Mixing-drying reactor

A mixing-drying reactor, which amixon developed for a manufacturer of pesticides, can process sub-stances of widely differing consistencies. The machine, which dries in a fine vacuum and performs an important process step in the synthesis of high-purity active ingredients, is also very flexible with re-gard to the filling level. When active ingredients are synthesised in the production of pharmaceuticals or the manufacture of pesticides, the consistency of the product frequently changes during the mixing and drying process. Plants that additionally process different active ingredients must therefore exhibit a high degree of flexibility. Processing of products with completely different consistencies
This requirement is fulfilled by a mixing-dryer / reactor that amixon has developed and manufactured for a well-known manufacturer of pesticides. The plant can process mixtures with dusty, flaky and powdery consistencies just as well as pasty, sludgy and viscous products. This is particularly important in the case of high-performance mixing-dryers, since viscoplastic phases have to be passed through in many drying processes. Typical is the transition from a pumpable suspended mass to a viscoplastic, rubber-like substance. As the liquid phase portion is further reduced, the mixture first becomes crumbly and granulate-like, then powdery and free-flowing. Combination of mixing and drying
The synthesis process requires the essential process steps to take place in the liquid phase. During the multi-step manufacturing process, different liquids are used in each case for rinsing and extracting. Transformation into a powder takes place in the last synthesis step by means of contact drying. The flexibility requirement is also satisfied with regard to the mixing process: the machine is suitable both for the careful homogenisation of the mixture and also for more intensive disagglomeration. In order to exclude unde-sired reactions and to ensure a constant quality level, the process takes place in a fine vacuum of 0.1 Torr (0.133 mbar). Constantly high mixing quality with widely differing filling levels
This flexibility also applies to the quantities that are mixed and dried. The reactor supplies a constantly high mixing quality with filling levels from 10 to 100 %. A very high degree of residue emptying is achieved when changing products thanks to the SimConvex® mixing tool developed and patented by amixon. In order to achieve this, the outer contour of this mixer is shaped like a sinusoidal curve. The mixture is conveyed upwards along the wall of the vessel and flows downwards in the centre of the con-tainer. This geometry guarantees that all of the mixture flows down to the base of the container during the emp-tying process. Mixing and drying in a fine vacuum
The vacuum mixer-dryer is capable of manufacturing a high-purity active ingredient. The mixing device is driven only from above and is fully heatable. The shaft seals of the mixing device shaft and the cutting rotor are imple-mented as face seals. In addition, the sealing valve at the end of the mixing chamber cone, which works without dead spaces, is highly gastight. Developed and manufactured for the highest requirements
The mixing chamber of the reactor was manufactured from Hastelloy C 22. This material achieves a high strength and is at the same time resistant to corrosion. The entire plant was manufactured according to the prin-ciples of ‘Good Manufacturing Practice' (GMP) and according to the requirements of the FDA. All qualification steps took place according to GMP. The complete documentation of development, manufacturing and commis-sioning also meets the high requirements of the pharmaceutical industry. Amixon was able here to fall back on its extensive experience in the development of mixers and reactors for customers in the pharmaceutical production industry. For European customers the machines are manufactured according to GMP principles. Certification to ASME, which is continuously renewed, facilitates the production of mixing plants for the pharmaceutical industry in the USA. In the past, amixon has already developed and pro-duced numerous mixing-drying reactors for pharmaceutical applications with container sizes from 1 to 15,000 litres.