Air Atomizing Design, Features & Introduction

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2 Atomizing Design, Features & Introduction atomizing spray nozzles produces fine mist spray wit te elp of compressed air, liquid breaks into small droplets as air provides saring effects on liquid droplets. Various spray pattern are available, tere are categized into Flat and Round spray patterns. Te droplet size can be adjusted by flow adjustment of compressed air. atomizing nozzles are divided into two types Internal and External mix air atomizing nozzles. Tose are available in various metals. An air atomizing spray nozzles can wk on tree principles as below : 1) Pressure Principle 2) SIPHON Principle ) Gravity Head Principle 1) Pressure Principle is supplied in pressurised fm wit te elp of pump pressurised container, separate compressed air is needed 2) Sipon Principle Sipon principle is utilised to lift liquid from certain eigt from spray nozzle, suitable were pump pressurised container of liquid is not available. ) Gravity ead Principle Gravitational ead of liquid is utilised to feed liquid to te spray nozzle, suitable were pump pressurized container of liquid is not available

3 ???? Coice of spray Nozzles Eac spray set-ups consists of an air cap and liquid cap wic provide a specific spray pattern capacity and coverage perfmance Inside Body Mixing and air streams meet witin nozzle and are mixed togeter and expelled troug te same ifice. Tis internal mixing means te streams are not independent; a cange in air flow will affect te liquid flow. Tis makes precise metering of te liquid me difficult tan wit an External Mix Set-up. Internal Mix set-up are able to produce te finest atomization of any of te XA set-ups, but tey are generally not suitable f use wit liquids wic ave a viscosity tat is above 200 centipoise. ANNULAR AREA Feed? Feed Internal Mix Set-Ups & mix inside te nozzle Out Side Body Mixing Te air and liquid streams exit te nozzle independently and are combined and mixed outside of te nozzles. Because tere is no connection between te air and liquid lines witin te nozzles, te air and liquid flow rates can be controlled independently, allowing precise metering of te liquid. Te atomization can be controlled by adjusting te air flow rate me air produces finer atomization. In most cases tese set-up do not atomize as finely as Internal Mix Setups. Orifice? feed? feed? External Mix Set-Ups & exit independently and combine outside te nozzle External Mix Set-up may be used wit liquid aving a viscosity above 200 centipoise and f abrasive suspensions. Spraytec provides Engineering guidance f spraying ig viscosity liquids. Orifice Applications 1. Tablet Coating 2. Tin Film Coating. Humidification 4. Paper Moisturising 5. Dust Suppression Optional Features 1. Manual Sut-off / Cleaning Needle 2. Automatic self Cleaning Needle. Auto sut-off Arrangement Material Code M1 = SS0/SS04 M2 = SS16/M2L=SS16L M = Brass (Nickel Plating on Request) M4 = SS410/ M4-=SS10 87

4 CAIA Series Flat Internal Atomizing Spray Nozzles DESIGN / SPRAY CHARACTERISTICS Flow Rates and Dimensions Pressure-fed, Internal Mix, Flat Spray Pattern, " and " Pipe Sizes, BSP NPT Standard Materials: Nickel-plated Brass, 0 Stainless Steel and 16 Stainless Steel. Internal mix Flat fan, wide angle spray patterns Very fine atomization (range 45 and 120 ) Pipe Size Model No. Bar Bar Bar Bar Bar Spray Dimensions l/ l/ l/ l/ l/ C Effective Spray Lengt (mm) Max. Spray Lengt (m) CAIA CAIA CAIA CAIA CAIA CAIA CAIA CAIA C Effective Spray Lengt 88 16

5 CAEA Series Flat External Atomizing Spray Nozzles DESIGN / SPRAY CHARACTERISTICS External mix: allows spraying of viscous materials Variable atomization Moderate spray angle (range ) Precise metering of te liquid flow rate C Effective Spray Lengt Flow Rates and Dimensions Sipon-fed, External Mix, Flat Spray Pattern, " and " Pipe Sizes, BSP NPT Pipe Size Model No. Bar Bar Bar Bar Bar Spray Dimensions l/ l/ l/ l/ l/ C" Effective Spray Lengt(mm) Max. Spray Lengt (m) CAEA CAEA CAEA CAEA CAEA CAEA Standard Materials: Nickel-plated Brass, 0 Stainless Steel and 16 Stainless Steel. 89

