gf 5-insert for procell labsystem plug flow in the ... · wet raw material dries while moving ......
TRANSCRIPT
GF 5 - inser t for ProCell LabSystem
Plug flow in the laboratory unitWith the GF 5 several process steps are
possible. The solid raw material is con-
tinuously supplied. It moves in a circle
through the processing chamber, which
is divided into four sections. The first
three can be equipped with nozzles for
spray granulation, agglomeration, encap-
sulation and coating. In the final chamber
the product is dried before leaving the unit.
Continuous dryingThe GF 5 can work as a continuous dryer.
Wet raw material dries while moving
through the processing chamber from inlet
to discharge. Therefore the GF 5 is the ideal
equipment downstream of continuous wet
granulators.
Small production equipmentUp to 15 kg/h wet granules can be dried in
the GF 5. Within one day up to 400 kg dry
granules can be produced. Hence the
GF 5 can be used as small production unit.
Flexible ProCell LabSystemThe GF 5 is once more enhancing the
flexibility of the ProCell LabSystem. Batch
sizes between 1.4 and 38 liter, continuous
capacities between 0.2 and 15 kg/h and
multiple process possibilities making it the
most versatile equipment on the market.
Glatt Ingenieurtechnik GmbH • Nordstraße 12 • 99427 Weimar/Germany • Phone: +49 3643 47 0 • eMail: [email protected]
NEW!
ENCAPSULATION
DRYING
SPRAY GRANULATION
COATING
AGGLOMERATION
ProCell
GF
AGT
Rotor
We set the standard
P r o C e l l L a b S y s t e m
SPOUTED BED
continuous
FLUID BED
batch
POWDER LAYERING
SPRAY GRANULATION
AGGLOMERATION
ENCAPSULATION
COATING
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The ProCell LabSystem is designed
for testing of spouted bed and
fluid bed processes in the single
kg-scale:
• spray granulation
granules and pellets from liquids
• agglomeration
granules from powder
• coating
of particles with liquids
• encapsulation
of liquids
• powder layering
coating of particles with powder
Spouted bedUsing the unique and patented spou-
ted bed technology the particles
within the ProCell are fluidized with-
out a bottom screen and directed to
the spraying nozzle. By this means
it is possible to work with very low
product temperatures and short resi-
dence times. As a result temperature
sensitive materials are treated very
gently. Proteins, enzymes and micro-
organisms were dried in the ProCell
with very little loss of activity.
The process air velocity declines
rapidly in the process chamber of the
ProCell and allows the production of
very fine particles. On the other hand
large particles, like catalyst carrier
rings can be fluidized without using
prohibitive quantities of process air.
The high air velocities in the slot en-
sure a very robust process, especially
when processing sticky materials.
Lumps that may have formed are still
moved, break down again and are
carried out of the process chamber.
Fluid bedUsing different process chambers
– AGT and GF – allows the evaluation
of fluid bed processes.
Inlet air chamber and process cham-
ber are separated by a bottom screen
and the product is homogenously
fluidized.
The cylindrical AGT insert allows high
fluidizing velocities.
The conical GF insert is designed for
the production of agglomerates and
for coating processes, also with the
option Wurster-process.
RotorIn this process inlet air chamber and
process chamber are separated by
a moving rotor plate. The particles in
the process are spheronized by the
rotating movement. Simultaneously
liquid and powder can be introduced
by means of a tangential spray nozzle
to coat particles with powder.
FlexibilityBy means of the side discharge and
the zig-zag sifter all processes can
be run continuously. All particles
below the desired particle size are
returned to the process chamber.
Alternatively, the discharge can be
closed and all processes can be run
in batch mode.
In all process chambers, liquid can
be sprayed either from top or from
bottom.
The capacities depend on the size of
the process chambers, the inlet air
volume and inlet air temperature.
P r o c e s s e s
micro-organisms, spray granulation, ProCell
fungicide, spray granulation, AGT
proteine, spray granulation, ProCell
olive, agglomeration, GF
enzyme, coating, GF
vitamin, spray granulation, ProCell
F l e x i b l e U n i t : P r o C e l l – G F – A G T –
ProCell system– for spray granulation, encapsulation,
agglomeration and coating in the
spouted bed
ProCell 5 - insertworking volume 0.4 – 8 l
ProCell 10 - insertworking volume 0.8 – 16 l
AGT system– for spray granulation and
encapsulation in the fluid bed
AGT 150 - insertworking volume 1.4 – 5.8 l
spraying rate
ca. 0.2 –18 l/h (depending on product)
performance
max. 250 m3/h air flow
at max. 200° C inlet air temperature
optional:
- max. 500 m3/h air flow
(external fan)
- max. 300° C inlet air temperature
utility requirements
compressed air 6 bar (g)
power 31 kW
dimensions
weight 1300 kg
main measurements refer to drawing
GF system– for spray granulation, encapsulation,
agglomeration and coating in the
fluid bed as well as Wurster-coating
GF 3 - insertworking volume 2.5 – 10 l
GF 7 - insertworking volume 10 – 38 l
1000
1610
920
2830
2350
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R o t o r
Rotor system– powder layering, pelletizing and
direct pelletization with the rotor
Rotor 300 - insertworking volume 1 – 3 l
fertilizer, coating, ProCell
tomato, agglomeration, GF
ceramic, spray granulation, AGT
lavender oil, encapsulation/spray granulation, ProCell
PUFA, encapsulation/spray granulation, ProCell
sugar and starch, powder layering, Rotor
Closed loop processIn addition to the exhaust gas treat-
ment by internal or external filter or
by cyclone and external filter a full
closed loop is available. The process
gas is dried with a condenser and a
desiccant wheel before returning to
the process. The desiccant wheel
may also be used alone in order to
control the inlet gas moisture.
