Baghouse Solutions for Pharmaceutical Granulation Processes
- Mixing of powder components – The initial pharmaceutical powders are loaded into the granulator, where they are uniformly mixed.
- Granule drying – Simultaneously with the granulation process, drying occurs, ensuring that the granules reach the optimal moisture content and stability.
- Air filtration – Anti-static filtration material is used to prevent static charge buildup and ensure the safety of the process.
- Explosion protection – The built-in explosion-proof port reduces the risk of equipment and personnel damage in case of dust ignition.
Initial Data
Client Communication
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. |
- 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.
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 |
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:
- Install a special baffle plate for the initial settling of part of the dust.
- Use a flat rectangular-section bag.
- Manufacture the Baghouse Blizzard 3 in an explosion - and fire-proof design.
- Equip the unit with a fan (2,700 m³/h) in an explosion - and fire-proof design.
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 |
I am sending you the signed and approved drawing Blizzard 3 with Fan.
Please provide an invoice for payment.
Proposed 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
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).
Conclusion
Best Baghouses for Pharmaceutical Powder Particles
Vladimir Nikulin
