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Spray Agglomeration

Spray Agglomeration: Free flowing Particles from Powders


A powder or fine granulate is fed into the plant as the precursor and fluidised. A liquid (aqueous solution, emulsion, suspension or melt), which acts as the “adhesive” or binder, is sprayed on to the fluidised particles and causes them to agglomerate.

Process Technology for Spray Agglomeration

Using spray agglomeration dusty or lumpy powders can be converted into free-flowing, readily dosable granulates. The selected binding agent may even be an aqueous solution of the same precursor or, for example, a further component of the final formulation.

The binder sprayed in dries or solidifies on the surface of the powder and “glues” the particles more or less securely together; the intention is to build a “snowflake” structure in the resulting agglomerate. These mostly have a lower fracture strength than the original powder particles, but feature better wettability and redispersibilty in water. For these reasons agglomerates are especially suitable for the manufacture of “instant” products, and for direct compression into tablets.

Results and Advantages of Spray Agglomeration

  • Improved wetting and redispersibility compared with powders
  • Particles with improved solubility in water
  • Easier to dose and process than powders
  • Identical stoichiometry of all components in each individual particle
  • Particles suitable for tablet pressing (direct compression)
  • Suitable for the manufacture of “instant” products