Dry granulation of pharmaceutical powders

With the Pharmapaktor® Serie (Pharmapaktors series L, K, and C 250) from Hosokawa Alpine, active substance mixtures are processed into granulate.

For this, the powder is first pressed into flakes/pellets. These are often crushed with a Flake Crusher into granulate.

Compaction (dry granulation) is understood to be the compression of powder between two synchronized, counter-rotating rollers. The powder is fed to the counter-rotating rollers in a regulated manner. Here, adhesive forces between the product particles are created under high pressure between the rollers.

For capsule or sachet filling the granulate must be de-dusted in a screening machine. The sieved fines can then be directly fed to the Pharmapaktor again

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Cost-effective size reduction of polymers

The Granulator – PL polymer line from Hosokawa Alpine was specially designed for the cost-effective size reduction of mouldings, blown containers, sprues, flashes and other polymers. They are a synonym for a wide range of different mill designs intended for use as auxiliary and main mills.

This series features three various models, each engineered with dual-scissor-cut rotor mechanisms, an efficient product feeding apparatus, noise-suppressing elements, and a compressed and sleek architectural design.

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Cost-effective granulation at an attractive price

CL Compact granulator for cuttable products, from Hosokawa Alpine offers all the integrated technology necessary for the cost-effective comminution of all kinds of plastics. Developed as a universal granulator, it is characterized by a modern and user-oriented machine design as the starting point for custom-designed complete systems.

The universality and the technical features shift the product line right into the center of the customized systems for the recycling of plastic waste and plastic film of all types and shapes as well as other cuttable materials.

Its cross-scissor-cut rotor guarantees optimum material intake and distribution and thus high throughput rates at reduced energy consumption.

The typical materials processed are: PVC, Nylon, HDPE, LDPE, PP, ABS, PET, PC– TPU, PS, Cu, Copper wire, cables and many other materials.

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High troughput proven economical granulation

The Ro Rotoplex from Hosokawa Alpine consists in a cross-scissor-cut rotor that offers process technological superiority, saves energy, increases the service life, and improves the material feeding characteristics. These large granulators are capable of extremely high capacities due to our unique design and multiple knife geometry. Besides the classic field of plastics size reduction, Rotoplex large-scale granulators are exemplary for fiber, film, purgings, wire and cable and many more difficult materials.

Characterized by performance capacity, economy, and operating reliability. High-grade spheroidal graphite cast iron ensures that even in continuous heavy-duty operation, the Rotoplex granulators do their job reliably over many years.

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Compacts and Granulates Powdery Materials

Hosokawa Alpine’s Industrial Compactors and Granulators offer precise powder processing for chemical, pharmaceutical, and mineral industries. This equipment efficiently compacts and granulates diverse materials including powders and granules through high-pressure roller grinding and pelletizing. Designed for continuous, high-speed operations, it seamlessly integrates into your production line with PLC-controlled automation for streamlined processes.

Ideal for creating products like catalyst pellets, fertilizer granules, and extended-release tablets, it enhances flow properties and minimizes dust through its multi-stage compaction process. Available in corrosion-resistant materials like stainless steel, it adheres to GMP and FDA standards, ensuring compliance for pharmaceutical applications.

The system supports up to 50 tons per hour, optimizing energy use by 20% with variable-speed motor technology. Its construction allows for effortless cleaning, featuring a CIP system to maintain hygiene standards without cross-contamination. Comprehensive engineering support and customization options are available, including varying rotor speeds and chamber sizes to match specific processing needs.

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Processes and Classifies Diverse Material Types Efficiently

The Alpine Multiprocessing System from Hosokawa Alpine is an innovative solution designed to handle a wide range of material processing tasks with unmatched versatility and efficiency. What sets this system apart is its ability to integrate multiple mill types into one mobile and compact unit, allowing seamless transitions between grinding and classifying processes. This system is ideal for applications in the chemical, food, pharmaceutical, and recycling industries, producing end-products like titanium dioxide pigment, lithium-ion battery components, and lactose powders.

The operational principle relies on a modular design with interchangeable mill types, enabling R&D and pilot-scale operations to execute various processes such as grinding, milling, and compacting with ease. With the capability to support both small R&D labs and large-scale production facilities, this system ensures scalability and flexibility in production.

