+44 (0) 1494 792898 sales@ytron-quadro.co.uk

Lab Compaction System (LCS)

The Fitzpatrick Company pioneered the development of particle size reduction and forming technology, with the development of the Lab Compaction System, Contained Compaction System roll compactor and FitzMill, Fitzpatrick has been constantly evolving powder processing technology and in conjunction with Quadro developed the Scalable Lab System.

The Lab Compaction System (LCS) uses the same mechanical force as the larger production Contained Compaction System (CCS) to create a densified sheet of material. This “ribbon” will then be milled/granulated to form a desired particle size, typically to improve the original powder characteristics such as density & flowability. 

With the LCS, this is now possible on batch sizes as little as 10g with a capacity of up to 6kg/hr.

Lab Compaction System Benefits:
  • Ideal for proof-of-concept work or low volume production
  • Manufactured with Fitzpatrick’s high-precision, twin-feed screw system
  • 20kN/cm roll force equivalent to production-scale systems
  • Complete disassembly of all contact parts for a thorough strip-down and clean between batches/products to reduce the risk of cross contamination.
  • Touchpad HMI for all independent feed & compaction controlled variables
  • Consistent compaction mechanism ensures easy scale-up to larger production CCS models
Optional Extras:-
  • Upgrade available for containment systems
  • cGMP software option
  • Varied roll surfaces to suit a wide range of applications

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SDx Series

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products. The newest development is SDx Series which combines the Quadro Flexsift and the Fitzpatrick Hammer Mill. All three process heads are interchangeable on the same drive platform which uses Smart-Detect to ensure the process head is operating in the correct operating parameters.  The SDx is used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries.

Quadro Engineering Corp. and The Fitzpatrick Company have launched the SDx Series – Smart Drive Exchangeable Platform, the world’s first production-scale milling and screening platform offering three distinct powder processing solutions on a single, common drive.  They include Fitzpatrick’s FitzMill, Quadro’s Comil and FlexSift Security Screening technologies. 

The new platform gives operators the ability to quickly and easily interchange the three heads in order to fulfil specific processing requirements, improve production efficiencies and reduce bottlenecks. Like the SLS-Scalable Lab System, the SDx Series utilises SMART-detect, a unique equipment feature that automatically recognises the head being installed and adjusts RPM to the appropriate level for optimum material processing, thereby eliminating operator error. This makes each process scalable and repeatable to ensure the same target particle size distribution you achieve today on Fitzpatrick and Quadro equipment is still achievable with the SDx, with the added benefit of reduced capital investment and overall equipment footprint.

Key features:-

  • 3 interchangeable process solutions on a single common drive
  • Suitable for both continuous and batch production environments
  • Suitable for dry milling and/or wet material conditioning
  • Minimal product losses/hold-up
  • Repeatable PSD and capacity rates from existing models
  • Sanitary greaseless gearbox/drives
  • Manufactured to cGMP guidelines 

 Typical applications for the SDx Series

  • Dry powder deagglomeration and size reduction
  • Sizing and grading of powders
  • Wet mass granulation for efficient and even drying
  • Fine particle size reduction
  • Size reduction of heat sensitive products
  • Security screening of free flowing and sticky products

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Ytron Y Directed Jet Mixer

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

Ytron-Y directed jet mixer generates an axial flow of fluids through the Y rotor stator head giving rapid homogeneous mixing without aeration.

Principle:-

The Ytron Y creates an axial jet stream to homogeneously mix liquids with a viscosity of up 50,000 mPa*s (approx.) without air entrainment. Because of its design, vortex formation (which is normally associated with conventional agitators) is eliminated to provide much more efficient mixing.

Key features:-

The Ytron Y mixing head with its built in vertical flow deflectors guides the jet stream, without rotation, far into the body of the product.
The rotor-stator principle, in combination with the stator tube, prevents any rotational stream and vortexing. This also removes the need for baffles in the tank, removing any dead spots and reducing cleaning time.
The robust construction does not require bearings or seals to be immersed in the liquids removing product contamination risks.
Shaft seals are selected according to the requirements. Options including radial seal ring, single or double acting mechanical seal (-1 to 10 bar) are available.
Available with CIP and designs to specifically help cleaning.
Drive motors with power from 0.25 to 55kW are available in the standard designs.
Modular design system allows the choice of the best mixing technology for each individual application.

Advantages of the YTRON-Y
  • Axial flow pattern
  • Powder Additions via YTRON Y ByPass Venturi effect
  • Perfectly homogenous mixing
  • No air entrainment
  • No sedimentation, even with heavy suspensions
  • Very short process times due to extremely rapid circulation in the vessel
  • No floating of product on the surface
  • Rapid mixing of entire container contents
  • No in tank baffles/flow deflectors required, flow deflectors are integrated on stator
  • Low shear due to short residence time in the YTRON-Y mixing head
  • High shear design also available
  • Side entry for large vessels: Air cushion prevents product from contacting the mechanical seal surfaces at the top of the shaft.
Disadvantages of Conventional Agitators
  • Radial flow pattern (rotational flow)
  • Non-uniform and incomplete mixing
  • Vortex formation means significant aeration
(Possible result: Oxidation, change of colour, poor mixing, poor heat transfer)
  • Sedimentation
  • Floating of powders on surface of liquids
  • Timely and inefficient mixing
  • Incomplete mixing of the vessel contents
  • Dead zones around the area of the baffles
  • Local shear forces, long process times
  • Side entry: Product contacts the seal direct

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Ytron Z In-line Homogeniser

YTRON specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

High shear homogeniser for the size reduction and emulsion generation of slurries and liquid/liquid mixtures.

