SIZE REDUCTION TECHNOLOGY
HOSOKAWA Alpine
Size Reduction Technology
Process Solutions for Granulation
Requirements
Alpine offers a variety of techniques Materials of Construction, Controls and Drives
tailored to meet the requirements of Finishes Alpine also offers several options for
your business. Although all of the product contact the control of these machines. Your
Pharmaceutical parts of the BEXMILL ABM series and choice range from manual speed
Food the Flake Crusher AFC series are controls through to variable speed
Chemical constructed from stainless steel, you drives for precision motor adjustment
Our technology increases and homo- can request custom construction from with integrated feedback loops.
genizes the bulk density of materials, other materials such as Hastelloy. The Standard electrical construction is
breaks down agglomerates and flakes Pre-Crusher APC series can also be NEMA 4X.
from roller compaction or other constructed from carbon steel.
processes. Granulating these by- The following finishes are available: The machines are suitable for ATEX
products improves flow properties. Ceramic linings zones 1 and 21
Brush finished
Mechanically and electropolished
Particle Size Capabilities
Pre-Crusher APC-P
Pre-Crusher APC-D
Flake Crusher AFC
BEXMILL ABM
100 µm 1 mm 10 mm 50 mm
2
BEXMILL ABM
Flexible, gentle processing Applications
Easy clean design Homogenization of particles
Conical mill design De-agglomeration of agglomerates
Vertical rotor Grinds oversized particles
Large inlet opening Improves flow characteristics
Minimal airflow Granulates roller compacted
material
Downstream of mixers, dryers and
fluid bed dryers
Prior to packaging equipment
Pages 4 - 7
Flake Crusher AFC
Fine, but not too fine Applications
Horizontal mill rotor De-lumping
Cylindrical rotor design Granulates flakes
Cage supported screen Homogenization of powders
Granulates soft to medium hard
materials with a definite top size
Pages 8 - 9
Pre-Crusher AFC-P / AFC-D
Ideal for preparing material Applications
Synchronous counter-rotating Performs first size reduction step
rolls prior to fine grinding
Pin or disc breaking device Dustfree size reduction
Low energy consumption Flake breaking
Creates free flowing material from
lumps
Page 10
Services Technologies Product Types
Technical testing center Compaction Flakes
Customer site visits and Briquetting Granules
seminars Granulation Briquettes
Manufacturing Size reduction of granules Pellets
Research and design Pelletizing Spherical granules
Systems design Extrusion
Feedback and control systems Spheronization
Automation
Validation
Page 11 Page 12
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BEXMILL ABM
High Capacity and Versatile Production
The BEXMILL ABM series offers you a The BEXMILL can be operated in a You can change screens quickly
variety of production capabilities. Our continuous or batch process. Granu- without any tools to avoid costly
machines can handle both small lation takes place between the downtime. Either way, the BEXMILL
laboratory requirements and large conical rotor and screen. Soft to maximizes process effectiveness while
production rates of up to 8 tons per medium hard flakes in a variety of reducing process costs.
hour. sizes can be granulated in one pass.
Because our machines are versatile, Your required particle size can be
they can be delivered with many achieved using a variety of inter-
accessories and in different con- changeable screens. This gentle size
figurations. For example, machines reduction avoids product damage
are available in both portable or and generates a minimal amount of
stationary designs. fines.
4
Hosokawa Alpine technology is more
than granulation and agglomeration
technology. We offer complete
technical solutions from product
feeding through to packaging. We
can plan and manage the entire
project from conception through to
training.
Technical Data
Model Drive Through put kg/h
kW Min. / Max.
ABM 150 1,5 20 / 200
ABM 200 4,0 100 / 1000
ABM 300 7,5 500 / 4000
ABM 400 15,0 1000 / 8000
Plant for the production of
pharmaceutical granules with a
maximum granule size
5
BEXMILL ABM
Easy Clean Design
The combination of the rotor speed
and screen selection determines the
final particle size distribution (a, b).
The critical gap between the rotor
and screen can be adjusted manually
o r a u t o m a t i c a l l y. T h e r o t o r i s
designed for long life and maximum
performance. Rotor seals are also
available with air or Nitrogen pur-
ging.
The BEXMILL is the perfect machine
for your GMP facility to process
pharmaceuticals.
All product contact gaskets and seals
use FDA approved materials.
Each unit can be custom designed to
accommodate a wide variety of up-
stream and downstream con-
nections. For example, inlets and
outlets of the mill can be designed
with beaded collars, tri-clamp
connections, or vacuum connections
(c).
a
Product contact areas can be washed
using CIP systems (d).
A telescopic outlet (e) can be used for
inline fixed installations. The
telescopic transitions are flanged to
the mill for a dust tight seal. All
flanges are machined. Silicone
gaskets are used between flanges.
The design eliminates the need for a
fixed pipe system between com-
ponents. It also facilitates the screen
changing process.
b c
d e
6
Mill Screens
Round hole
Rasp
Square hole
Rectangular
Screen hole sizes of 0,5 to 10 mm
Mill Rotor
2-arm-, 3-arm-, 4-arm-,
5-arm-rotor
Round profiled rotor arms for
moist product
Edge profiled rotor arms for dry
products
Exact rotor gap adjustment
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Flake Crusher AFC
Fine, but not too fine
Principle of Operation
The rotor cuts the material through a
screen surface using a rasp screen or a
hole screen. The throughput, particle
size range and crushing intensity are
governed by the rotor speed, while
the upper limit of the particle size is
dictated by the screen. Final screening
of the product to remove oversized
material is not necessary.
