Elevating control strategies for fluidised bed drying to the next level
CONTROL & AUTOMATION VALUE-ADDED UPGRADES
OPTIMAL
Elevating control strategies for fluidised bed drying to the next level
The intrinsic capabilities of fluidised bed dryers ( FBDs ) in achieving precise , controlled , and uniform drying of wet solids have made them indispensable in a multitude of sectors . To harness the full potential of these systems , companies must keep pace with advancements in control technologies and industrial automation . Through value-adding upgrades to existing systems , end users can both improve the performance of these machines and open the door to the opportunities that smart manufacturing holds .
Alan Messenger , Sales Director at Optimal Industrial Automation , looks at how manufacturers and processors can advance their fluidised bed dryers to enhance competitiveness and profitability .
Offering a highly efficient drying method , FBDs play a fundamental role in various manufacturing industries , including pharmaceutical , chemical , and food & beverage . These machines can deliver high drying rates and short cycle times , ultimately helping companies maximise throughput . Also , thanks to their thermodynamic efficiency and ability to uniformly reduce moisture and minimise the potential for mechanical damage to materials , they can drive quality-centric operations .
In addition , FBDs help the formation of strong bonds for the agglomeration of powder formulations and make it possible to obtain perfectly compressed products , such as tablets and caplets . As a result , these units are extremely popular when handling powders or granules , such as granulation operations for oral solid dosage ( OSD ) pharmaceutical production .
Moreover , they have a direct impact on the characteristics of a product , such as shelf life and quality . By reducing water content in end products , the rate of both biological contamination and undesirable reactions are slowed , improving storability and transportability .
It ’ s all about control Beyond the key role of FBDs in effective drying operations , industry players also profit from the long service life of these machines , which can exceed 35 years . Due to the absence of moving parts , they require limited maintenance , lowering operational expenses and downtime .
The robust nature of these units , however , doesn ’ t mean that the system cannot benefit from upgrades . In fact , as the market places ever more demanding requirements on producers , continuously advancing manufacturing operations is a must to remain competitive . Typically , regular updates to control systems enhance time- , cost- , and energyefficiency , while outdated setups may lead to under- or over-drying , affecting product quality and value .
The recent quantum leap in control technologies and digital solutions has unleashed a number of new , highly advantageous opportunities for FBD-based processes in a very short time . By adopting smarter control systems that communicate with key sensors and analysers as well as monitoring and visualisation platforms , it is possible to develop a greater understanding of FBD units , their components , processes , feedstocks and products .
Users can leverage these insights to better manage their activities , from equipment maintenance to fluidisation and drying conditions . The response can be manual or automated , with FDBs accurately and precisely self-regulating their operations to improve efficiency , product quality and resource utilisation . Ultimately , within fully automated setups , FBD control can enable the development of interconnected , smart manufacturing frameworks that futureproof production operations .
Perhaps more importantly for companies in highly regulated sectors , the use of advanced control systems can help store valuable process information as well as produce documentation for quality audits , supporting regulatory compliance and current Good Manufacturing Practices ( cGMP ).
Advancing FBD control through collaborations
The upgrade of control systems for FBDs should be customised to the specific application while also taking a number of factors , such as compatibility with existing components as well as safety and regulatory compliance , into consideration . Therefore , it is advisable for end users to collaborate with a knowledgeable
40 PECM Issue 71