VFC-5 to VFC-500 FLO-COATER OPERATION INSTRUCTIONS
Page -1- CONTENTS PAGE NUMBER System Description... 2 Flo-Coater Description... 4 Operation of a Flo-Coater... 8 Selective Operator Control... 9 Operating Tips... 10 Product Discharge... 11 WIP System... 12 Cartridge Filters... 16 Pulse Air Reservoir Max. Air Pressure... 17
Page -2- SYSTEM DESCRIPTION A Flo-Coater System is designed to process various materials into more desirable forms to enhance flowability, dispersibility, compressibility, bulk density, and other physical characteristics. Regardless of the industry (food, pharmaceutical, chemical, etc.) Vector has the expertise needed to tailor Flo- Coater equipment to specific process requirements. In order to offer Flo-Coater equipment capable of meeting specific process requirements, yet versatile enough to cover all of the aspects of Flo-Coater technology, Vector employs a system concept. Each component plays an integral role in the overall performance of a given process. Vector s Flo-Coater Systems consist of five basic components: 1. Flo-Coater component 2. Air Handler component 3. Control System component 4. Solution Delivery component 5. Exhaust Blower component FLO-COATER The processing of product is accomplished in the Flo-Coater unit. Incorporated into the Flo-Coater are the components necessary to accommodate a large variation of process parameters used in the agglomeration, coating and drying of product with minimal waste, damage and contamination under safe conditions. Please refer to the Flo-Coater Description section of this manual for a complete description of the Flo-Coater.
Page -3- SYSTEM DESCRIPTION AIR HANDLER Process air is drawn through the Air Handler, where it is treated and filtered to obtain the desired level of temperature, moisture, and filtration required for a particular process. Ducting must be installed between the Air Handler and the Flo-Coater. This treated process air enters the rear of the Flo-Coater through the inlet air plenum. CONTROL SYSTEM The Control System allows the operator to start-up, adjust process parameters, monitor and shut-down the Flo-Coater unit from one location. Please refer to the Control System section of this manual for a more complete description. SOLUTION DELIVERY The Solution Delivery System includes the Flo-Coater spray gun(s), atomizing air, and the pump unit. The pump is remotely located and delivers solution to the Flo-Coater spray guns via tubing. The Solution Delivery System is optional equipment and may be customer supplied. EXHAUST BLOWER Ducting must be installed between the Flo-Coater and the Exhaust Blower. The Exhaust Blower provides the motive force to pull process air from the Air Handler and through the Flo-Coater.
Page -4- FLO-COATER DESCRIPTION Vector s Flo-Coater System provides a controlled environment for agglomeration, coating and drying product with minimum waste, damage, and contamination under safe conditions. The basic Flo-Coater unit has five (5) sections (Figure 1): 1. The Inlet Air Plenum 2. Product Container 3. The Expansion Chamber 4. The Filter Chamber 5. Explosion Venting Figure 1. Basic Flo-Coater Unit
Page -5- FLO-COATER DESCRIPTION Vector offers three (3) basic Flo-Coater types ranging from.63 liters to over 1500 liters. The standard Flo-Coater is designed with a single expansion/filter chamber and may be purchased with only one size of product container. The standard model can also be supplied with a separate expansion/filter chamber, allowing for the use of multiple types/sizes of process inserts The 'M' or 'Multi' model features an enlarged filter chamber and increased height expansion chambers, providing the highest versatility under the most demanding processing conditions. All units are built using our standard 2-bar design; however, they may also be built using 12-bar standards. INLET AIR PLENUM Process air is drawn through the Inlet Air Plenum using the exhaust blower. As the process air moves through the product container insert, the product is lifted into the expansion chamber. Air temperature is measured in the ducting of the inlet air plenum. PRODUCT CONTAINER INSERTS Product is loaded into a product container insert. The insert is then lifted into processing position with lifting cylinders. Process air flows through the product screen in the lower section of the product container and into the expansion chamber. This screen keeps product from falling into the inlet air plenum. A sample port and viewing windows(s) aid the operator in monitoring the process. Differential pressure across the product container is measured and displayed. The standard product container is the basic granulator container. This insert is used for product agglomeration and drying. Optional inserts are the Wurster Container (used primarily for coating of powders and beads) and the Rotor Container (used primarily for product spheronization). These containers are interchangeable in the Multi models.
Page -6- FLO-COATER DESCRIPTION EXPANSION CHAMBER (Multi models) The Expansion Chambers on these models allow for greater versatility in the size of the product container inserts and also provides a greater level of deceleration when high air velocities are needed. The Expansion Chamber is where the fluidizing motion occurs, and spray is applied to the product. Spray guns are mounted on this chamber through ports either peripherally or centered inside the chamber. Air/product temperature is measured in the lower section of this chamber. FILTER CHAMBER The filter chamber houses the cartridge filters that filter process air before it is pulled through the exhaust plenum. The filters allow process air to pass through the filter media while retaining product in the process chamber. To keep the filters clean, product is expelled from the filters using a pulsing action - short blasts of air administered at predefined intervals. This allows Vector s Flo-Coater to maintain continuous process air flow. Differential pressure across the filters is measured and displayed. Air temperature is measured in the ducting of the exhaust air plenum. EXPLOSION VENTING Vector Flo-Coaters are built to withstand the initial shock of a deflagration and allow it to safely vent through an explosion relief. An explosion relief vent is standard equipment on all Flo-Coaters.
