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Complete catalog

Complete catalog

Product catalog summary

Overview: This document is a comprehensive catalog for the pharmaceutical and biologics industries, offering a wide range of products and technical resources. It is an online-only resource featuring performance data, specification sheets, product videos, and downloadable 3D models.

Technical Reference: This section provides detailed information on spray nozzles, including pressure drops, water flow through pipes, spray performance considerations, and common nozzle problems. Key tables offer unit equivalents for volume, pressure, and linear measurements.

Tablet Coating: Discusses the processes and equipment used in tablet coating, emphasizing precision in spray application for uniform coating.

Fluid Bed Processing: Details the use of fluid bed technology in pharmaceuticals for drying, granulating, and coating particles, highlighting its efficiency and uniformity.

High-Shear Granulation: Describes the high-shear granulation process used to mix powders and form granules, critical for tablet production.

Spray Drying: Explains the spray drying process, converting liquid formulations into dry powders, a common method in pharmaceutical manufacturing.

Vessel Cleaning: Covers cleaning processes for vessels used in pharmaceutical production, ensuring compliance with hygiene standards.

Specialty Nozzles: Focuses on the design and application of specialty nozzles for specific pharmaceutical processes, ensuring optimal performance and efficiency.

Solid Dosage Processing: Discusses the processing of solid dosage forms, such as tablets and capsules, including equipment and techniques to ensure quality and consistency.

Appendix: Provides additional resources and references for further information on the topics covered in the catalog.

Online Resources: Includes links to additional online resources, such as literature, performance data, and 3D CAD models, accessible through the spray.com website.

Technical Reference Overview: This document provides a comprehensive guide on spray nozzle performance, focusing on impact, spray patterns, and pressure considerations. It includes detailed tables and charts to assist in understanding the effects of various factors on spray performance.

Impact and Spray Coverage: Impact is a critical measure of spray nozzle performance, expressed as impact per square inch (cm). It depends on the spray pattern distribution and angle. The document provides formulas to calculate theoretical total impact and unit impact, emphasizing that solid stream nozzles offer the highest unit impact. The impact decreases with increased distance from the nozzle.

Pressure and Flow Rate Considerations: The document outlines the relationship between flow rate, pressure, and impact. It provides formulas for estimating pressure drops across different flow rates and pipe sizes. The rated capacities for valves, strainers, and fittings are typically based on a 5% pressure drop of their maximum operating pressure.

Spray Performance Factors: Several factors affect spray nozzle performance, including viscosity, surface tension, and temperature. High viscosity liquids require higher pressure for spray pattern formation, while surface tension affects minimum operating pressure and spray angle. Temperature changes can influence viscosity and specific gravity, impacting flow rate and spray performance.

Common Spray Nozzle Problems: The document identifies common issues such as erosion, corrosion, clogging, and improper assembly that can affect nozzle performance. It emphasizes the importance of regular maintenance and inspection to detect wear and prevent performance degradation.

Maintenance and Inspection: A checklist for regular maintenance is provided, highlighting the need for visual inspections and monitoring of spray patterns and drop sizes. Consistent evaluation helps in early detection of wear and ensures efficient spray performance.

Technical Document Summary:

1. Product Quality and Application Results: Ensure uniformity of spray coverage for flat spray nozzles on a manifold. Spray patterns should be parallel, with spray tips rotated 5° to 10° from the manifold centerline.

2. Spray Nozzle Alignment: For centrifugal pumps, monitor flow meter readings or measure spray output to detect increases. Compare with manufacturer’s catalog or new nozzles. For positive displacement pumps, monitor liquid line pressure for decreases; flow rate remains constant.

3. Flow Rate and Spray Pressure: Monitor for increases in liquid volume sprayed for centrifugal pumps; pressure remains constant. For positive displacement pumps, monitor pressure gauge for decreases and potential clogging.

4. Preventing and Solving Spray Nozzle Problems: Follow safety instructions to prevent injury and ensure proper operation. Recognize system pressure limits and ensure compatibility with chemicals used.