YTRON Z vs High Pressure Homgeniser footprint

Principle:-

One or more liquid phases, as well as unsuspended particles, are passed by a forced-feed passage through the rotor/stator system. The In-line-principle effects a defined and reproducible application of shear forces.
With the parameters of slot width, number and distance of the shear slots, number of rotor/stator sets used, rotational speed and flow rate, the desired dispersing or homogenising effect, can be infinitely adjusted.
Conventional batch processes often require recirculation and lead to a localised over-shearing of the product. This also leads to irregular treatment of the batch.
In contrast, the YTRON-Z ensures a homogeneously and reproducibly dispersed product in a single pass.

Advantages of YTRON-Z
  • The forced feed passage allows reproducible results
  • Gentle treatment of shear sensitive products, e.g. STRETCHING of yoghurt, direct curd products, fromage frais and cream cheese at low speed
  • High speed operation to effect a continuous emulsificaton reaching a droplet size as low as 1 µm for various emulsions (o/w and w/o) and dispersions
  • Up to three slotted rows of teeth with variable slot widths and finest distance of the slots in each rotor/stator set
  • Reactor chamber houses up to three rotor/stator-sets
  • Hygienic execution available for use in the food, cosmetic and pharmaceutical industry

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Ytron ZC

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

Powder incorporation device for gelling, thickening and difficult to wet powders

The ZC principle animations

Principle:-

The powder is sucked in by the strong negative pressure created by the ZC-reactor head. Immediately after contact with the liquid phase the powders are instantly wetted and thoroughly dispersed.
This process is actually completed before the powder is fully hydrated.
Due to the extremely short time shear forces are applied, the process is a very gentle one. In most cases a single pass operation ensures that even when processing extremely shear-sensitive thickeners and gelling agents, the highest viscosities are achieved.

Keeping the dispersing capabilities and efficient pumping separate makes the dispersing reproducible and efficient
The power introduced via the YTRON-ZC is used only to a limited degree to creating a pumping pressure. The main part of it is used to effectively disperse or wet out, the dry matter in the liquid phase.
In combination with the appropriate pump selected for the relevant liquid phase, an extremely high pumping efficiency is achieved.
For low viscosity products centrifugal pumps are used, for intermediate and high viscosity products positive displacement pumps are recommended.
In the high viscosity range, 80 % or more of the energy can be saved in comparison to conventional processes.
This means; NO heating of the product due to mechanical energy input above the minimum during dispersion.
Reproducable results are normally achieved in a single pass.
The product is subject to a homogeneous, uniform dispersing or shearing effect as it passes through the reactor head. There is no portion of the flow required to bypass the shear head for pumping the liquid in a loop.

The ZC principle is also used in three other executions for different process requirements:
Advantages of YTRON-ZC
  • Extremely difficult to wet out powders are processed in a single pass.
  • The defined application of shear forces results in a STRETCHING ® effect of the molecular chain which therefore leads to an increase in viscosity.
  • A selection of rotor/stator slot widths are available depending on the application.
  • No air entrainment other than the air included in the powder phase.
  • Batch time reduced to the minimum.
  • Significantly higher yield due to an intensive wetting out of the powders
  • Feeding directly from BigBag or silo is also possible.
  • Perfectly wetted-out products are achieved in the shortest time.
  • CIP and SIP available.
Carbopol: Up to 10% concentration
Xanthan: Fully “wetted” in a single pass

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Comil - Underdriven

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System, the SLS, the High Energy H20 Comil for API milling, the in line FlexSift for security screening and the F10 fine grinding mill. Quadro milling and vacuum transfer systems are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries

Since the development of the Underdriven Comil and the introduction of the U20 in the late 1990s, the Underdriven design has become the industry standard due to ease of integration, innovative design, flexibility and scalability.

Comil U3

(Bench Top Unit)

Comil U5

(Bench Top Unit)

Comil U10

Comil U20x

Comil U30

(Through The Wall Design)
The Underdriven Comil’s smaller footprint, inline design and extremely short head height provide for easy integration into processing environments where space is limited. A large-diameter infeed and “straight through” housing promote unhindered inline product flow for quicker discharge. The innovative spacerless design allows for quick changeover of impellers and screens, plus, specialised tooling is available to meet all process requirements.

Available in five models, the Comil Underdriven is scalable in capacity from several kilos to over 10,000kg/hr.

Benefits of the Underdriven Comil:

  • Uniform particle size distribution
  • Positive 360° product discharge
  • Scalable capacities
  • Quick and easy tooling change with Spacerless design
  • Easy clean design (CIP Available)
  • Small foot print
  • Various “In-line” and “Through the Wall” designs for easy system integrations
  • cGMP design
  • Low dust
  • Low RPM/energy consumption
Comil Model
U3
U5 SLS
U10
U20x
U30
Capacity (kg/hr)
20 100 390 1,9503a 3,9003b
Approximate Dimensions (mm)
L 507 636 1,350 1,656 1,947
W 203 424 711 762 792
H 432 507 1,181 1,644 1,828
Screen Diameter (mm)
41 83 127 203 305
Motor Power (kW)
0.24 0.75 1.5 4 7.50
  1. Capacities are based on standard pharmaceutical placebo with 3% crystalline cellulose (CMC).
  2. Capacities may vary significantly based on product characteristics, particle granulometry, inlet and discharge conditions.
  3. For some products, capacities may reach the following higher limits: (a) 6,800kg/hr, (b) 15,900kg/hr.
  4. Dimensions are based on stand alone units and not integrated into a process system.

