Wet Granulation

Dense, dust-free, compact granules.

Homogeneously distributed components.

Ideal extrusion properties.

High-shear granulation for dust-free and compact granules from powder

Wet granulation (also wet blending) in the high-shear mixer is a classic process for building up granules from powder. This process is used when rapid agglomeration to form relatively compact granules is desired and the solid, pre-applied starting materials have low adhesive properties of their own. Powdered substances, such as vitamins, trace elements and other food supplements, can be adjusted to the desired dosage in suitable carriers and mixed homogeneously. But liquid active ingredients, such as enzymes, can also be incorporated and distributed in a matrix – for example starch or cellulose – by means of wet granulation. The wet granules are then dried to dust-free particles.

The agglomerates/granules produced in this way have a compact, extremely stable structure with a higher density than spray agglomerates from the fluid bed. They have good flowability and can be pressed.

Alternatively, the moist mass also serves as a starting mixture for further processing into pellets by means of low-pressure extrusion.

The dried granules or extrudates can be protected or functionalized (release control, color branding, taste/odor masking and others) against external influences (moisture, UV light, …) with a subsequent coating.

The process is also suitable for dedusting powders. Here, oils are mixed into the powders very quickly and homogeneously. Application examples for this can be found in products for hair cosmetics, among others.

For this process, Glatt offers highs-hear granulators with different batch sizes for use in the bulk solids processing industry.

Product properties of agglomerates from highshear wet granulation at a glance:

Dust-free
Particles

Compact
Structure

High
Bulk Density

Good
Flow Behavior

Good
Dosability

Good
Dispersibility

Good
Solubility

Wide
Grain Size Spectrum

Ideal Properties
for Extrusion

A product container is charged with powder and this is moistened or sprayed with melt to build up cohesive forces. The liquid can be polar or apolar and should be able to dissolve the powder surface. If necessary, a binder is added to strengthen the cohesive force. The metered distribution of the granulating liquid via a spray nozzle, as well as the simultaneous, vigorous mechanical mixing of all input materials, ensures uniform distribution of all components in the granules.

Depending on the downstream sieve, a wide particle size range with agglomerate sizes between 0.1 mm and 10 mm is possible.

Product examples for wet granulation

Starch, wet granulation + coating

Graphite, wet granulation

Iron, food supplements, extrusion

CoQ10, extrusion

Hair color, extrusion

The process of highshear wet granulation in detail

A binder liquid is added to powdery particles in a closed container, which has mixing tools and a chopper. Dense granules are formed via resulting liquid and solid bridges. 

Learn more about this process in the video on the right.

Stable, very dense and compact agglomerates from powder by means of highshear granulation

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