Integrated Filtration, Washing and Drying Production Line

I. Core Host Equipment (Three-in-One Host)

1. Integrated Filtration, Washing and Drying Machine

• Vessel System: A pressure-resistant and sealed vessel made of high-quality 316L stainless steel/Hastelloy is used, equipped with a jacket for heating/cooling functions to ensure stable material processing at appropriate temperatures.
• Filtration Unit: A metal sintered filter plate (or filter cloth) at the bottom is adopted to support positive pressure/vacuum filtration, enabling efficient solid-liquid separation to meet the filtration requirements of different materials.
• Agitation System: A hollow shaft heating system combined with a lift-type blade with forward and reverse rotation functions allows for uniform material mixing and efficient heat transfer, making it particularly suitable for high-viscosity material processing.
• Spraying and Washing: Spray balls are configured at the top and sides to achieve multi-stage solvent distribution for all-round material washing, improving washing efficiency and reducing impurity content.
• Drying System: Vacuum drying is combined with jacket/heating of the stirring shaft, or hot nitrogen gas circulation is adopted to achieve rapid and uniform drying, which is especially friendly to heat-sensitive materials to ensure product quality.

• Discharging Device: Equipped with a pneumatic discharging valve (or screw conveyor), discharging is convenient and can be flexibly selected according to the characteristics of the material to ensure continuous production.

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II. Supporting Auxiliary Equipment

1. Upstream Supporting Equipment

• Reactors/Crystallizers: Reactors/crystallizers are designed for material synthesis or crystallization. By precisely controlling reaction conditions, an ideal suspension is formed and stably transported to the three-in-one host, laying a good foundation for subsequent processing.
• Pumps: Appropriate screw pumps, diaphragm pumps, etc., are selected to smoothly and efficiently pump the reaction liquid or crystallization liquid into the three-in-one host, ensuring trouble-free material transfer and avoiding blockages and leaks.

2. Filtration Power System

• Vacuum Pumps: Various options such as Roots vacuum pumps and liquid ring pumps are available to provide sufficient negative pressure for filtration. When paired with a vacuum buffer tank, they stabilize filtration pressure, enhancing filtration efficiency and quality.
• Air Compressors/Nitrogen Compressors: These supply the pressure required for positive pressure filtration and provide inert gas protection to meet explosion-proof requirements, ensuring safe and reliable production, especially for flammable and explosive materials.

3. Washing System

• Solvent Tanks: These store various washing liquids (e.g., water, ethanol, acetone). Depending on requirements, heating/cooling functions can be equipped to ensure suitable washing liquid temperatures, improving washing efficiency and optimizing product quality.
• Metering Pumps: High-precision gear pumps, plunger pumps, etc., are used to accurately control the amount of washing liquid, achieving precise washing, avoiding solvent waste and reducing production costs.

4. Drying System

• Condensers: Tubular condensers are selected for efficient solvent condensation and recovery, reducing solvent loss, minimizing environmental pollution and improving production efficiency.
• Condensate Receiver Tanks: These collect condensed solvents, which after treatment can be returned to the solvent tank for solvent recycling, creating a green production mode.
• Hot Air Circulation System (Optional): Comprising a heater, fan and filter, this system is used for hot air drying. By precisely controlling drying temperature and air volume, it further enhances drying efficiency and quality stability.

5. Downstream Supporting Equipment

• Grinders: If dried materials become lumpy, a gas flow grinder can be used to restore material flowability, meeting subsequent process requirements and ensuring product performance.
• Sifiers: 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 with 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: Various sensors (temperature, pressure, pH, etc.) are integrated to achieve automated process control. By accurately monitoring production parameters, stable production operation is ensured, reducing manual intervention and improving production efficiency and product quality consistency.
• CIP/SIP System: A must - have for the pharmaceutical industry, this system meets the requirements for in - place cleaning and sterilization, ensuring equipment cleanliness and compliance with Good Manufacturing Practices (GMP) for drug safety.

7. Environmental Protection and Safety Equipment

• Waste Gas Treatment Devices: Technologies such as activated carbon adsorption or condensation recovery are used to 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 configured to ensure production safety and minimize risks.
• Waste Water Treatment Units: These treat washing waste liquids and are equipped with facilities such as neutralization 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

1. Matching Material Properties
   • For corrosive materials: corrosion-resistant materials such as Hastelloy or PTFE lining are available to extend equipment service life and prevent material contamination and equipment damage.
   • For heat-sensitive materials: vacuum drying combined with low-temperature condensation is prioritized. The drying temperature is precisely controlled to prevent material denaturation from high temperatures, ensuring product quality and activity.
2. Production Capacity Requirements
   • For small - scale trial lines: a host with a volume of 50 - 500L and a micro vacuum pump are used to meet the needs of research, small - scale trials, etc. This reduces investment costs and facilitates process exploration and optimization.
   • 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.
3. Industry Standards
   • For the pharmaceutical industry: strict compliance with GMP standards is required. 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 customized 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.

• 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.

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