Internal bag filterIn order to work with smaller product
volumes the ProCell LabSystem is
equipped with a bag filter. The
smaller surface of the filter means
that less product is collected in the
filter. Easy cleanability of the bags in
the laundry machine is an additional
advantage.
WIP-filterFor improved cleaning the ProCell
LabSystem can be equipped with a
WIP-filter. WIP nozzles are integrated
in the filter plate and automatically
clean the filter housing and the filter
cartridges or filter bags.
Threefold nozzleIn some special applications, two
liquids must be sprayed in parallel.
Therefore the ProCell LabSystem can
be equipped with a threefold nozzle.
Two liquids are pumped separately
to the tip of the nozzle and atomized
by compressed air.
P r o d u c t F l o w i n t h e P r o C e l l L a b S y s t e m
Spraying of meltsHeated hoses, atomizing air heater
and insulated nozzles allow for
spraying of melts of products with a
melting point of up to 100°C. This
process is used for example to coat
particles with fat to protect them
against moisture.
bag filter
processingchamber
insulated spray nozzle spray nozzle - two pipe designatomizing air heater
externalfilter(option)
dust
exhaust
supply of liquids
heating(option)
process airfiltrationheating
discharge of solids
zig-zagsifter
product-discharge
internal filter
feed of solids
compressed air
closed loopprocess gas
(option)
dust recycle
cyclone(option)
We set the standard
A d d r e s s e s
Worldwide service to the customer
Glatt GmbH Process TechnologyWerner-Glatt-Straße 179589 Binzen/GermanyPhone: +49 7621 6 64 0Fax: +49 7621 6 47 23eMail: [email protected]
Glatt Maschinen- & Apparatebau AGKraftwerkstrasse 64133 Pratteln 1/SwitzerlandPhone: +41 61 8 26 47 47Fax: +41 61 8 26 48 48eMail: [email protected]
Glatt Systemtechnik GmbHGrunaer Weg 2601277 Dresden/GermanyPhone: +49 351 25 84 0Fax: +49 351 25 84 328eMail: [email protected]
Glatt Air Techniques Inc.20 Spear RoadRamsey, NJ 07446 USAPhone: +1 201 8 25 87 00Fax: +1 201 8 25 03 89eMail: [email protected]
Glatt Pharmatech SASUParc Technologique6, rue Louis Néel21000 Dijon/FrancePhone: +33 3 80 74 32 64Fax: +33 3 80 74 43 95eMail: [email protected]
Glatt Norden ApS.Skøjtevej 27-312770 Kastrup/DenmarkPhone: +45 48 14 22 44Fax: +45 48 14 22 55eMail: [email protected]
Glatt Protech Ltd.Swannington Rd.Cottage Lane Ind. Est.Broughton AstleyLeicester LE9 6TU/Great BritainPhone: +44 1455 28 58 58Fax: +44 1455 28 55 10eMail: [email protected]
Glatt Ingenieurtechnik GmbHMoskau/Russlandул. Обручева, 23 - корп. 3
117630 Москва/Россия
Phone: +7 495 78742-89Fax: +7 495 78742-91eMail:[email protected]
www.glatt.com
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T e c h n o l o g y C e n t r e
Testing – analyzing – scale-upSeveral laboratory units are available for
trials in our technology centre. Therefore
you are flexible to find the ideal process
for your product.
The characteristics of your products e.g.
particle size, particle size distribution, par-
ticle shape, residual moisture, bulk density,
angle of repose, attrition, steam sorption etc.
can be tested and evaluated in detail in our
modern analysis laboratory.
After successful lab trials, pilot scale trials in
our technology center are the next step.
Based on the pilot trials we will design your
production plant.
Rent or buyIt's your choice. Configurate your ProCell
LabSystem according to your product
requirements. We will support you with
installation, commissioning and training
of your personnel.
Glatt Ingenieurtechnik GmbHNordstraße 12
99427 Weimar/Germany
Phone: +49 3643 47 0
Fax: +49 3643 47 12 31
eMail: [email protected]
analytical laboratory
pilot plant ProCell/GF 25
C o n t i n u o u s T e c h n o l o g i e s
W e s e t t h e s t a n d a r d
● S p r a y G r a n u l a t i o n
● A g g l o m e r a t i o n
● C o a t i n g
● I n s t a n t i a t i o n
● P e l l e t i z i n g
● E n c a p s u l a t i o n
● D r y i n g
GF
AGT
ProCel l
G l a t t . D i f f i c u l t p r o c e s s e sm a n a g e d b y e x p e r i e n c e a n dk n o w h o w .