5. General Safety Instructions: Read all safety and operating instructions before use. Use appropriate safety equipment when handling hazardous chemicals.

6. Tablet Coating Overview: Tablet coating involves applying an “edible paint” to dosage forms. Modern coatings are typically film coatings requiring precise control of spray parameters.

7. VMAU Spray Nozzles: VMAU nozzles offer modular design for various applications, maximizing uniform spray distribution and reducing maintenance downtime.

8. Anti-Bearding Set-Ups: P-Series Anti-Bearding Set-Ups reduce nozzle build-up and maintenance downtime, improving process quality and productivity.

9. Ordering Information: Specify body style, spray set-up, and actuator assembly for VMAU nozzles. Options include standard and sanitary bodies with various connections.

10. JAU and J-Type Spray Set-Ups: Interchangeable spray set-ups for different performance needs, available in standard and anti-bearding versions.

Overview: The document provides detailed information on JAU and JAUSF spray nozzle set-ups, modular air atomizing manifolds, and fluid bed processing techniques, specifically focusing on granulation and coating processes.

Spray Nozzle Set-Ups: The JAU and J-Type spray set-ups consist of a fluid cap and an air cap, each with specific part numbers. The document details various configurations, including anti-bearding set-ups, which are designed to prevent material build-up on the nozzle. The JAUSF nozzle is an updated version designed for sanitary applications, offering improved cleanability and similar performance to the standard JAU nozzles.

Modular Air Atomizing Manifolds: The 54000 series manifolds are customizable systems designed to reduce costs and maintenance. They are lightweight, easy to clean, and ideal for spraying viscous liquids. The manifolds can house multiple spray nozzles and are available in standard, large capacity, and recirculating configurations.

Fluid Bed Processing: Fluidized beds are used in the pharmaceutical industry for drying, granulating, and coating. The document explains the fluid bed granulation process, which involves suspending particles in an air stream and spraying a liquid to form granules. It distinguishes between dry and wet stage granulation, with the latter allowing for denser products.

Wurster Coating: This process is used for coating particles in a fluid bed, where particles are separated and coated in an air stream. The document describes the process and its application in coating various formulations.

Top-Spray Granulating Nozzles: The document details R&D and production scale top-spray granulating nozzles, highlighting their features, benefits, and ordering information. These nozzles are designed for precision granulation and are available in various configurations to suit specific system requirements.

Overview: The document provides detailed information on various fluid bed coating nozzles designed for different scales of operation, including R&D, pilot, and production scales. It also covers high-shear granulation and spray drying technologies.

1. Fluid Bed Coating Nozzles:

R&D Scale (54057 Nozzles): Designed for small-scale applications, these nozzles offer medium to fine spray with materials like 316L stainless steel and FDA-approved Teflon® gaskets. They feature a full circular cone spray pattern and are suitable for Wurster coating.
Pilot Scale (54499 Nozzles): Intended for pilot and small production scales, these nozzles provide fine spray with narrow full cone patterns. They facilitate easy scale-up from R&D to larger batches.
Production Scale (46910/46915 Nozzles): Customizable for larger systems, these nozzles improve Wurster coating applications with options for air-actuated liquid shut-off and various orifice sizes.

2. High-Shear Granulation:

High-shear granulation is used to create dense granules from powders for tableting or coating. The process involves mixing powders with a liquid in a sealed bowl using a high-speed chopper tool.
Custom-fabricated granulation lances are available, offering threadless, sanitary designs with materials like 316L stainless steel.

3. Spray Drying:

Spray drying produces dried powder from liquid solutions using hot gas. It is suitable for temperature-sensitive materials like foods and pharmaceuticals.
The SV Series SprayDry® nozzles feature maximum-free-passage orifices and a one-piece swirlchamber for consistent performance and resistance to wear.

Key Features and Benefits:

Materials used include 316L stainless steel, EPDM O-rings, and FDA-approved Teflon® gaskets.
Customizable options for nozzle lengths and configurations to meet specific system requirements.
Online resources and interactive PDFs are available for detailed performance data and 3D CAD models.