6 Pipe Size Model No. Bar Bar Bar Bar Bar Spray Dimensions l/ l/ l/ l/ l/ C" Effective Spray Lengt(mm) Max. Spray Lengt (m) CAEA CAEA CAEA CAEA CAEA CAEA CAEA CAEA CAEA Standard Materials: Nickel-plated Brass, 0 Stainless Steel and 16 Stainless Steel. CAEA Series Flat External Atomizing Spray Nozzles 90 16

7 DAIA Series Full Cone Internal Atomizing Spray Nozzles DESIGN / SPRAY CHARACTERISTICS Internal Mix Very fine atomization Full Cone spray pattern ( range 45 to 120 ) Moderate fward spray projection C Effective Spray Lengt Full Cone spray pattern ( range 15 to 0 ) Flow Rates and Dimensions Pressure-fed, Internal Mix, Wide Angle Round Spray Pattern, " and " Pipe Sizes, BSP NPT Pipe Size Model No. Bar Bar Bar Bar Bar Spray Dimensions l/ l/ l/ l/ l/ C Effective Spray Lengt(mm) Max. Spray Lengt (m) DAIA DAIA DAIA DAIA DAIA DAIA Standard Materials: Nickel-plated Brass, 0 Stainless Steel and 16 Stainless Steel. 91

8 DASA Series Full Cone Sipon Atomizing Spray Nozzles DESIGN / SPRAY CHARACTERISTICS Lowest flow available Very fine atomization Narrow spray angle (12-25 ) Full cone pattern St to moderate fward spray projection B Effective Spray Lengt Flow Rates and Dimensions Sipon-fed, External Mix, Round Spray Pattern, " and " Pipe Sizes, BSP NPT Pipe Size Spray Set-up Number ATOMIZING AIR 450 mm Gravity Head 00 mm Capacity in l/ (Liters Per Hour) 150 mm 100 mm 200 mm Sipon Heigt 00 mm 600 mm 900 mm Spray Dimensions at 200 mm. Sipon Heigt B Effective Spray Lengt(mm) Max. Spray Lengt (m) DASA DASA DASA DASA DASA DASA Standard Materials: Nickel-plated Brass, 0 Stainless Steel and 16 Stainless Steel

9 Literature Tablet Coating Process It is te process to apply coating material on external surface of tablets to enance its efficiency and properties. Today many solid parmaceutical dosage mediums are produced wit coatings, eiter on te external surface of tablets, on materials dispensed witin gelatine capsules. Coating serves a number of purposes rigt from protecting stomac lining from aggressive drugs to protecting te tablet from stomac acids. It also elps in maintaining te sape of te tablet and tus can offer a delayed release of te medication. But f good results, a better coating medium is required. And te same can be fulfilled by Tablet coating spray nozzles. General purposes of tablet coating Covers unpleasant taste, colour and odour Cemical and pysical protection from environment To control te release of drug wit enteric coating It protects drug from gastric surrounding of stomac Provide way to identify te drug and improves appearance Results of bad coating Sticking picking Rougness Twinning Peeling Cracking Example of Bad Tablet Coating Granulation Wit RMG / HSG Also known as wet granulation process. material is loaded into bowl aving agitat and copper and mixed rigously ten binder material is sprayed from top and granules are fmed. Good quality granules are foundation f good quality tablet. Various liquid blinders are used f wet granulation. Spraying binder over bulk material could reduce wet granulation cycle time and increase productivity. 9

10 Fluid-bed System Fluid bed process consists of following applications : 1. Drying Process o f extracting moisture from solid bulk material by making it fluidized wit ig flow blow of air, so moisture is removed omogeneously and all over surface of every single particle. 2. Granulation/ Agglomeration P o w der particles of bulk material bonded by liquid fine spray. could be water an ganic solvent and te powder material will be mixed togeter. Agglomerate as less strengt of particle bond.. Coating Fluidized p a r ticles are coated wit spray of coating material wic enances. coating film must be very unifm over te particle surface. 4. Tangential Coating Centrifugal m o tion is used f making sperical pallets, at te same time particles are bonded by binder liquid. layering also can be done in same way. Top spray Bottom spray Tangential spray 94 16

