What are the different types of granulation?

When customer choose the right model of granulator, they always wondering which machine need to choose. Before we choose the right model of machine, we need to understand What are the different types of granulation?

What is granulation and purpose?

Granulation is the process of transforming a powder or granular material into a granulated or block-like form through mechanical action by adding adhesives and/or solvents. The volume of the particles after granulation is larger than that of the raw material, and the surface area of the particles is smaller. This process imparts better fluidity, coating properties, and storage stability to the material. The purpose of granulation is to improve the fluidity of the material, enhance storage performance, improve the stability and solubility of the product, and facilitate transportation, processing, and usage.

Classification of granulation methods:

The classification of granulation methods is mainly based on the following factors:

1. If classify according to the Particle morphology:

Particles can be spherical, cubic, prismatic, flat, conical, bar-shaped, and so on. Different particle morphologies require different granulation methods.

2. If classify according to the Powder properties:

Powder properties, including particle size, particle size distribution, specific surface area, free flow, and other factors, influence the choice of granulation method.

3. If classify according to the Granulation principle:

The granulation principle includes physical and chemical principles. Different granulation principles have different characteristics and application ranges.

1). Droplet granulation: Droplet granulation involves spraying a solution or suspension uniformly onto a flowing bed of particles, and then granulating it by drying. This technology is widely used in pharmaceuticals, cosmetics, food, chemicals, and other industries. Droplet granulation produces particles with high uniformity and large specific surface area, but requires drying afterward and consumes a lot of energy.

2). Wet granulation: Wet granulation involves mixing powder and an adhesive with a small amount of water and/or organic solvent to form granules, followed by drying. This technology is commonly used in pharmaceuticals. Wet granulation is suitable for producing large particles, but requires a lengthy drying process with high energy consumption.

3). Dry granulation: Dry granulation involves solid dispersion and pulverization of powder without water or solvent, using mechanical methods such as cold pressing or dry pressing. This technique saves time, energy, and reduces dust production. However, dry granulation is better suited for high-content particles, though the particle quality may be relatively poor and the discharge rate low.

4. If classify according to the Method of manufacturing:

Several common granulation methods and their characteristics include:

1). Physical method:
a. Rolling method: This basic mechanical granulation method uses rotating rollers to press powder into particles of a specified shape. It’s suitable for materials with large particles, high strength, and high wear resistance.
b. Spray drying method: This method involves atomizing a solution or suspended material into small particles in a sprayer, then drying them to form particles of a specified size. It suits materials with poor dispersion and thermal stability.


2). Chemical method:
a. Impregnation-drying method: This method involves impregnating the material in a solution containing talc powder, clay, and other solid substrates, then forming particles through drying and screening. It’s suitable for high-density particles.
b. Precipitation method: This method uses chemical reactions to precipitate two or more substances, then forms particles after washing and drying. It suits unstable and easily decomposed materials.

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5. If classify according to the Granulation processes:

These include cold cutting and hot methods:

1). Cold cutting method: This is the most common granulation method for thermoplastics due to its relatively simple equipment and process. It involves grinding fine powder, drying it, adding an adhesive, and creating a good flow of particles with a size of approximately 0.1 mm.
a. Drawing sheet cold cutting: Material is refined into sheets by kneading, then cooled and cut into grains.
b. Extruded sheet cold cutting: Kneaded material is plasticized by an extruder, extruded into sheets, and then air-cooled or naturally cooled to be pelletized.
c. Extruded cold cutting: Material is formed into a round strip by an extruder, cooled by air or water, and cut into cylindrical particles by a granulator.
2). Heat method:
a. Dry heat: The cutter rotates close to the machine head template to directly cut the extruded hot round strip material into pellets.
b. Underwater heat: A new polyolefin plastic granulation technology where the head and cutter work in circulating warm water.
c. Air heat: Similar to dry heat, this method prevents particle sticking by cooling the grain through blast air or spray warm water

References:

  1. A critical review on granulation of pharmaceuticals and excipients: Principle, analysis and typical applications;
  2. GRANULATION TECHNIQUES: AN OVERVIEW;
  3. Granulation techniques and technologies: Recent progresses;
  4. An Overview of the Dry Granulation Process;
  5. Granulation process analysis technologies and potential applications in traditional Chinese medicine.

