LG Series Roller Compactor

Working Principle          

The powder material is fed into the screw feeder through the stirring feed device, then the pre-compacted material is fed into the compacting zone of the two counter-rotating rollers and compacted into flakes. The flakes are cut into small non-continuous flakes by the pre-crusher, then the non-continuous flakes enter the two-stages granulating device to be crushed and granulated to the qualified granules with increased bulk density and good flowability. In the whole process, the material is totally isolated with the outside to ensure clean and avoid any contamination.

There are manual and automatic operation modes in real production. After setting the pressure parameter, the system can adjust the rotating speed of screw feeder automatically by monitoring the gap between two rollers to ensure the uniformity of material feeding and flake thickness, so as to get the qualified granules with stable quality and uniform particle size distribution.

Pharmaceutical Roller Compactor Overall Layout

1.Stirring Feed Unit

• There is a natural exhaust channel inside the stirring feed unit for natural exhausting air to ensure the powder material is smoothly fed into the screw feeding unit.
• There is a stirring device inside the feeding channel to smash the block materials and clusters for smoothly feeding.
• There is a material level sensor to detect material level for automatic operation.

2.Screw Feeding Unit

• Adopting the horizontal screw feeding unit to ensure uniformly feeding material and accommodate to the roller with bigger width. The rotating speed of the screw is continuously adjustable and set the upper &lower limits.
• There is a vacuum exhaust device to effectively decrease the air content of the material and increase the compactness of material and granules output.
• The parts, such as the front and rear liners which contact the materials, are made of stainless steel or food-grade polymer material, have good corrosion resistance, and are convenient for dismantlement and cleaning.

3.Roller Compacting Unit

• Display, adjust and control the hydraulic support force through the touch screen to ensure stable pressure during compacting and uniform granule density.
• Gap between two rollers can be monitored and controlled automatically to ensue uniformity of flakes during continuous production.
• The roller is cooled forcefully by using chiller controller to adjust the water temperature, its easy and stable operation ensures that the increase of roller temperature is effectively controlled in the compacting process, so as to adapt to compact the heat sensitive materials.
• The water chiller is arranged outside the roller compactor to facilitate the adjustment of circulating water temperature and volume. Ring groove water channel is set inside the roller, the roller temperature is lower than room temperature during operation, and the cooling effect is good.
• Cantilever-type design of rollers for easy dismantlement and cleaning.
• Two rollers are made of stainless steel and vertically arranged. The roller surface is serrated. The excircle surface is specially heat treated by advanced quenching process, with high hardness and long service life.
• The end faces of both sides of the rollers are equipped with food-grade polymer material, effectively reducing the fine powder content of the product.
• The scrapers close to the surface of the upper and lower rollers can timely scrape the powder adhering to the roller surface effectively.
• The inspection window and sampling port on the hold-down sealing cover is designed for monitoring the compacting and granulating conditions, as well as the thickness and hardness of the formed flakes.
• The pre-crusher can break the large flakes into small pieces, effectively prevent the bridging block (bridging arch), to ensure the high efficiency of granulation.
• Rollers with different kinds of surface to be provided:  One kind of roller is included in the quotation, the other two kinds of roller are as options.

4.Crushing and Granulating Unit(two-stage granulation)

• The rotating speed of the two-stages granulating device can be adjusted continuously in the set speed range and displayed, to effectively reduce the fine powder content of the product.
• Optional screens for getting granule with different size.
• Gap between granulating rotor and screen is adjustable by rotating the eccentric rod.
• D-shape arranged screen for granulating can increase its working surface, and increase processing volume and yield of granules.

5.Electrical Control Unit

• Using programmable controller (PLC) and colorful touch screen for manual and automatic control, monitors the radial gap of rollers.
• Adopting 15- inch IPC colorful touch screen with the functions of displaying system pressure, rollers gap and cooling water temperature, and automatic displaying faults, functions of automatic stop, alarm and help menu.
• The motors of screw feeder, rollers and single-stage granulating unit adopt the converter separately, the speed can be adjusted continuously with upper& lower limit. At the same time, the interlocking control and protection function of start-up sequence and stop sequence is provided.
• The running time of each motor can be accumulated.
• The system has the safety protection functions of motor overload and electrical system, emergency stop and system access control, etc.
• The system has the functions of overload, over voltage, under voltage, phase deficiency, zero deficiency and phase sequence monitoring.
• The system has three-color light to indicate the status of operation, stop and fault.
• Electrification meetsthe IEEE safety standards and RCD is provided to minimize the impact in case of electrocution.
• All driving parts areproperly covered.

6.Overall Characteristics

• Machine design and control placement conformsthe ergonomic requirements and ensure overall good ergonomics.
• Modular design for easy dismantlement and cleaning.
• Full stainless steel design with excellent corrosion resistance.
• All parts contacting with materials (except for screw feeder, roller nut, pre-crusher, granulating rotorand compacting roller), are made of high quality 316L stainless steel and food-grade polymer material in line with GMP standard.
• Compact structure and humanized design with beautiful appearance.
• Sound Level : no more than 75dB.
• The outer surface of equipment is treated with stainless steel hairline process.
• Excellent sealing of the whole equipment with high protection level.

7.Configuration

• PLC, HMI and low voltage electric elements：Siemens(Germanbrand) product
• Converter：Siemens (Germanbrand) product
• Displacement sensor：MEASUREMENT product，DC-EC series
• Vibrating Fork Level Switch (level sensor): NIVOCONT product，RKN series.
• Hydraulic system：HAWE(Germanbrand) pump, HYDAC accumulators,TECSIS(German brand) pressure sensor.
• Motor/Reducer：JIE,JIAOXING,DELI ,etc (China topbrand) product.