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Jan Kirchhof, Glatt Ingenieurtechnik GmbH, Germany, reports on a laboratory experiment with phosphorus fertilizers and two current projects. » originally published in the trade magazine ‘World Fertilizer’, issue 11/2021, Palladian Publications Ltd. In the March 2019 issue of World Fertilizer, Glatt discussed the ‘PHOS4green’ process for the production of ready-to-use fertilizer from phosphorus-containing sewage sludge ash. This technique was designed to meet the legal phosphorus recovery requirements stated in the ‘German Fertilizer Ordinance’ (DüV), which will apply from 2029 onwards, and the ‘Sewage Sludge Ordinance’ (AbfKlärV) of 2017. As a result of this legislation, an increasing number of public sector, industry, research and political players are joining forces to jointly invest in and develop new phosphorus recovery strategies. In mid-June 2020, the European Commission also reviewed the ‘Sewage Sludge Directive’ (86/278/EEC).[1] Three stakeholder organisations, including the European Phosphorus Platform (ESPP), the German Phosphorus Platform (DPP) and the Dutch Nutrient

Closing the Loop: Phosphate fertilizer from sewage sludge ash. Glatt’s PHOS4green technology provides an economically and ecologically viable solution suitable for closing the phosphorus cycle. Ash-based recycling processes are among the most promising and economically attractive options when it comes to implementing the legally stipulated phosphorus recovery. The first fertilizers produced using the PHOS4green process have been available on the German market since June. The technology, which breaks down the phosphorus contained in sewage sludge ash and makes it reavailable in marketable end products, was developed by plant engineering and process expert Glatt Ingenieurtechnik in cooperation with fertilizer specialist Seraplant. (Article in German language) » Author: Jan Kirchhof, Senior Sales Manager Process & Plant Engineering, Glatt Ingenieurtechnik GmbH » originally published in the magazine ‘Verfahrenstechnik’, issue November/2021, Vereinigte Fachverlage

Glatt has expanded its range of services and capacities at the company’s Technology Centre in Weimar for trials and sample development When developing and launching new products, speed is a critical factor. However, sensitive ingredients and solvent-based processes often present manufacturers with technological challenges. In process expert and plant manufacturer Glatt’s upgraded technology centre, support from initial idea and scale-up to industrial production is readily available. At the company’s Technology Centre in Weimar, Glatt operates a unique fluid bed system that processes solvent-based products in a vacuum or using nitrogen as the process gas. As such, demand is high for scale-up tests, product sample production or short-term contract manufacturing services until the client’s own production plant has been commissioned. However, a new fluid bed granulator and coater for innovative solvent-based processes has recently become available. The batch-mode apparatus is ideal for small and medium campaigns that include frequent cleaning cycles. Special explosion protection measures, a 12

The outsourcing of production and the division of labour are key factors for seizing market opportunities and growth in the post-industrial age. For decades, large companies have outsourced production capabilities, thus driving globalisation –but also contributing to the decline of domestic industries. Digitalization, however, means it makes sense for more and more well-known global players to relocate production back to Europe. Contract manufacturing, for example, gives an idea of where this journey can take us. For a long time, the outsourcing of certain manufacturing tasks promised potentially large cost-savings for companies, with personnel-intensive business areas reduced in size or even closed completely and processes – from toy production to the manning of telephones – relocated in order to save time and money. At the same time, service providers who were not only able to cope with special projects, but were also increasingly able to build up technological know-how, found an increasing demand for their services. The reason for this was – and still is – the continued and growing need for tailor-made

An overview of essential oil and vitamin case studies Phytochemicals are increasingly found in many food, chemical and agricultural items. Product and process optimization is becoming ever-more important in all of these industries, with a focus on quality, manufacturing efficiency, stability and formulation costs. Essential oils are volatile substances with a relatively high vapor pressure; they are susceptible to oxidation and light and may change or may even lose their properties when directly exposed to stressors. Like other sensitive, volatile, odor- or taste-intensive liquid active ingredients, they must therefore be protected from the environment or vice versa. For this protection and to simplify handling — as well as for better dosage and targeted release — these substances are therefore progressively offered and used in encapsulated and/or free-flowing forms. Various processes can be used to deliver products with a compact structure. During process development, the most suitable procedures and equipment