Granulator for Sale:

Additionally, Chinese medicine formula particles have the following disadvantages:

  • High preservation requirements: Granules have high packaging requirements; if the granules are unsealed, they are more susceptible to moisture, shortening their shelf life.
  • Granules are generally taken in water: Improper brewing methods can make some granules difficult to dissolve, potentially making the drug hard to swallow. Soak granules in warm water for better dissolution. If a small amount of sediment appears, boiling water can be used again. Avoid taking granules that have an odor, caking, or mold.
  • Patent system barriers: Single TCM formula particles are protected by patents, making it difficult to overcome these barriers in the short term.
  • Hygroscopicity: Some varieties are hygroscopic, which can cause caking; others may have loose particles and more fine powder.
  • Introduction of TCM Compound Granules: TCM compound granules combine the advantages of TCM formula granules and better align with the pharmacology theory of TCM compounds. By combining traditional Chinese medicine with modern pharmaceutical technology, they are more suitable for the contemporary pharmaceutical market. Chen Kaixian, a member of the National Committee of the Chinese People’s Political Consultative Conference (CPPCC), suggested that the state should allow for the production, filing, supervision, and use of traditional Chinese medicine or classic prescription co-decoction granules under drug management regulations. This would promote the clinical application of traditional Chinese medicine compounds made of granules and encourage the development of the traditional Chinese medicine industry.

The advantages of Feed Pellet:

Pellet feed has the following advantages:

  • Comprehensive nutrition and digestion absorption: Pellet feed contains a variety of nutrients required by animals, and these nutrients are evenly distributed in the pellets, helping to improve digestibility and utilization of the feed.
  • Reduced waste: Pellet feed is less likely to scatter during feeding, which helps to minimize feed waste.
  • Cleanliness: The surface of pellet feed is smoother than that of powder feed, which reduces the risk of bacteria and eggs breeding and helps maintain a clean feeding environment.
  • Ease of transport and storage: Pellet feed has a high density and small size, making it easy to store and transport. It is also less prone to classification.
  • Prevention of picky eating: Pellet feed can prevent animals from being picky eaters, ensuring a balanced intake of nutrients.
  • Improved returns: The pelleting process involves moisture, temperature, and pressure, which cause physicochemical reactions such as starch gelatinization and increased enzyme activity, leading to improved feed conversion.
  • Nutritional level control: Feed formulations and particle sizes can be adjusted as needed to meet the nutritional needs of different animals.
  • Reduction of automatic grading of feed ingredients: In the process of storing and transporting powdered feed, different particle sizes and weights can cause separation. This issue is eliminated when using pellets.
  • Reduced risk of salmonella: The high-temperature steam conditioning and granulation process can kill salmonella in animal feed.

Despite these advantages, pellet feed can be relatively expensive to produce. Therefore, when choosing pellet feed, it is important to consider its benefits and costs comprehensively.

  • Avoids Picky Eating in Animals: The compound feed formula contains a variety of raw materials and comprehensive nutrition, which prevents animals from selecting their preferred food from the powder and rejecting other ingredients. Pellet feed maintains uniformity during storage, transportation, and feeding, reducing feeding loss by 8-10%.
  • Increases Feed Yield: During the granulation process, the combination of water, temperature, and pressure induces some physical and chemical reactions in the feed, such as starch gelatinization and enhanced enzyme activity. This allows animals to digest the feed more effectively, leading to weight gain. Feeding birds and pigs with pellets can increase feed conversion (i.e., efficiency) by 10-12% compared to meal feed. The average daily weight gain is 4%, and the feed-to-meat ratio is 6%. Feeding chickens can reduce the feed-to-meat ratio by 3-10%.
  • More Economical Storage and Transportation: Granulation increases the bulk density of feed by 40-100%, reducing storage capacity and transportation costs.
  • Good Flowability and Easy Management: Many powders, especially those with low specific gravity and fluffy feeds, as well as those with molasses, high fat, or urea content, often stick to the sides of feed banks. However, pellet feed has good flowability and rarely causes adhesion. As a result, pellet feed is preferred on large-scale dairy or poultry farms that use automatic feeders.
  • Reduces Automatic Classification of Feed Ingredients and Environmental Pollution: During powder storage and transportation, classification can occur due to differences in the volume and quality of various powders. After granulation, feed components do not segregate, and the particles produce much less dust and pollution to air and water compared to powder during the feeding process.
  • Eliminates Salmonella in Animal Feed: Salmonella can remain in the tissues of animals after ingestion, and people who consume infected animals may contract Salmonella enteropathy. The use of steam high-temperature conditioning and granulation can eliminate Salmonella in animal feed.

Advantages and Disadvantages of Plastic Particles

Advantages of Plastic Particles

Lightweight: Plastic particles are much lighter in weight compared to metal, wood, and other raw materials. This significantly reduces the weight of the product, making handling and use easier.

Low Cost: Plastic particles are generally more affordable compared to other raw materials, making them cost-effective and widely used in various industries.

Stable Performance: Plastic particles exhibit stable performance, are easy to control, and can be customized to meet different usage needs.

Good Processing Performance: Plastic particles offer excellent processing performance and can be molded through various methods such as injection molding, extrusion molding, and pressing molding to suit different industry requirements.

Disadvantages of Plastic Particles

Difficult to Dispose of: Disposing of used plastic products can be challenging. While recycling is an option, it requires special treatment for effective recovery, and recycling rates may be relatively low.

