Spray Agglomeration

Porous, excellent soluble granules.

Homogeneously distributed components.

Ideal instant properties.

Porous, highly dispersible granules from powders with homogeneous distribution of components

When powdery substances are to be dissolved or dispersed in hot or cold liquids, agglomerates from the fluid bed represent a significant quality improvement. The porous structure of the particles and their increased surface area are decisive for the improved wetting and solubility behavior, the ease of application and ultimately the commercial success of your product.

Fluid bed or spouted bed spray agglomeration is a common shaping process for optimizing the properties of powders. In this process, we convert dusty, non-flowable and often poorly soluble particles into free-flowing agglomerates or granules with excellent solubility. The process is particularly suitable as a precursor for tabletting and for the production of, for example, detergents, fertilizers, crop protection agents, beverage powders and other instant products as well as hydrocolloids or even sweeteners and sugar substitutes.

This process improves flow behavior and eliminates negative effects such as dusting.
Combining several product components into agglomerates avoids segregation effects of powder mixtures.
For instant application, wettable, loose granules with good sinking behavior are produced, which dissolve very well.

Spray agglomeration is carried out in fluid bed systems or spouted bed systems in batch operation as well as in continuous operation.

Product properties of granules from spray agglomeration by fluid bed or spouted bed at a glance:

Dust-free
Particles

Porous
Structure

Low
Bulk Density

Excellent
Wettability

Superior
Solubility

Very Good
Dispersibility

Optimal
Instant Behavior

Optimal
Compressibility/Compactability

Good
Tabletability

Defined
Particle Size Distribution

Very Good
Homogeneity

Ideal
Component Distribution

Good
Dosability

Good
Flow Properties

Granules with varying particle sizes, produced by fluid bed spray agglomeration

Typical sizes of the agglomerates range from 100 micrometers to 3 millimeters, while the starting materials can be in much finer form.

In spray agglomeration in the fluid bed or spouted bed, powder is sprayed with liquid until sufficient adhesive forces are created between the particles and they stick together. Simultaneous drying directly solidifies the agglomerate structure.

Depending on the required raw material or product properties, water or any other liquid solvent can be used for granule buildup and structure formation. Suitable binders or raw material components dissolved in the spray liquid can also be used in spray agglomeration to generate additional adhesive forces or increased tack or product strength.

Due to their porous character and their large surface structure, the agglomerates are much easier to wet, very soluble and optimally compressible. The dust-free, free-flowing products can be easily metered and optimally processed. The variable product parameters in the process, such as particle size distribution, bulk density or porosity, enable the targeted generation of a wide range of particle properties.

Product examples for spray agglomeration

Particle structure of a single orange juice granule, produced by fluid bed spray agglomeration

Orange juice, spray agglomerated

Orange juice granules before and after fluidized-bed spray agglomeration

Orange juice granules before (left) and after (right) spray agglomeration

Tomato, spray agglomerated

Olive, spray agglomerated

Tomato and olive mixture, spray agglomeration

Olive-tomato blend, spray agglomerated

Instant cocoa, spray agglomerated

Tea with milk and sugar, spray agglomeration

Tea with milk and sugar, spray agglomerated

Instant tea, spray agglomerated, SEM

Turmeric (Curcuma), spray agglomerated

Turmeric (Curcuma), spray agglomerated, SEM

Particle structure of a single bentonite granule particle, produced by fluid bed spray agglomeration

Bentonite, spray agglomerated

Process comparison for bentonite: agglomeration in a fluidized bed vs. wet mixing followed by extrusion in a low-pressure extruder

bentonit powder before (left), after wet mixing + extrusion (top right), after fluid bed agglomeration (bottom right)

particle structure of carbon carbide granules alongside the solid starting material from which they were formed by fluid bed spray agglomeration

carbon carbide before (left) and after (right) spray agglomeration

glass powder granules next to the solid starting material from which they were formed by fluid bed spray agglomeration

Glass powder before (left) and after (right) spray agglomeration

Hair color, spray agglomerated

Hydrocolloid, spray agglomerated

Catalyst, spray agglomerated

Detergent, spray agglomerated

Here you will find many more product examples.

