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Home / Case Studies / Baghouse Solutions for Pharmaceutical Granulation Processes

Baghouse Solutions for Pharmaceutical Granulation Processes

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Client
Our client is an innovative pharmaceutical company specializing in the development and production of medicinal products, tablets, and capsules. The company's plant is equipped with advanced machinery, including STREAM dryer-granulators, which ensure high-quality granulation and compliance with strict GMP (Good Manufacturing Practice) standards.
Production Process
The granulation process in the STREAM dryer-granulator includes several key stages:
  1. Mixing of powder components – The initial pharmaceutical powders are loaded into the granulator, where they are uniformly mixed.
  2. Granule drying – Simultaneously with the granulation process, drying occurs, ensuring that the granules reach the optimal moisture content and stability.
  3. Air filtration – Anti-static filtration material is used to prevent static charge buildup and ensure the safety of the process.
  4. Explosion protection – The built-in explosion-proof port reduces the risk of equipment and personnel damage in case of dust ignition.
Problem
During the granulation and drying process of pharmaceutical powders, fine dust is generated. The suspended particles of active substances can penetrate the working area. When there is a high concentration of powder in the air, there is a risk of spontaneous ignition.
Current system component
There is no direct air purification equipment installed on the granulator. The existing system does not provide full protection for the operators and the environment, so an additional solution for air filtration is required.
Temperature
The air temperature after drying in the granulator is 50–80°C. After primary cooling, the temperature ranges from 30–50°C.
Gas/Dust
Pharmaceutical powder particles generated during granulation.

Initial Data

Client Communication

Client:
Good afternoon.
Our company requests you to provide a commercial proposal for the supply of an air filtration and ventilation unit in accordance with the completed questionnaire.

Description of the Technological Process

Granulation of powders in a fluidized bed.

Basic description of the production process

The granulation process of raw materials in powder form is carried out in the STREA dryer-granulator. During granulation, powder granules of 1–2 mm in size are obtained.

Volumetric flow rate (m³/h) and temperature of the gas-dust flow entering the filtration system

No more than 6,000 m³/h

Emission characteristics of the objects:

- Dust concentration at the inlet to the gas cleaning system (mg/m³)

No more than 25 g/m³

- Size of captured particles and fraction distribution, granulometry

• Min value 10 µm

• Max value 500 µm

Harmful gases at the inlet of the gas cleaning system

None

Physical properties:

• Angle of repose

30–45°

• Hygroscopicity

Present in some formulations

• Tendency to stick together

Yes

• Abrasiveness

No

• Flammability

No

• Explosiveness

Yes, due to dust content in the airflow

Required material for equipment manufacturing

Structural steel

Operating mode of the equipment (continuous/intermittent)

The STREAM dryer-granulator operates in an intermittent mode. Equipment downtime occurs during loading of raw materials and unloading of the finished product. During this time, filter cleaning can be performed. The average process time for granulate preparation is 1.5 hours.

Characteristics of the existing gas-dust filtration system (if available)

Filtering elements inside the equipment housing.

Intended placement of the newly developed dust and gas filtration system

The dust and gas filtration system will be installed outdoors.

Preferred filter regeneration method

Compressed air cleaning. Vibration cleaning is desirable, provided that vibration of filter plates is achieved using compressed air rather than an electric motor with cams.

Compressed air (allowable consumption, operating pressure, purification class, etc.)

There is a compressor unit for producing and purifying compressed air with a capacity of 3,000 l/min at a pressure of 10 bar.

Discharge method

Manual

Explosion and fire safety requirements

Explosion-proof and fire-protected design.

Need for recirculation of cleaned air

Discharge of cleaned air into the atmosphere.

STREAM dryer-granulator
STREAM dryer-granulator
Scheme
Scheme
Features of the STREAM Dryer-Granulator
  • Used in the production of pharmaceutical products, tablets, and capsules.
  • Powder granulation improves material properties and reduces airborne dust levels.
  • Using a fluidized bed granulator for powder granulation enhances material solubility.
  • Enables simultaneous mixing, granulation, and drying in a single cycle.
  • Equipped with an antistatic filtration material to ensure safe operation.
  • The fluidized bed granulator is fitted with an explosion protection port to prevent harm to operators or staff in case of an explosion.
  • The granulator has a sealed structure, preventing dead zones, ensuring easy cleaning, and eliminating cross-contamination, thereby complying with GMP standards.
Engineer Torch-Air:
Good afternoon,
The commercial offer is attached to the file.