What is now Glatt Ingenieurtechnik
Weimar was founded in 1981 as
innovation group “Continuous Fluid Bed
Technology” within the research
department of a large East German
machine manufacturer. The task of the
group was the introduction of the
newly developed AGT technology in
the industry. Already in 1983, the first
production sized unit, an AGT for the
granulation of potash solution was
commercialized.
When the East German industry
was privatized this group was
taken over by the Glatt company and
founded as Glatt Ingenieurtechnik
in 1991. This was the start of a success
story. The staff quadrupled within
10 years.
In 1996, Glatt developed the Glatt
Fluid Bed (GF) in order to increase
the flexibility of the continuous fluid
bed processes. Originally used for
drying and cooling of solids, today
difficult agglomeration and coating
processes can be accomplished with
the GF technology.
The combination of 50 years
experience with Glatt batch units
in Binzen and 20 years continuous
processing in Weimar results in a
powerful know-how.
Besides equipment for the chemical
industry, Glatt Ingenieurtechnik
Weimar offers high quality equip-
ment for the food industry. Designed
according to GMP rules these units
reach the well known quality of Glatt
equipment and can be cleaned with
WIP/CIP systems.
AGT 400, constructed in 1981
B a c k g r o u n d
C o n t e n t s
Product Advantages 3
Continuous Fluid Bed
– GF 4
Continuous Fluid Bed
– AGT 6
Continuous Spouted Bed
– ProCell 7
Explosion Protection 8
Cleaning Systems 9
Process Development 10
Engineering 11
Technical Data 12
Product References 14
Glatt Service Program 15
Addresses 16
We s e t t h e s t a n d a r d
3
P r o d u c t A d v a n t a g e s
T h e p l u s p o i n t s o f c o n t i n u o u sp r o c e s s e s .
● constant product
quality
● narrow grain size
distribution
● dustfree and compact
granules
● well dispersable
and excellent soluble
agglomerates
● easy to dose and to
transport due to
good free flowing
properties
● constant filling
weight and volume
for packaging and
pressing due to
constant bulk density
● good storage properties
due to a clear reduction
of hygroscopicity
● no segregation of
the components of a
mixture
Granules
Agglomerates
Coated crystals
A g g l o m e r a t i o n .S p r a y g r a n u l a t i o n .C o a t i n g .O n e u n i t f o r a l lp r o c e s s e s .
Afluid bed is formed when an
upward flow of process air lifts
small solid particles. As a result
the small particles move rapidly within
the fluid bed and ensure a very efficient
heat and material exchange between
the bed and the fluidizing air. The
temperature in the fluid bed is constant
across the whole height of the bed.
This ensures a gentle drying
of temperature-sensitive products.
Besides simple drying and cooling
processes fluid bed equipment
is used to build particles from
powder - agglomeration - or from
liquids - granulation - and to coat
particles - coating.
The continuous Glatt fluid bed GF can
accomplish all these processes.
Since the inlet air plenum is divided
into multiple chambers it is possible
to introduce air with different velocities
and different temperatures into the
processing chamber. By this means
and by correct placement of the
nozzles in the fluid bed, it is
possible to set completely different
conditions in different sections
of the processing chamber.
In the process, shown in the principle
picture, agglomerates are formed from
powder above the first two inlet air
chambers. The agglomerates are dried
above the third inlet air chamber and
are cooled above the forth before they
are discharged as finished product.
4
Principle of the continuous Glatt fluid bed process
Glatt fluid bed granulator GFG 1200
C o n t i n u o u s F l u i d B e d – G F
F l e x i b l e p r o c e s s e sa n d f l e x i b l e d e s i g n .
Glatt units offer significant process
and construction flexibility.
The standard unit consists of structural
components – processing chamber,
internal filter, feeding device, discharge
device and spraying system. These
components can be changed indepen-
dently to meet the demands of the
process.
If necessary the internal filter is
replaced by a lid and installed ex-
ternally.
The design of the spraying system
allows a change of the installation of the
nozzles even after the commissioning of
the plant. Hence the unit can be easily
adjusted to new process demands and
product properties.
Depending on the quality require-
ments of the end product Glatt offers
two versions:
● Standard chemical plant design
For plants with only one product or
plants were product change is
possible without special hygienic
requirements.
Simple construction.
For high inlet air temperatures
and large throughputs.
● Standard food plant design
For plants with high requirements
on cleanability, demand for frequent
product changes.
High surface quality of product
wetted parts to meet hygienic
demands.
Low inlet air temperatures for
temperature sensitive products.
5
F l e x i b l e C o n s t r u c t i o n
Glatt fluid bed granulator GFG 500,chemical plant design
Glatt fluid bed coater GFC 750
ProCell 20, food plant design
T h e r i g h t m i x t u r e w i t h i n t h e A G T .
The AGT (unit for continous granu-
lation drying) has a round bottom
screen. The entire fluid bed is always
ideally mixed.
The product is discharged by means
of a centrally arranged discharge pipe.
The grain size of the product is
determined by the velocity of the
discharge air.
In most AGT processes a liquid raw
material is dried while building up
particle size. It is also possible to add
continuously solid raw material. The
fluid bed guarantees that all raw
materials are mixed homogeneously
in the final product.
The exhaust air is cleaned externally.
All dust is recycled into the processing
chamber were it is needed as seed
material for the granulation process.
