Integrated Granulation

Integrated Granulation Line

The Force Multiplier^® - Integrated Pharmaceutical Wet Granulation Suite

The Force Multiplier^® is Gansons complete integrated wet granulation line, combining a High Shear Mixer Granulator, inline wet mill, Fluidised Bed Dryer, inline dry mill, and IBC Lift Blender under a single centralised automation platform. It eliminates manual inter-equipment transfers, reduces operator touchpoints, and delivers predictable, reproducible batch outcomes at up to 18 tonnes per day. The Force Multiplier^® is the preferred wet granulation solution for the world’s fastest-growing regulated generic pharmaceutical manufacturers.

Granulation Lines in Aurobindo

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Granulation Lines in Sun Pharma

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Kg of Tablet Produced everyday

High Shear Mixer Granulator (HSMG)

The core wet granulation unit. Iwata™ impeller and chopper design, dead-spot-free bowl geometry, electromechanical endpoint detection, 12 Bar shock pressure resistance, ATEX rated configurations. See the HSMG product page for full technical detail.

Inline wet mill

De-lumps wet granulate mass immediately on discharge from the HSMG before it enters the dryer. Lumps transferred directly to a FBD dry only on the surface, leaving wet centres that cause inconsistent moisture content and extended drying times.

Fluidised Bed Dryer with Cyklon^®

Gansons proprietary Cyklon^® air distributor reduces drying time by up to 70% versus standard FBDs. Granules are dried uniformly and gently. See the FBD product page for full technical detail.

Lifting device with inline dry mill

A hydraulic lifting device raises the dried product container from the FBD and docks it to the inline dry mill for post-drying particle sizing, removing a manual transfer step. The dry mill delivers the target particle size distribution in a single automated step, ready for compression.

IBC Lift Blender

Lubricant addition and final blend are performed inside the IBC without material transfer. The blend is transferred directly to the tablet press, completing the granulation-to-compression sequence without a single open powder transfer.

Increased efficiency

Compact Footprint: The design allows for a space-efficient setup without compromising on throughput
Line-Balanced Configuration: Optimized for maximum throughput, ensuring that each component operates efficiently within the overall system
WIP system for in-situ cleaning (can be recipe driven)
Predictable scalability from R&D to production

Increased Output with improved safety

Closed transfer of materials ensures minimal operator exposure
Safety interlocks
12-Bar shock-resistant designs available for structural integrity and containment
ATEX rated (flame proof) designs based on zoning requirements. All components are by default compliant to a Zone 2/22 production environment

Increased Output with improved safety

Closed transfer of materials ensures minimal operator exposure
Safety interlocks
12-Bar shock-resistant designs available for structural integrity and containment
ATEX rated (flame proof) designs based on zoning requirements. All components are by default compliant to a Zone 2/22 production environment

Automation and Control

Gansons equipment is available with an integrated intelligent automation platform. Key features include:

PLC/SCADA-based control with touch-screen HMI
Centralised recipe management with role-based access control
IoT enabled for remote monitoring and pre-emptive analytics
Integrable with any site architecture including MES, ERP, and LIMS
Customised reporting and smart graphs for lot reproducibility
Industry-leading IPC processors for fast, reliable control performance
21 CFR Part 11 compliant automation available as an add-on for regulated pharmaceutical facilities
GAMP 5-aligned computerised system validation documentation supplied with 21 CFR Part 11 configurations

Compliance and Certifications

Frequently asked questions

What does the Force Multiplier^® include?

Five integrated units: HSMG, inline wet mill, FBD with Cyklon^®, lifting device with inline dry mill, and IBC Lift Blender, all operating under a single centralised automation platform.

Why is an inline wet mill important in a granulation suite?

Lumps from the HSMG dry only on the surface in the FBD, leaving wet centres. The inline wet mill de-lumps the granulate mass immediately on HSMG discharge, ensuring uniform particle size, consistent drying, and better granule structure for compression.

What throughput can the Force Multiplier^® achieve?

Up to 18 tonnes per day in high-capacity configurations. Individual line sizing is customised to customer throughput requirements, regulatory environment, and facility footprint.

Is the Force Multiplier^® suitable for HPAPI manufacturing?

Yes. Closed material transfer throughout the line eliminates open powder handling. ATEX rated and 12 Bar configurations are available. Gansons process technology team provides OEB-specific containment assessments for HPAPI granulation projects.