The batch technology is an alternative, when fast throughput times do not matter and fixed batch sizes are to be processed or when a frequent product change is planned. NEUHAUS NEOTEC fluidised bed plants are versatile and flexible. They can process a variety of products and refine powders, granules or pellets or shape liquids to particles.
In addition to drying, batch plants are used for agglomeration, spray granulation, coating or micro-encapsulation.
Our plants are of modular design. They can be adjusted in many ways to the planned process, the desired functionality and the prevailing conditions, such as GMP or space available. Product and technical areas are separated from each other. The basic NEUHAUS NEOTEC plant consists of the Batch FB fluidised bed apparatus, the inlet air and exhaust air systems and the control unit. Various options can be retrofitted to meet future requirements efficiently. In the NEUHAUS NEOTEC pilot plant, all processes can be developed, tested and verified both on laboratory and pilot scale.
Examples for the application of the batch fluidized bed technology
- Agglomeration of instant drinks such as cocoa, fruit drinks
- Microencapsulation of vitamins or probiotics
- Spray granulation of fertilisers
- Agglomeration of instant soups and sauces
- Uniform drying of pharmaceutical active ingredient mixtures or wet granulates
- Granulation of pharmaceutical tablet mixtures
- Fat Coating of food or feed products
The planning of a fluidised bed plant requires a lot of specialized knowledge, this does not only concern all details of process technology. Our expertise includes not only the perfect engineering, but also in-depth knowledge of raw materials and substances, regulations and standards, production processes, industries, markets and trends.
The configuration of your plant depends on several factors: Which batch sizes do you plan to process? What is the starting material, which final product do you want? Which constructional requirements, which standards do you have to fulfil?
The fluidised bed apparatus is the core component of the plant. Numerous options are available to equip the plant in accordance with the application to be fulfilled. Depending on the design, fluidised bed processes such as drying, agglomeration and spray granulation can be carried out discontinuously in this system. Size and execution of the plant, the plant design and the peripheral components are individually adapted to the respective product and process requirements.
- Dust and gas-tight plants
- Execution according to GMP guidelines
- CIP or WIP concepts
- Top or bottom spray
- Wurster coating / spouted bed coating
- Pressure shock resistant design up to 12 bar
- Inert gas mode and closed loop operation
- Various product feeding and discharge methods
Batch plants are less complex than continuously working systems. But the more efficient and flexible a batch plant should be, the more important is the overall engineering from the process technology to the selection of the appropriate peripherals.
The NEUHAUS NEOTEC fluidised bed system combines proven expertise in process technology with practical process control and maximum flexibility in construction and functionality of the plants.
The batch plants of NEUHAUS NEOTEC are pressure-shock resistant up to 12 bar. This increases the operating safety, while reducing space requirements, assembly and installation costs of the plant.
The size of a batch plant depends primarily on the product quantity to be processed in one batch; it determines the product bowl size and thus the plant dimension. NEUHAUS NEOTEC designs for you batch plants up to a size of 2,000 litres.
Inlet Air Handling
For constant and reproducible results, process air must be available in a defined quality appropriate for the process. Filter stages, antifreeze systems, dehumidification or humidification of the process air - everything is customized to your requirements.
Exhaust Air Treatment
On the exhaust air side of the fluidised bed plant, in addition to the exhaust air fan, further air handling components can be integrated optionally to remove dust from the exhaust air or to recover heat. These include police filters, cleanable filters or solvent recovery.
The batch plants can be equipped with single-chamber, double-chamber vibrating and cartridge filter systems.
The control system is an essential quality feature of the plant. NEUHAUS NEOTEC develop their own compatible hardware and software solutions which are tailored to a reliable, user-friendly plant operation. Graphical interfaces give a detailed view of the parameter settings, e.g. for the creation of a recipe. An intuitive user interface simplifies the control of the processes. All control programmes (PLC) can be connected via various bus interfaces with connected production plants and external control or evaluation units. Maintenance, fault diagnosis and support are provided worldwide.
Further optional components of a batch plant:
- Product supply and discharge system
- Product conveying systems
- Mechanical granulation systems
- Grinding of the raw materials
- Transport and bagging devices