In recent years, such devices have become widely adopted in the production of penicillin sodium and semi-synthetic antibiotics. With the rapid progress of GMP certification in the 21st century, China's pharmaceutical machinery industry has actively developed or replicated similar imported equipment. However, due to limitations in processing accuracy and process control, domestically produced three-in-one equipment is mainly used for non-sterile active pharmaceutical ingredients (APIs).
Centrifugal three-in-one equipment enhances the traditional vertical filter centrifuge by adding hot air drying functions, using filter bags or metal plates. The overall production process is similar to that of tank-based three-in-one systems, but the integration of centrifugal spin-drying significantly reduces batch processing time. However, the limited capacity of the centrifuge bin restricts its use to medium and small-scale sterile bulk pharmaceutical production. This equipment allows the bin and transmission components to be separated into sterile and non-sterile areas, making maintenance easier without entering the sterile environment, thus improving operational convenience. Recently, joint ventures in the domestic pharmaceutical industry have introduced such equipment, and imitation versions have also emerged in the market.
Spray dryers are commonly used for liquid materials such as solutions, emulsions, suspensions, and pastes. The drying process involves filtering air, heating it, and passing it through multiple stages before directing it into the drying chamber. The material is atomized via a centrifugal disc or pressure nozzle, forming fine droplets that come into contact with the swirling hot air, leading to rapid evaporation and quick drying. These machines are ideal for drying antibiotics like streptomycin and gentamycin, as well as various biological extracts from the API industry.
Boiling bed CIP and SIP systems are highly efficient for drying powders, granules, and fibrous materials. During operation, the material is introduced from the top while hot air is blown in from the bottom through a porous distribution plate. This creates a fluidized state, enabling intense heat and mass transfer, which greatly improves drying speed and efficiency. The system allows for particle size grading, with coarse particles discharged from the bed and fine powder collected by a dust collector. Some models include built-in bag dusting systems, reducing space requirements and investment costs. These systems are fully enclosed and suitable for CIP (clean-in-place) and SIP (sterilize-in-place), making them popular in antibiotic and semi-synthetic antibiotic production.
Fluidized bed dryers are divided into standard and vibratory types. Most drug drying processes benefit from the vibratory version, where vibration motors induce movement, allowing materials to leap forward while being fluidized by hot air at the bottom. This results in even temperature distribution, high thermal efficiency, and excellent heat and mass transfer. The upper chamber maintains slight negative pressure, helping to remove humid air and discharge dry material efficiently. These dryers are ideal for granules, powders, rods, and filaments, and are widely used in high-volume pharmaceutical intermediate production.
Freeze dryers, also known as lyophilizers, are essential for drying heat-sensitive or easily oxidized substances. They consist of a drying chamber, vacuum system, heating system, and refrigeration system. Freeze dryers come in different sizes, from small experimental models to large industrial units. They are critical in the production of APIs and formulations, especially for products like ampicillin, blood products, vaccines, and antibodies. To ensure product homogeneity, it is recommended to integrate a powder mixer during the drying process. High reliability and complete sterilization capabilities are key requirements for these systems. Temperature uniformity across shelves is crucial, with a maximum difference of no more than 1.5°C.
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