The process of spray agglomeration in the fluid bed in detail

Granule formation in the process of spray agglomeration

Conversion of dusty, non-flowable and often poorly soluble powder particles into free-flowing agglomerates or granules with excellent solubility.

The combination of several product components into agglomerates avoids segregation effects of powder mixtures.

In spray agglomeration, very small powdery particles are moved in the fluid bed or spouted bed and sprayed with a binder liquid. By forming liquid bridges, the particles combine to form agglomerates. The spraying process is continued until the desired size of the agglomerates is reached. After evaporation of the residual moisture in the capillaries and on the surface, voids form in the granules, while the new structure is further strengthened by the hardened binder. Due to the low kinetic energy in the fluidized bed, we thus obtain porous structures with a large number of internal capillaries. By dissolving the surface or adding binders to the solvents, the granules are stabilized after drying. Due to the relatively low mechanical compaction in the fluidized bed, the agglomerates/granules are loose, have a coarse structure as well as a large surface area with low bulk density and are thus excellently soluble in water.

Fluffy, porous, excellently soluble and well flowing granules from powder by spray agglomeration

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Glatt continuous spray agglomeration in the fluid bed,
top spray

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Glatt batch spray agglomeration in the fluidized bed,
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From the product idea to production

In our Glatt Technology Center, we provide you with access to sophisticated technologies and support in formulation, product and process development, tailored to your individual requirements. The process always starts with tests on a laboratory system. The in-house analytics laboratory enables in-process analyses to adapt particle properties to the respective application. For reliable scale-up, process and operating parameters are determined on pilot plants. Through contract manufacturing at Glatt, your new powders, pellets or granules can be manufactured, filled, packaged and delivered directly in agreed quantities. As a plant manufacturer, Glatt provides all services from project initiation, development and realization through to turnkey production in your own plant.

Hot melt fluidized bed granulation – An effective low shear method for the manufacture of polymer pellets with high additive load (Poster)

By using functional additives, essential properties like thermal stability, thermal conductivity, UV-stability, burning behavior or antistatic properties of polymers and polymer-ceramic composites are adjustable. The Poster shows that solid or liquid additives can be embedded homogeneously in polymer pellets. The structure of shear sensitive materials is not affected by spray granulation of hot-melts. Very high additive loads can be realised by combined spray granulation and agglomeration, for applied pigment weight fractions of up to 80 % are realizable.

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Further information on this topic and related topics can also be found in the following publications:

Glatt technical article on ''Spray agglomerating plant-based milk alternatives for optimised product properties'', published in the trade magazine 'Food & Ingredients Turkey', issue December/2021, ISTMAG -ISTANBUL MAGAZINE GROUP

Published article: ‘Spray agglomerating plant-based milk alternatives for optimised product properties’ PDF, English

Glatt's technical article on 'Process technologies for optimizing detergent manufacturing', published in SOFW, issue 10.2020, Verlag für chemische Industrie H. Ziolkowsky GmbH.

Published article: ‘Process Technologies to Optimize Detergent Manufacturing’. PDF, English

Glatt technical article on ''Shaken or Stirred - Agglomeration with fluidized bed technology'', published in the trade magazine Asia Food Journal', September-October/2016 issue, Contineo Media Pte Ltd.

Published article: ‘Shaken or Stirred – Agglomeration with fluidized bed technology’ PDF, English

Glatt technical article on 'Instantisieren leicht gemacht - Agglomeration durch Wirbelschichtverfahren - Granulate aus Pulver', published in the trade magazine 'PROCESS', issue 02/2013, VOGEL Communications Group GmbH & Co. KG

Published article: ‘Instantizing made easy – Agglomeration by fluid bed process – Granules from powder’ PDF, German

Glatt article on 'Für den schnellen Genuss - Wirbelschichtanlagen im Batch- oder Konti-Betrieb', published in the trade magazine 'P&A Prozessdigitalisierung Automation', issue 05/2017, publish-industry Verlag GmbH

Published article: ‘For quick enjoyment – Fluid bed systems in batch or continuous operation’ PDF, German

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Spray Agglomeration

Porous, excellent soluble granules.

Homogeneously distributed components.

Ideal instant properties.

Porous, highly dispersible granules from powders with homogeneous distribution of components