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Troubleshooting - Granulation Problems and Solutions


Problem:

Solution:

Lumps or oversized Particles

Excess product moisture

Excess partial product moisture

Too sticky polymer

Too high local binder concentration

Lumps or oversized Particles

Lower the spraying rate

Increase inlet air and product temperatures

Increase atomizing and microclimate pressure

Increase process air flow

Check function of the spraying nozzle

O-rings

Liquid tip, spray air tip

Fines

Insufficient product moisture

Insufficient local product moisture

Instable granules

Mechanical Impact

Too low local binder concentration

Fines

Decrease product temperature

Decrease inlet air volume

Shorter drying time

Lower atomizing and microclimate pressure

More appropriate binder

Increased binder amounts

Higher binder concentration in solution

Reduce possible spray drying effect

Width particle size distribution

Excess product moisture

Excess local product moisture

Instable granules

Mechanical impact

Inhomogeneous granulation (Product falls after the granulation from the dome or filter)

Wide particle size distribution

Lower or increase spraying rate

Adjust inlet air and product temperatures

Adjust product temperatures

Adjust atomizing and microclimate pressure

Check function of the spraying nozzle

Decrease the friability of the granules



PEOPLE ALSO READ: End Point Determination in a Wet Granulation Process


Powder layer at the dome and filters

Recondensation

Electrostatics and bad flowability

Particle size of the starting material

Too fine granules

Powder layer at the dome and filters

Pre-heating of the fluid bed

Adding more water to the spraying liquid

Lower inlet air temperature

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

Low yield with clean dome and filters

Broken sealing at the filters

Damages at the filter socks

Starting material is passing the filters

Low yield with clean dome and filters

Replace Sealing

Replace filter socks, do not repair

Use filter socks with Teflon membrane (pore size ~ 1 µm)

Low density of the product

Pre-Milling of the starting material

Pre-movement of the starting material in the fluid bed

Very high product moisture content

Prewetting of powder before start of binder application

Transfer to RMG

Low spraying rate

Reduce the binder concentration

Increase the hose size

Pre-pressure on binder vessel

Heat up the spraying liquid

 

 



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No sufficient air supplies

Shorten cleaning cycle

Increase cleaning pressure

Granulate faster

Decrease the air amount

 

Segregation of the product

Charge with low inlet air

Change excipients (particle size)

Start charging good flowable powders

Pre-granulate small particles

 

Inhomogeneity of low quantity ingredients

Add the ingredient to the granulation liquid

Lumps or oversized Particles in the RMG

Excess Product moisture

Excess partial product moisture

Too excessive granulation

Lumps or oversized Particles

Lower spraying rate

Increase spraying rate

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



PEOPLE ALSO READ: Working Principle and Applications of FBD (Fluid Bed Dryer)


Fines

Insufficient product moisture

Instable granules

Insufficient granulation

Fines

Increase spraying rate

Increase the liquid amount

Faster agitator speed

Increase granulation time

Inappropriate binder

Insufficient binder amounts

Segregation in the RMG

Adjust the agitator speed

Adjust mixing time

Add the ingredient after wetting

Blockage of the Wet Mill

Wrong set up of the mill

Product flow to the mill

Blockage of the Wet Mill

Increase speed of knife

Use wider mesh size

Use sieve with square holes

Use round knife

Decrease the agitator speed during discharge


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