High Shear Granulator

High shear granulator is a key equipment to make powder or viscous materials into uniform granules by high-speed shear force, which is widely used in the fields of medicine, chemical industry, food, new energy materials and so on. The following is a detailed analysis of its working principle, structural features, applications and advantages:

Material mixing and wetting
Powdered material and liquid binder (such as water or solvent) are added to the mixing barrel, through the high-speed rotation of the stirring paddle to achieve rapid and uniform mixing, the formation of wet soft materials. This process is accomplished in an enclosed environment to ensure material uniformity and clean operation.

Shearing and granulation
When the material reaches a certain degree of wetness, the high-speed rotating cutting blade (horizontal rotary blade or vertical blade) shears and extrudes the soft material. For example, the rotary blade of the horizontal shear granulator rotates in the opposite direction to the mixing paddle, cutting large particles into small ones and forming spherical particles through friction and rolling action. The combination of cutting speed, blade design and material fluidity affects the uniformity and shape of the granules.

Drying and Sieving
Wet granules are usually dried further to remove moisture, and then separated by a sieving system to produce finished granules that meet the size requirements.

Core Components

• Mixing drum and paddle: Used to contain and mix the material, usually designed in cylindrical or conical shape, made of corrosion-resistant materials (e.g. 316L stainless steel).
• Cutting blade: Horizontal rotary blade or vertical blade, the rotating speed can reach 20000 r/min, suitable for efficient shearing of different materials.
• Integrated design: part of the equipment adopts CIP (Cleaning in Place) optimized design, pipeline and valve sealing integration, easy to clean and fast material replacement.

Auxiliary system

• Cooling device: temperature control by jacket or fan to prevent material overheating and denaturation.
• Air flow and return system: using air ducts or return rings to guide the material circulation, to avoid agglomeration and improve the density of accumulation.

• Pharmaceutical industry: Preparation of tablets, capsules of traditional Chinese medicine extract particles or chemical particles, especially suitable for viscous material spherical granulation.
• New energy materials: lithium battery cathode materials (such as lithium ternary, lithium iron phosphate) coating and granulation to ensure material uniformity and electrochemical properties.
• Food and chemical industry: preparation of food additives, pesticide granules (e.g. WDG), as well as powder metallurgy, nano-materials mixed granulation.

High efficiency and flexibility

• High particle forming efficiency and controllable particle size range through high speed shear and reverse motion design.
• The modular structure supports the joint use with fluidized bed dryer to form a continuous production line.

Highly adaptable

• It can handle highly viscous materials (e.g. Chinese herbal medicine extract), and prevent agglomeration through the return ring and movable platen.
• Some models support the addition of pigments or functional additives to realize multi-purpose granulation.

Easy cleaning and maintenance

• The CIP design reduces the risk of cross contamination, and the removable blades and screens are easy to maintain.

High shear granulator has become an indispensable granulation equipment in modern industry by virtue of its high efficiency shear, flexible structural design and wide applicability. The future development direction may focus on intelligent control (e.g., automatic adjustment of particle size) and integration of green energy-saving technologies to meet higher standards of industrial demand.

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