Overview: The document provides detailed information on various SprayDry® nozzle series, including SV, SK, and SB, as well as vessel cleaning solutions for bioprocessing applications. It highlights the features, benefits, and specifications of each nozzle type and offers guidance on selecting and optimizing cleaning solutions.

SprayDry® Nozzles:

SV Series: Features include a large maximum-free-passage to reduce clogging, rated at 10,000 psi, and quick delivery. Dimensions and weight are specified for different inlet connections.
SK Series: Produces a fine, hollow-cone spray with a narrow drop size distribution. Available with hand-tight and maximum-free-passage features, and 145 orifice insert/core combinations. Key features include anti-bearding design and improved sanitary features.
SB Series: Similar to SK series, with over 120 orifice insert/core combinations. Features include hand-tight design, anti-bearding design, and improved sanitary features.

Vessel Cleaning Solutions:

Application Overview: Emphasizes the importance of sterility and cleanability in bioprocessing, with a focus on bioburden control.
Hygienic Equipment Cleaning: Regular cleaning is essential for bioburden control. Spray device selection is critical for effective cleaning.
Vessel Review: Considers vessel size, nozzle size, and internal geometry for optimal cleaning.
Clean Utilities and Process Review: Evaluates clean utility capacity, chemistry, temperature, and air blows.
Cleaning Methodology: Describes CIP, SIP, and WIP methods, emphasizing the need for ASME® BPE standard compliance for high bioburden control applications.

Selection and Optimization Tips:

Factors such as flow rate, spray impact, and device review are crucial for identifying the best tank cleaning solution.
Spray Analysis and Research Services offer advanced analysis using CFD and PDI technology.

Custom Solutions:

Custom-fabricated wands, manifolds, and other solutions are available to optimize spray performance and simplify system installation.
Metallic and non-metallic solutions are offered, with materials compliant with ASME® BPE standards.

Precision-Drilled Spray Balls:

Customizable solutions for biopharmaceutical tank cleaning, with precision-drilled orifice patterns and compliance with ASME® BPE standards.

Fixed and Fluid-Driven Rotary Nozzles:

TankJet® 63225-3A Fixed Spray Balls: Ideal for sanitary rinsing, with features like 316L stainless steel construction and custom drilling options.
TankJet® 30473 Fluid-Driven Rotary Nozzles: Designed for effective cleaning of small vessels, with self-lubricating and self-draining features.

Overview: The document provides detailed technical specifications and ordering information for various fluid-driven rotary nozzles used in tank and vessel cleaning applications. These nozzles are designed for efficient cleaning with features tailored to different industrial needs.

Specifications:

TankJet® 30473 Nozzles: These nozzles are fluid-driven rotary nozzles with various inlet and nozzle types. They are available in materials like TEFLON and stainless steel, suitable for different pressure capacities ranging from 10 psi to 50 psi.
TankJet® 28500 Nozzles: Ideal for cleaning tanks up to 18 feet in diameter, these nozzles feature a rotating spray head and are made from non-metallic materials. They conform to 3A sanitary standards and are available with USP Class VI Viton O-rings.
RevoJet® Nozzles: These nozzles provide high-impact, low-volume cleaning for large vessels. They are available in eight capacity sizes and are constructed from 316SS with PEEK bearings.
TankJet® 14 & 19 Nozzles: Designed for tanks up to 12 feet in diameter, these nozzles offer dynamic rotary cleaning with a sleek design to prevent residue buildup.
TankJet® D41800E Nozzles: These regulated nozzles are suitable for medium-sized tanks and feature a hygienic three-piece design with self-flushing bearings.

Performance Data: The document includes performance data for each nozzle type, detailing capacity in gallons per minute (GPM) and liters per minute (LPM) at various pressures.

Ordering Information: Each nozzle type has specific ordering instructions, requiring details such as nozzle type, spray pattern, inlet connection, material code, and capacity size.

Applications: The nozzles are suitable for various cleaning applications, including CIP systems, vessel cleaning, and hygienic applications in industries such as food and beverage, pharmaceuticals, and chemical processing.