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Comil Overdriven

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System (SLS), the U21 high efficiency Comil, the High Energy H20 Comil for API milling, the in-line FlexSift for security screening and the F10 fine grinding mill. Quadro milling and vacuum transfer systems are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries

The Quadro Comil Overdriven unit was the original conical screen mill developed by Quadro Engineering in the 1970s for uniform size reduction and deagglomeration and it is used in many industries across the world.

Comil 199

Comil 196

Comil 194

Comil 197

The Overdriven Comil is used in major manufacturing facilities in more than 50 countries around the world for uniform size reduction or deagglomeration of wet, dry, heat sensitive, sticky or fatty products. With many tooling options and combinations gained from decades of experience, the Comil can process many powder/granulated products. The Comil can be integrated into any system or process with the design expertise, flexibility and support offered by Quadro.

Benefits of the Overdriven Comil:

  • Uniform Particle Size Distribution
  • Positive 360° Product Discharge
  • High Capacity
  • Choke/Flood Fed
  • Easy Clean Design (CIP Available)
  • Low Dust
  • Low RPM/Energy Consumption
  • Low Noise
  • Various Frame/Feed/Discharge Designs

The Comil also has special tooling designed for the delumping of packaged fruit.

Comil Model
197
194
196
198
199
Capacity (kg/hr)
360 1,8003a 3,6003b 7,2003c 14,4003d
Approximate Dimensions (mm)
L 572 1050 1270 1730 2130
W 318 700 890 890 1170
H 802 1620 1740 1730 2110
Screen Diameter (mm)
127 203 305 603 761
Motor Power (kW)
1.5 4 7.5 15 22
  1. Capacities are based on standard pharmaceutical placebo with 3% crystalline cellulose (CMC).
  2. Capacities may vary significantly based on product characteristics, particle granulometry, inlet and discharge conditions.
  3. For some products, capacities may reach the following higher limits: (a) 6,800kg/hr, (b) 15,900kg/hr, (c) 27,000kg/hr, (d) 54,500kg/hr.
  4. Dimensions are based on stand alone units and not integrated into a process system.

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Quadro Comil

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System, the SLS, the High Energy H20 Comil for API milling, the in line FlexSift for security screening and the F10 fine grinding mill. Quadro milling and vacuum transfer systems are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries.

The Comil has become the standard across many industries for size reduction and deagglomeration. 

Typical applications are: coarse grinding and chopping of dry material, size reduction of wet material, de-lumping of agglomerated wet or dry material, pulverising, solid blending, granulating compacted material, processing slurries and liquids, processing and conditioning wet and dry materials, pureeing and emulsifying.

  • Size reduction for the pharmaceutical, food and chemical industries
  • Capacities from a few grams to several tons/h
  • Wide range of blades available
  • CIP/WIP and cGMP designs for the pharmaceutical applications
  • Reduced explosion hazard with milling in an inert atmosphere (ATEX)
  • Customised design to suit specific process needs
  • Automated controls, if required designed to be compliant to GAMP 5.0 and 21 CFR part 11

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ZC ViscoTron

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

The YTRON ZC can be uprgradred to a ZC ViscoTron by adding a positive displacement pump on the inlet and outler. The Viscotron has been developed to incorporate powders into viscous liquids as well as products with a high powder/liquid ratio.

The ViscoTron uses the same powder incorporation technology seen in the YTRON ZC but it has the addition of 2 positive displacement pumps for the product inlet and outlet.

Using the YTRON ZC ViscoTron is a huge benefit when adding large ratios of powder:liquid, even more so when the liquid is already high in viscosity. Using a single pass or re-circulation loop, we can achieve a powder/liquid ratio of up to 50%.

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Scalable Lab System

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System (SLS), the High Energy H20 Comil for API milling, the in line FlexSift for security screening and the F10 fine grinding mill. Quadro mills are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries.

The Scalable Lab System brings 4 particle size reduction techniques together with one drive platform using Smart-Detect technology, which can also be found in the new SDx Series, the heads can be swapped within seconds with no additional set up required.

The SLS gives the reassurance that particle sizes and distributions achieved in the lab can be directly transferred to the production-scale equipment.  The operating parameters are simply transposed from small-scale to full-scale production.

Key size reduction and material processing technologies are possible from one single platform.  Using the interchangeable heads you can achieve lab scale conical milling, hammer millingsecurity screening and high energy milling.  Its bench-top size is space-saving as well as a cost-effective solution.

 

U5 Comil
L1A Fitzmill
S5 Flexsift
H5 High Energy Mill

Key features:-

  • Suitable for both R&D and production environment
  • Suitable for dry milling and/or wet material conditioning
  • 4 interchangeable process solutions
  • Minimal product losses/hold-up
  • Scalable PSD and capacity rates
  • Scalable across our entire size reduction range

 Typical applications for the SLS

  • Dry powder deagglomeration and size reduction
  • Sizing and grading of powders
  • Wet mass granulation for efficient and even drying
  • Fine particle size reduction
  • Size reduction of heat sensitive products
  • Security screening of free flowing and sticky proucts

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VMI TURBOTEST

VMI, with over 50 years experience in developing and manufacturing mixing technology lead the way in the mixing of cosmetic and pharmaceutical creams and lotions. The equipment range includes laboratory scale mixers for atmospheric and vacuum mixing requirements and large scale vacuum processing systems

The VMI TURBOTEST is the ideal versatile bench top mixer for R&D with a range of tooling options and a number of integrated safety features. The ergonomic design and programmable control make the TURBOTEST versatile and easy to operate.

