Lödige Process Technology

Continuously from powder to granulate – this new Lödige System offers several advantages:
 

• Less product handling and exposure
• Less cleaning
• Continuous process monitoring - PAT
• Less manpower
• Lower production cost
• Quick return on investment

Mode of operation

> Continuous Granulator CoriMix® CM
High speed mixer designed to intermix liquid or pasty components into dry powder. The high shear force introduced by the granulating tools generates a uniform wet granulate structure.

> Continuous Fluid Bed Dryer WFP
The dryer uses traditional and practice proven fluid bed technology. While beeing dried, the product is simultaneously transported by the airflow through the dryer. At the end of the machine the dry granulate is discharged for further downstream processes.

The granulator and the dryer are the heart of the Lödige continuous wet granulation line – a complete production line from powder components to the tableting-ready granulate. The line also includes dosing units, mixers, sieves and the overall control system.

Thanks to the continuous operation the product is handled only at the beginning and end of the production line. In between it passes from one machine to the other, from one process step to the next – without handling and product exposure. Less operator interaction results in a safer process and a reduction of manpower. Continuous operation also means short downtimes and less cleaning. The continuous operation allows to produce the same product at much lower cost.

Main products – amongst others - are well known analgesics as well as antibiotics.

The LFP series completes our range of systems in compliance with GMP conditions for

• Mixing (GMP® Mixers / Mixing granulators MGT)
• Granulating (Mixing Granulators MGT / CoriMix® CM)
• Drying (LFP / DRUVATHERM® VT) and
• Coating (LFP / LHC).

The Lödige Fluid Bed Processors, which are available as laboratory models, Pilot Plant models and production units in graduated sizes with max. working volumes from 3 kg up to 1800 kg, are designed for

• Drying
• Instantising
• Granulating and
• Coating

of several materials.

Mode of operation
The processor runs in batch operation. The heated inlet air homogeneously flows through the special designed Conidur® bottom into the product vessel, fluidizes the product and keeps it in constant motion. This ensures an excellent heat transfer and high drying rate. Integrated jet filters separate the product area from the pure gas area. The product particles are held back in the processor and retained in the process. The process air leaves the processor at the top.

Product handling can be carried out manually or by means of a pneumatic system. The Fluid Bed Processor LFP offers the advantages of high degree of flexibility (25% - 100% working volume), quick and easy filter replacement and easy cleaning. The Lödige LFP has as a standard a mobile product vessel, Conidur® bottom, individual jet filters, 12 bar pressure burst resistance and a variable spray system.

A wide range of options ensures customizing of the Fluid Bed Processor to your requirements and conditons (WIP system, flame proof, liquid dosing system, Wurster system, tangential spray system).

The LFP Fluid Bed System includes not only the processor, but also air unit, exhaust air system, controls, quick acting valves and liquid addition. The Fluid Bed Processor and the complete unit technology are operated by a PLC or by computer-aided controls. The computer-aided controls enable 21 CFR Part 11 compliant operation.

• GMP design
• Mixing tool can be raised up for easy inspection
• User friendly controls with predefined process steps
• Machine ready for connection
• Also available as Single Pot Mixing Granulator

MGT
In the mixing granulator individual components of a recipe are homogenized by the vertical mixing impeller and a separately driven chopper. Binding agent is then added for wet granulation in the same machine. In order to dry the product, the mixing granulator can be designed as a Single Pot MGT-S (prepared for stripping and vacuum cleaning).

Mode of Operation
A three-arm mixing impeller rotates close to the wall and base of the vertical, cylindrical mixing drum. The shape and peripheral speed are coordinated in such a way that the mixing product forms a vortex. The product is moved in both horizontal and vertical plains and mixed quickly and intensively, even if the components have widely differing granular structures, bulk densities, particle shapes and surface conditions. If necessary a separately driven chopper disperses any lumps in the product, ensures uniform moistening and wet granulation and provides streak-free intermixing of colorants. The optional controls provide a wide range of predefined process steps. The operator selects the requested steps and enters the parameters (for example mixing time, temperature, etc.). The selected steps form the complete process.

Range of Application

• Pharmaceutical industry (granulation of tablet recipes)
• Spices industry (intermixing extracts)
• Cosmetics industry (production of face powder)

Lödige Ploughshare® Mixers operate on the hurling and whirling principle introduced by Lödige to the industrial mixing technology and technical literature. Fitted with mixing elements specifically adapted to individual applications, the Lödige Mixers achieve mixes of high quality.

The mixers ensure batch and continuous processes as follows:

• Optimal quality mixes in short mixing times
• Maximum homogeneity of the mix
• Gentle treatment of products
• Constant reproduceability of the mix quality
• Reliable availability of the system
• Easy accessibility to all inside parts of the mixer
• GMP compliance on demand
• Highest throughputs in short mixing times
• Granulated material achieved at short retention time

Mode of operation
The positioning, the peripheral speed and the geometric form of Ploughshare® Shovels, rotating close to the wall of a horizontal drum, are coordinated in such a way that they counteract the centrifugal force and produce a three-dimensional movement of the product.

The so-called fluid bed generated mechanically in this way ensures gentle and intensive mixing of the components. All the product is constantly involved in the mixing process – there is no dead or low-movement zones in the mixing drum.
The resultant individualisation of the particles in the mix (fluid bed) ensures the addition of liquids and coating of the particles with ease. Choppers can be used to promote the mixing movement, disperse lumps and achieve granulation processes.

Range of application

• Processing powdery, granular and fibrous components
• Addition of liquids for moistening and granulation
• Processing fragile materials
• Addition of viscous materials, for example fat, lecithin and similar in the mix
• Production and premixes for frequent change of product

Features of the continuous process:
The continuous process is operable at filling grades between 20 and 50 % without influencing the mix quality. The mixing elements are adjusted in order to achieve constant back-mixing during the whole residence time prior to discharge the mixed product via the outlet for further processing. The adjustment of the outlet size by means of a slide or an adjustable weir has a direct influence on the residence time.

Range of application

• Processes requiring high throughputs
• Processing powdery, granular and fibrous components
• Addition of liquids for moistening and granulation
• Compensation of dosing fluctuations