Page -7- FLO-COATER DESCRIPTION EXPLOSION VENTING (Continued) The relief vent can be either on the top or the rear of the Filter Chamber. The relief vents consist of one or more openings in the chamber that are proportional to the inside area of the chamber. Two different types of relief vents are available: gasket panels or hinged doors. The vents open when a positive pressure of less than.1 Bar (1.45 PSI) is created in the chamber; thus the ability to safely relieve pressure generated by a deflagration. If an explosion vent is impractical or a Total Product Containment system is required, alternative Flo-Coater designs may be employed. Specifically, a suppression system may be applied to a standard 2-Bar machine. An alternate method would be the installation of a 12-Bar Flo-Coater unit. In either instance, the explosion vent is no longer required.
Page -8- OPERATION OF A FLO-COATER Operation of the Vector Flo-Coater is controlled through a Vector Control System. Each control system shipped from Vector has been tailored to the specific needs of the customer. The following information is generic and applicable to the general operation of the Flo-Coater System. For specific details about the Control System, please refer to the Control System Operating Instructions in this manual. BASIC FLO-COATER OPERATION Flo-Coater equipment can be used for mixing, drying, granulating and coating. It conforms to GMP standards, and is constructed for easy and thorough cleaning. Several types/sizes of process inserts are used to achieve the desired characteristics of the finished product. Filtered, conditioned process air is drawn through the product bed at sufficient velocity to suspend and mix the product. If the process requires only drying the product, the conditioned air is drawn through the product until a predetermined moisture content is achieved. If the product to be dried is a wet granulation of high moisture content, or has poor fluidization for any reason, the Bed Pulse function can be used to assist in product movement.
Page -9- OPERATION OF A FLO-COATER BASIC FLO-COATER OPERATION If the process requires agglomeration of fine powders then water or other solvent, or a granulating liquid containing a suitable binder, is applied to the fluidized product. This liquid is typically applied via a pneumatically atomizing spray gun in sufficient quantity and over a sufficient period of time so as to produce a granule with the desired size, shape and structure. The product is then dried and cooled prior to removal from the Flo-Coater. If the process requires coating of a powder or granulate, then a suitable coating liquid is applied to the fluidized product in such a way as to minimize agglomeration and maximize the efficiency of transfer to produce the desired functional characteristics. The product is then dried and cooled prior to removal. During all of the above processes, cartridge filters or screens are used to retain fine particles and return them to the process using the Filter Pulse function. Frequency and required pressure of the filter pulse are adjustable as required for individual processes. SELECTIVE OPERATOR CONTROL Selective operator control of the Flo-Coater process is accomplished by controlling each process step. The operator can select the steps needed for processing specific applications. A step can also be bypassed at any time. Control of the Flo-Coater process is accomplished through the operator interface panel. Refer to the Operator Interface Panel section of this manual for specific process control instructions.
Page -10- OPERATION OF A FLO-COATER OPERATING TIPS There are situations in fluidizing granulation where desired products cannot be immediately obtained, resulting from characteristics of material properties and selected binding liquids. Optimum conditions will be discovered by altering conditions and repeating experiments. In discovering optimum conditions, the adjustment of sprayed liquid is especially important. The relationship between product granule size and spray condition is described below: In the granulation process, product granule size and uniformity is influenced by the amount of liquid sprayed, how fast it is applied, and how uniform the spray is. A. When a larger particle size is desired: < solution delivery rate may be increased. < spray air pressure may be decreased. < increase binder solution amount, solids content, viscosity. Product temperature may need to be decreased. < nozzle orifice diameter may need to be increased to accommodate higher flow rate.
Page -11- OPERATION OF A FLO-COATER OPERATING TIPS (Continued) B. When a smaller particle size is desired: < solution delivery rate may be decreased. < spray air pressure may be increased. < decrease binder solution, solids content, viscosity. Product temperature may need to be increased. < nozzle orifice diameter may need to be decreased to maintain proper pressure drop through spray gun with decreased flow rates. PRODUCT DISCHARGE Discharging the product from the Flo-Coater can be accomplished using several different methods. < The product container can be removed from the Flo-Coater and product can be scooped out or the container can be inverted to unload product. < Product can also be suctioned out of the product container using a vacuum system. < Bottom discharging product container options are also available. The method of discharge is dependent on the type of product being processed and equipment available.