6
C o n t i n u o u s F l u i d B e d – A G T
Processing chamber, AGT 400
Unit for granulation drying AGT 2700
Principle of theAGT process
E f f i c i e n t p r o c e s -s i n g o f d i f f i c u l tf l u i d i z a b l ep r o d u c t s
Particles in the Glatt Spouted Bed
are fluidized by a flow of upwards
streaming process air.
The process air enters the processing
chamber through slots at the side and
not through a bottom screen, like in fluid
bed processes.
The cross section of the processing
chamber is significantly increasing
towards the top, resulting an a sharp
decrease of the fluidizing velocity of the
process air. This results in a controlled
flow pattern of the particles in the pro-
cessing chamber.
Nozzles in the processing chamber can
be arranged in top spray or bottom
spray position. Since they are arranged
in the middle of the two slots they spray
at the point of the highest energy input.
Features of the ProCell
● no bottom screen
● highest process air velocity in the
center of the spouted bed
● sharp decrease of the fluidizing
velocity along the height of the
processing chamber
Advantages of the ProCell
● fine particles can be fluidized
● large particles and irregularly
formed particles can be fluidized
● gently drying of temperature-
sensitive products
● process air volume can be adjusted
to the energy demand of the process
● high process stability due to resis-
tance against stickiness and lumps
● short processing times at high spray
rates
7
View into the processing chamber
Region of operation for fluidized bed (blue)and extended region of operation forProCell (red)
transportvolume
processair volume
particel size
fluidizingvolume
Principle of ProCell process
Pilot plant ProCell 20
C o n t i n u o u s S p o u t e d B e d – P r o C e l l
8
S e c u r i n g a s a f e s o l u t i o n .
Mixtures of dust and air do
frequently provide an explosion
risk. Glatt equipment can therefore
be equipped with explosion protection
measures.
Continuous units usually offer explosion
suppression systems. The pressure
inside the unit is constantly monitored.
A developing explosion will
cause a very fast pressure
rise inside the processing
chamber. If such a sharp
pressure rise is monitored,
pressurized vessels with
extinguishing powder
are emptied into the
processing chamber.
A developing explosion is by this means
stopped in a matter of milliseconds. The
fluid bed equipment needs to withstand
only a pressure of less than 1 bar.
For equipment in the food industry
the explosion protection system can also
be equipped with hygienic flanges and
food compatible powder.
Alternatively, Glatt equipment can be
equipped with explosion venting
devices.
E x p l o s i o n P r o t e c t i o n
AGT 400 with explosion protection system
1. ignition
time: 0 ms
2. sensors sense the pressure rise
time: 20 ms
3. extinguishing powder is discharged
time: 30 ms
4. the extinguishing powder extinguishes theexplosion flametime: 50 ms
9
A s c l e a n a sy o u l i k e .
Simple cleaning is a cornerstone
in the design of all Glatt equipment.
Easy access to all parts of the machi-
nery, correctly placed revision doors
and cleaning water drains as well as
the installation of cleaning nozzles are
part of this philosophy.
Units for the food industry which have
to be cleaned frequently for hygienic
reasons are offered with comprehensive
wash in place systems. Glatt has many
years of experience with the design of
WIP and CIP systems.
Many design criteria need to be
addressed to ensure an automatic
cleaning e.g.:
● high surface quality of all
product contact parts
● easily detachable spray
nozzles
● special flanges without gaps
● special sensors for process
parameters
● correct arrangement of
cleaning nozzles
● optimal drainage of
cleaning water
In every unit the cleanability of the fil-
ter is decisive for the cleaning system.
Glatt offers three designs to meet diffe-
rent demands:
● two sets of filters which are
exchanged and cleaned outside
● sintered ceramic filters which can
be cleaned in place but need to
be checked afterwards
● Glatt metal cartridge filters
SC SuperClean® which can be
cleaned in place and guarantee
absolute cleanness
C l e a n i n g S y s t e m s
Glatt metal cartridge filter SC SuperClean®
Principle of automatic cleaning
Flush mounted, hydraulically extendingwashing nozzle
WIP skid
L o n g e x p e r i e n c e – S h o r t p r o c e s s .
Process development is per-
formed in Glatt laboratories
where the experience of the customer
with his product is combined with
the process know how of the Glatt
engineers.
First feasibility trials are carried
out in small batch and continuous
units with a throughput of 1-2 kg/h.
Further process development is
done on pilot scale units with up to
50 kg/h throughput. Based on the
determined parameters our engineers
scale up and size the production
equipment for the desired throughput.
Fifty years experience and the
process simulation program
ChemCAD are the powerful tools
used when scaling up.
After a thorough process develop-
ment experience Glatt guarantees
certain product and process
parameters.
The laboratory units are mobile.
Customers can rent the units
for product development in their
own laboratory.
P r o c e s s D e v e l o p m e n t
Laboratory unit ProCell 5 for spouted and fluid bed processes
Pilot plant ProCell 20 Analytical laboratory
10
S e r v i c e a s r e q u e s t e d ,e n g i n e e r e d s u c c e s s p r o v i d e d .
Besides the core unit GF or AGT,
Glatt delivers all peripheral
equipment necessary for the operation
of the process, like fans, pumps and
transport systems.