Glatt PHOS4green plant for fertilizer production with phosphorus from sewage sludge ash at Seraplant in Haldensleben, Saxony-Anhalt, Germany started up Residue-free production of ready-to-use fertilizer from phosphate-containing sewage sludge ash is now possible, thanks to plant manufacturer and process expert Glatt Ingenieurtechnik, and fertilizer specialist Seraplant. After a 20-month construction period, the first production plant for phosphate-containing mono and complex fertilizers made from recycled sewage sludge ash is now in operation. Seraplant operates the new plant at its headquarters in Haldensleben, Saxony-Anhalt, Germany. Glatt Ingenieurtechnik, a globally active plant engineering company, was responsible for the process development and construction. The official commissioning on May 31, 2021, was attended by Prof Dr Armin Willingmann, Saxony-Anhalt’s Minister for Economics, Science and Digitalization. Seraplant invested more than 20 million euros in the new production facility, with the support of the state of Saxony-Anhalt. As a result, more than 20 new jobs have been created in the southern

Fluidised bed and spouted bed processes offer manufacturers almost unlimited possibilities in terms of optimised particle design and the functionalisation of ingredients, the properties of which can be fine-tuned Fluidised bed and spouted bed processes by Glatt offer manufacturers almost unlimited possibilities in terms of optimised particle design and the functionalisation of ingredients, the properties of which can be fine-tuned using spray granulation, agglomeration, microencapsulation and coating. The consumer demand for fortified products is constantly growing and has been well received by end users. The form in which health-promoting probiotics, dietary fibres or antioxidants are consumed depends on both the preferences and everyday habits of the individual: some prefer sports drinks, protein bars or enriched iced tea, whereas others favour more direct dosage forms, such as effervescent tablets, sachets or capsules. However, although the manufacturing processes associated with these products present numerous challenges, a universal requirement is that functional ingredients must be stable during storage, precisely dosed, dissolve quickly or have a depot effect. Key

Meet the Glatt experts in an online course about Fluidized Bed Technology, from May 19 - 21, 2021. Part of the Seydlitz Engineering Courses Fluid bed equipment design Do you want to learn more about fluid bed equipment design and what options it allows in terms of dust removal and material recycling, feed and product discharge, or residence time and residence time distribution? Lecture on fluid bed design and operation In his lecture on "Fluid bed granulation/coating - equipment design and operations", Didier Schons, Glatt Ingenieurtechnik, will explain these topics, presenting the differences between batchwise and continuous operation, as well as various aspects for particle and product flow. You will learn more about open and closed process gas systems as well as about the premises for the use of multi-purpose plants. The explanations will be illustrated by means of selected case studies. More information on the full event of the Seydlitz Engineering Courses can be found through the link under ’More information’. Outcome Through alternating presentations, exercises and plenum discussions

Webinar-Recording of POWTECH Virtual Talks Volume 7.0 | Handling of sensitive bulk products before and after production processes Glatt fluidized bed spray granulation was part of POWTECH Nuremberg Virtual Talks “Processing fragile bulk materials”. Missed the webinar? You can now re-watch - free of charge - the recording of Didier Schons’ presentation and discussion on the topic of "Producing dust-free granules by drying and granulating liquids in just one process step". Powders and liquids can be granulated, coated, encapsulated, dried and functionalized by fluidized bed and spouted bed technology in only one step. Learn more about intelligent particle design to generate and functionalize powders and granules with adjustable properties. Product properties such as freedom from dust, particle size and particle size distribution, porous or compact structure, particle density, bulk density, homogeneity, hygroscopicity, surface quality, abrasion resistance, solubility, shelf life, dosing, flowability, flow behaviour, optical attractiveness, taste or smell, release behaviour/depotting