Specifications:

Characteristic

Data

Air capacity, m³/h

6,000

Filtration area, m²

70

Filter bag material

Polyester

Density

500 g/m³, calendered (burned to a smooth surface) on one side

Hydraulic resistance, Pa

2,000

Maximum vacuum, Pa

5,000

Operating temperature in the filter, °C

Up to 150

Short-term temperature (no more than 5 minutes), °C

Up to 160

Dust concentration at filter inlet, g/m³ (max)

80

Dust concentration at filter outlet, mg/m³

5-10

Compressed air pressure, bar

5-7

Compressed air consumption for cleaning, L/min

300

Weight, kg

1,900

Client:
Good afternoon,
Thank you for your prompt response. I have forwarded the materials for review.
I kindly request you to prepare a commercial offer for the Baghouse Blizzard 3 with a capacity of 2,700 m³/h.
Additionally, please include the following specifications:
  1. Install a special baffle plate for the initial settling of part of the dust.
  2. Use a flat rectangular-section bag.
  3. Manufacture the Baghouse Blizzard 3 in an explosion - and fire-proof design.
  4. Equip the unit with a fan (2,700 m³/h) in an explosion - and fire-proof design.
Looking forward to your proposal.

Engineer Torch-Air:
Good afternoon,
Attached is the drawing with the explosion relief membrane.
In response to all your previous inquiries: Yes, all requested modifications are possible in this Baghouse unit.

Baghouse Blizzard 3 – Specifications

Characteristic

Data

Air capacity, m³/h

3,000

Resistance, Pa

2,000

Maximum cleaned gas temperature, °C

150

Filtration area, m²

27

Filter bag material

Polyester

Dust concentration at filter inlet, g/m³ (max)

30

Dust concentration at filter outlet, mg/m³

5-10

Compressed air pressure, bar

5-7

Compressed air consumption, L/min

100-200

Control and automation cabinet

1 unit

Material

Carbon steel

Explosion relief membrane (pressure relief membrane)

Included

Additional grounding

Included

Antistatic filter elements

Included

Client:
Good afternoon,
I am sending you the signed and approved drawing Blizzard 3 with Fan.
Please provide an invoice for payment.

Proposed Solutions

To address the client's requirements for an air filtration and ventilation system compatible with the STREAM dryer-granulator, we propose the following solutions:

BAGHOUSE BLIZZARD 3 (2,700 m³/h)
A high-efficiency baghouse filtration unit designed to handle the specific dust characteristics generated during pharmaceutical powder granulation.
Key Features:
  • Airflow capacity: 2,700 m³/h
  • Explosion-proof and fire-protected design
  • Custom dust-settling baffle plate to reduce airborne particle concentration
  • Flat rectangular-section filter bags for optimized filtration efficiency
  • Integrated explosion relief membrane for safety compliance
  • Antistatic filter elements to prevent static charge buildup
  • Fan (2,700 m³/h) in explosion- and fire-proof execution
BAGHOUSE BLIZZARD 3 (3,000 m³/h) – ALTERNATIVE OPTION
A slightly higher-capacity filtration system for cases where increased airflow is needed.
Key Features:
  • Airflow capacity: 3,000 m³/h
  • Polyester filter bags with a 27 m² filtration area
  • Dust concentration at inlet: Up to 30 g/m³
  • Dust concentration at outlet: 5-10 mg/m³
  • Compressed air regeneration system with a 100-200 L/min air consumption
  • Control and automation cabinet included
  • Explosion relief membrane and additional grounding for safety
  • Structural carbon steel construction for durability

IMPLEMENTATION CONSIDERATIONS
  • The filtration system will be installed outdoors to optimize space utilization within the facility.
  • The system will operate intermittently, allowing for filter cleaning during downtime.
  • Compressed air cleaning is the preferred regeneration method, with optional vibration cleaning using compressed air pulses.
  • The cleaned air will be discharged into the atmosphere (no recirculation required).
These proposed solutions ensure compliance with GMP standards, enhanced safety, and optimized air filtration to protect both operators and the production environment.

Conclusion

This dust collector has been operating at our client’s facility since 2018. Since then, we have supplied the client with three additional baghouses. The fact that the client has become a regular customer demonstrates that they are fully satisfied with the quality of our equipment. Working with us is convenient and pleasant.
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Blizzard Baghouse for Pharmaceutical Powder-2
Blizzard Baghouse for Pharmaceutical Powder-3
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
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