the most
critical requirement of pharmaceutical products. From
the user‘s point of view, flexibility is a decisive characteristic of a pharmaceutical machine, specifically in a time
of ever tighter markets.
The WP 200 Pharma meets both requirements – defined
porosity of the final product, and flexible use of the machine. Due to its consistent modular design, the WP 200
Pharma can be dismantled practically
without special tools.
Rollers 4 (protective shroud removed) and flake crusher 5 .
Cantilever bearing design of rollers for easy replacement or
cleaning.
Numerous special or customized designs available
upon request.
Two-stage granulating unit in
diagonal design 7
(protective shroud removed).
The granulator screens are
exchangeable, and the
particle size of the final
granule is determined by the
mesh size and screen design.
Technical Data
Examples of Granules
Roller Compactors and Granulators
WP 200 Pharma
Antibiotics
Riboflavin
Natrium Bicarbonate
Spice extract
Lactose
Flavours
Throughput, continuous operation
10 to 250 kg/hr
Granule size
variable
Maximum compacting pressure
18.4 kN/cm of roller width
Installed power
approx. 29 kVA
Weight
approx. 2,000 kg (complete unit, excluding
control cabinet)
Material of construction
1.4571 (complete), 316 Ti
Material of construction: Rollers
1.4122
Material of construction: Product touching seals
FDA approved materials
Applications
For many years pharmaceutical corporations all over the world have been using roller compactors made by
Alexanderwerk to produce granules, and to further process tablets or capsules, Life-Science products, flavours,
instant powders, or intense sweeteners.
www.fabermoldenhauer.de
Machine control separate from the machine (not shown).
Alexanderwerk AG Kippdorfstraße 6 –24 42857 Remscheid/Germany
P +49 (0)2191 79 50 F +49 (0)2191 79 53 50 [email protected] www.alexanderwerk.com
No liability will be accepted for errors or omissions. Subject to change (246-9011)
Technical Data
Examples of Granules
Roller Compactors and Granulators
WP 200 Pharma
Antibiotics
Riboflavin
Natrium Bicarbonate
Spice extract
Lactose
Flavours
Throughput, continuous operation
10 to 250 kg/hr
Granule size
variable
Maximum compacting pressure
18.4 kN/cm of roller width
Installed power
approx. 29 kVA
Weight
approx. 2,000 kg (complete unit, excluding
control cabinet)
Material of construction
1.4571 (complete), 316 Ti
Material of construction: Rollers
1.4122
Material of construction: Product touching seals
FDA approved materials
Applications
For many years pharmaceutical corporations all over the world have been using roller compactors made by
Alexanderwerk to produce granules, and to further process tablets or capsules, Life-Science products, flavours,
instant powders, or intense sweeteners.
www.fabermoldenhauer.de
Machine control separate from the machine (not shown).
Alexanderwerk AG Kippdorfstraße 6 –24 42857 Remscheid/Germany
P +49 (0)2191 79 50 F +49 (0)2191 79 53 50 [email protected] www.alexanderwerk.com
No liability will be accepted for errors or omissions. Subject to change (246-9011)