Additional Features: Some nozzles offer removable spray heads for easy maintenance, integrated lances for CIP applications, and electrostatic spray systems for precise coating applications.

Product Overview: AccuJet Ultrasonic Spray Systems are designed for high-precision coatings, utilizing ultrasonic atomizing nozzles that produce fine sprays through sonic vibrations. These systems are ideal for applications requiring thin film and micron coatings.

Features and Benefits:

Ultrasonic Atomizing Nozzle: Utilizes patent-pending nanotechnology for precise spray patterns, reducing overspray and waste.
Ultrasonic Spray Controller: Maintains consistent spray with self-adjusting features, capable of controlling up to three nozzles, and offers remote control capabilities.

Operating Principles: Ultrasonic nozzles use high-frequency vibrations to create small, uniform droplets. The droplet size is determined by the vibration frequency, with higher frequencies producing finer droplets.

Applications: These systems are used in high-precision coating, spray drying, and humidification.

Performance Data: The document provides detailed performance data, including water flow rates, air pressure, and drop sizes, which are critical for optimizing spray applications.

Ordering Information: Details on ordering ultrasonic spray systems, including nozzle types, air caps, and material codes, are provided to assist in selecting the appropriate configuration.

GunJet Spray Guns: These spray guns are suitable for clean-up, rinsing, and blow-off applications, offering adjustable spray patterns and corrosion resistance.

WindJet Air Nozzles: WindJet nozzles improve performance in drying, cooling, and coating applications by providing a controlled flat fan distribution of compressed air.

Solid Dosage Processing: Fluid Air, a division of Spraying Systems Co., specializes in equipment for solid dosage processing in the pharmaceutical industry, offering customizable systems for fluid bed drying, granulation, and coating.

MAGNAFLO & MAGNACOATER Fluid Bed Systems: These systems are customizable for superior performance in solid dosage processing, featuring tapered expansion chambers and agitator rakes for improved granulation and process time reduction.

Ultrasonic Air Atomizing Lance: Integrated into fluid bed systems for enhanced spray distribution and precision in coating processes, offering adjustable shaping air pressure and flow rates.

Overview: This document provides detailed information on various pharmaceutical processing systems, including high-shear granulators, size reduction systems, tablet coating optimization systems, and process control software. It outlines the features, benefits, and specifications of each system, catering to different scales of production from R&D to full-scale manufacturing.

High-Shear Granulators:

Features and Benefits: Optimized bowl geometry for efficient mixing, hydraulic drive system, and options for one-pot processing.
Scales: R&D (PX1), Pilot (PX25 - PX150), and Production (PX250 - PX1250).
Specifications: Detailed specifications for each model, including chopper power, bowl volume, impeller speed, and power.
Safety Tip: Interchangeable bowls for processing hazardous compounds safely.

Size Reduction Systems (GRANUMILL):

Features and Benefits: Variable speed rotor, quick-release housing, and robust rotor design.
Scales: R&D (GRANUMILL Jr.), Pilot (GRANUMILL 007), and Production (GRANUMILL 014).
Specifications: Speed, particle size, throughput, and system dimensions.
Safety Tip: Flexible containment enclosures for safe processing.

Tablet Coating Optimization System (TABCOATER):

Overview: Designed to upgrade existing coating equipment with new components.
Features and Benefits: Manifold with VMAU spray nozzles, automated process controls, and customized fluid delivery skids.
Safety Tip: Flexible containment systems for cost and time efficiency.

Batch Architect Process Control Software:

Overview: Flexible software for controlling batch-type equipment.
Features and Benefits: Manual machine control, GUI, recipe control, and electronic batch record logging.
Safety Tip: Software virtualization technology for cost reduction.

Retrofit Services:

Overview: Services to update and enhance existing equipment with new technology and features.
Features and Benefits: Equipment upgrades, new function conversions, and control system updates.
Safety Tip: Revitalize existing equipment with new nozzles and lances.

Accessories:

Sanitary Mounting Clamp: Allows 360° indexing of manifolds for optimal positioning.
O-Ring Kits and Tube Fittings: Spare kits and fittings for easy installation and maintenance.

