A tangential-spray rotor granulator uses a rotating disc at the bowl base (100–600 RPM) combined with tangential-entry fluidising air to create a centrifugal-helical particle motion — particles spiral inward and upward past tangential spray nozzles at the bowl wall. Processing 2–200 kg batches, it produces spherical, dense, highly uniform granules (D90 0.5–3.0 mm, sphericity >0.95) enabling simultaneous granulation-coating in a single step — producing pellets equivalent to extrusion-spheronisation without a separate extruder.
The rotating base disc (100–600 RPM) centrifugally projects particles to the bowl wall; fluidising air enters tangentially, lifting particles upward in a spiral helical path. Tangential spray nozzles at mid-bowl apply binder or coating solution to passing particles — each particle receives controlled exposure per revolution. Combined centrifugal and fluidisation forces compact agglomerates into dense spheres. Layering rate and disc speed independently control granule size and sphericity — achieving mean circularity >0.95 without a separate spheronisation step.
Challenges
Rotor Speed DoE with Power Map per API Bulk Density
Two-variable DoE identifies optimal disc RPM and air flow for each product class.
VFD Disc Speed with Inline PSD Probe Feedback
Real-time PSD adjustment maintains target D50 throughout full granulation batch.
Height-Adjustable Spray Arm (50–200 mm Range, Motorised)
Nozzle arm maintains constant nozzle-to-bed distance as bed height increases.
Constant Tip Speed Scale-Up (RPM = Tip Speed ÷ π × D_disc)
Peripheral disc velocity held constant — equivalent centrifugal field at all scales.
Pre-Load MCC or Sugar Seed Pellets Before API Powder
Seed pellets provide immediate centrifugal mass — prevents wall adhesion on start-up.
Solutions
- Rotor Speed DoE with Power Map per API Bulk Density: Two-variable DoE identifies optimal disc RPM and air flow for each product class.
- VFD Disc Speed with Inline PSD Probe Feedback: Real-time PSD adjustment maintains target D50 throughout full granulation batch.
- Height-Adjustable Spray Arm (50–200 mm Range, Motorised): Nozzle arm maintains constant nozzle-to-bed distance as bed height increases.
- Constant Tip Speed Scale-Up (RPM = Tip Speed ÷ π × D_disc): Peripheral disc velocity held constant — equivalent centrifugal field at all scales.
- Pre-Load MCC or Sugar Seed Pellets Before API Powder: Seed pellets provide immediate centrifugal mass — prevents wall adhesion on start-up.
Applications
- Pharmaceutical: Spherical pellet for MR capsule fill, controlled-release multi-particulate systems.
- Nutraceuticals: Spherical vitamin and mineral pellet for smooth-swallow capsule and sachet.
- Food & Beverage: Spherical flavour bead, instant beverage dense spherical granule production.
- Chemical: Spherical catalyst support pellet, specialty chemical dense granule production.
- Cosmetics: Spherical exfoliant bead, mineral cosmetic dense spherical granule production.
Models & Capacities
2C. Tangential-Spray Rotor Granulator — Models & Capacities | |||||||||||
Model | Net Vol. [L] | Batch Size [kg] | Disc Ø [mm] | Disc Speed [RPM] | Inlet Air [m³/h] | Granule D90 [mm] | Sphericity | Spray Rate [g/min] | Bowl Ø [mm] | Bowl H [mm] | Connected Load [kW] |
FBG-RT-002 | 3 | 2 | 200 | 100–600 | 100–400 | 0.5–3.0 | >0.95 | 10–50 | 400 | 500 | 10 |
FBG-RT-010 | 15 | 10 | 350 | 100–500 | 300–1,200 | 0.5–3.0 | >0.95 | 50–200 | 600 | 700 | 20 |
FBG-RT-030 | 45 | 30 | 500 | 100–450 | 800–3,000 | 0.5–3.0 | >0.95 | 150–500 | 850 | 950 | 38 |
FBG-RT-060 | 90 | 60 | 650 | 100–400 | 1,500–6,000 | 0.5–3.0 | >0.95 | 250–900 | 1,100 | 1,200 | 65 |
FBG-RT-120 | 180 | 120 | 850 | 80–350 | 3,000–10,000 | 0.5–3.0 | >0.95 | 500–1,500 | 1,400 | 1,500 | 110 |
FBG-RT-200 | 300 | 200 | 1,100 | 60–300 | 5,000–16,000 | 0.5–3.0 | >0.95 | 800–2,500 | 1,700 | 1,800 | 165 |
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