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Trouble Shooting (Granulation)

This document lists common problems that can occur during granulation processes and their potential solutions. It addresses issues such as lumps or oversized particles, fines, wide particle size distributions, powder layers on equipment, low yields, densities, and spraying rates. For each problem, one or more possible causes are identified along with recommended process parameter adjustments, equipment modifications, or material property changes that may solve the problem.

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807 views2 pages

Trouble Shooting (Granulation)

This document lists common problems that can occur during granulation processes and their potential solutions. It addresses issues such as lumps or oversized particles, fines, wide particle size distributions, powder layers on equipment, low yields, densities, and spraying rates. For each problem, one or more possible causes are identified along with recommended process parameter adjustments, equipment modifications, or material property changes that may solve the problem.

Uploaded by

Tue
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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com

TROUBLE SHOOTING
GRANULATION PROBLEMS AND SOLUTIONS
Problem: Solution:
Lumps or oversized Particles Lumps or oversized Particles
Excess product moisture Lower the spraying rate
Excess partial product moisture Increase inlet air and product temperatures
Too sticky polymer Increase atomizing and microclimate pressure
Too high local binder concentration Increase process air flow
Check function of the spraying nozzle
O-rings
Liquid tip, spray air tip

Problem: Solution:
Fines Fines
Insufficient product moisture Decrease product temperature
Insufficient local product moisture Decrease inlet air volume
Instable granules Shorter drying time
Mechanical Impact Lower atomizing and microclimate pressure
Too low local binder concentration More appropriate binder
Increased binder amounts
Higher binder concentration in solution
Reduce possible spray drying effect

Problem: Solution:
Width particle size distribution Wide particle size distribution
Excess product moisture Lower or increase spraying rate
Excess local product moisture Adjust inlet air and product temperatures
Instable granules Adjust product temperatures
Mechanical impact Adjust atomizing and microclimate pressure
Inhomogeneous granulation (Product falls Check function of the spraying nozzle
after the granulation Decrease the friability of the granules
from the dome or filter)

Problem: Solution:
Powder layer at the dome and filters Powder layer at the dome and filters
Recondensation Pre-heating of the fluid bed
Electrostatics and bad flowability Adding more water to the spraying liquid
Particle size of the starting material Lower inlet air temperature
Too fine granules Reduce-spraying rate at beginning
Adding of Aerosil to powder mixture before
charging
Increase microclimate (effect of spray drying)
Increase granulation effect
Increase inlet air amount in final phase of
discharge step

Problem: Solution:
Low yield with clean dome and filters Low yield with clean dome and filters
Broken sealing at the filters Replace Sealing
Damages at the filter socks Replace filter socks, do not repair
Starting material is passing the filters Use filter socks with Teflon membrane ( pore
size ~ 1 m )

Problem: Problem:
Low density of the product Low spraying rate
Pre-Milling of the starting material Reduce the binder concentration
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Pre-movement of the starting material in the Increase the hose size


fluid bed Pre-pressure on binder vessel
Very high product moisture content Heat up the spraying liquid
Prewetting of powder before start of binder
application
Transfer to HMG

Problem:
No sufficient air supply
Shorten cleaning cycle
Increase cleaning pressure
Granulate faster
Decrease the air amount
Problem:
Segregation of the product
Charge with low inlet air
Change excipients (particle size)
Start charging good flowable powders
Pre-granulate small particles
Problem: Solution:
Inhomogeneity of low quantity ingredients Add the ingredient to the granulation liquid

Problem: Solution:
Lumps or oversized Particles in the HMG Lumps or oversized Particles
Excess Product moisture Lower spraying rate
Excess partial product moisture Increase spraying rate
Too excessive granulation Use the chopper
Decrease the liquid amount
Faster agitator speed during liquid adding
Slower agitator speed during granulation
Shorter granulation time
Add the liquid by using an atomizing nozzle

Problem: Solution:
Fines Fines
Insufficient product moisture Increase spraying rate
Instable granules Increase the liquid amount
Insufficient granulation Faster agitator speed
Increase granulation time
Inappropriate binder
Insufficient binder amounts

Problem: Solution:
Segregation in the HMG Adjust the agitator speed
Adjust mixing time
Add the ingredient after wetting

Problem: Solution:
Blockage of the wet mill Blockage of the Wet Mill
Wrong set up of the mill Increase speed of knife
Product flow to the mill Use wider mesh size
Use sieve with square holes
Use round knife
Decrease the agitator speed during discharge

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