Integrated Filtration, Washing and Drying Production Line | Zhanghua

II. Supporting Auxiliary Equipment

1. 1.Upstream Supporting Equipment

2. Reactors/Crystallizers: Wuxi Zhanghua Pharmaceutical Equipment Co., Ltd. has designed reactors and crystallizers where material synthesis or crystallization occurs. By finely controlling reaction conditions, an ideal suspension is formed and steadily transported to the three-in-one host, setting a solid foundation for follow-up processes.

Pumps: Appropriately selected screw pumps, diaphragm pumps, etc., smoothly and efficiently pump reaction liquids or crystallization liquids into the three-in-one host, guaranteeing trouble-free material transfer and preventing blockages and leaks.

2. Filtration Power System

Vacuum Pumps: A variety of options, such as Roots vacuum pumps and liquid ring pumps, are available to provide ample negative pressure for filtration. When used with a vacuum buffer tank, they stabilise filtration pressure, thereby enhancing filtration efficiency and quality.

Air Compressors/Nitrogen Compressors: These supply the pressure needed for positive pressure filtration and offer inert gas protection to meet explosion-proof requirements, ensuring safe and reliable production, particularly for flammable and explosive materials.

3. Washing System

Solvent Tanks: Storing various washing liquids (e.g., water, ethanol, acetone), these tanks can be equipped with heating/cooling functions as needed to ensure suitable washing liquid temperatures, improving washing efficiency and boosting product quality.

Metering Pumps: High-precision gear pumps, plunger pumps, etc., accurately control the amount of washing liquid, achieving precise washing, minimising solvent waste and cutting production costs.

4. Drying System

Condensers: Tubular condensers are chosen for effective solvent condensation and recovery, reducing solvent loss, lessening environmental pollution and enhancing production efficiency.

Condensate Receiver Tanks: These collect condensed solvents, which after treatment can be returned to the solvent tank, enabling solvent recycling and fostering a green production mode.

Hot Air Circulation System (Optional): Comprising a heater, fan and filter, this system is used for hot air drying. By accurately controlling drying temperature and air volume, it further improves drying efficiency and stability.

5. Downstream Supporting Equipment

Grinders: If dried materials become lumpy, a gas flow grinder can restore material flowability, meeting subsequent process requirements and ensuring product performance.

Sifters: Vibration sifters and other equipment control the particle size of the finished product, ensuring uniformity and compliance with quality standards and customer requirements.

Packaging Systems: Equipped with automatic weighing and packaging devices featuring dust-proof designs, these systems enable precise and efficient packaging of finished products, enhancing product value and facilitating storage and transportation.

6. Control System

PLC/DCS System: Integrating various sensors (temperature, pressure, pH, etc.), this system achieves automated process control. By accurately monitoring production parameters, it ensures stable production operations, reduces manual intervention and boosts production efficiency and product quality consistency.

CIP/SIP System: Essential for the pharmaceutical industry, this system meets in-situ cleaning and sterilisation requirements, ensuring equipment cleanliness and compliance with Good Manufacturing Practices (GMP) for drug safety.

7. Environmental Protection and Safety Equipment

Waste Gas Treatment Devices: Using technologies like activated carbon adsorption or condensation recovery, these devices effectively treat organic waste gases, reducing emissions, maintaining a clean workshop environment, protecting employee health and helping enterprises meet environmental compliance requirements.

Explosion-Proof Systems: For processing flammable and explosive materials, explosion-proof motors, nitrogen protection and other explosion-proof devices are installed to ensure production safety and minimise risks.

Waste Water Treatment Units: These treat washing waste liquids and are equipped with facilities such as neutralisation tanks and membrane filters to achieve standard-compliant waste water discharge, reducing environmental pressure, enhancing the corporate environmental image and promoting sustainable development.

III. Typical Process Flow Diagram

[Reactor] → [Pump] → [Three-in-One Host]

↓

[Vacuum Pump] ← [Condenser] ← [Drying Exhaust Gas]

↓

[Solvent Recovery Tank] ← [Condensate]

↓

[Crusher] → [Sifter] → [Packaging Machine]

IV. Key Points for Equipment Selection

Matching Material Properties

For corrosive materials: corrosion-resistant materials such as Hastelloy or PTFE lining are offered by Wuxi Zhanghua Pharmaceutical Equipment Co., Ltd. to extend equipment service life and prevent material contamination and equipment damage.

For heat-sensitive materials: vacuum drying combined with low-temperature condensation is prioritised. The drying temperature is carefully regulated to prevent material denaturation from high temperatures, ensuring product quality and activity.

Production Capacity Requirements

For small-scale trial lines: a host with a volume of 50 - 500L and a micro vacuum pump are employed to meet the needs of research, small-scale trials, etc. This reduces investment costs and facilitates process exploration and optimisation.

For industrial-scale production lines: a host with a volume of 1 - 10m³ and a multi-stage vacuum system are used to efficiently handle large-scale production tasks, ensuring production capacity and helping enterprises increase production scale and enhance market competitiveness.

Industry Standards

For the pharmaceutical industry: strict adherence to GMP standards is essential. The production line is equipped with complete CIP/SIP and validation documents to ensure equipment cleanliness and sterility, guaranteeing drug quality and safety, and helping enterprises pass pharmaceutical regulatory reviews.

For the chemical industry: explosion-proof and waste gas treatment are key considerations. Explosion-proof schemes and efficient waste gas treatment systems are customised based on the characteristics and process requirements of chemical materials to ensure safe production and environmental compliance, meeting the strict safety and environmental standards of the chemical industry.

V. Common Configuration Schemes

Pharmaceutical Aseptic API Production Line: Three-in-one host + aseptic reactor + low-temperature condenser + CIP/SIP + isolator packaging. This fully ensures the aseptic production of medicines, meets strict quality control requirements, is suitable for the production of high-value aseptic APIs, and enhances the quality and market competitiveness of medicines. Wuxi Zhanghua Pharmaceutical Equipment Co., Ltd. has extensive experience in designing and manufacturing such production lines.

Chemical High-Purity Material Production Line: Three-in-one host + explosion-proof nitrogen system + solvent recovery tower + gas flow crusher. This ensures safe and efficient chemical production, achieves high solvent recovery rates and uniform finished product particle sizes, meets the production requirements of the chemical industry for high-purity materials, and helps chemical enterprises produce refined and high-end products. Wuxi Zhanghua Pharmaceutical Equipment Co., Ltd. can provide customised solutions based on specific customer requirements.

Wuxi Zhanghua Pharmaceutical Equipment Co., Ltd. is dedicated to offering customers customised technical solutions for integrated filtration, washing and drying production lines. Based on customer requirements, material properties and process requirements, we precisely select and match equipment to ensure perfect integration of the production line with the production process. This enables fully enclosed and automated production from material feeding to finished products, significantly improving production efficiency and reducing pollution risks. It helps enterprises move towards more intelligent and eco-friendly production.