VMI have developed the TURBOTEST for laboratory use to help with development of formulations with an extensive range of mixing turbines for different product rheologies.

 

Key features:-
  • Speed range from 50 to 3,300rpm
  • Mixing capacity from 200ml to 20litres
  • Programmable controller for up to 10 phases of time and speed control
  • Large choice of Impellers, turbines and rotor stator heads available
  • Integrated safety features including beaker clamp and height sensor with safety switch
  • Designed for easy clean and simple removal of tooling
  • Can be scaled to larger mixers
  • Hazardous area designs available

VMI TURBOTEST Variants

VMI have also developed other variants of the TURBOTEST expanding the range to include more of an industrial process and ATEX environment capabilities. The SUPERTEST, SUPERTEST ATEX and AIR SUPERTEST use the same mixing turbine range which is interchangeable amongst the four models. The four units share many similarities; including the intergrated safety interlocks as well as performance capabilities but each can be used in a different environment.

SUPERTEST

VMI’s SUPERTEST sacrifices the sleek laboratory look for a higher motor power for use on larger quantities of viscous liquids at a more cost effective solution.

SUPERTEST ATEX

VMI’s SUPERTEST ATEX is suitable for ATEX Zones 1 & 2 (ATEX II 2G) including the ATEX rated user interface and has the same safety features as the other variants.

Air SUPERTEST

The AIR SUPERTEST offers the same power output as the SUPERTEST but is driven using a 750W air motor, so it can by used in a ATEX environment. ATEX II 2 G, Zones 1 and 2 Compliant.

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VMI ULTRALAB®

VMI, with over 50 years experience in developing and manufacturing mixing technology lead the way in the mixing of cosmetic and pharmaceutical creams and lotions. The equipment range includes laboratory scale mixers for atmospheric and vacuum mixing requirements and large scale vacuum processing systems.

The Ultralab® is a laboratory scale R&D homogeniser with vacuum mixing and heat transfer capabilities. It is scalable from the TURBOTEST and upwards to larger productions scales using the TRILAB & TRIMIX.

 The VMI ULTRALAB® has been designed to develop cosmetic products in small quantities in the laboratory. The ULTRALAB® allows for the perfect transformation of products with a wide range of viscosity. This versatility is particularly shown in the quick-change emulsifiers’ and turbines (mixing heads). The unit covers all mixing operations: heat exchanges, suspension, homogenising, dissolution, dispersion and emulsion. By using its double top mounted central agitation with independent speed adjustment, the ULTRALAB® has been designed to develop cosmetics products such as creams, gels, ointments and make-up products in laboratory and in small quantities (500 – 3,000 ml) with the primary focus on scaling up to larger production.

Key Features:-
  • Perfect for R&D and small-scale production
  • Vacuum mixing
  • Heating and cooling
  • Batch size range: 500-3,000ml
  • Double mixing action
  • Homogeniser for emulsions, dispersions and dissolutions
  • Anchor with scrapers for optimal heat transfer
  • Variable mixer speed:

– Central agitator speed range: 50-5,000rpm
– Anchor agitator speed range: 10-250rpm

  • Mixing vessel and height limit safety interlocks
  • Heat insulated vessel

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ZC ContiCone

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.
Continuous process for gelling, thickening and difficult to wet powders
The YTRON ZC ContiCone uses the ZC technology and provides a continuous process by instantly dispersing a dosed quantity of powder into a metered flow of liquid product maintaining the correct ratio throughout the entire process.

Principles:

The ContiCone is a unique product based on the proven YTRON-ZC technology. The ContiCone enables you to instantaneously disperse or incorporate a dosed quantity of solids into a metered liquid flow. The ContiCone’s techonology allows a high level of accuracy at high concentrations of continuous dispersion of powders in a single pass.

Advantages of the ContiCone:

  • Continuous powder dispersion/incorporation unit
  • High accuracy of continuous dispersion up to 50% concentration
  • Minimises dust because of the closed design
  • Liquid capacity ranges from 700-18,000 l/h
  • Powder capacity ranges: 500-4,500 kg/hr
  • Small footprint area

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VMI TRILAB

VMI, with over 50 years experience in developing and manufacturing mixing technology lead the way in the mixing of cosmetic and pharmaceutical creams and lotions. The equipment range includes laboratory scale mixers for atmospheric and vacuum mixing requirements and large scale vacuum processing systems

The VMI TRILAB is a versatile R&D tool for the preparation of creams and pastes with integrated vacuum system, melting, heating, and cooling. The TRILAB mimics the larger production TRIMIX and can be used for small scale production and product development

Principle of Operation

The integrated mixing tools of the TRILAB gives three independently controllable actions with the surface scraper, rotor/stator and central agitation impeller.
Powders and liquids can be introduced from above or directly into the rotor/stator high shear head under vacuum. Internal circulation from the agitation impeller ensures all product is evenly mixed and is circulated to the shear head.
Surface scraping blades ensure interchange of product at the vessel wall giving efficient heating or cooling as required.

