GEA Single Pot Processors (One-Pot Processor) offer a choice of mixing, granulation and drying options integrated into one processing vessel. With our help, choose the most appropriate technique for your product.
A single pot processor is a high-shear mixer-granulator that is also equipped with drying technologies. Thus, single pot processing is the production of pharmaceutical granules using a wet granulation process in which dry mixing, liquid addition, wet granulation, drying and sizing of the granules is done in one machine.
|Bowl Volume (Litres)||7.9||27||77||153||303||400||614||900||1166|
|Typical Batch Weight @ 0.6 g/ml (kg)||3||11||30||60||120||160||240||350||480|
Effervescent granules and tablets are a popular dosage form for many active ingredients. The production of these products requires special attention. The UltimaPro™ FZ is specifically designed for the production of effervescent granules using the water-based reaction method, but its flexibility makes it suitable for all production methods of effervescents: 2-step and 1-step using solvents, 1-step using water.
For effervescent processes using water, excellent control of the reaction process is required to achieve more stable formulations. The UltimaPro™ FZ enables this by fast onset of drying using vacuum (optionally assisted by microwaves for even faster drying times), leak-tight operation and a specially designed, balanced vacuum system.
The use of vacuum for drying, combined with an inertization system using minimal amounts of nitrogen, allows the use of solvents for processing. The ingenious vacuum system with condenser allows for easy recovery of the solvent, thus minimizing solvent emission and reducing waste.
For more information, take a look at the the tab on Solvent-based Production.
The UltimaPro™ FZ is a Single Pot Processor equipped with a very efficient vacuum system, with a special balanced design for water-based effervescents. The bowl is leak-tight to enable a vacuum level of <3 mbar to be achieved. Recipes can be integrated for standard effervescent formulations.
Vacuum drying is the basic drying technology with the option of adding microwaves for even faster processing times, higher yield and more stable end product.
The production of highly potent compounds requires special care to avoid exposure of the operators to the drug as well as cross-contamination of other products manufactured in the same facility. The UltimaPro™ HC is specifically designed to allow fully contained production of highly potent compounds, avoiding all contact between product, operator and environment.
The concept of a Single Pot Processor in itself already ensures contained processing by executing granulation and drying in one vessel and thus avoiding product transfers. Additionally, the UltimaPro™ can be equipped with several features to optimize the containment of toxic pharmaceutical products.
The product feed and discharge valve can be equipped with Buck® Valve high containment technology and even isolator boxes if required by the customer.
A sampling valve that allows the operator to take samples during the process without having to stop the machine, open the bowl, or even open a port in the lid, can be integrated into the processing vessel and adapted to different containment levels. The sample container is completely contained allowing the sample to be transported to the QC lab without exposure to the atmosphere.
The concept of containment not only applies to the production area. When working with organic solvents, recovery and containment of these solvents is as important as containment of the product itself. The UltimaPro™ is equipped with a very efficient recovery system that can recover more than 99% of the used solvents.
Even for cleaning, the concept of containment is applied. The UltimaPro™ can be supplied with a wide range of washing-in-place and fully automated cleaning-in-place options.
The UltimaPro™ HC is a Single Pot Processor equipped with appropriate containment tools for loading and discharging (Hicoflex®, MC valves, etc.); a full, validatable CIP system; contained sampling options or PAT for endpoint determination; and an optimized vacuum system with HEPA filter.
Vacuum drying is the basic drying technology with the option of adding microwaves for increasing yield through optimization of the process parameters, reducing wet lumps and sticking.
Organic solvents are still widely used for pharmaceutical wet granulation for numerous reasons. The UltimaPro™ Eco is specifically designed for processing organic solvent based granulations in a safe and efficient manner by addressing the two main issues related to using solvents: explosion risk and solvent emission.
There is a risk of explosion when using solvents during granulation and drying or certain dry products with a low MIE. By eliminating one of the sources necessary to create an explosion, this risk can be effectively mitigated; the Single Pot System relies on an inertization procedure to achieve this. The oxygen in the bowl is replaced by nitrogen in an automatic cycle. Oxygen sensors can be provided to ensure the level is below the explosion limits.
Another advantage of using a single pot processor for solvent processes – related to explosion safety – is the fact that drying takes place in a vacuum, and is therefore in an oxygen deprived situation (even without inertization).
GEA is available to help you with extensive in-house experience in establishing a risk-based approach for validation and for HAZOP studies.
The UltimaPro™ Eco is a Single Pot Processor equipped with a very efficient vacuum system, allowing easy recovery of the solvent vapors up to 99.5%. Optionally, police condensers or active carbon filters can be integrated to eliminate all solvent emissions. The whole system is designed, executed and certified to comply with the ATEX guidelines.
Vacuum drying is the basic drying technology with the option of microwaves for faster processing times.
With the high-shear granulation technology as the basis, Single Pot Processing relies on the application of a vacuum within the bowl to dry the wet mass. This technique allows drying of pharmaceutical compounds at low temperature, and for minimal environmental exhaust through very efficient solvent recovery, even if organic solvents are used for granulation. The vacuum drying process can be enhanced by the Transflo™ technique or microwave drying.
Vacuum drying is the underlying drying principle of Single Pot processing. By lowering the pressure in the system, the evaporation temperature of the granulation liquid is decreased, thus reducing the processing temperature and the overall energy input required for drying. To achieve an optimal drying efficiency, the vacuum system of the UltimaPro™ range has been designed with special care. Excellent solvent recovery and a competitive drying rate can be achieved by incorporating condenser systems and selecting the right pumps. Different configurations are available to suit any process requirements.
Microwaves can be added as an additional energy source to further advance the drying process. Because of the additional energy added to the process, microwave drying is without a doubt the fastest drying method available in Single-Pot Systems. Our system is equipped with control and safety features to ensure excellent process control and complete safety for product, operator and equipment.
Process optimisation depends on efficient, effective cleaning. Clean-in-Place (CIP) systems can be incorporated into all the equipment produced by GEA for the pharmaceutical industry, including fluid bed dryers, high-shear granulators and liquid dosage formulation systems. Automating the cleaning process ensures repeatability, allows validation and minimizes downtime.
GEA supplies fluid bed processors (known as fluid bed Multi-Processor™ in the USA) for blending, granulating, drying, pelletizing and coating for the pharmaceutical industry.
A complete range of technologies for R&D designed for specific applications, our small-scale range covers every aspect of pharma oral solid dosage production, from high shear mixers, fluid bed dryers and single pot systems to extruders and spheronizers, blenders and containment solutions, right through to tablet compression.
Whether the customer’s requirement is for high shear mixing or granulation, GEA has a solution for every processing challenge and can help select the technology that is most suitable for your Pharma application.
The Lighthouse Probe™ can be used for real-time monitoring of chemical and pharmaceutical processes and provides in-process window cleaning at any time, recalibration during the process, full CIP (cleaning) of wash housing and seal, and a clear view inside – even in difficult conditions.
At the heart of GEA's small-scale and R&D approach is PharmaConnect®, which allows a number of diverse process modules from GEA companies to be docked to one control unit.
PMA™ High Shear and PMA-Advanced™ Mixer and Granulator is a multipurpose processor that's equally suitable for the high speed dispersion of dry powders, aqueous or solvent granulations, effervescent production and melt pelletization for Pharma applications.