Further equipment needed for an opti-
mal handling of the raw materials and
the product can also be commissioned,
like mixers, dosing devices and
packaging machines.
Modern software tools, like CAD and
FEM are used to provide an excellent
service to the customer. For simulation
of the process gas flow in our equipment
we are using EFD.lab.
Glatt also works as a prime contractor,
designing and commissioning entire
plants, including the building.
Control system as desired.
Standard Glatt equipment is controlled
with a PLC by SIEMENS (Europe)
or by ALLAN BRADLEY (USA).
On request different control systems
can be used. Several other systems
have successfully been installed,
such as Mitsubishi and Freelance.
The process visualization is generally
done using the desired program.
Installation, start up and training.
Glatt offers expertise in the installation
and commissioning of the plant.
Glatt engineers start the plant up and
train the customer staff.
Good technical support and a prompt
spare part service provide long term
customer satisfaction.
11
E n g i n e e r i n g
Production plant, GFG 850
Simulation of the process gas flow withEFD.Lab
12
T e c h n i c a l D a t a
Continuous Fluid Bed – GF and Continuous Spouted Bed – ProCell
main dimensions
agglomeration processes
spray granulation processes
Continuous Fluid Bed – AGT
main dimensions
spray granulation processes
type 20 50 125 250 350 500
processing chamber m2 0.2 0.5 1.25 2.5 3.5 5.0
processes spray granulation, agglomeration, coating, instantiation, pelletizing, drying,
raw materials liquid solutions, suspensions, melts
solid powder, granules, cristals, extrudates
width B 3) mm 780 910 1200 1400 1600 1800
lenght L mm 1000 1400 2300 3300 3900 5000
height H 3) 4) mm 3300 3500 4800 5000 5200 5300
filter system cartridge filter / bag filter / sinter plate filter
inlet air temperature 1) °C 90
water evaporation 2) kg/h 15 40 100 195 275 385
inlet air temperature1) °C 175
water evaporation 2) kg/h 30 80 200 400 560 800
remarks: 1) value for standard design2) estimated value for common air flow rates3) depending on product and process, normally smaller in case of agglomeration, higher in case of spay granulation4) depending on filter system, normally smaller in case of cartridge filter and sinter plate filter, higher in case of bag filter
type 400 800 1200 1500 2200 2600
bottom screen area m2 0.1 0.5 1.1 1.8 3.8 5.3
processes granulation, agglomeration
raw materials liquid solutions, suspensions, melts
solid powder, granules, crystals
diameter processing chamber D1 mm 400 800 1200 1500 2200 2600
diameter expansion chamber D2 mm 800 1500 2200 2700 3800 4500
height H mm 3600 4300 5000 5500 6800 7800
inlet air temperature 1) °C 250
water evaporation 2) kg/h 60 240 540 840 1800 2500
remarks: 1) value for standard design2) estimated value for common air flow rates
13
750 1000 2000
7.5 10 20
cooling and combinations
2100 2300 2800
6500 7700 12500
5500 5600 6300
580 770 1540
1200 1600 3200
3000
7.1
3000
5200
8500
3400
14
We s e t t h e s t a n d a r d
P r o d u c t R e f e r e n c e s
E x p e r i e n c e w i t h m a n y p r o d u c t s .
C o n t i n u o u s q u a l i t y f o r :
Chemical industry
aluminum oxide
aluminum sulfate
antacid
copper hydroxide
detergent
detergent components
epoxide
hexamine
polymers
potash
potassium acetate
potassium benzoate
potassium formiate
potassium phosphate
potassium sulfate
silica
silica carbide
sodium acetate
sodium phosphate
surfactant
waterglass
xanthane
zeolithe
zirconium oxide
Food industry
baby food
chocolate drink
citric acid
coffee powder
cocoa powder
dextrose
dietary food
flavors
fructose
gelatine
glutamate
gravy
instant tea
lactose
malt extract
milk powder
soups
sweetener
whey powder
yeast
Ceramic industry
electrical ceramics
glaze-pigment
porcelain
special ceramics
catalysts
Agriculture
fertilizer
lysine
pesticides
yeast
Biotechnology
amino acids
antibiotics
choline chloride
enzymes
micro-organisms
proteins
vitamins
15
E q u i p m e n t , e n g i n e e r i n g a n ds e r v i c e s , o u t o fo n e s o u r c e .
G l a t t e q u i p m e n t
Batch fluid bed equipment
as dryer, with spraying system
as granulator, with Wurster
insert for coating, with rotor
insert for powder layering.
Pan coater
for film coating of tablets.
Vertical granulator
for wet granulation of powders.
Pelletizer
for spheronization of extrudates.
Basket extruder
for extrusion of powder mixes.
Sieves
for reducing of oversized granules
to a defined grain size.
Product handling
containers, container blenders,
lifting systems, transport and
pneumatic conveying systems,
filling and discharging systems,
docking systems, isolation flap
systems, component weighing
systems, dosing systems,
washing systems, validation and
documentation.
E n g i n e e r i n g a n d s e r v i c e
Product development
development and optimization
of your products in Glatt
laboratories.
Engineering
Glatt engineers and commissions
production lines up to turn key
plants.