Glossary: Definitions of key terms such as active coating, API, ASME standards, and more, providing clarity on technical jargon used throughout the document.

Glossary of Terms:

Clean-in-Place (CiP): Equipment and techniques for cleaning process equipment without dismantling.
Drug: A substance for diagnosis, cure, treatment, or prevention of disease.
Electropolishing: An electro-chemical process to improve surface finish by removing a thin surface layer.
Enteric Coating: A barrier on oral medication to control absorption location in the digestive system.
Excipient: An inactive substance used as a carrier for active ingredients in medication.
Formulation: A mixture prepared according to a specific procedure.
Full Penetration: A type of weld where the weld metal extends through the complete thickness of the parts joined.
Installation Qualification (IQ): Documents verifying correct installation of system components.
Modified Release Coating: Coatings applied to alter the release of active pharmaceutical ingredients (APIs).
Operational Qualification (OQ): Documents verifying that components operate within established limits.
Passivation: Formation of a protective layer on stainless steel to prevent rust.
Process Qualification (PQ): Final qualification activity before process validation.
Quality Control: A process to review the quality of production factors.
Validation: Qualification of the manufacturing process to ensure stability and reliability.

Terms and Conditions of Sale:

Modification of Terms: Buyer's assent to terms is presumed from receipt without objection.
Price: Prices are subject to change, and payment is due 30 days after invoice.
Minimum Billing: Minimum order billing is $50.00.
Warranties: Products conform to specifications and do not infringe on intellectual property.
Limitation on Liabilities: Seller's liability is limited to the total amount billed.
Quality Assurance: Seller is not obligated to meet special Buyer specifications unless agreed upon.
Claims: Must be made within one year of receipt of goods.
Default in Payment: Seller may defer shipments or cancel orders if payments are not made.
Technical Assistance: Provided without charge, but Seller assumes no liability for advice.
Cancellation of Special Orders: Cannot be canceled or modified without Seller's consent.
Patents: Seller is not liable for patent infringement from Buyer's designs.
Complete Agreement: Terms constitute the entire agreement between Buyer and Seller.
Governing Law: Orders are governed by Illinois law.
Customer Return Policy: Returns are accepted with conditions, including restocking charges.

Catalog excerpts

Experts in Spray Technology

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phar maceutical s & biologi c s Ca t a l o g Technical Reference Specialty Nozzles Solid Dosage Processing Visit spray.com/pharmcatalog to find additional information on VMAU spray nozzles, including: online Resources Literature Bulletin 558, VMAU Spray Nozzles u Vessel Cleaning online R esources Spray Drying Throughout the catalog, additional resources are highlighted on each page where they are available. To access this extra content, simply click on the links (signified by u ) under each category to view the corresponding information. High-Shear Granulation ACCESSING ONLIN E CONTENT Catalog...

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Technical reference Estimating Pressure Drops Through Fluidline Accessories Basic Nozzle Characteristics Flow of Water Through Schedule 40 Steel Pipe Spray Drop Size (Atomization) Other Spray Performance Considerations Drop Size Terminology Common Causes of Spray Nozzle Problems Preventing and Solving Spray Nozzle Problems Spray Angle and Coverage General Safety Instructions spray.com | 1.800.95 SPRAY | Intl. 1.630.665.5000

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Technical reference TABLE OF EQUIVALENTS volumetric unit equivalents Cubic Centimeter Cubic Centimeter Fluid Ounce Pound of Water Liter US Gallon Cubic Foot Cubic Meter Fluid Ounce Cubic Foot Cubic Meter liquid pressure equivalents Lb/In2 (psi) Lb/In2 (psi) Ft Water Kg/Cm2 Atmosphere Bar Inch Mercury kPa (kilopascal) Inch Mercury Linear unit equivalents Micron Mil Millimeter Centimeter Inch Foot Meter miscellaneous equivalents and formulas Unit Ounce Pound Horse-Power British Thermal Unit Square Inch Square Foot Acre Unit Acre Fahrenheit (°F) Celsius (°C) Circumference of a Circle Area of a Circle...