Join the POWTECH Nuernberg Virtual Talks vol. 7 Glatt fluidized bed spray granulation will be part of POWTECH Nuernberg Virtual Talks “Processing fragile bulk materials”. April 27, 2021: 10:00 a.m. Register now and join the talk by Didier Schons about “Creating dust-free granules by drying and granulating liquids in just one process step”. Powders and liquids can be granulated, coated, encapsulated, dried and functionalized by fluidized bed and spouted bed technology in only one step. Learn more about intelligent particle design to generate and functionalize powders and granules with adjustable properties. Product properties such as freedom from dust, particle size and particle size distribution, porous or compact structure, particle density, bulk density, homogeneity, hygroscopicity, surface quality, abrasion resistance, solubility, shelf life, dosing, flowability, flow behaviour, optical attractiveness, taste or smell, release behaviour/depotting effect and others can be specifically influenced

This workshop on fluidized bed technology is a perfect combination of theory, hands-on training and demonstrations. 1-day-online-workshop april 29, 2021 The workshop provides the basics of drying, granulating, coating and pelletizing and outlines their applications in the powder processing industry. This workshop is the perfect investment for those who wish to acquire knowledge of fluidized bed technology. LESSONS (1) Granulation, Agglomeration, Pelletization Basic principles and applications; The presentation provides an overview on fundamental differences between various product structures, like granules, agglomerates and pellets, as well as on their application in regards to their properties. Additionally, an insight into the general set-up of typical process equipment is given. The presentation is completed by an overview of the particulate systems produced in industrial scale fluidized bed processes. (2) Process development and industrial scale-up For spray granulation applications; Technical concepts for larger scale fluidized bed spray granulation plants will be

Plant protection products, be they herbicides or fungicides, must be dust-free, free-flowing, stable, safe to handle + provide good redispersibility properties. Product development usually focuses on the optimization of successful products: That means improved effectiveness and storage, safer handling and easier dosing. As well as these long-standing challenges, however, farmers and manufacturers of crop protection products are facing an increasingly fragmented market with regionally specific requirements. Due to globalisation and imbalances in the ecosystem, it is becoming increasingly necessary to control pests in a targeted manner and protect plants from previously unknown threats. Yet a growing market for organic farming means an increase in demand for biological or biodegradable crop protection agents which are obtained, for example, by fermentation processes. Industrial processing means these intermediate products are not temperature-stable and require gentle treatment at low temperatures. A further challenge is climate change: Cultivated areas in normally temperate climate regions are now exposed to weather events such

Sensitive raw materials, especially those that are volatile or of natural origin, require particularly gentle process conditions. Spray granulation, spray coating and (micro)encapsulation procedures have proven to be methods of choice, as they enable high yields, low temperatures and bespoke properties. When it comes to cosmetics, product development often focuses on proven, multifunctional ingredients. This is in addition to the ongoing demand for natural ingredients, as consumers increasingly look for effective cosmetic products that neither harm their health nor the environment. Glatt Ingenieurtechnik, the German expert in particle design, process development and plant engineering, offers unique particle processing solutions based on fluidised bed and spouted bed technologies for essential oils, collagens, active substances, stabilizers, enzymes, fragrances, aromas, vitamins and controlled release products, all of which can be optimally produced, protected and refined. Efficient fluidised and spouted bed processes Unique flow, mechanical and thermodynamic properties make fluid bed technology

Cleaning agents and detergents can be produced environmentally friendly and effective, using fluid bed and spouted bed technologies. Experts from Glatt Ingenieurtechnik explain. As a manufacturer of consumer goods, the detergent industry must respond to megatrends like no other. One of these drivers is sustainability; eco-friendly biosurfactants have been available since 2009 and, now, alternative complexing agents such as α-ADA or MGDA-Na3 can be produced from renewable raw materials and used to replace phosphates. According to the German Zukunftsinstitut (Future Institute), the neo-ecology megatrend is causing a reorientation of the values of global society, culture and politics and will have a defining impact on the 2020s [1]. Consumers and business partners alike are asking about transparent value creation and whether social aspects are being considered. As an example, seamless traceability has long been standard practice. Yet, the ongoing microplastics debate calls for a rethink when it comes to encapsulated fragrances or when the fibres of functional clothing have to be fished out of wastewater. Solutions for all these requirements can