Qualification and validation
Glatt supplies all documents
needed for a comprehensive
qualification and validation of the
equipment.
Toll manufacturing
Glatt also manufactures product
with Glatt equipment. So you
can considerably shorten your
time to market.
Training
Glatt offers courses on specific
subjects or organizes individual
training programs.
G l a t t S e r v i c e P r o g r a m
Technology center, Binzen
Wo r l d w i d e s e r v i c e t o t h e c u s t o m e r .
Glatt Pharmatech SASUParc Technologique6, rue Louis Neel21000 Dijon/FrancePhone: +33 3 80 74 32 64Fax: +33 3 80 74 43 95eMail: [email protected]
Glatt Protech Ltd.Swannington Rd. Cottage Lane Ind. Est.Broughton AstleyLeicester LE9 6TU/Great BritainPhone: +44 1455 28 58 58Fax: +44 1455 28 55 10eMail: [email protected]
Glatt Norden ApS.Skøjtevej 27-312770 Kastrup/DenmarkPhone: +45 48 14 22 44Fax: +45 48 14 22 55eMail: [email protected]
Glatt Ingenieurtechnik GmbHMoscow/Russia119034 г. Москва/РоссияГагаринский пер., 3 – под. 3, 4-ый этажPhone: +7 495 787 2408Fax: +7 495 787 2409eMail: [email protected]
www.glatt.com
Glatt Air Techniques Inc.20 Spear RoadRamsey, NJ 07446 USAPhone: +1 201 8 25 87 00Fax: +1 201 8 25 03 89eMail: [email protected]
Glatt Maschinen- & Apparatebau AG Kraftwerkstrasse 64133 Pratteln 1/SwitzerlandPhone: +41 61 8 26 47 47Fax: +41 61 8 26 48 48eMail: [email protected]
Glatt Ingenieurtechnik GmbHNordstraße 1299427 Weimar/GermanyPhone: +49 3643 47 0Fax: +49 3643 47 12 31eMail: [email protected]
Glatt GmbH Process TechnologyWerner-Glatt-Straße 179589 Binzen/GermanyPhone: +49 7621 6 64 0Fax: +49 7621 6 47 23eMail: [email protected]
Glatt Systemtechnik GmbHGrunaer Weg 2601277 Dresden/GermanyPhone: +49 351 25 84 0Fax: +49 351 25 84 328eMail: [email protected]
We s e t t h e s t a n d a r d
A d d r e s s e s
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We set the standard
From the ideato turnkey production Consulting
Engineering
Implementation
P ro c e s s a n d P l a n t E n g i n e e r i n g
Pharmaceutical industryBiotechnologyFood industryFeed industryFine chemical industryChemical industry
2
G l a t t - y o u r p a r t n e r f o r p l a n t e n g i n e e r i n g
From the idea to turnkey production
In the last two decades, Glatt Engineering has imple-
mented a variety of projects for different industries all
over the world. Our track record includes both exten-
sion or modification of existing and also construction
of new production facilities - in parts or completely.
Incorporated in the international Glatt Group we have
unrestricted access to comprehensive expert know-
ledge from more than 50 years pioneering and ex-
periences in process technology.
Many processes in today's solid pharmaceuticals
production would not be imaginable without Glatt‘s
technologies – Glatt owns patents in many fields.
Innovation and continual further development of our
equipment, up-to-date market-oriented services for
product development of new dosage forms, authority
approved contract production at Glatt-owned produc-
tion sites, but also a close contact to international
research institutions and to researching industrial
partners enable us to solve even the complexest
implementation of formulation requirements for and
with our customers.
As a reliable project partner we offer full GMP and
environmental compliance in all fields. Applying them
ourselves we are familiar to latest regulations. We
anticipate market trends at an early stage and help to
develop them. All of which enables us to provide
sophisticated, customer-specific and tailored solutions
and to guarantee smooth processes by professional
project management.
Our projects are not only focussed on processes for
the production of solid pharmaceuticals but also on
the production of liquid pharmaceuticals by sterile
and non-sterile processes.
Apart from these longstanding traditions in the phar-
maceutical industry, Glatt Engineering is increa-
singly active in the food/feed, fine chemical and
chemical fields where an increasing demand for
well-aimed product refinement opens new markets
that can benefit from gathered experiences and the
use of proven technologies.
Process EquipmentProduct Development
3
Contract Manufacturing Process and Plant Engineering Qualification/Validation
ServicesConsulting, engineering and implementation
also as general contractor
ProjectsProcesses, production lines and complete
production facilities
FocusPharmaceutical industry with solid and liquid
dosage forms by sterile and non-sterile
processes
Biotechnology
Food and feed industry
Fine chemical and chemical industry
4
Glatt – a reliable project partnerEfficient processes, future-oriented technologies, high-
quality products, flexibility, security and time to market.
The success of your investment depends on a variety of
factors. These parameters are both guidelines and motivation
for us. Together with you we will find and implement an
integrated and tailored solution that ensures your
competitiveness on tomorrow's markets.
