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Mixing-drying reactor for the synthesis of plant protection active ingredients

A mixer/vacuum dryer/synthesis reactor developed by amixon® for a manufacturer of crop protection productscan process substances of widely varying consistencies. The operator can also use the new machine particularly flexibly with regard to different batch sizes. The active ingredient preparationtakes place in various synthesis stages and is completed with vacuum mix drying.

During the synthesis of active substances, the consistencies of the reaction products often change. It does not matter whether they are Active Pharmaceutical Ingredients (API´s) or plant protection products. Consistency changes often occur even after the synthesis reactions have been completed. In vacuum mix drying, pumpable suspensions become free-flowing powders. Synthesis plants usually serve as multi-purpose plants for various synthesis steps and must operate reliably regardless of the rheological properties of the reactants and products.

This requirement is met by a new amixon® vacuum mixing dryer/synthesis reactor developed for a well-known active ingredient manufacturer. The plant can process solids in dusty, fluffy and powdery consistency. The same plant can also process pasty, sludgy and viscous products.

amixon® synthesis reactor/ vacuum dryer

Mixing, Reacting, vacuum drying, powder formulation

During the synthesis of active substances, the consistencies of the reaction products often change. It does not matter whether they are Active Pharmaceutical Ingredients (API´s) or plant protection products. Consistency changes often occur even after the synthesis reactions have been completed. In vacuum mix drying, pumpable suspensions become free-flowing powders. Synthesis plants usually serve as multi-purpose plants for various synthesis steps and must operate reliably regardless of the rheological properties of the reactants and products.

This requirement is met by a new amixon® vacuum mixing dryer/synthesis reactor developed for a well-known active ingredient manufacturer. The plant can process solids in dusty, fluffy and powdery consistency. The same plant can also process pasty, sludgy and viscous products.

Plant diagram

Powder formulation takes place in a subsequent plant. amixon® powder mixers are located directly above the filling plants. The packaged powder concentrates are portioned in such a way that they can be handled safely in the agricultural industry.

Pumpable, chewing gum-like, crumbly, dusty

Typical is the transition from a pumpable suspension to a viscoplastic, chewing gum-like substance. As the liquid phase content continues to decrease, the mass initially becomes crumbly and lumpy. It then becomes grainy. Subsequently, a moist bulk material is present, which finally becomes a free-flowing active ingredient powder.

Even in multi-stage synthesis processes, the first stage begins with dissolving the powdered base chemical in a suitable liquid feed and ends with a drying process in a vacuum contact dryer. At the end of each synthesis, the liquid is crystallised. Several washing processes follow. At the end, the centrifuge-moist crystal mixture must be gently dried. The granular structure of the bulk material should be retained, as dust components are undesirable.

amixon® process units achieve an ideal mixing result even when operated particularly slowly. Even then, there is good heat transfer. Low speeds mean that the mixing and drying process is particularly gentle. If required, the same apparatus can also be used for intensive desagglomeration.

Particularly high vacuums enable the evaporation of liquids at low temperatures. This is always an advantage when the active ingredients are temperature-sensitive..

Highly pure and gas-tight

If further powder components are to be added to the dry material before filling, this is done in the same machine. A mixing tool with a helix-shaped outer contour rotates in the centre of the conical-cylindrical mixing chamber. This conveys the goods upwards along the wall of the vessel; once they reach the top, the goods flow downwards in the centre. The mixer-dryer-reactor delivers ideal mixing qualities at filling degrees of approx. 15 to 100 %. Residue-free emptying of the container takes place with the aid of the patented SinConvex® mixing tool.

The vacuum mixer dryer is capable of producing high-purity active ingredient preparations. The mixing unit is only driven from above and can be fully heated. The shaft seals of the mixer shaft and the cutting rotor are designed as mechanical seals and are gas-tight sealed. The closure fitting at the end of the mixing chamber cone, which operates without dead space, also has a particularly high gas tightness.

The mixing chamber of the reactor is made of Hastelloy C 22. This material has a high strength and is at the same time particularly corrosion resistant. The entire plant complies with the principles of "Good Manufacturing Practice" (GMP) and the requirements of the FDA. All qualification steps are carried out according to GMP. The complete documentation of development, production and commissioning also meets the high requirements of the pharmaceutical industry amixon® has produced numerous mixing-drying reactors for chemical and pharmaceutical applications with vessel sizes from 1 to 25,000 l. The range extends to small and large vacuum mixing dryers/synthesis reactors.

View into the amixon® dryer/reactor. The target jet cleaners are Atex-compliant and can remain in the pressure/vacuum-proof reactor.

View into the amixon® dryer/reactor. The target jet cleaners are Atex-compliant and can remain in the pressure/vacuum-proof reactor.

About the company: Mixer made to measure

The requirements for a preparation mixer are always individually shaped. For process testing, amixon® has more than 30 test mixers at its pilot plants in Paderborn, Memphis (USA), Osaka (Japan), Bangkok (Thailand), Tianjin (China) and Satara (India). As an individual contract manufacturer, the manufacturer implements customer wishes down to the last detail, with a team of 130 employees realising a high degree of vertical integration at the sole production site in Paderborn. The after-sales service team is responsible for the maintenance and testing of the equipment after commissioning. The amixon® Excellent Service" is a worldwide concept with bases in Paderborn, Memphis, Osaka and Bangkok. In addition to the offer of "lifelong" equipment maintenance, the service staff, but also operators and developers, are trained here to be able to carry out inspections and maintenance themselves.

 

For more information on crop protection and active ingredient formulation, see our blog articles:

Plant protection products (Part 1)

Plant protection products (Part 2)

 

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