Glatt Fluidized Bed and Spouted Bed Processes @ Virtual Process Show 8-11- September 2020 Drying and granulation of solutions, suspensions, emulsions and melts in a single process step. Generation of functional, dust-free granules with homogeneous component distribution and adjustable particle sizes. Your benefits: * Greater functionality, stability and protection for your products during processing, handling and storage * Improved flowability and dissolution properties, no separation of components, compact form for coatings * Safer for operators and the environment: Prevents contact allergies and burns

Enhancing continuous spray agglomeration processes - set up in just 12 days At Health ingredients Europe 2018 in Frankfurt, Germany, plant manufacturer Glatt Ingenieurtechnik will be presenting a newly developed modular and compact plant concept for continuous spray agglomeration. Featuring multi-step and multi-zone processing, the GF ModFlex is compact, flexible and features a new control system developed by Glatt. As more and more people adopt better-for-you diets, the demand for enriched and sugar-free foods, on-the-go drinks and dietary supplements is rising. But protein shake consumers will only become repeat purchasers if the powder dissolves quickly and without lumps; similarly, eaters of vegan ice cream won’t appreciate the presence of ice crystals in their tasty treat. Spray agglomeration during fluid bed processing ensures that proteins and sweeteners such as maltitol or cellulose derivatives can be properly wetted, have a more porous surface and are more flowable and easier to dose. Their bulk density is also significantly reduced,

for continuous spray agglomeration of food and feed ingredients Based on proven fluidized bed technology Glatt offers a newly developed compact, flexible and modular plant concept for maximum process flexibility, reduced investment costs, low operation costs, minimum space requirements, maximum flexibility, fast installation by plug & play, and safe operation due to hygienic design (EHEDG), high filter performance, integrated WIP, and dust Ex-design (St 1).

Glatt presents a new fluid bed design for continuous spray agglomeration for food ACHEMA 2018, Hall 3.0, Booth F1: At ACHEMA, the leading international trade fair for the process industries in June in Frankfurt am Main, market leading supplier of fluidized bed and spouted bed technologies, Glatt, will showcase several new developments, including a new modular and compact plant concept for continuous agglomeration - focused on food applications - as well as a modular control system that’s easy to customize. For the first time, Glatt will introduce a compact, newly developed fluidized bed plant concept for the continuous fluid bed spray agglomeration of fine powders and powder blends. GF ModFlex enables the production of uniformly porous, virtually dust-free, outstandingly soluble and very easily dosed granules. The process also ensures the homogenous incorporation of ingredients into agglomerates. Being a gentle process, the nutritional and functional properties of the ingredients are preserved. When it comes to product quality, the systems designed

for cleaning in running fluid bed operations With Glatt Ingenieurtechnik’s newly developed spray nozzle device, the inner tube can be removed and cleaned safely while the process is still running. When it comes to spray granulating, spray agglomerating or spray coating and drying food ingredients by fluidized or spouted bed technology, spray nozzles play a key role in quality control. With its hygienic, explosion-proof removable spray nozzles for the food and pharmaceutical industries, particle design specialist Glatt Ingenieurtechnik sets new standards in process safety and plant availability. If unexpected quality issues arise during the fluidized bed process, such as particles becoming too large or coarse, it might be because of a change in the nozzle spray pattern. Sticky or crystallizing spray fluids such as salts or sugar may induce fluctuations in the spray pattern, and also hygroscopic products which sometimes remain in the plant during downtime. A spray unit consists of a fluid-carrying inner

Inline particle measurement allows differentiated process control in the granulation To achieve a high quality production results, Permanent measurements and checks during the process are indispensable. Since sampling and evaluations are very aufwndig laboratory and provide only delayed opening information is precisely in these production areas inline measurement, with can be checked at any time and possibly affect the processes, particularly important. The IPC Process Center GmbH & Co. KG, a company of the Glatt Group, the innovative granules and pellets for producing the pharmaceutical and food industry, uses therefore for permanent monitoring of their sensitive processes inline particle probes of Parsum GmbH. With the accuracy of the probes IPP 70-S and IPP 70-Se the Korngrenverteilung the intermediate and end products is constantly under control, so that the processes can, accurately controlled. The optimal Prozessfhrung significant financial savings are possible. The installation of two inline-probes fr gives us the advantage that the production