The Construction
The rotor is installed in a dust-tight
welded casing. The screens are
fastened to a supporting basket. Two
eccentric cam tensioning devices
allow adjustment of the screen basket
relative to the rotor for maximum
grinding efficiency and screen life.
8
Disassembling and Cleaning
All parts in contact with the product
being processed, including the rotor,
screen with basket and cam
tensioning devices, are easily
disassembled from the front.
Cleaning and disassembly can be
done in a few minutes without the
need for removal of the Flake
Crusher from the process.
Connection with Other
Equipment
The Flake Crusher makes a dust tight
connection with other equipment in
the operation.. For cleaning only the
quick-acting clamping device is
opened. The Flake Crusher is moved
to the front, out of the operating
area, on rails.
Accessories
The Flake Crusher AFC can be
equipped to suit each individual
application.
Feed and discharge hoppers
Flanged connections
Air purged seals
Track beam version
Dust exhaust connections
Mounting stands with rollers
Hopper with safety grid for
manual feeding
Screen hole sizes of 0,8 to 8 mm
Technical Data
Model Drive Throughput kg/h
kW Min. / Max.
AFC 200 0,75 50 / 500
AFC 300 1,1 75 / 750
AFC 400 1,5 100 / 1000
AFC 500 2,2 125 / 1250
AFC 600 2,2 150 / 1500
9
Pre-Crusher AFC-P / AFC-D
Low Energy - High Yield
Principle of Operation
Materials drawn in continuously
through the two synchronous
counter-rotating rolls. The peripheral
speed is set to match the throughput.
A very low grinding energy
consumption, as well as the
synchronous speed of the rolls assures
a nearly dust-free crushing process.
The Construction
All Pre-Crushers APC use a welded
casing with external bearing design
for low maintenance and high
reliability. Various materials of
construction are available depending
on the application. The separately
driven crusher rolls utilize an electric
drive without the need for gearing.
Crushing Roll Design
Pins (Model APC-P)
The design employing wear
resistant pins is used for the
prebreaking of thick flakes and
coarse feed material.
The material is crushed into pieces
approximately 20 to 30 mm.
Discs (Model APC-D)
The design employing discs is used
to crush thinner flakes to a final
size of less than 5 to 15 mm.
Hardness of pins
Shape of laser-cut discs
Requirement of hardfacing
Crusher gap
Types of materials of construction
Technical Data
Roll diameter 300 mm
Working width 200 to 800 mm
Drives 2 × 1,5 to 2 × 4,0 kW
1. Basic material, 2. Compactor,
3. Pre-Crusher APC, 4. Bucket elevator,
5. Fine breaker, 6. Screen, 7. Granules
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HOSOKAWA Alpine Technology
... More Than Just Machines
The HOSOKAWA Alpine
Test Center
Extensive know-how is available in
the Hosokawa Alpine test center to
provide technical and economical
solutions.
Customer tests are performed daily in
our testing facilities - a laboratory for
pharmaceutical applications as well as
a test center providing both the
complete machine equipment and a
pilot plant used for scale-up of
processing plants. Our analytical lab
can quickly analyse the product. The
results of our tests are not only the
production of samples or machine
configurations but also an individual
system design and complete process
engineering for your needs.
Development and Design
To accommodate our technology to
your application we use modern CAD
and our own fabrication. We develop
and manufacture new machines,
plants and processes to be able to
produce granules with specially
tailored properties. Due to the in-
tensive and worldwide cooperation
especially with sister companies and
research institutes we have a high
development potential at our
disposal, which we can offer for your
application.
Validation
We can validate both machines and
plants according to your given
standards (IQ and OQ validation).
Control and Automation
Process Logic Control (PLC) is standard
and can easily be interfaced with
other main process control and data
logging systems on your plant. Our
COMPACT CONTROL enables process
automation and visualisation
including process monitoring, data
gathering and diagnosis of errors.
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HOSOKAWA ALPINE
Agglomeration Technology
We bring your powder into shape
HOSOKAWA ALPINE Compaction The ALPINE Technologies Registered Trademarks:
P.O. Box 1152 Machines and complete plants for Kompaktor®
D-74207 Leingarten / Germany Compaction Pharmapaktor®
Tel.: ++49 (0)7131 / 898669-0 Briquetting
Fax: ++49 (0)7131 / 898669-309 Granulation
Size reduction
E-Mail: Pelletizing
[email protected] Extrusion
Spheronization
Delivery address:
Daimlerstr. 8
D-74211 Leingarten / Germany
Size Reduction - Oe - Schweikert - 06/14 - Printed in Germany
Hosokawa Alpine Compaction is a member of the Hosokawa Micron Group,
responding to global needs through emphasis on materials science and
engineering. The Group is an international provider of equipment and
technology for powder and particle processing, plastics processing and
confectionery products. The Group maintains facilities for research,
engineering, manufacturing and service in each of the world’s major industrial
markets.
