What Is a High Shear Granulator?
A High Shear Granulator is a type of granulating equipment that forms granules by adding a liquid binder to powdered materials and agitating them at high speed. The granules are formed through the shearing action that occurs during this process.
As a type of wet granulator, it is also referred to by other names, such as high shear mixer granulator, high-speed mixer granulator, or agitating granulator. It can be used for a wide range of applications, from dry powder mixing to wet granulation. After wet mixing and granulation, the granules can be directly transferred to a dryer to produce dried granules. This equipment is widely used in fields such as chemicals, food, and electronics, with various models available for both R&D and production.
Applications of High Shear Granulators
High Shear Granulators are widely used in various industries, including pharmaceuticals, chemicals, food, and electronics. Examples of their applications in different fields include the following:
1. Food Industry
- Batter mixes
- Instant food products
- Seasonings
- Spice and herb mixtures
- Granulated sugar
- Compressed sugar tablets
- Health foods and supplements
- Food additives
2. Chemical Industry
- Plastic coloring
- Masterbatch production
- Powder blending with liquid additives
- Powder coatings
- Natural fibers
- Metals and metal oxides
- Ceramics
- Cellulose and nanocellulose
- Carbon and CNT (Carbon Nanotubes)
3. Pharmaceutical Industry
High Shear Granulators are used in the pharmaceutical industry for the production of fine granules, granules for tablets, and granules for capsules. They are also used in the manufacturing of pesticides.
- Granules for oral tablets
- Granules for capsules
- Other medical applications include ceramic dental mixtures.
- Cosmetics Industry
- Eye shadows and eye colors
- Face powders
Principle of High Shear Granulations
1. Wet Granulation Process
Wet granulation performed by a High Shear Granulator utilizes the adhesive force of water or a binder solution to form granules. The process involves dripping or spraying a solution of water or binder onto powder, wetting it, and then drying the material to form granules. The spray method provides more uniform granules and is particularly suitable for granulating materials rich in additives like alginates, sugars, or oils.
2. Mechanism of High Shear Granulator
The High Shear Granulator consists of a mixer with impeller blades and a vertical chopper. The mixer blades lift the raw materials from the bottom of the container, creating a vortex, and causing the materials to flow and tumble, resulting in thorough mixing. During this process, particles are formed into granules through compression and collision. The high-speed rotation of the vertical chopper, attached to the side of the container, shears and breaks down the particles, enabling further granulation with uniform particle size distribution. Wet granules between 1.5 and 5 mm in size can be produced through this process. The wet granules can also be sent directly to a dryer to produce dried granules.
3. Materials Used for Equipment Construction
Materials such as SS304, SS316L, titanium, and duplex stainless steel are commonly used for the construction of High Shear Granulators, ensuring durability and cleanliness.
Types of High Shear Granulators
Various models of High Shear Granulators are available, with operation capacities ranging from 30L to 360L, and mixer speeds from around 105 rpm to 400 rpm.
Depending on the application, factors such as mixer speed, chopper speed, solution feeding rate, granulation time, and discharge control can be adjusted. Proper product selection based on functional requirements is essential for optimizing performance in different use cases.