Environmental Pollution: Plastic processing can generate harmful gases and waste. Improper handling of these byproducts can lead to environmental pollution.

Susceptibility to Aging: Plastic particles can undergo chemical reactions with oxygen, ultraviolet light, and humidity, leading to aging, deformation, and a shorter lifespan.

Low Durability: Plastic products generally lack the high strength of metal materials, making them prone to mechanical damage and deformation.

Conclusion

In conclusion, particles are widely used in industrial production due to their many advantages. However, their disadvantages and limitations should be carefully considered. It’s essential to balance product quality with environmental protection and efficient resource use to ensure the sustainable production and use of products. LKMixer are manufacturer for granulator, please contact us for more information.

About LKMixer

LKMixer is a professional manufacturer for fertilizer production line, grinder, mixer and granulator, shredder. These machines are widely used in food, pharmaceutical, cosmetic, health care products and chemical industries. The Food materials like Peanut, mushroom, seeds, potato, bean, tobacco, salt, cannabis, tea, Sugar, corn, Coffee, rice, pepper, grain as so on. Grinders have many types such as Pulse Dust Grinder which suitable for zero pollution environment, Turbine Mill  which is suitable for coffee bean, 12-120mesh all can meet, Ultrafine Grinding Mill covers 80-200mesh, and also Winnowing Dust Grinder or other grinding machines like SF Hammer. Welcome to contact us for details. Contact us for more information. Proposal, catalog, quotation. Mobile/WhatsApp: +86 18019763531 Tel: +86 21 66037855 Email: sales@lkmixer.com

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FAQ(Click and See More)

Why Choose Us?

We have 20 years manufacturing experiences; 15600 cubic meters factory area; 5000sets annual capacity; 55 professional engineers;

What’s your main maket?

South America: Brazil, Colombia, Peru, Bolivia, Uruguay, Paraguay ;Romania;
USA with UL Certification
Middle East: Saudi, Arabia, Oman, Turkey
Europe: Russia, Australia, Belarus, Ukraine, Poland

Can you support OEM?

– Yes, OEM or ODM. Machine can be customized according to customer detail requirement, including capacity and voltages, motor certifications.
– Drawing and raw materials also can be customized.

 What after-sale services?

– 7*24 customer service online;
– 7*24 engineers online services;
– 12 months warranty services.

WHAT kind of MACHINE YOUR COMPANY HAVE?

We majorly produce CRUSHER, GRINDER, MIXER, and also have auxiliary machines like DRYER, GRANULATOR, VIBRATING SIFTER, CONVEYOR, etc. 
We can customize whole production line according to your capacity, material, output sizes of mesh and mm of granule and powder.
 

CAN YOU GIVE ME GUIDE ON OTHER MACHINE ? TO FULL MY PRODUCTION LINE

YES ! Our f have factory build more than 20 years now, we can design and customize whole line, besides of the grinding machine, mixing machine, we can also fully support to provide the washing machine, cutting machine, drying machine, packing machine, filling machine. Though we are not producing these machine, but our brother companies co-work together for over 20 years, we have rich experience in providing you a full effective production line, fully automatically or semi-automatically.

HOW TO VISIT YOUR COMPANY? 

Our Factory located in Jiangsu Province, very near to Shanghai, you can fly to Shanghai Pudong Airport, we pick you up and take you by car 2 hours ride, can reach our factory, welcome your visit.

WHAT’S YOUR BEFORE & AFTER SERVICE ?

1) Before your purchasing, we need to know your detail request, such as what kind of material you want to grind and mixing, what final product powder or granule you want to reach. Because different material and powder sizes request of different machine to do. We can provide professional advice and rich experience help to choose machine. Most of the products we have already did before for other customer, trail test or run mass production, so we knows which machine is best in performance of grinding and mixing. This is of very importance in helping you choose the right model. We also wish this can help our customer a lot. Even the material we didn’t do before, we will prepare the same material and to do the trail test and send video to you for your reference.
2) One Year guarantee of machine quality. If the machine have problem within one year, we will send you the spare parts to you for replacement, but this not including the damage caused by human causes. We also have 24 hours on line guide for customer, if you have operation difficulty, we will guide by video and on line communication with our engineer for your emergency debug.
3) For small machine, we sell with whole machine, it’s no need to install, and easy to operation, no problems for operation. While for large machine, its’s also not difficult to install with video guideline, but if you need, we can assign our technicians to go abroad, the round ticket, food and residents will be paid by customer.

HOW ABOUT YOUR PAYMENT TERM? 

Our payment term is T/T. 50% payment in advance, rest of 50% payment finish before the goods shipped. When we finish the machine production we will do trail test and run the machine take videos for your green light. You pay the rest of 50% payment then.

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