Definition: Granulation is the process of collecting particles together by creating bonds between them.

Bonds are formed by compression or by using a binding agent

Dry Granulation without using a liquid solution
Wet Granulation addition of a liquid solution (with or without binder)
Primary powder particles are aggregated under high pressure

Roller
Compacti
on

Powder is
squeezed
between two
rollers to
produce sheet
of material

Slugging

Large tablets
produce in
heavy duty
tablet press

Dry granulation

Wet Granulation

This class of process includes Fluid beds, tumbling

drums & pans, and mixer-granulators

Mechanism

Wetting, nucleation and binder distribution

Consolidation and growth

Attrition and breakage

Granulation and drying in the same equipment

Granulation is controlled by moisture content of

the bed

Too high moisture content will de-fluidize the bed

and in too low moisture, no agglomeration will
occur

Granules obtained are more porous than those

obtained from shear mixers

Fluidized bed Granulator

Spray Arrangements

Tumbling Granulation

Particles are set in motion by the tumbling action caused by the balance between gravity and
centrifugal forces

Includes discs, drums, pans and a range of similar equipment

Characteristics of tumbling granulators

Product granule size in the range of 2 to

20mm

Not suitable for producing very small

granules

Good for producing high density balls or

pallets

Capable of handling very large

throughputs

Extensively used in mineral processing

and fertilizer granulation

Disc Granulator

Rotating disc with a rim to hold the

tumbling granules

Powder feed continuously fed to the

disc, typically at the edge of the rotating
granulator bed

Liquid binder is added through a series

of single fluid nozzles distributed across
the face of the bed

Drum granulator

Typically used for high capacity applications and usually requires some type of recycle
depending on the product specification

Granulation where the only feed or the majority of the feed is a liquid or melt such as urea
granulation

Feeds may be either pre-moistened by mixers to form granule nuclei or liquid may be sprayed
onto the tumbling bed via nozzles or distributor pipe system

Scrapers are often but not always used to limit build up on the drum wall

Drum Granulator

Mixer-Granulator

The High Shear Mixer-Granulator is a multi-purpose processor equally suitable for high speed
dispersion of dry powders, and aqueous or solvent granulations

Melt Granulation: Melt agglomeration is a process by which agglomeration is obtained through

the addition of either a molten binder liquid or a solid binder which melts during the process

Agglomerates are formed by agitation of the mixture

The mechanism of melt granulation is similar to that of wet granulation

Mixer-Granulator

Double shaft paddle Mixer-Granulator

Dual counter-rotating shafts run the length of the device

The paddles move material from the bottom of the trough, up the middle, and back down the
sides creating a kneading and folding effect that intimately mixes the material

Typical Use: Mixing, conditioning, or agglomerating

Granulators in different Industries