How to Choose the Right Pressure Shock Resistance (2 / 12 BAR) for Your Fluid Bed Processor

Fluid bed processors are essential in pharmaceuticals, chemicals, and food processing industries for applications like drying, granulation, and coating. A key consideration when selecting a fluid bed processor is its pressure shock resistance—how well the equipment can handle sudden pressure changes without sustaining damage.

Why Explosion happens in fluid beds?

Static discharge poses a significant safety risk in fluid bed systems due to particle-to-particle collisions during product fluidisation. When solvents are used in binding solution preparation, they release flammable vapours that serve as fuel. Combined with product particles as the combustible medium and oxygen in the inlet air, these factors create conditions conducive to an explosive environment.

Why must safety always be considered the highest priority in fluid beds?

• Human Safety: Fluid bed operations involve potential risks such as chemical explosions, static discharges, and equipment malfunctions, which can result in severe harm to personnel. Ensuring safety mitigates these dangers and protects human lives.
• Environmental Safety: Explosions or leaks can lead to contamination of the surrounding environment, releasing hazardous chemicals and causing long-term ecological damage.
• Equipment Protection: Preventing damage to expensive machinery safeguards assets, minimises utility disruptions, and reduces production downtime, avoiding significant financial and operational losses.

Prioritising safety ensures seamless operations while protecting people, assets, and the environment.

Which safety parameters should you consider when selecting fluid beds?

• Equipment must be pressure shock resistant designed (2 / 12 BAR)
• Selecting the components as per the process requirement eg. Flame-Proof Design, ATEX-certified components
• Guidelines & Training for the operator to handle material & solvents as per product & process safety requirements

Which designs are safe – 2 BAR or 12 BAR?

When properly implemented, both 12-bar non-venting and 2-bar vented systems methods offer equal levels of safety.

However, the choice between them depends on the specific application, each offering distinct advantages depending on operational needs.

2 BAR vs 12 BAR fluid bed comparison

Why 2 BAR equipment are safe?

Fluid bed systems operate on the negative pressure principle. However, when a small pressure surge occurs, or in the event of an explosion, positive pressure is generated within the equipment. A properly designed system with venting mechanisms, such as rupture discs, ensures safety by sensing this positive pressure and instantly releasing the excess pressure to prevent damage.

2 BAR equipment is safe when correctly designed and implemented, as it incorporates safety features like rupture discs, which protect both the equipment and operators by maintaining controlled pressure levels and mitigating high-pressure risks effectively.

How can the safety of a 2 BAR system be enhanced?

• Use explosion-proof components and accessories.
• Use anti-static components like Filter Bags or Socks.
• Install pressure relief valves, e.g. Quick Acting Stop Valves at the inlet & exhaust duct to ensure the safety of the AHU and exhaust system like. Blower & Scrubber.
• Prefer ATEX-certified or Flame-Proof components like switches, operating & control panels, motors, pumps, sensors and other components.
• Use of flame-quenching systems or fire suppression systems at the explosion flap.
• Adhere to relevant safety standards and regulations.
• Ensure proper grounding to prevent static discharge.
• Regularly inspect and maintain all system components.
• Required training for the machine operators

Why 12 BAR Fluid Bed are introduced?

The introduction of 12 BAR fluid beds is primarily driven by the need to comply with strict European Union (EU) environmental regulations. These systems address stringent environmental standards and emission controls, making them critical in regions with rigorous compliance requirements.

It is important to note that the adoption of 12 BAR fluid beds is unrelated to improvements in product quality, equipment safety, or human safety. Their primary focus lies in meeting environmental norms rather than enhancing operational or safety performance.

Why must all equipment connected to a 12 BAR fluid bed system also be rated for 12 BAR?

When a 12 BAR system is required, it is essential that all connected equipment (Eg. Rapid Mixer Granulator) and accessories (Eg. Vacuum Transfer Systems, Wet & Dry Mass Transfer Systems, Wet & Dry Mills) are also rated for 12 BAR to ensure system-wide safety and integrity. If any connected component is not rated for the same pressure, it becomes a weak point where pressure could escape, potentially causing catastrophic failure.

In the event of a primary explosion in the fluid bed, the resulting pressure can propagate to the connected equipment, leading to a secondary explosion. To prevent such risks, all components must be designed to withstand the same pressure level, maintaining a uniform safety standard throughout the system.

Territory-wise Regulatory Considerations for Pharma Manufacturers:

• India: Pharma manufacturers in India often prefer 2 BAR systems because of less stringent environmental regulations; however, companies can prefer 12 BAR systems for additional environmental safety.

• USA: Pharma manufacturers in the USA often prefer 2 BAR systems because of less stringent environmental regulations; however, companies can prefer 12 BAR systems for additional environmental safety.

• Africa, Middle East & Latin America: Pharma manufacturers in ROW markets often prefer 2 BAR systems because of less stringent environmental regulations; however, companies can prefer 12 BAR systems for additional environmental safety.

• European Union (EU): In the EU, 12 BAR systems are mandated to comply with strict environmental regulations.

Choosing the right pressure resistance for your fluid bed processor depends on your geographical location and their environmental safety policies but not on process requirements & product quality.

anish pharma offers both 2 BAR and 12 BAR fluid bed processors to meet your specific needs. Whether you’re dealing with moderate or high-pressure process requirements.  Our equipment ensures safety, efficiency, and regulatory compliance across pharmaceutical and food processing industries.