We develop, engineer and implementStandalone systems and equipment for research,
development and production up to complete plants
• New construction
• Modification and modernization
• Extension
Our service portfolio• Consulting and support in the project development phase
• Conception and engineering of processes and buildings
• Purchase and expediting
• Project management for engineering and implementation
• Authority approval management
• Licence procurement
• Construction scheduling, management and supervision
• Installation and installation supervision
• Commissioning and commissioning supervision
• Qualification and validation
• Operator training
• Complete project documentation
• After-sales services (maintenance/upkeeping)
Individual service or complete packageIt is your decision how much responsibility you grant us.
We are your reliable partner in all project stages as:
• Engineering contractor
for individually selected engineering contents such
as process engineering/optimization, qualification/
validation, no matter whether feasibility studies,
concepts, basic and/or detail engineering is involved
• General contractor
with general engineering from project concept up to
constuction with overall project responsibility including
EPCM services up to turnkey implementation
O u r s e r v i c e p o r t f o l i o
5
Glatt Engineering
6
FeasibilityStudies
ConceptualDesign
BasicEngineering
DetailEngineering
ProcurementDelivery
ConstructionInstallationSupervision
Start-up(Qualification)(Validation)
After-Sales-Service
P r o j e c t r e a l i z a t i o n w i t h G l a t t c o m p e t e n c e
Independent engineeringbased on state-of-the-art technology
Engineering
Procurement and Delivery
Supervision and Training S
After-Sales-Service
consulting,
concept-, basic & detail
engineering
spare parts, maintenance,
trouble-shooting,
modifications
process equipment
construction, installation,
commissioning, start-up
(qualification/validation)
Project Management:
an
an
o
an
an
o
7
ervices
Licensor
other detail engineering
services, e.g. architecture,
civil engineering, logistics
process equipment,
logistic, media, etc.
construction, installation,
commissioning, start-up
(qualification/validation)
start-up
spare parts, maintenance
costs, resources, time & risks
licenses,
technology transfer
Partners
Suppliers
Suppliers Licensor
Suppliers
Profit from the complete know-how of theGlatt group of companies
nd and
or
nd
or
nd and
nd
or
new dosage forms, based on our own
technologies
Product Development
own, approved and GMP conform production
(pharmaceutical, food and feed industry)
over 50 years experience in the design and
construction of fluid bed systems, high shear
mixers, drum coaters, sieves and various
systems for solid product handling
in Binzen (D), Pratteln (CH), Dresden (D),
Weimar (D), Ramsey (USA)
as well as the TTC Technology Trainings Center
in Binzen (D)
Contract Manufacturing
Process Equipment
Technology Centers
8
P h a r m a c e u t i c a l i n d u s t r y
Solid and semisolid dosage forms fromsterile and non-sterile processes- Tablets/film-coated tablets, sugar-coated pills,
capsules, sachets, powders, ointments/cremes,
suppositories
Liquid proprietary medicinal productsfrom sterile and non-sterile processes- Infusion solutions in bottles/bags
- Injection solutions in ampoules, phials, vials,
carpules, prefilled syringes
- Tinctures, extracts, juices, drops
GMP solid productsWithin the scope of 3 turnkey projects
for the contract manufacturer IPC Inter-
national Processing Center GmbH,
Germany, in Dresden several produc-
tion buildings were built for granulation,
coating, classifying, mixing, grinding,
weighing and packaging including raw
material and product logistics as well
as an individual cleanroom concept
with ventilation and air-conditioning
equipment including a plasma incinera-
tion plant. Project period: 2004 – 2009
Plot area: 60 000 m2, therefrom
approx.. 3 000 m2 for production
Infusion solutions (LVP)As EPCM contract partner for
OOO Gematek from Moscow Glatt
engineered and constructed a new
production facility for infusion solution
in Tver, Russian Federation. It uses
blow-fill-seal technology in PE bottles
with capacities of 500, 250 and 100 ml
and can produce 2 400 bottles per hour
(12 to 16 million bottles/year).
Project period: 08/2002 – 10/2004
Overal plot area: 2 300 m2,
(reconstruction of a production hall)
API of an X-Ray Contrast AgentDue to a request from GE Healthcare
AS, Norway, of changing from batch to
a cost efficient continuous processing,
Glatt was awarded with the contract
for engineering and delivery of the
total process equipment. The implemen-
tation work at site, including qualifi-
cation and support during validation,
was done during running production.
The product line is unique since it’s
FDA approved for continuous produc-
tion of an API for parenteral drugs.
Capacity: 270 kg/h
Project period: 05/2005 – 09/2006
360 m2 on 3 floors
9
Blood plasma products- Albumin
- Immunoglobulin
- Factors VIII and IX
Vaccines- Injection solutions in ampoules, phials, vials,
carpules, prefilled syringes
Insulin- Solutions and suspensions in vials Blood plasma products
On behalf of ROSPLASMA and within
the scope of a turnkey project Glatt is
engineering and implementing a new
production facility for plasma fractio-
nation (600 000 l blood plasma/year)
and diverse products in Kirov, Russian
Federation. Establishing a network of
plasma collection and pheresis centres
in the Kirov region with project plan-
ning, delivery and installation of pre-
fabricated modules.
BCG vaccineIn 2000, under the management of
Glatt as general contractor for Biomed
from Kiev, a new production plant for
BCG vaccine was constructed on
their Lwow site, Ukraine, by the re-
construction of an existing building.
Behring Werke AG, Marburg,
Germany, was the licensor.