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Technical reference basic nozzle characteristics BASIC NOZZLE CHARACTERISTICS Spray nozzles are precision components designed to yield very specific performance under specific conditions. To help you determine the best nozzle type for your application, the following reference chart summarizes the performance that each nozzle type is designed to deliver. Spray pattern: FLAT SPRAY (TAPERED) General Spray Characteristics A tapered-edge flat spray pattern nozzle is usually installed on a header to provide uniform coverage over the entire swath as a result of overlapping distributions. Designed to...

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Technical reference spray drop size (atomization) SPRAY DROP SIZE (ATOMIZATION) Accurate drop size information is an important factor in the overall effectiveness of spray nozzle operation. Drop size refers to the size of the individual spray drops that comprise a nozzle’s spray pattern. Each spray provides a range of drop sizes; this range is referred to as drop size distribution. Drop size distribution is dependent on the spray pattern type and varies significantly from one type to another. The smallest drop sizes are achieved by air atomizing nozzles while the largest drops are produced by...

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Technical reference drop size terminology DROP SIZE TERMINOLOGY Terminology is often the major source of discrepancy and confusion in understanding drop size. The mean and characteristic diameters are the diameters extracted from the drop size distribution (see Figure 1). To compare the drop size from one nozzle to another, the same diameters have to be used as the source of comparison. For example, one cannot compare the DV0.5 from one nozzle to the D32 from another nozzle. The following lists the most popular mean and characteristic diameters, definitions and most appropriate use. Drop size...

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Technical reference CAPACITY Nozzle capacity varies with spraying pressure. In general, the relationship between flow rate and pressure is as follows: Nozzle Type Hollow Cone Nozzles (All) Full Cone Nozzles (Vaneless) Full Cone Nozzles (15° and 30° Series) Flat Spray Nozzles (All) Solid Stream Nozzles (All) Spiral Nozzles (All) Full Cone Nozzles (Standard) Full Cone Nozzles (Square Spray) Full Cone Nozzles (Oval Spray) Full Cone Nozzles (Large Capacity) Q: Flow rate (in gpm or l/min) P: Liquid pressure (in psi or bar) n: Exponent applying to the specific nozzle type Since the specific gravity...

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Technical reference spray angle and coverage SPRAY ANGLE AND COVERAGE Tabulated spray angles indicate approximate spray coverages based on spray of or distribution of water. In actual spraying, the effective spray angle varies with spray distance. Liquids more viscous than water form relatively smaller spray angles (or even a solid stream), depending upon viscosity, nozzle capacity and spraying pressure. Liquids with surface tensions lower than water will produce relatively wider spray angles than those listed for water. This table lists the theoretical coverage of spray patterns as calculated...

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Technical reference IMPACT Impact, or the impingement of a spray onto the target surface, can be expressed in several different ways. The most useful impact value with regard to spray nozzle performance is the impact per square inch (cm). Basically, this value depends on the spray pattern distribution and spray angle. To obtain the impact per square inch (cm) [pounds (kg)-force per square inch (cm)] of a given nozzle, first determine the theoretical total impact using the following formula: Then, from the chart below, obtain the impact per square inch (cm) as a percent of the theoretical total...

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Technical reference estimating pressure drops through fluidline accessories ESTIMATING PRESSURE DROPS THROUGH FLUIDLINE ACCESSORIES The rated capacities listed in this catalog for valves, strainers and fittings typically correspond to pressure drops of approximately 5% of their maximum operating pressure. Use the following formula to estimate the pressure drop of other flow rates. Q: Flow rate (in gpm or l/min) Accessory rated capacity For pressure drop information on a specific product, contact your local sales engineer for data sheets listing pressure drops at various flow rates. Maximum recommended...

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Technical reference flow of water through schedule 40 steel pipe FLOW OF WATER THROUGH SCHEDULE 40 STEEL PIPE Flow gpm (l/min) Pressure Drop in psi (bar) for Various Pipe Diameters* 0.125” Recommended capacity range for each size is displayed in bold type. *Psi values are based on a pipe length of 10 feet. Bar values are based on a pipe length of 10 meters.

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