Available with a range of options for increased versatility.

Key features:-

  • Fully scalable to production sized TRIMIX
  • Compact design for laboratory use
  • Can be used for small scale production
  • Designed for extremely high product recovery
  • Simple hand feed and vacuum product entry
  • Designed for easy clean and simple removal of tooling
  • No external recirculation loop gives full control of mixing and minimises losses

Typical applications for the TRILAB

  • Viscous, Pasty products
  • Pharmaceutical, cosmetic, food and chemical creams and pastes
  • Formulation development and small product manufacturing

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VMI TRIMIX

VMI, with over 50 years experience in developing and manufacturing mixing technology lead the way in the mixing of cosmetic and pharmaceutical creams and lotions. The equipment range includes laboratory scale mixers for atmospheric and vacuum mixing requirements and large scale vacuum processing systems.

The VMI TRIMIX is a complete three stage mixing solution for the manufacture of creams and pastes. with options for integrated vacuum mixing system, wax melting, heating and cooling the TRIMIX can be used as a stand alone mixer or part of a larger system.

Key Features:-
  • No external recirculation loop gives full control of mixing and minimises losses
  • Designed for extremely high product recovery
  • Fully scalable from TRILAB & ULTRALAB
  • Integrated Turnkey system for a complete production process
  • Working volumes up to 20,000 litres
  • Premix vessels can be integrated with a range of mixing tools
  • Vacuum mixing for process and product introduction
  • Designed for easy clean and simple removal of tooling
  • CIP available
Typical Applications for TRIMIX:-
  • Viscous, Paste like products
  • Hand Creams & Sanitisers
  • Shampoos, Conditioners, Body Washes
  • Pharmaceutical Rubs & Oitnments
  • Complex formulations & rheologies

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Contained Compaction System

The Fitzpatrick Company pioneered the development of particle size reduction and forming technology, with the development of the Lab Compaction System, Contained Compaction System roll compactor and FitzMill, Fitzpatrick has been constantly evolving powder processing technology and in conjunction with Quadro developed the Scalable Lab System.

Roller Compaction uses mechanical force to create a densified sheet of material which can be granulated to form a desired particle size, typically to improve powder characteristics such as flowability and density.

CCS “Through the Wall” Design

CCS 320 Pilot Scale

Principle of the CCS

Fine powders can be processed into densified sheets in the CCS roll compactor by the use of mechanical pressure exerted on two counter-rotating rolls. The densified sheets can then be granulated to any desired particle size distribution.

  • Roller compaction for the pharmaceutical, food and chemical industries
  • Capacities from a few grams to 400 kg/h
  • Complete granulation lines and fully integrated systems are available
  • Optional vacuum deaeration system
  • cGMP and WIP designs for pharmaceutical applications
  • Product Containment and Inert Atmosphere System for toxic and hazardous products (ATEX)
  • Automated controls, if required designed to be compliant to GAMP 5.0 and 21 CFR part 11
  • Fully scalable processes throughout the CCS range

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VolumControl

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met

The VolumControl system is used for the volumetric in-line sampling of powders and granules. A simple design for a quality sample.
The VolumControl is suitable for the sampling of powders out of the process flow at atmospheric pressure and can be mounted in a gravity line or on the wall of a silo/reactor. A Fully automatic version is also available.

Closed containment sampling for safe operation and environmental protection.

Operation
The VolumControl system is based on the principle of an air/air actuator where its pneumatic operation can be automated
An air cylinder extends a single moving plunger into material then immediately withdraws, carrying the sample of product. Sample sizes of 18, 50 or 100cc can be taken depending on the sampler selected.

The control unit adjusts the cycle rate to change the sampling volume/duration. Closed contamination free sample filling on any bottles/vials with an appropriate adapter. Accurate sampling is provided suitable for physical, chemical, biological analysis.

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PowerProof

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met

Control the quality of your incoming raw materials with accuracy using the PowerProof

The PowerProof sampler is designed for taking samples of incoming raw materials for quality control checks.
It allows cross sectional samples to be obtained from normally inaccessible parts in sacks, drums, big-bags and bulk tanks.

The PowerProof sampler allows a representative sample of powders to be taken at each stage of penetration of the probe into the material to be collected.

Features
  • Easy to clean
  • Easy to handle
  • Due to its patented dismantling system, the 304L stainless steel boring tube and spiral are easily disconnected from the drive
  • If necessary the parts can be sterilised in an autoclave, all without the use of tools
  • Completely portable, independent and ergonomic
  • Powered by a rechargeable battery (pneumatic option is available)
  • Reliable and robust
  • Dead space is minimised to avoid contamination

Depending on the direction of rotation it can be used for either sampling or purging. One drive motor can be used with a variation of probes. Probe lengths range from 300mm to 1500mm Precision engineered with the boring tube and conveying screw manufactured from 100% stainless steel and all welds are carried out under argon atmospheric conditions.
The passivated finished stainless steel parts are fully tested prior to despatch.

All LaboControle samplers are precision engineered and designed to comply with the inspection requirements of the pharmaceutical, food and chemical industries, in accordance with BPF, GMP, FDA, HACCP, ISO recommendations and procedures for good sampling practices.

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PowControl

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met

Control the quality and collect accurate samples directly from the process in safety with the PowControl system.

