About Compaction Granulation
Compaction granulation, or agglomeration, is the process of converting fine dry powder into larger particles. Dry compaction granulation is achieved by sending dry powder material between two rollers. These rollers exert immense pressure on the material which compacts the material together. When the compacted material exits the rollers it then breaks into flakes because it is brittle. The flakes are then ground to create granules of varying sizes. Because of the size variance, the material is filtered and granules of the desired size are collected while granules of incorrect size are re-compacted and sent through the process again. The collected granules can be packaged and sold to consumers or sent to the next phase of the manufacturing process.
Benefits of Compaction Granulation
Compaction granulation gives manufacturers the ability to control a variety of physical and chemical properties associated with products composed of solid particle material. This is important because controlling these properties is often essential to creating a commercially viable product with the right performance attributes. The following demonstrate the benefits of compaction granulation.
Better Flow Properties: Proper compaction granulation can help ensure that material can be easily moved, poured or stored with minimal caking or clumping. If a product has poor flowability it can result in an inefficient manufacturing process or impact the products efficacy in commercial applications.
Reduced Attrition: Proper compaction can also help ensure the proper bulk density and granule homogeneity. This is often essential for products that require a specific time release or dissolution profile.
Decreased Dusting: Agglomerating powdered material is of significant importance to solid products that are applied over a wide area like agricultural chemicals. If particles are not large enough then their application may be easily disrupted by wind or rain. Furthermore, excessive dust may prove a manufacturing risk if the material is a combustion hazard.
Ease of Transportation: Compacted material can require less volume to transport and store than uncompacted material. Additionally, when blended material of two or more components is transported, the components may unevenly disperse and settle in its container which can disrupt its ultimate application. By compacting the blended material settling issues may become resolved.
Equipment for Dry Compaction Granulation, Agglomeration and Particle Sizing
- Compaction Granulation: 50(2), 75(2), 150(2) & 300 ton Bepex MS Roll Compaction Equipment
- Particle Size Reduction: Comill, Hammermills
- Particle Size Selection: Sweco, Mid-western, Rotex Screeners (3)
Compaction Granulation At Stellar
Stellar Manufacturing understands that every client has a unique product with different chemical and physical properties. Through our contract manufacturing services, we develop a customized plan to process our client’s material that meets their specific particle size and performance criteria. We understand that a quality result in each step of manufacturing process is critical to our client’s success. When a client chooses us for their toll manufacturing they can feel comfortable knowing we have an on-site QC laboratory ensuring product quality and consistency.
Stellar’s compaction and agglomeration capabilities include fully integrated 50, 75, 150, and 300-ton compaction systems. Our dry granulation process allows our customers to choose particle size ranges specific to their product application. We perform particle enlargement or reduction in an integrated production system and can produce particles in the 70 mesh to 1/2” range. We provide this service as a stand-alone offering or as part of a larger, integrated program including tableting, briquetting, and packaging.