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            [post_title] => Micron Xerbis Agitated Media Flash Dryer
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Mikro ACM® Air Classifying Mills were invented by HMPS in the late 1960’s and are one of the most versatile types of size reduction equipment available in the market. These units while being capable of producing fine, medium and coarse grinds for a wide variety of materials for Food, Pharmaceutical, Chemical and Mineral industries, require very little maintenance over their life span. The basic design of these mills is the impact size reduction that is coupled with an internal dynamic classifier which controls the outlet (product) particle size via recirculating the coarse particles back into the grinding zone.

There are seven main factors which determine particle size distribution for the Mikro ACM® Air Classifying Mill. When varied, the rotor type and speed combined with the liner and hammer count affects the production of fines. The separator type and speed affects the top size of the product. And lastly, the airflow governs the throughput as well as top size and fines generation. With the endless available options a machine can be configured to process just about any material that is below MOH’s hardness of 5.

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The Alpine UPZ Ultraplex Fine Impact Mill are truly flexible. Designed with ultimate versatility in mind, this one unit can accomplish a multitude of size reduction tasks. A wide variety of grinding inserts are available through the entire line of mills. The mill is also offered with a counter-rotating (Contraplex) set of pins for added shear for difficult to mill products. The pharmaceutical version of this work horse has been designed specifically for cGMP compliance from the ground up. Size reduction of soft to medium soft material can be accomplished at rates from 3 to 700 Kg/hr depending on feed material and final size requirements.

Alpine UPZ Ultraplex Fine Impact Mill can also be integrated into Stott Isolators. This arrangement provides a completely integrated system capable of containment levels as low as 1 micro-gram/cubic meter.

Operation of the mill is simple. Material is introduced to the mill via feed device such as a rotary air lock or volumetric/gravimetric feeder through the mill's inlet. The inlet directs the material to the grinding chambers center. The grinding toll rotates at high speed, creating centrifugal force that will accelerate the pharma-powder outwards. The particles outward flow hurls them at high speed against the pins or other grinding media where the impact will cause the particles to fracture.

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In an Active Freeze Dryer, the product is first frozen dynamically by moving it in a specially designed chamber. Whether the material to be dried starts off as a liquid, granular solid or paste, the forced motion inside the drying chamber ensures that it freezes in the form of free-flowing solid granules.

Once the product is fully frozen, a deep vacuum is applied and the sublimation starts. Heat applied to the vessel jacket is effectively distributed throughout the product due to the dynamic environment. The initially coarse, frozen granules gradually shrink as the ice structure connecting the frozen material sublimes, yielding a loose powder consisting of fine, dry particles.

As the solvent disappears, the product temperature starts to rise until it equals the jacket temperature. This marks the end of the drying process. Once the vacuum has been released, the chamber is opened and the powdered product can be discharged.

Typical applications include pharmaceuticals like antibiotics, proteins, collagens, APIs and electrolytes. This new technology has also proven its suitability to the freeze drying of special materials like nano-materials, polymers, ceramics, pigments, fillers, lime stone, catalysts, glass powder and salts.

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Protected by additional patents, the TTSP tandem toner classifier is a refinement of the TSP toner classifier, primarily with the aim of improving the precision of cut even further by means of two consecutive classifying stages. At the same product loading of the classifying air, the tandem toner classifier achieves a much higher precision of cut than the TSP, or at a constant coarse product quality, achieves a higher loading factor. This makes it possible to almost treble the throughput in comparison with the TSP.

Because of the dust explosion hazard associated with processing toner, the classifiers are designed to be explosion-pressure-shock-proof to 10 bar over-pressure.

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Shurfeed™ cutting chamber design allows material to fall directly in front of the rotating knives and to be pulled quickly through the cutting action for fast, complete granulation without piece bounce and flyback. Three steep angle rotor knives and two bed knives mounted in Double Angle Cut™ configurations reduce energy consumption, noise, heat and fines, while increasing throughput.

Shurfeed® cutting chamber design allows material to fall directly in front of rotating knives to be pulled quickly through the cutting action for fast, complete granulation without piece bounce and flyback. Only Polymer Systems gives a clear, unobstructed feed opening equal to rotor diameter for maximum performance through every inch of the cutting circle. This unique design maximizes granulator capacity, eliminates bottlenecks at the entrance to the cutting chamber and dramatically increases effective screen area for fast throughput. Ask for a comparison!