Batch and continuous granulation and coating in one equipment for maximum process flexibility Weimar, August / 19 / 2014 – In a world of short-living products, flexibility of production equipment may give the leading edge on the market. For fluid bed processes, Glatt has designed and installed this flexibility in large scale. The AGT System can be equipped with an AGT insert for continuous spray granulation, a GF insert for continuous agglomeration and coating and a Vario insert for agglomeration and coating in batch mode. With this equipment even contract manu-facturers achieve the flexibility that they need to serve multiple cus-tomers. One unit with high capacities ensures low production cost. All inserts are shown at the Powtech 2014 in laboratory scale with the ProCell LabSystem. Fluid bed equipment can be used for spray granulation, agglomeration and coating. The process can be controlled and the product quality optimized by changing various parameters, including the design of the processing chamber. Laboratory equipment for feasibility trials typically

Laboratory fluid bed all-rounder now available in its 100% explosion pressure proof PRO version Glatt"s ProCell LabSystem – the most flexible laboratory fluid bed unit on the market – will be introduced in a fully explosion pressure proof PRO version at POWTECH 2013. Integrated in a mobile main unit, this modular lab all-rounder thus allows the use of all process options for batch and continuous fluid bed, spouted bed or rotor processes for a great variety of material systems such as powders entailing the risk of dust explosion up to hybrid mixtures. This compact and modular lab system allows you to process all dusts of the classes St-1 and St-2 as well as organic solvents. Users can benefit from considerable savings in safety reviews prior to trials or production while being prepared for the processing of future product generations. Using the proven concept of "avoiding ignition sources" an explosion is very unlikely. If an explosion occurs nevertheless, it will be enclosed within the explosion pressure proof ProCell LabSystemPRO and there

Processing of all St-1 and St-2 dusts and their hybrid mixtures The ProCell LabSystem – the most flexible fluid bed laboratory unit for granulation processes – is introduced in explosion pressure proof design at ACHEMA 2012. All St-1 and St-2 dusts, which means almost all common solid materials, can be processed in the lab unit. By this means the time needed for safety review prior to trials can be considerably reduced. In addition the equipment is safe for the future – even with products, not known today, tests will be possible. The proven concept of “avoiding ingnition sources” is still applied and makes explosions highliy unlikely. Yet, in case of an explosion, it is contained inside of the equipment. Solvents can also be processed, using additional equipment. In this case the solvents and explosive dust form hybrid mixtures. An explosion of these mixtures is also kept inside the pressure shock resistant ProCell LabSystem. When processing solvents not only explosion protection but also the environment and the cost

Product safety for food, biotechnology or similar applications Apart from the legal requirements in particular the EHEDG guidelines provide valuable directions and specifications for the hygienic and aseptic design of equipment, systems and complex production facilities. These have also to be considered for a hygienic conception of production processes for solid product forms. As a system provider of equipment for solids process engineering and an active member of the EHEDG-subgroup "dry material handling" Glatt Ingenieurtechnik Weimar makes its contribution to the development of guidelines in this field. Results from many years of experiences are considered in the relevant documents. To be able to produce under hygienic conditions a HACCP concept is developed together with the customer. Various requirements resulting from this concept have to be considered. Glatt Ingenieurtechnik has many years of experiences in this field. Several production facilities with specific hygienic and cleaning requirements have already been

Cleanability of fluid bed units in all scales Fluid bed and spouted bed units of Glatt are used to produce or improve granules and pellets. Spray granulation, agglomeration, coating and encapsulation are the most common processes. Glatt is supplying production size equipment with automatic cleaning systems since several years. Now it is possible to test the cleanability of the equipment in all scales. At Powtech 2011 Glatt will show a new feature of the largest mobile lab unit – a WIP system. The ProCell LabSystem is now equipped with cleaning nozzles in the filter plate and in the processing chamber, which clean the unit without the need to open it. Two different filter types can be used in the ProCell LabSystem – pleated cartridges and washable filter bags. The cartridges are only precleaned in the unit – the narrow places in the pleats must be cleaned manually. Still the WIP system makes sure the operator does not get in contact with the dry dust. The filter bags can be completely cleaned in the unit.