11 Coating Spray Nozzles RC Series Spraytec's RC Series tablet coating spray nozzle are specially designed to meet GMP requirements were surface texture plays very imptant role. Te unique Cap design makes it Anti Bearding and keeps coating process sutdown free, tus iger production ratio and quality requirements are acieved. RC series spray nozzle is a compact device incpating of independent controls f, Atomizing and Fan f fine tuning of spray capacity, droplet size and spray patterns. It is available in wide variety of spray setups tat give a complete selection of flow rate and flat spray patterns. R series spray nozzles are externally mix nozzles. Tis means te liquid and air are mixed outside of air cap to produce complete atomized spray. Te liquid atomization is controlled by varying atomizing air and fan air pressures witout canging liquid flow rates. Te flat spray pattern is controlled by varying te fan air pressure in conjunction wit te atomizing air. Tis is effective f ig viscosity liquids, coatings and suspensions. Tablet coating spray nozzle features a cylinder f controlled "on-off" operation. Te cylinder controls a liquid clean-out/ Sut-off needle wic also cleans te liquid ifice. Spray Nozzle Type RC Spray Type : bne Atomised ifice size Range (standard) mm 0.8 -, () Solution Flow Rate (typical per nozzle) Liters/our 6-0 Atomizing Pressure Range bar - Spray Widt Pressure Range bar - Maximum Compressed Pressure bar Compressed Consumption bar) ³/our 16 Seal Material (standard) ceck compatibility f ganic use FDA Approved 95

12 Coating Spray Nozzles RC Series DESIGN FEATURES 1. Separate atomizing and fan air lines f complete control. 2. Provides variable coverage and fine control of drop size witout affecting liquid flow rates.. Higer atomizing air pressure yields fine droplet size. 4. Higer fan air pressure yields broader patterns. 5. Non clogging and anti - bearding design Te R Series coating Spray Nozzle are a compact, precision nozzles. Incpating independent controls of liquid atomizing air and fan air f fine tuning of spray capacity droplet size and spray patterns. It is available in a wide variety of spray Set-ups tat give a complete selection of flow rates and flat spray patterns. Atom Fan Part Details Details of Inlet Connections 1 Lock Nut 7 Cup Seal Packing 2 Cap 8 Needle Assembly Fluid Cap 9 S pring 4 Seal 10 Strainer Disc 5 Body 11 End Cap 6 Spacer 96 16

13 RB Series Flat External Mix Coating Spray Nozzles Design Summary : RB Series variable spray nozzles provide unifm spray distribution wit unifm droplet sizes, even wen spraying viscous fluids. F finest tuning of liquid flow rate along wit spray pattern and droplet sizes independent controls are given in spray nozzles assembly.. Suitable f large scale production. F various settings of spray droplet sizes separate air controller is given in spray nozzle assembly. Additional inlet /outlet pt allows f liquid re-circulation tat effectively maintains te flow of viscous liquids. Having removable auto sut off and spring loaded needle cylinder assembly is provided f maintenance. ( Orifice Range : to MM) Part Details Details of Inlet Connections : 1 Lock Nut 2 Cap Fluid Cap 4 Body 5 Cylinder (Needle) Assembly Wit fan air: Flat Spray Pattern. Witout fan air: Round Spray Pattern. 97

14 RAS Flat External Mix Coating Spray Nozzles Orifice Range : 0.5 to 1.2 MM RAS type tablet coating spray nozzle is very compact and ligt weigt design and it comes wit 4 pts of controls. Externally mixed atomized spray properties could be canged as per need wit fine tuning of individual pressures of Atomizing air, Fan & liquid pressure. Integrated needle assembly provide te Auto-sut off and Auto Cleaning of liquid ifice. RAS type spray nozzle is suitable f Lab-coater, Auto Coater and Conventional coater. Spray setup available wit Flat Fan, and Round Pattern. All Sealing materials are FDA Approved. Part Details Details of Inlet Connections 1 Lock Nut 9 Needle 2 Cap 10 Needle Nut Fluid Cap 11 Needle Spring 4 Body 12 Packing Screw 5 Seal 1 Rear Spring 6 Seal Guide Packing 14 Retainer Nut 7 Piston 15 End Cap 8 Seal 98 16