Based on the principle of the Archimedes screw, the PowControl allows representative samples of powders to be taken directly from the process in continuous or sequential mode from a gravity process line, from the wall of a silo or a reactor.
Used extensively in the chemical, pharmaceutical and food industries, PowControl in-line sampler allows representative, continuous, grab or composite sampling of free falling powders in a chute, or bulk powders in a filled vessel.
The frequency and duration of sampling can be programmed according to the individual process

The material used and the innovative solution provided for easy cleaning respond to the hygiene and safety principles required by the European Directive 93/68/CEE

This sampler is precision engineered and designed to comply with the inspection requirements of the pharmaceutical, food and chemical industries, in accordance with BPF, FDA, HACCP, ISO recommendations and procedures for good sampling practices.

Representative sampling from a chute or a filled vessel
Few wearable parts, and no ball-bearing
All parts in contact with the product are 316L stainless steel
Easy cleaning of the contact components
Sample can be collected in either sachets or bottles
ATEX versions available, classified to II 3D or 2D – zones 21 or 22 (dust)

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IsoControl

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met.

The IsoControl for in-line volumetric sampling of liquids.

The IsoControl is widely used in the dairy industry to sample milk deliveries across a complete batch.

The IsoControl takes volumetric samples of liquids in-line, with a sampling volume per cycle of 0.5ml. The sampling bottle is screwed onto the adaptor piece for a secure and water tight fit. The sample bottles are available in volumes of 125ml, 250ml and 500ml. We can also provide customer made adaptors to fit specific sizes.

The IsoControl is easy to operate using the touch screen HMI available from LaboControle. The simple robust design requires little maintenance to minimise the downtime.

It also ensures consistent and reproducible sampling due to the minimisation of the dead volumes in the product.

All metallic parts are made of 316 stainless steel
O-rings are manufactured in Buna with FDA certificate. Other materials are available on request.

To see the IsoControl Sampling device YouTube video demonstration click here

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FlowControl

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met

The FlowControl sampler is designed to take samples of powders and granules from pressurised pneumatic lines.

Pneumatic FlowControl
Manual FlowControl

The FlowControl sampler operates using a pneumatic pinch calve or a ball valve. Opening the valve allows the powder within the pipeline to be collected in the sample bottle which is installed at the outlet of the sampler. The sampler is fitted with either a filtration capsual or connected directly to a dust extraction already installed on site.

The FlowControl has an easy installation, is a hygienic way of sampling and requires very little maintenance.
Specifications:
  • 1 SS male fitting 1″ (DN 25) for welding to your existing pipework
  • 1 air pinch valve with rubber sleeve FDA & BGVV certified (or any other manual valve available)
  • 1 SS transfer hose
  • 1 HDPE bottle – sampling volume : 1 or 2 liters
  • 1 PTFE bottle adaptor with vent outlet
  • 1 sterile air filter in PP 1/8″ with membrane PTFE 0.2micron
  • A control cabinet with PLC allowing representative sampling on defined duration can also be supplied

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EasyProof

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met

EasyProof samples liquid from a tank or drum up to a depth of 4m and viscosities up to 500cps.

This patented motor driven LaboControle sampler is completely portable and allows the vertical sampling, or crossing of layers of liquids, in drums or tanks up to a depth of 4m, 500cps viscosity and maximum temperatures of 50C, checking also for sedimentation in the bottom of containers.
It is made up of a peristaltic pump adapted to a removable, stainless steel cylinder with clip allowing easy connection of the probe to a battery powered drive motor with a switch for sampling or reverse for purging.

The peristaltic pump is fitted with a flexible PVC or Silicone 6/10 tubing and is the only part in contact with the liquid to be sampled and can be rinsed clean or even changed easily.
To help drop the hose into the liquid, a stainless steel nozzle can be fitted. The upend of the hose is placed into a sampling bottle located in a Stainless steel sampling basket adjustable in height below the pump.

Features

  • Easy to dismantle and clean
  • Speed variations letting you control the rate of flow into the sampling bottle, thus avoiding the risk of spillage
  • Pneumatic/Explosion proof is available

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Labocontrole Accessories

Labocontrole sampling devices for Powders, Liquids and Gases are designed to meet the specific requirements of raw and in process materials. With manual devices and automated samplers for the food, chemical and pharmaceutical industries all QA needs can be met

Control-it
The Control-it Sampling Control Seals are based on a highly adhesive backing in order to repair sacks after sampling.

They are used to :
Ensure a perfect sealing of containers (paper or plastic bags, BigBags, …) after sampling, even if powder has been spilled on the surface
Avoid product spillage after the sampling and the risk of environmental contamination
Provide the inviolability of the packaging and avoid the risk of crossed contamination
Identify that sampling has been conducted: customized printed seal with specific text or colour marking available

Food grade
Food contact high adhesive HDPE film backing
Meeting applicable FDA and BGVV standards for direct contact with dry & moist, non-fatty food Alimentary
Conformity Declaration certified by the supplier

Standard
Super adhesive aluminium backing
Round labels – 95 mm diameter
Marking QUALITY CONTROL : white text on blue background 3 languages available
Rolls of 1000 pcs

Customised
Custom labels are available upon enquiry. You can choose your logo, texts, colours, sizes, backing, etc…
Please contact us to discuss your personal needs.