Page -12- WASH-IN-PLACE SYSTEM The Wash-in-Place (WIP) system provides the operator with an easy method of cleaning the Flo-Coater. A WIP assembly consists of a tube equipped with a nozzle head. All surfaces of the Flo-Coater unit are within the spray pattern of the nozzle. The WIP assemblies are easily removed for periodic cleaning and maintenance. A drain located in the bottom of the inlet plenum allows cleaning solutions to exit the Flo-Coater during the wash process. In addition, the cleaning solution drains through the discharge port in the product container. FOR MAXIMUM PERFORMANCE, IT IS RECOMMENDED THAT ALL WIP ASSEMBLIES IN THE PRODUCT AREA ARE REMOVED PRIOR TO PROCESSING OR DISCHARGING OF PRODUCT. OPERATION OF THE WIP SYSTEM The operation of the Wash-in-Place system can be controlled manually or automatically dependent on the control system. Refer to the Controls section of this manual for more detail. Regardless of the method of operation, the following steps should be taken BEFORE activating the WIP System.
Page -13- WASH-IN-PLACE SYSTEM BEFORE ACTIVATION CAUTION! The exhaust blower should NEVER be ON while cleaning the Flo-Coater unit. Cleaning solution used during the wash process will cause damage to the blower and other exhaust components. 1. The exhaust blower can be turned on to facilitate drying ONLY when small beads of cleaning solution remain in the unit. Evaporation of the small amount of cleaning solution occurs before reaching the exhaust duct work. The customer remains responsible for ensuring that exhaust ducting is sealed prior to beginning the wash process. Cleaning solution can become trapped in the exhaust duct work and prove to be a contaminate for future batches if not properly removed. 2. On 2-bar machines, remove the inlet duct seal BEFORE activating the WIP System. Although the cleaning solution will drain from the inlet plenum, removal of this weldment will keep cleaning solution from entering the inlet duct work. A drip pan placed under the inlet duct will catch the overflow. The 12-bar machines are equipped with drains. 3. If the Product Container does not have a drain, remove the perforated plate and product screen BEFORE activating the WIP System. These items should be washed separately.
Page -14- WASH-IN-PLACE SYSTEM OPERATION OF THE WIP SYSTEM (Continued) BEFORE ACTIVATION (Continued) 4. Install all WIP tubes and nozzles in appropriate locations. Refer to WIP installation instructions. For maximum cleaning performance, start at the top of the Flo-Coater unit and work down. AFTER CLEANING 1. The WIP system assists personnel and should not be relied upon to clean detailed areas. Close inspection after every cleaning is recommended, particularly around the following areas: a. Any gun port, window enclosure or sample port b. Any location where powder can become trapped - ie. seals between product container and expansion chambers, etc. If necessary, repeat the cleaning procedure. AFTER CLEANING 1. During cleaning, cleaning solution may accumulate in the pulse valves. Pulsing the filters will remove this solution.
Page -15- CARTRIDGE FILTER PULSING The Cartridge Pulse is designed to periodically expel accumulated product that adheres to the filter material eventually plugging the filter. The pulse function is accomplished by a blast of compressed air from the exhaust plenum side of the cartridge filter into the expansion chamber. OPERATION OF THE PULSE FUNCTION CAUTION! The cartridge pulse function MUST NEVER be initiated under the following conditions: 1. When the exhaust damper is fully closed or the explosion vent may blow out. 2. If pulse air reservoir pressures exceed recommended maximum pressures damage to filter may occur. A regulator and gauge is mounted on the pulse air reservoir to regulate the air pressure. This regulator is preset with recommended maximum pressures at the factory and should not be reset without consulting Vector Service.
Page -16- PULSE AIR RESERVOIR RECOMMENDED MAXIMUM AIR PRESSURE Flo-Coater Model Regulator Part Number Diaphragm Valve Part Number Recommended Max. Pressure VFC-30 - VFC-30M HCA-1151-2 HCA-5404-4 25 PSIG VFC-60 - VFC-60M HCA-1151-2 HCA-8311-4 25 PSIG VFC-120 - VFC-120M HCA-1151-2 HCA-8311-4 25 PSIG VFC-200 - VFC-200M HCA-1151-1 HCA-5404-4 85 PSIG VFC-300 - VFC-300M HCA-1151-1 HCA-5404-4 85 PSIG VFC-500 - VFC-500M HCA-1151-2 HCA-8311-4 25 PSIG VFC-5MX HCA-1151-2 HCA-5404-2 25 PSIG VFC-15MX HCA-1151-2 HCA-8311-4 25 PSIG VFC-30X - VFC-30MX HCA-1151-2 HCA-5404-4 25 PSIG VFC-60X - VFC-60MX HCA-1151-2 HCA-8311-4 25 PSIG VFC-120X - VFC-120MX HCA-1151-2 HCA-8311-4 25 PSIG VFC-200X - VFC-200MX HCA-1151-2 HCA-8311-4 25 PSIG VFC-300X - VFC-300MX HCA-1151-2 HCA-8311-4 25 PSIG VFC-500X - VFC-500MX HCA-1151-2 HCA-8311-4 25 PSIG