15 RCS Flat External Mix Coating Spray Nozzles Wit Flow Control Witout Flow Control Orifice Range : 0.5 to 1.2 MM SPRAYTECH S Latest Development, RCS series coating spray nozzles offers very compact design wit innovative flow control feature. Tis feature offers te user to take te RCS coating nozzle from te lowest 20 ml to its max limit is just a spin. RCS type coating spray nozzle is very ligt weigt and features anti bearding air cap design wic eliminates te deposition of material over te air cap and abolises bearding over gun. RCS comes wit individual pts f liquid, Atomizing, Fan control and auto sut-off f total control. Also as it is as external mixed design tus, atomized spray properties could be canged as per need wit fine tuning of individual pressures of Atomizing air, Fan & pressure. Innovative needle assembly provides te Auto-sut off and Auto Cleaning of liquid ifice. RCS type coating spray nozzle is suitable f Lab-coater, Auto Coater and Conventional coater. Spray setup available wit Flat Fan, and Round Pattern. All Sealing materials are FDA Approved. Part Details Details of Inlet Connections 1 Lock Nut 2 Cap Fluid Cap 4 Body 5 Needle Assembly 6 Needle Spring 7 End Cap 8 Ceck Nut 9 Flow Adjustment Screw 99

16 FBP Top Spray Nozzle & Lance Spraytec's Top Spray Nozzles are design f Large Scale, Medium Scale and Lab Scale Fluid Bed Processs. Manufactured accding to GMP and available in wide range of spray rates. And external mix spray setup enances te spray quality and distribution in optimum way. Design Features Available in 1,, 6, 7 spray eads Available in various spray angles (Top down spray) Auto-sut off Feature Anti-drip spray eads Long Life Lance design Compact design of spray nozzle Homogeneous spray distribution Fine droplet size, best f dry granulation, pallet coating, and agglomeration. GMP Suitable design Anti-clogging lance Made from SS16L and All O-rings from FDA Approved material Custom made designs available

17 FBP Bottom Spray Nozzle & Lance (Wurster Coating) Spraytec s specially designed and customizable Fluid bed Bottom spray (Wurster coating) nozzle elps to improve te wurster coating application and also makes it possible to attain ig-quality results in coating pellets and particles. Designed f All type of Bottom Spray Coating, Allegiant spray distribution and fine droplets results in optimum quality of coating. Ligt weigt design and easy to control te spray parameters. Minimum internal parts ence less maintenance, Design Features Optimum spray quality Anti-drip spray tip Auto-clean needle assembly Easy to assemble and dismantle Special air cap design to avoid material build-up GMP Suitable design Anti-clogging lance Available wit various ifices sizes Made from SS16L and All O-rings from FDA Approved material Custom made designs available 101

18 RMG / HSG Top Spray Nozzle & Lance Spraytec's RMG / HSG Top Spray Nozzles & Lance are design f Large Scale, Medium Scale and Lab Scale Rapid Mixer Granulat and Hig - Sear Granulat f Wet Granulation. Superi spray quality produces best in class granules from bulk. Manufactured accding to GMP and available in wide range of spray rates. And external mixing spray setup enances te spray quality and distribution in optimum way. Spray Nozzles and special purpose lance designs available Design Features Available in 1,, 4 spray eads Available in various spray angles Auto-sut off feature Anti-drip spray eads Long Life Lance design Compact design of spray nozzle Homogeneous spray distribution Fine droplet size, best f wet granulation, GMP Suitable design Anti-clogging lance design Made from SS16L and All O-rings from FDA Approved material Custom made designs available

19 Spray angle range : 60º - 80º Flow range : 10 LPM to 50 LPM Features: Anti drip Spray setup Auto sut off Finest droplet Size Internal Mix Setup Special Design F R&D & Pilot RMG / HSG Equipment Spray angle range: 20º - 90º Flow range : 1 LPM to 8 LPM 10

20 Mounting Assembly Accessies Optional Accessies available f R series coating spray nozzles F round rod (ACC405) F Hex rod (ACC406) (ACC006) (ACC005) (ACC0) (ACC04) (ACC05)