Insulin (SVP)Glatt as general contractor for Bio-
med, a Kiev-head-quartered pharma
producer, performed comprehensive
engineering services for the new
construction of a production and
bottling plant for ultrapure insulin.
Capacities: 6 000 vials/h up to 12 million
vials/year. For this, an existing building
in Kiev, Ukraine, was reconstructed.
Hoechst AG, Frankfurt, Germany, was
the licensor.
B i o t e c h n o l o g y
10
F o o d a n d f e e d i n d u s t r y
Granules and pellets as intermediate andfinal products- Instant products as quick-soluble agglomerates
- Food and feed ingredients such as flavors,
enzymes, proteins, vitamins
Yeast- Soft and dry yeast as baking additive
Dairy products- Baby food, yogurts, quark, milkshakes
Baker's yeastAl Shaba Yeast Factory is a Syrian
yeast producer. From 2003 to 2006,
this company appointed Glatt with the
modernization and extension of their
production site in Aleppo, Syria, to
increase the daily output of soft and
dry yeast from 32 tons to 50 tons. Glatt
implemented this project as EPCM
service provider from the survey of
existing plant up to production hand-
over.
Baby and children foodThe Russian company GP VVO Selk-
hospromexport appointed Glatt to be
the general contractor for enginee-
ring and construction of a new milk
processing and dairy line in Brjansk,
Russian Federation. In 2004, a modern
production facility for liquid and
pasteous baby and children food
products, yogurt and fruit juices pro-
cessing up to 30 000 litres raw milk per
day was accomplished by the recon-
struction of an existing building.
FlavorsPhytosynthese in Riom Cedex, France,
produce encapsulated flavors for food
and feed applications. Glatt delivered
a spouted bed granulator ProCell 125
for spray granulation and incapsulation
of emulsified oils as a complete plant
and headed its commissioning.
Production capacity: 50 – 100 kg/h,
Project period: 01/2007 – 11/2007.
11
F i n e c h e m i c a l a n d c h e m i c a l i n d u s t r y
Granules and pellets as intermediate andfinal products- Fertilizers, pesticides, detergents and detergent
components, enzymes, potash, polymers and
many more
Chemical products- manufactured, prepared and processed, e.g. to
improve storage and transport properties PotashWithin the scope of a turnkey project,
Pottaschewerk Staßfurt, Germany,
appointed Glatt with engineering and
construction of the most advanced
potash production plant in the world at
that time with a fluid bed spray gra-
nulation plant and a yearly output of
20 000 tons potash (potassium
carbonate K2CO3).
Project period: 1999 – 2001
Detergent componentsZschimmer & Schwarz, Germany,
produce water softeners. Glatt
delivered a fluid bed granulator
GFG 500 including building for the
spray granulation of these products
as a turnkey project. All that the client
provided were media and liquid raw
materials. Water evaporation capacity
approx. 700 kg/h
Project period: 10/1999 – 07/2000
Sodium cyanide as briquettesIn Saratov, Russian Federation, Glatt as
general contractor for the Russian
Lukoil group, implemented a produc-
tion facility for sodium cyanide (NaCN),
which is an important raw mateial for
gold mining, with DuPont, USA, as
licensor.
Produced NaCN having a purity >98%
is pressed to briquettes and packed
into 50 kg steel drums
Plant capacity: 15 000 t/year
Project period: 30 months (2005 – 2008)
Our Headquarter
Our PresenceGlatt Engineering is a business unit of Glatt Ingenieurtechnik GmbH
headquartered in Weimar with branch offices in Wiesbaden, Scandinavia,
France, Switzerland, Russia, India and the USA.
At present, the Glatt Group employs approx. 1500 employees in more than
20 companies worldwide.
Numerous representative offices are at your disposal, offering Glatt's
complete services. This means: reliability, financial security, and worldwide
service for your projects.
Certified according to DIN EN ISO 9001
© GL
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G l a t t E n g i n e e r i n g
We set the standard
Glatt Ingenieurtechnik GmbHNordstraße 1299427 Weimar/GermanyPhone: +49 3643 47-0Fax: +49 3643 47-1231eMail: [email protected]
International located:
GermanyGlatt Ingenieurtechnik GmbHNordenstadter Str. 3665207 Wiesbaden/GermanyPhone: +49 611 89069-7Fax: +49 611 89069-88eMail: [email protected]
RussiaGlatt Ingenieurtechnik GmbHул. Обручева, 23 - корп. 3
117630 Москва/Россия
Phone: +7 495 78742-89Fax: +7 495 78742-91eMail: [email protected]
IndiaGlatt (India) Pharma Engineering Pvt. Ltd.13 Ground Floor Palam Marg, Vasant ViharNew Delhi – 110057/IndiaPhone: +91 11 46052960Fax: +91 11 46052964eMail: [email protected]
SwitzerlandPharmatronic AGHohenrainstraße 104133 Pratteln/SwitzerlandPhone: +41 61 826-9726Fax: +41 61 826-9727eMail: [email protected]
USARamsey Design Group(Division of Glatt Air Techniques Inc.)20, Spear Road, Ramsey, NJ 07446/USAPhone: +1 201 825-1391Fax: +1 201 825-0389eMail: [email protected]
www.glatt.com