FlexStream is a multi-purpose processor that addresses the shortfalls of traditional fluid bed processing, including linear scale-up, fully contained loading and unloading for pharmaceutical applications.

Traditional Fluid Bed Technology

Fluid bed operations—such as drying, granulation, and particle coating—are essential steps in the production of solid dosage forms. Despite widespread adoption, the technology presents several limitations. Each unit operation typically requires dedicated machinery or process containers to achieve optimal performance.

Scale-up can be challenging due to varying bed heights and inconsistencies between fluid bed systems. While fluid bed granulation produces granules with good compressibility, they may be mechanically weak and exhibit poor flow characteristics compared to high-shear granulation. Some formulations are incompatible with fluid bed granulation altogether. In addition, coating applications using conventional Wurster columns face issues such as scale-up difficulties, coating material loss, and product agglomeration.

FlexStream Technology

GEA’s FlexStream technology transforms fluid bed processing by enabling drying, granulation, and pellet (or tablet) coating within a single, versatile module. This multipurpose processor addresses the limitations of traditional systems by offering linear scale-up, fully contained loading and unloading, and superior product homogeneity in terms of loss on drying (LOD) and particle size distribution (PSD).

With a single product container used for all unit operations, FlexStream reduces both the system footprint and installation height, simplifying facility design and process flow.

The FlexStream Concept

FlexStream enables seamless transitions between drying, granulation, and coating without the need for mechanical adjustments. Extensive test data demonstrates superior product quality compared to conventional top-spray granulation and Wurster coating systems, with measurable benefits in process efficiency and final product consistency.

Key Features

• WIP and CIP: Automated cleaning ensures repeatability, supports validation, and reduces downtime.
• Rapid Discharge with Lean Phase Conveying: Enabled by a Non-Sifting Gill Plate, airflow from above and below the distributor ensures efficient granule discharge.
• Through-the-Wall Installation: Keeps auxiliary equipment outside the cleanroom, simplifying GMP compliance.
• Solvent Emission Control: Open- and closed-cycle options are available for the removal or recovery of organic solvents.
• Spraying Systems: Custom-configured nozzles, pumps, and liquid preparation units tailored to process needs.