Sample Bottles
HDPE bottles with large bottle neck
Bottle made of high density polyethylene. PP screw cap 100% tight. Transport, boring and crushing resistant in accordance with IP2 standards.
Printed: material, minimal thickness of the bottle wall, volume, year of manufacturing, IP2 seal.
Temperature limits : +120C / -100C

PP bottles with small bottle neck
More rigid than polyethylenes
Autoclavable
PP screw cap
Maximum temperature : +135C

Sampling Station
To help make sampling easy for the operator we really have thought of everything on the LaboControle sampling trolley:
clamp fixing for the probes
washing bottle holders
waste bin bag support
sampling label & tubing distributors
drawers
Features
This sampling trolley is robust, light, and resistant to corrosion as it is manufactured from Stainless Steel
2 drawers, 2 guard rails on 3 sides, 4 75mm diameter castors (2 with foot- brakes), 4 round rubber bumpers
1 shaft with clamps allowing horizontal movement along 2 horizontal rails
1 fixing flange for the peristaltic pump
2 side rails with clamps to hold the probes

Dimensions: height – 1600mm, width – 750mm, depth – 500mm

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Quadro H20 High Energy Comil

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System, the SLS, the High Energy H20 Comil for API milling, the in line FlexSift for security screening and the F10 fine grinding mill. Quadro milling and vacuum transfer systems are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries.

Quadro Engineering has recently developed and introduced a breakthrough in cone milling technology resulting in a dramatic reduction in API particle size distributions previously unattainable by conical mills. The Quadro High Energy H20 Comil, with ground breaking re-engineered drives, spindles and new proprietary screen efficiency designs, can shift PSDs to finer particle targets by 30-70% Compared to other technologies, the H20 Comil is effective in producing narrower (tighter) particle size distribution spans, improving on-target milling by 30-60%. With the ability to control and shift PSDs – the H20 Comil allows manufacturers to maximize the amount of milled product within the desired target – reducing (and potentially eliminating) the need for screening over/under sized particles; resulting in less waste.

Unique value-added customer benefits of the new H20 Comil

Unparalleled size reduction performance with conical milling technology

Typical particle size distribution in the 250 < d97 < 400µm range

Ability to consistently control & shift particle size distribution targets

Higher throughput and yield than conventional mills of equivalent foot print

Narrower particle size distributions (less waste and less rework) than traditional milling

Improves on-target milling by 30-70%

Reduced need for screening over and under sized particles

Enhanced product flow with optional dosing valve eliminates pneumatic handling or product collectors

Compact in-line configuration with standard triclamp connections

Quick and easy access to product contact components which reduces cleaning and changeover times

Easily portable which provides flexibility to operate in non-dedicated suites, therefore reducing the need for multiple units

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Quadro FlexSift

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System, the SLS, the High Energy H20 Comil for API milling, the in line FlexSift for security screening and the F10 fine grinding mill. Quadro milling and vacuum transfer systems are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries.

Based on the established Quadro cone mill platform the FlexSift frange from Quadro gives high capacity safety screening and delumping

S20 Flexsift

S5 Flexsift

The Quadro FlexSift pre-screens material before entering downstream equipment protecting from contamination of final processed product and preventing damage caused by foreign material entering the process.

Principle of Operation

The infeed product is introduced into the 360 degree screen chamber, the rotation of which causes the powder to pass through the screen whilst unwanted oversize material is retained within the screen
Agglomerated material can be delumped using a breaker bar, ensuring maximised product recovery without modifying the core particle size.
Unwanted/tramp materials can then be removed at the end of the process.

Key features:-

  • High capacity screening.
  • Compact footprint compared to conventional sieve decks
  • Low noise
  • Modular design system for integration into new or existing processes.
  • No vibration
  • Bolted or TriClamp construction for high levels of containment
  • Easy clean design
  • Quick and simple screen change

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Quadro F10 Fine Grind

Quadro Engineering, the innovators of the Comil conical screen mill, continue to develop and innovate with new products such as the new Scalable Lab System, the SLS, the High Energy H20 Comil for API milling, the in line FlexSift for security screening and the F10 fine grinding mill. Quadro milling and vacuum transfer systems are used in a wide range of powder processing applications in the Food, Pharmaceutical and Cosmetics industries.

Recently introduced by Quadro, The F10 Fine Grind system provides a compact mobile fine grinding mill with integrated feeder, filter separator and air unit.

The F10 Fine grind is a complete solution for powder milling with uniform size reduction from an integrated mobile unit

Principle of Operation

Powder from the integrated screw feeder is subjected to particle on particle collisions as well as impact forces from the beater arm to generate a consistent and finely ground product
Air conveying is used to transport the ground product out of the mill to the filter separator and additional cooling is achieved with a jacketed mill body for heat sensitive products

Key features:-

  • Compact, mobile design
  • Low noise levels
  • Integrated air handling system and controls
  • Narrow particle size distribution
  • Simple disassembly with minimised parts for ease of cleaning
  • Quiet operation
  • Filtered air for product safety

Typical applications

  • Active Pharmaceutical Ingredients
  • Nutraceuticals
  • Fine Chemicals and excipients
  • Cosmetic powders
  • Herbs, Spices and Flavours

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Ytron Y ByPass

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

Ytron-Y directed jet mixer with ByPass uses the axial flow of fluids through the Y rotor stator head which generates suction with the Venturi effect to allow the addition of powders directly into the mixing zone for rapid dispersion without aeration.

Principle:-

The YTRON Y ByPass uses all the benefits from the YTRON Y Directed Jet Mixer but provides a safer, cleaner and more efficient way of dispersing or incorporating powders into liquids. With the addition of the ByPass tube, you can now add powders directly into the mixing head of the YTRON Y, ensuring all of the powder is immediately wetted and dispersed. This helps speed up mixing times as well as reducing the dust created from other conventional methods.