ProCell LabSystem for testing fluid bed and spouted bed processes „ProCell LabSystem“ is not only the new name of the largest mobile Glatt lab unit –but, all fluid bed and spouted bed processes can be tested in batch and continuous mode with only one equipment. The continuous operating mode is especially preferred for the liquid-only , spray granulation process. In batch mode this process can be tested only within narrow limitations. The “ProCell LabSystem” has evolved from the lab unit ProCell 5, which has been sold and rented to numerous customers. This customer experience and satisfaction was driven by the excellent operating reliability and process flexibility of the equipment. The “new” lab unit will now offer four different process systems.. Customers can select one, two, three or all four process options, based on the needs of the desired product or project, as necessary. Using the “ProCell-system”, spouted bed processes can be tested. The spouted bed technology is extending the possibilities to process

No dismantling of filter bags during wash cycle Wash in place – bag filters have also existed for several years. Glatt has frequently used them for the design of continuous fluid beds. Washing nozzles are installed in the clean and raw gas chamber at the top of the filter bags. During the wash cycle they flush the filter bags from the raw gas side and wash down all the dust on the surface. The quality of the washing process depends on the product. Our experience shows that in many applications the filters are clean for the next product. In order to improve the efficiency of the WIP step and to adjust the design of the specific granulator needs, we have now developed our own design of spray nozzles and filter bags. The filter has been installed in a GFG 250 and will soon be tested in full scale. Tests on our pilot unit were successful in 2008. After washing and rinsing the filter bags are dried in the fluid or spouted bed unit, and the next production campaign can start. This filter has a walk-in clean gas chamber

For continuous fluid bed and spouted bed equipment Fluid bed and spouted equipment requires additional space to service the filter on top of the already tall equipment. Up to 2.5 meters are required above the fluid bed contraption in order to exchange 6 m long filter bags. Glatt has now integrated horizontal filters into the fluid bed. The height of the equipment is decreased by putting the clean gas chamber to the side, resulting in no space being required above the fluid bed unit. Doors on the side of the clean gas chamber enable easy access to the filter elements. Exchanging of the filter elements is in actual fact easier from the side compared to the top. A further advantage is the possibility to design the room at the side of the clean gas chamber as a wash room with a solid floor and tight connection to the fluid bed unit. The dust-loaden filters are handled only within this room, contaminating no other parts of the plant with the filter dust. Having removed the filter plates the complete fluid bed unit can

The Austrian plant engineering and construction company AMMAG is specialised on spray granulation / coating and bulk material handling (conveying, silos, big bags, dosing and weighing). Own test plants in lab and pilot scale are used to test all process steps and to develop new products together with the customers. Toll manufacturing of these joint developments is possible, too. AMMAG has developed and constructed a novel laborscale spraygranulator A-WT 25. Air supply/-heating station and process-modul are designed in sparate units. Favorable design and a well elaborated plant concept, makes the A-WT 25 multi-purpose and in conformity with ATEX. The granulator can be operated in top - or bottom spray mode with different positions for the nozzels. An up-to-date control- and visualization system and changeable granulation-baskets for different batch-sizes give additional advantages to the user. Thus, first feasibility studies and small productions in the field

granulating with optimised energy efficiency and pneumatic conveying with minimised attrition Price leadership is difficult to achieve in the western economies; therefore AMMAG focus on the fortification of its innovative strength on within its own 70 years of experiences and core-competencies in the fields of bulk materials handling and fluidised bed spraygranulation. Following this visionary approach, AMMAG is further extending its Technical Centre, already the most modern of its kind in Austria, and has developed a laboratory granulator for the testing of new processes in the fields of spray granulating, coating, agglomeration and for the development of new products in close cooperation with clients. The second expansion of the pilot plant regards the business field: pneumatic conveying systems: a 40 m test line for pneumatic dense phase conveying and one for leanphase conveying in vacuum and pressure mode have been installed. AMMAG provides its research-infrastructure and its plant engineering competence both to foodstuffs and chemical industry leaders