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Target

  • Applications:  While most customers use the air jet sieve to determine the particle size of dry powder ranging from as fine as 20 µm / #635 (mesh) up to 4,750 µm / #4 (mesh), some utilize the particle size analyzer to determine the average particle size below a specified cut point; such as D90 < 50 µm.  Others use the air jet sieve to confirm that a powder top size does not exceed product specifications. The Mikro Air Jet Sieve® MAJSx can even be used as a small lab-scale classifier to remove the fine particles out of a sample or as a dedusting system to remove undesirable dust from small batches.

    How it Works: The Mikro Air Jet Sieve® MAJSx utilizes test sieve screens and the pneumatic sieving principle to enhance the accuracy and reproducibility of particle size analysis. This method has become the preferred standard for such tasks as quality assurance of incoming raw materials, process control, and verification of final product specifications. While under negative pressure, a positive upward air flow is emitted from the rotating slit wand which continuously disperses particles across the surface of a test sieve screen. Those particles that are smaller then the opening of the test sieve screen pass through and are carried away from the sample, leaving the particles larger than the sieve opening on top of the test sieve screen. Particle size within the range of 20 to 4,750 µm can quickly be determined. The unique rotating slit wand feature also reduces, and in many cases, eliminates the need for tapping or brushing, thus enhancing the analysis reproducibility. The overall system is designed for cleaner operation and requires less counter space than other types of analytical equipment.

    Key Operating Parameters Enhance Repeatability & Reliability: The sieving time plays a major role in determining particle size with an air jet sieve. Excessive sieving time can lead to particle degradation due to attrition. In most dry powder applications, Hosokawa recommends a two-minute sieving time cycle which provides ample time for the particles of the entire sample to pass through the sieve screen or be retained.

    Sieving vacuum pressure between 8-16 inches of water column is recommended during a sieve analysis. If the pressure is too low, the air velocity passing through the rotating wand may not be sufficient to evenly disperse the entire sample. If the pressure is too high, the air velocity could generate enough force to further grind material as the sample repeatedly impacts the sieve screen and sieve cover.

    A sample volume between 10 and 100 grams is recommended in most air jet sieve particle analyzers, depending on the density of the material being tested. Samples larger than 100 grams have the potential to blind the test sieve screen and affect the analysis results.

    Test sieve screen quality and integrity is critical in any particle size analysis process. Hosokawa provides test sieve screens that are 99% accurate. Test sieve screens with damage such as holes, tears, scratches, waves, or other imperfections are not recommended. Sieve screens should be routinely re-certified to insure accurate analysis results.

    Performance at an Economical Cost: Certified pre-owned Hosokawa Air Jet Sieves analyzers start at $4,400. Prices can vary dependent on the number of sieve screens required, vacuum selection, balance type, optional components, taxes, and shipping.

    • Pre-Owned Air Jet Sieve Particle Size Analyzers – from $4,400

    Price Disclaimer: Prices listed are subject to change without warning and do not include taxes, shipping, or import fees or the cost of any accessories or ancillary equipment not included in the quotation.

    American Made: A long-time industry leader, Hosokawa developed air jet sieving technology in the early 1960's and has refined and elevated its technology to meet the latest market needs. The Mikro Air Jet Sieve® MAJSx is manufactured in the U.S. and comes with our pledge for performance and dependability. These innovative products have earned a reputation for accuracy and reliability as evidenced by the thousands of installations worldwide. 