By using the YTRON Y technology, the powders are immediately dispersed and homogeneously mixed without air entrainment caused by vortexing and without the use of baffles which create dead spots in the mixing vessel.

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Ytron XC

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

Powder incorporation device for high ratio addition of non-thickening powders.

Principle:-

Powders and compounds with a tendency to form lumps are continuously incorporated inline and effectively dispersed. This means that even in a single pass, very high concentrations can be achieved.
The first stage in the reactor head creates a strong negative pressure and sucks the solids phase in.
Immediately after contact with the liquid phase, this premix of the 2 phases is impelled against the XC impact chamber plates where the powder is dispersed/dissolved into the liquid phase.
The second stage discharges the homogeneously wetted product.

Advantages of YTRON-XC
  • Complete wetting out of the powders in a single pass
  • Concentrations of up to 40% are possible in a single pass
  • No air entrainment other than the air included in the powder phase
  • Batch time reduced to a minimum
  • Higher product yield due to the intensive wetting of the powders
  • Low intensity mixing due to high impact frequency instead of high shear
  • Feeding directly from Big Bag or silo is possible
  • CIP and SIP available

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YTRON PID

Ytron specialise in the design, innovation and manufacture of a range of mixers and homogenisers for the production of homogeneous, air free liquids pastes and suspensions, with over 40 years application experience in all areas of industry including Food, Beverage, Dairy, Pharmaceutical, Cosmetic and Chemical processes.

The YTRON PID is a powder incorporation unit for “difficult to wet” powders such as CMC, Xanthan & Guar Gum.

These products are referred to as “difficult to wet” because of the immediate reaction taking place when they are in contact with water; individual particles of the hydrophilic polymer begin to swell causing the surfaces particles to cross-link to form a tough outer skin which prevents the completion of the hydration process.
This results in an agglomeration of particles which are wetted on the outside with a dry powder lump on the inside often known as “fisheyes”.

If you attempt to achieve a homogeneous dispersion by smoothing out the lumps by means of high shear methods, the polymer molecular chain may be broken which will effect the end result considerably by altering the characteristics of the final fully hydrated product.

Principle:-

The thickener or gelling agent is sucked out of a hopper, bigbag or a silo into an injection chamber where it is pre-wetted by the liquid phase. This pre-wetting process is guaranteed to happen without sticking.
The pre-wetted product is then forced to pass through the ZC Rotor/Stator which ensures a perfectly wetted out product in a single pass.
Sticking powders, deposits or lump formation on the contact surfaces of the powder/liquid injection chamber are totally eliminated during either continuous or short process intervals.

Advantages of YTRON-ZC PID
  • Extremely difficult to wet-out powders are processed without any problems
  • Free flowing powders mean that reproducible results will be achieved
  • Concentrations of over 20% can be achieved in one pass
  • Sticking, clogging or lump formation in the contact areas liquid/powder is totally avoided
  • The required concentration is achieved by the appropriate adjustment in the injection chamber
  • Powder consumption will be significantly reduced by the intense wetting out of the product
  • STRETCHING® of the molecular chain achieves a higher viscosity and therefore higher yields compared to conventional methods
  • Cleaning even between short process intervals and after a product change is totally unnecessary
  • Pre-wetting of the powders in the injection chamber without sticking
  • No damage of the product during process through the rotor/stator system, as the contact time takes only a fraction of a second
  • A pump installed downstream achieves the discharge of the uniform product even at high concentrations and viscosity
  • Sticking powders, desposits or lump formations are totally eliminated on both the contact surfaces of the “powder/liquid” injection chamber and in the dispersing reactor
  • Cleaning, even between short process intervals, is totally unnecessary
  • The required concentration is achieved by the appropriate adjustment of the injection chamber

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FitzMill

The Fitzpatrick Company pioneered the development of particle size reduction and forming technology, with the development of the Lab Compaction System, Contained Compaction System roll compactor and FitzMill, Fitzpatrick has been constantly evolving powder processing technology and in conjunction with Quadro developed the Scalable Lab System.

Fitzpatrick Hammer Mills produce the smaller PSDs and are more suited to abrasive and difficult to mill products.  They are the mill of choice when you need to precisely control the particle size reduction process.

It is important to get the feed throat angle matching the material characteristics; a vertical inlet for fragile material or horizontal for fine grinds.

The blades can be knife-edged for “cutting effet” or blunt-edged for more impact and aggressive particle size reduction.  A blade with reversible edges becomes truly versatile, being able to match any product requirement.

Typical applications are: coarse grinding and chopping of dry material, size reduction of wet material, de-lumping of agglomerated wet or dry material, pulverizing, solid blending, granulating compacted material, processing slurries and liquids, processing and conditioning wet and dry materials, pureeing and emulsifying.

  • Size reduction for the pharmaceutical, food and chemical industries
  • Capacities from 50 g up to 100 tons/h
  • Wide range of blades available
  • CIP/WIP and cGMP designs for the pharmaceutical applications
  • Product Containment System (PCS) for toxic and hazardous products
  • Reduced explosion hazard with milling in an inert atmosphere (ATEX)
  • Customized design to suit specific process needs
  • Automated controls, if required designed to be compliant to GAMP 5.0 and 21 CFR part 11

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