Automation is facilitated through a PLC-controlled interface, allowing precise control and integration into existing production lines. Built for efficiency, the system features energy-optimized motor controls that reduce power consumption, and it is constructed from high-quality materials that ensure durability and resistance to corrosion.

Compliant with GMP standards, the system provides easy cleaning and maintenance solutions, minimizing downtime with quick changeovers and clean-in-place options. Customizable features and engineering support offer tailored solutions to meet specific production needs, making the Alpine Multiprocessing System a versatile powerhouse in material processing.

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Pelletizes with Precision and Consistency

The Gear Pelletizer AGF GCS & AGF GMS from Hosokawa Alpine is an efficient pelletizing solution designed for various industries, including chemicals, food processing, and recycling. Utilizing counter-rotating hollow-toothed rollers, it ensures uniform extrusion and consistent pellet size, enhancing material flow and handling. Ideal for producing granulates across diverse applications such as lithium-ion batteries, spices, and recycling processes. This equipment excels in continuous and manual operations, offering flexible integration into existing production lines. With robust construction, it can process powders and granules efficiently and reliably. Available with engineering support for tailored customization, it ensures seamless integration and optimal performance.

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Reduces Plastic Waste to Granules

The Polymer-Line PL Granulator by Hosokawa Alpine is engineered to address the low-dust comminution of plastics and polymer waste, optimizing processes for plastic manufacturers and recycling companies. Its innovative cutting chamber geometry, featuring a cross-scissor-cut rotor, ensures efficient size reduction with minimized dust generation and energy consumption. Ideal for applications ranging from HDPE bottles to PVC granules, this granulator supports continuous and manual operations in sectors like chemicals, pharmaceuticals, and food processing.

The Polymer-Line PL accommodates robust processing capabilities with a drive power of 45 kW and a cutting rotor diameter of 450 mm, efficiently managing diverse materials such as polypropylene pellets and post-consumer recycled plastics. Its design allows seamless integration into existing production lines, with optional PLC controls enhancing automation. Sound insulation options are available to reduce operational noise, making it suitable for various industrial environments.

This granulator supports easy cleaning and maintenance, with rotatable screen and stator knives usable on four sides to extend operational life. The Polymer-Line PL’s customizable features ensure compatibility with specific production needs, while its durable construction guarantees long-term reliability in intensive industrial settings.

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Efficiently Cuts and Granulates Plastic and Rubber

The Rotoplex Ro by Hosokawa Alpine is a versatile granulator renowned for its robust construction and efficient cutting capabilities, designed for heavy-duty applications in plastics, rubber, and recycling industries. Integrating the patented Alpine cross-scissor cut technology, it ensures high specific cutting capacity, vital for processing various materials including plastics, film, rubber, leather, and more. With energy-optimized operation, it maximizes throughput while minimizing mechanical stress, prolonging durability even in continuous, high-speed operations. Available in sizes from 15 to 500 kW, it supports a range of applications from processing industrial wax and polymer coatings to preparing composite material granules and lithium-ion battery components. The Rotoplex Ro’s modular design allows easy integration into existing production lines, supported by options for stainless steel construction for enhanced corrosion resistance. Its engineering accommodates rotor knives usable on one side and stator knives on four sides for extended operational life. Offering optimal product feeding characteristics, this granulator ensures seamless automation and integration with existing control systems for streamlined operations, while its design allows easy access for maintenance and cleaning.

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Comminutes and Granulates Plastics and Films

The Compact-Line CL from Hosokawa Alpine is a versatile granulator designed for the efficient comminution of plastics and films. Engineered with a patented cross-scissor cut rotor, it ensures optimal material intake, reducing energy consumption while enhancing throughput. Ideal for applications in chemicals, food, and recycling industries, it efficiently processes materials into granules and powders, supporting a wide range of end-products like dyestuffs, fertilizer pellets, and soap pods.

The system features an electrohydraulic dual opening mechanism for easy access and cleaning, cutting down time between product changes. Available in capacities ranging from 30 to 500 kW, it offers modular design options for swift integration into existing lines. Its robust construction with standard and special wear protection makes it suitable for high-load operations. The Compact-Line CL supports continuous and high-speed operations, with a user-oriented design that permits rotation of the screen and straightforward adjustments of rotor and stator knives for reduced maintenance and spare part needs, ensuring longevity and cost-efficiency.

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