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For example, a rotary drum dryer was used to dry materials that had been wet milled. A separate grinding/de-agglomeration process followed the drying operation. The Mikro LGM® Long Gap Mill is Hosokawa's solution for streamlining these two operations into one continuous process. This type of dryer is commonly referred to as a "gap" type mill. It is called a "long" gap mill because of the long annular gap path the process material takes from the inlet to the discharge. By combining several operations such as flash drying, de-agglomeration and surface coating into one operation, a Mikro LGM® Long Gap Mill eliminates the need for multiple material handling systems which subsequently increases process efficiencies. The dried powders often do not require any further size reduction. Both slurries and wet cake can be handled. The Mikro LGM® Long Gap Mill modular design expands its range of applications beyond drying and deagglomeration. For dry grinding, modular options include: direct and independent drive classifiers; pre-grind rotor stage; an integrated jet mill and variable stage rotor design. The smaller size Mikro LGM® Long Gap Mills are engineered with a split body housing for easy maintenance and cleaning. The LGM processes high moisture materials in wet cake form as well as dry solid feed stocks up to one inch. Finished product particle sizes of D97 < 10 microns can be achieved. The Mikro LGM® Long Gap Mill has demonstrated superior performance over all other mechanical mills in reducing grit from pre-sized and agglomerated powders. Typical results are less than 1 part per million (ppm) residue on a 44 micron sieve starting from a feed stock with a residue of 120 ppm. This performance is achieved with a powerful grinding mechanism coupled with a precision internal air classifier. The air classifier is designed for a theoretical cut point of 2-5 microns, depending on the particle density. Rejected particles are forced away from the classifier wheel and redirected outside of the mill back to the material inlet using a patented re-circulation system. [post_title] => Mikro LGM ® Long Gap Mill [post_excerpt] => [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => mikro-lgm-long-gap-mill [to_ping] => [pinged] => [post_modified] => 2021-05-03 11:55:51 [post_modified_gmt] => 2021-05-03 15:55:51 [post_content_filtered] => [post_parent] => 0 [guid] => [menu_order] => 7 [post_type] => hm-products [post_mime_type] => [comment_count] => 0 [filter] => raw ) [19] => WP_Post Object ( [ID] => 1076 [post_author] => 2 [post_date] => 2015-01-06 10:52:36 [post_date_gmt] => 2015-01-06 10:52:36 [post_content] => The Mikro® Classifier is characterized by its optimized cyclone-classifier principle. Because of the optimized flow pattern and the use of a high-efficiency classifying wheel, the Mikro® Classifier is especially suitable for ultrafine classifying operations in in-line mode.


    The feed product is fed tangentially to the top of the classifier. The classifying wheel separates the feed product into a coarse fraction and a fines fraction. The classifying air and the fines pass through the classifier wheel, whereas the coarse material settles on the housing wall. A flow of secondary air introduced tangentially above the product discharge recirculates any unclassified material to the classifying wheel for renewed classification, whereby agglomerates are dispersed and the material is then distributed uniformly in the classifying zone. The optimized classifying wheel geometry results in a high product yield at an extremely high precision of cut. In addition, the low pressure drops result in low energy consumption and correspondingly lower operating costs.

    The Mikro® Classifier was designed for all types of fine to medium-fine products. It is especially suitable for powder coating classification aimed at reducing the ultrafine portion under 5 – 10 µm.

    [post_title] => Mikro® CC Air Classifier [post_excerpt] => [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => mikro-classifier [to_ping] => [pinged] => [post_modified] => 2021-05-22 02:46:44 [post_modified_gmt] => 2021-05-22 06:46:44 [post_content_filtered] => [post_parent] => 0 [guid] => [menu_order] => 0 [post_type] => hm-products [post_mime_type] => [comment_count] => 0 [filter] => raw ) [20] => WP_Post Object ( [ID] => 1074 [post_author] => 2 [post_date] => 2015-01-06 10:52:36 [post_date_gmt] => 2015-01-06 10:52:36 [post_content] =>

    As requirements in the pharmaceutical industry continue to ask for tighter particle distributions, additional steps such as on-line classification may be required. The Mikro® Acucut Air Classifier utilizes dual stage operating controls to ensure sharp cuts and narrow band particle size distributions typically below the 10 micron range. This permits control of maximum and minimum particle size diameters with unparalleled accuracy. With precise control of the air flow and rotor speeds this unit will produce the same sharp cuts each time, every time. The high energy dispersion also ensures that the maximum percentage of fines is reclaimed. Easily operated, cleaned and maintained, the Mikro® Acucut Air Classifierr keeps downtime to a minimum.

    Options are available for effective control of product contamination, protection against corrosion, handling abrasive materials and classifying adhesive powders. The Mikro® Acucut Air Classifier is ideal for chromatography materials, alumina, silica, toner and metal powders. Extremely high dispersive energy applied to the process material ensures unparalleled yields even with sticky and difficult to disperse products.

    The Mikro® Acucut Air Classifier is a forced vortex unit designed to disperse, then classify fine particles into coarse and fine fractions. High energy dispersing air enters the rotor radially around the entire outer edge. Feed material enters this dispersion air zone through an inlet in the rotor ring. Particles are acted upon by centrifugal and drag forces. Air carries the dispersed fines inward to the central fractions outlet, coarse move outward to the rotor periphery. Cut points are adjusted by airflow, rotor speed or both.

