Yacheng / PILOTECH YC-1000 Integrated Laboratory Spray Dryer, Fluidized Bed Granulator & Coater
| Brand | Yacheng / PILOTECH |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | OEM Manufacturer |
| Model | YC-1000 |
| Power Supply | 220 V / 50 Hz, 5 kW |
| Heating Power | 3 kW |
| Spray Drying Capacity | 1500 mL/h |
| Fluidized Bed Granulation/Coating Capacity | 1000 g/batch |
| Inlet Air Temperature (Spray Drying) | 105–200 °C |
| Inlet Air Temperature (Fluidized Bed) | 40–150 °C |
| Peristaltic Pump Flow Rate | 0–1500 mL/h |
| Atomizing Air Pressure | 1–3 bar |
| Drying Chamber Volume | 10 L (Borosilicate Glass + Stainless Steel) |
| PID Temperature Control Accuracy | ±1 °C |
| Touchscreen Interface | Color LCD with Real-time Display of Inlet Temp, Fan Frequency, Fluid Bed Temp, Pump Speed, Pulse Cleaning Frequency |
| Construction Material | Full 316L Stainless Steel |
| Minimum Sample Requirement | 50 g |
| Footprint | 0.5 m² |
Overview
The Yacheng / PILOTECH YC-1000 Integrated Laboratory Spray Dryer, Fluidized Bed Granulator & Coater is an engineered platform for concurrent or sequential unit operations in powder processing: spray drying, fluidized bed granulation, drying, and film coating. It operates on the principle of rapid solvent evaporation via atomization into a heated air stream (spray drying), followed by controlled particle growth through binder solution spraying onto fluidized particles (top-spray or bottom-spray granulation), and final surface modification via polymer or functional excipient deposition under precise thermal and airflow conditions (fluidized bed coating). This multi-function architecture eliminates inter-system transfer losses, reduces cross-contamination risk, and enables direct process mapping from lab-scale formulation development to pilot-scale parameter optimization — critical for regulatory submissions under ICH Q5A–Q5E and FDA guidance on continuous manufacturing.
Key Features
- Single-platform integration of four core pharmaceutical and materials processing functions: spray drying, fluidized bed granulation, post-granulation drying, and aqueous/organic solvent-based coating.
- Ultra-low sample requirement: validated operation with as little as 50 g of feed material, minimizing API consumption during early-stage formulation screening.
- Compact footprint (0.5 m²) with castor-mounted frame, enabling deployment in ISO Class 7–8 clean benches or standard fume hoods without structural modification.
- Dual-zone thermal management: independent PID-controlled heating circuits for spray drying inlet air (105–200 °C) and fluidized bed air (40–150 °C), each with real-time digital feedback and ±1 °C stability.
- Full 316L stainless steel construction with borosilicate glass expansion chamber (10 L volume), compliant with ASME BPE-2021 surface finish standards (Ra ≤ 0.4 µm).
- Intelligent PLC control system with color LCD touchscreen interface displaying 12 real-time process variables: inlet temperature, fan frequency, fluid bed temperature, peristaltic pump speed (0–1500 mL/h), pulse cleaning interval, atomizing air pressure (1–3 bar), exhaust humidity (optional sensor), and system status flags.
- Fail-safe shutdown protocol: pressing “Stop” initiates staged cooldown — heaters de-energize immediately while fan continues at reduced speed for thermal dissipation, preventing thermal shock or heater coil damage.
Sample Compatibility & Compliance
The YC-1000 accommodates thermolabile actives (e.g., peptides, enzymes, probiotics) and low-melting-point excipients (e.g., PEGs, fatty acids) via adjustable inlet temperatures down to 105 °C and gentle fluidized bed processing. Its design conforms to GMP Annex 11 principles for automated systems: all process parameters are logged with timestamped audit trails, user access levels are configurable (operator, engineer, administrator), and data export supports CSV and PDF formats compatible with electronic lab notebooks (ELN) and LIMS integration. The system meets mechanical safety requirements per EN 61000-6-2/6-4 and electrical safety per IEC 61010-1. Optional validation packages include IQ/OQ documentation aligned with ASTM E2500 and USP <1058> Analytical Instrument Qualification.
Software & Data Management
The embedded HMI firmware records all operational parameters at 1-second intervals to internal flash memory (≥10,000 hours of continuous logging). Data export is password-protected and includes metadata (user ID, batch ID, start/stop timestamps, calibration history). Optional Ethernet or USB-C connectivity enables remote monitoring via Modbus TCP or OPC UA protocols. For regulated environments, optional 21 CFR Part 11 compliance module adds electronic signatures, biometric login, and immutable audit logs with SHA-256 hashing. All software updates are digitally signed and verified prior to installation.
Applications
The YC-1000 supports formulation development across multiple regulated and industrial sectors:
• Pharmaceutical R&D: immediate-release granules, sustained-release coated beads, inhalable dry powders, vaccine adjuvant carriers.
• Nutraceuticals & Food Science: microencapsulated probiotics, flavor oil protection, instant beverage agglomerates, enzyme stabilization.
• Advanced Materials: ceramic precursors (e.g., alumina, zirconia), polymer microparticles (PLGA, PCL), conductive carbon composites, catalyst supports.
• Agrochemicals: water-dispersible granules (WDG), controlled-release pesticides, coated fertilizer prills.
• Natural Product Processing: botanical extract encapsulation, essential oil retention, anthocyanin stabilization.
FAQ
Can the YC-1000 perform spray drying and fluidized bed coating in a single continuous run?
Yes — the system allows sequential mode switching without manual disassembly; however, full chamber purge and temperature equilibration between modes are required to prevent cross-contamination and ensure process reproducibility.
Is the borosilicate glass chamber rated for vacuum operation?
No — the expansion chamber is designed for atmospheric and slight overpressure operation only (max 0.2 bar gauge); vacuum compatibility requires optional reinforced viewport and sealing upgrades.
What validation support is provided for GMP-compliant labs?
Yacheng supplies factory-verified IQ/OQ protocols, calibration certificates traceable to NIST standards, and a URS template for customer-specific PQ execution; on-site SAT support is available upon request.
Does the system support organic solvent handling (e.g., ethanol, acetone)?
Yes — with optional explosion-proof motor, ATEX-rated electrical components, and inert gas (N₂) purging interface; solvent recovery module is available as add-on.
How is particle size distribution affected by the dual-atomization design?
The two-fluid nozzle enables fine droplet generation (Dv₅₀ ≈ 20–50 µm) with narrow span (RRSB slope > 1.8), confirmed by laser diffraction analysis of dried powders; fluidized bed residence time and binder viscosity are primary granule size determinants.
