Fluidised Bed Processor & Coater (FBPC)
The Gansons FBPC is a versatile air suspension processing system that performs drying, low-shear top-spray granulation, and Wurster bottom-spray pellet coating on a single platform. It is used in pharmaceutical, nutraceutical, and chemical manufacturing for producing granules, sustained-release pellets, enteric-coated particles, and taste-masked formulations. Gansons FBPCs are installed in facilities regulated by the US-FDA, UK-MHRA, EMA, WHO-GMP, and health authorities in over 50 countries.
Air Distribution Systems
The FBPC is available with three air distribution options.
- The Standard Perforated Air Distributor provides uniform vertical air flow, suitable for most drying and granulation applications.
- The ConidurTM Screen enables lateral movement of fluidising air through particulate substrate and facilitates improved drying efficiency.enables lateral movement of fluidising air through the substrate, improving drying efficiency for particulate materials with challenging flow properties.
- The Cyklon® Swirl-Flow® distributor is available for applications where maximum drying efficiency is required, introducing air in a cyclonic horizontal pattern that reduces drying time by up to 70%.
Top-spray granulation
In top-spray mode, the FBPC sprays binder solution downward into the rising fluidised powder bed.
- Droplets contact particles at the peak of their flight path, distributing binder uniformly before evaporation.
- This produces low-density, porous granules with good dissolution and flow properties, making it the preferred approach for immediate-release tablet formulations and for moisture-sensitive or shear-sensitive APIs where high-shear granulation is not suitable.
Top-spray granulation
In top-spray mode, the FBPC sprays binder solution downward into the rising fluidised powder bed.
- Droplets contact particles at the peak of their flight path, distributing binder uniformly before evaporation.
- This produces low-density, porous granules with good dissolution and flow properties, making it the preferred approach for immediate-release tablet formulations and for moisture-sensitive or shear-sensitive APIs where high-shear granulation is not suitable.
Wurster pellet coating
- The Wurster bottom-spray technique applies uniform thin-film coatings to pharmaceutical pellets, granules, and crystals.
- A cylindrical partition inside the product vessel creates a controlled particle circulation cycle. Particles move upward through a high-velocity spray zone at the centre, receive a uniform coat, decelerate in the expansion zone above, and recirculate downward for the next pass.
- Each particle completes thousands of coating cycles per batch, producing films of exceptional uniformity suitable for sustained-release, enteric, and taste-masking applications.
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
- GAMP 5-aligned computerised system validation documentation supplied with 21 CFR Part 11 configurations
Installed in facilities regulated by US-FDA, UK-MHRA, EMA, WHO-GMP, Japan-PMDA, TGA, SAHPRA, MCC, and health authorities in 40+ countries. CE, UL, ATEX, ISO, and IEC configurations available on request.
Capacity Range
Pilot and R&D scale
2L to 25L
Commercial scale
50L to 2000L
Frequently asked questions - GFBPC
What processes can the FBPC perform?
The FBPC dries granules and powders, performs low-shear top-spray granulation, and applies film coatings to pellets using the Wurster bottom-spray technique, all on a single platform with the same product vessel and air handling system.
What is Wurster coating?
Wurster coating is a bottom-spray, co-current technique where a nozzle at the base of the vessel sprays coating solution upward into the fluidised particle stream. Particles cycle through the spray zone repeatedly, resulting in highly uniform film coatings used for sustained-release, enteric, and taste-masked applications.
How does fluid bed granulation differ from HSMG granulation?
Top-spray fluid bed granulation is low-shear, producing porous, lower-density granules with excellent dissolution and flow. HSMG granulation is high-shear, producing denser granules preferred for high-compression tablet pressing. Selection depends on API properties, target dissolution profile, and downstream processing requirements.
Is the FBPC ATEX rated?
Yes. ATEX rated configurations are available for solvent-based coating and granulation processes. The applicable zone classification is determined by the client’s hazardous area classification or Gansons process risk evaluation.
Compliance and Certifications
Downloads
- Brochure – Gansons Fluid Bed Processor and Coater
Gallery