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    The wet material is fed through customized feeding systems into the grinding and drying section of the dryer's main body. The grinding rotor disperses the wet material into very fine particles and the fine particles are fluidized in the grinding chamber by temperature-controlled, hot gas coming in from the air heater.

    The hot air (or inert gas) can be heated up to 650 °C and as the wet product is dispersed, it is reduced in size in the bottom section of the dryer. The system is kept under a negative pressure by the exhaust fan and the surface area of the product is increased enormously so that water (or other solvents) is evaporated instantaneously.

    The dry and fine particles are conveyed with the gas stream to the top section of the dryer where a separator classifies the particles by size. Then the particles pass the classifier at the set cut point and are conveyed with the exhaust air to a powder air separating system like the cyclone, cyclone filter or cyclone scrubbers.

    The Micron Dryer flash dryer retains a fluidized bed of product in the drying chamber to ensure a low level of adhesion of wet material on the inside wall of the drying chamber. Moreover, process parameters like classifier speed and outlet temperature can be adapted to control moisture content and particle size of the end product.

    • Ultra fine regular end product - Due to its specially designed dispersion rotor, our flash dryers are able to produce ultra-fine powders in one step from suspensions, slurries, pastes and dough, filter cakes or wet powders.
    • High evaporation capacity - Due to the combination of high ?T with a good dispersion of the wet product in the air, our flash dryers can evaporate large quantities of liquids.
    • Compact design - Compared to other direct drying technologies, the flash dryer requires up to 50% less space.
    • Multi-purpose - Filter cake or slurry, in the same machine. Therefore with the Drymeister-H unlimited mechanical dewatering is possible previous to the final drying stage.
    • Easy access  - Either for cleaning, inspection or maintenance inside the dryer, our flash dryers offers the best accessibility from the market, regardless which size.
    • Various systems available - Open, closed- and recycle system concepts.
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  • Active Pharmaceutical Ingredients

    Pharmaceutical drugs are made up of two main ingredients: APIs and excipients. An Active Pharmaceutical Ingredient (API) is the primary, active components of a tablet or capsule that produces the effects of the drug. Excipients are the inactive components of the drug. 

    Particle size and the particle size distribution are crucial characteristics of APIs. The particle size of an API is usually less than 10 microns.  Most APIs are very cohesive and have bad flowing properties, which have an impact on the manufacturing process.

    When processing APIs, Hosokawa offers several types of size reduction mills to choose from. For finer products, the Alpine AFG Fluidized Bed Jet Mill and the Alpine AS Spiral Jet Mill have the ability to grind particles down to a particle top size of less than 5 microns.  

    The Alpine AFG Fluidized Bed Jet Mill  uses compressed gas that travels through a set of nozzles at extremely high velocities. Particles are drawn into the gas streams and are ground via inter-particle collisions in the jet stream.

    The Alpine AS Spiral Jet Mill  is designed for the micronization of pharmaceuticals and certain chemical powders. Material is injected into the grinding zone by gas nozzles. Material flows around the perimeter of the mill wall in a spiral manner resulting in particle-to particle attrition and impact against the mill walls. As the material gets finer and lighter the ground particles are drawn towards the outlet at the center of the milling chamber.

    For coarser products, Hosokawa produces the Mikro® UMP Pin Mill or the Mikro ACM® Air Classifying Mill.  The Mikro® UMP Pin Mill  was designed to meet the requirements of the Pharmaceutical Industry for both product performance and cleanability.

    The Mikro ACM® Air Classifying Mill  is significant in that it was the first milling system to incorporate an internal classifier, which is what allows it to have a particle size distribution of D98 < 20 microns.

    When it comes to mixing APIs, both low-shear and high-shear mixers can be used. For high-shear mixing, the Cyclomix  is recommended for its high speed, intensive paddle mixer, specially designed for cohesive powders with a high level of homogeneity in the end product.

    For low-shear mixing, the Nauta® Conical Screw Mixer  is recommended for its low-intensity mixing suited to delicate products and processes where very gentle mixing of large volumes of up to 100,000 liters.

    Hosokawa Micron Powder systems prides itself in understanding and meeting the needs and requirements of the pharmaceutical industry. Should you have any questions or would like to speak with a sales engineer, please do not hesitate to contact us.