Amoxicillin is a widely used semi-synthetic penicillin antibiotic, which is used to treat a wide range of diseases such as middle ear infections, streptococcal pharyngitis, pneumonia, skin infections, urinary tract infections, and can also be used in combination with other drugs to eradicate Helicobacter pylori bacteria, and the wide range of uses is driving its market growth. Continuous growth in the global population and rising demand for healthcare resources is driving the market expansion of basic drugs such as amoxicillin. Meanwhile, the aging population in the country is increasing and the elderly have relatively lower immunity and are more susceptible to bacterial infections, which has led to a corresponding increase in the demand for anti-infective drugs such as amoxicillin. In some emerging market countries, with the development of the economy and the improvement of healthcare infrastructure, the demand for antibiotics is increasing, providing new growth space for the amoxicillin market.
The amoxicillin market is highly competitive with numerous manufacturers across the globe. Competition among companies in terms of product quality, price, and branding may lead to competition for market share and price pressure, affecting companies' profit margins. Jinwang Drying researches and develops new amoxicillin drying process and technology to improve amoxicillin production efficiency and product quality, and reduce production cost so as to be more competitive in price. The new aseptic airflow dryer optimizes the drying link in the process of amoxicillin fine drying package, and fine que controls the drying temperature and time to improve the yield and quality of the product and reduce the residue of impurities and moisture. The new process adopts advanced intelligent control system, which can improve the efficiency and precision of production, reduce the interference of human factors, and ensure the stability and consistency of product quality.
Amoxicillin aseptic airflow dryer process flow
(1) Feed preparation
Material pretreatment: the need to dry amoxicillin materials for pre-treatment, such as filtration, concentration, etc., so that it reaches a suitable state for drying, such as amoxicillin solution spray drying to get powdered materials
Feeding system cleaning and disinfection: before feeding, the feeding system is thoroughly cleaned and disinfected to prevent impurities and microorganisms from mixing into the material and ensure the sterility of the feeding process. Usually use special cleaning agents and disinfectants in accordance with strict operating procedures.
(2) Heating and airflow generation
Air filtration: The outside air first passes through the air filter to remove the dust, impurities and microorganisms, etc., to get clean air to meet the requirements of aseptic production.
Air heating: the filtered air enters the heater, and the air is heated to the set temperature by steam, electricity, hot air furnace and other heat sources, generally according to the heat resistance and drying requirements of amoxicillin, the temperature is controlled in a suitable range, such as 100 ℃ ~ 200 ℃ or so.
Airflow formation: the heated hot air forms a high-speed flow of airflow to provide heat and power for the drying of materials, so that the materials can be fully suspended and dispersed in the airflow to increase the contact area with the hot air and improve the drying efficiency.
(3) Drying process
Material dispersion and transportation: the pre-treated amoxicillin material enters the drying tube through the feeder, and comes into full contact with the hot airflow. Under the action of the airflow, the material particles are quickly dispersed and suspended state, with the airflow in the drying tube to move quickly, to achieve full mixing of materials and hot air and heat and mass exchange.
Moisture evaporation: the heat in the hot airflow is transferred to the material, so that the moisture in the material evaporates rapidly. As the drying time is very short, generally 0.5~2 seconds, it can realize efficient drying in a short time, and at the same time, it avoids the problems of deterioration or destruction of active ingredients caused by prolonged exposure of materials to heat.
(4) Discharge and collection
Gas-solid separation: The dried material and exhaust gas enter the cyclone separator together, and the centrifugal force is utilized to separate the material particles from the exhaust gas. The material particles are collected at the bottom of the cyclone separator, while the exhaust gas is discharged from the top.
Finished Product Discharge: The collected dried amoxicillin finished product is discharged through the discharge port for subsequent packaging or processing. During the discharge process, the same care should be taken to maintain aseptic operation to prevent contamination of the finished product.
Exhaust gas treatment: the exhaust gas may contain a small amount of material dust and water vapor, in order to avoid pollution of the environment, need to be processed through the dust collector and other equipment to recover the material
dust, and at the same time make the exhaust gas meet the emission standards before discharging into the atmosphere.
(5) Equipment cleaning and sterilization
On-line cleaning: Immediately after the drying process, on-line cleaning is carried out inside the dryer, through spraying special cleaning liquid to clean the materials and impurities left on the inner surface of the drying tube, cyclone separator and other components, so as to prevent them from drying up and harboring bacteria.
Regular disinfection: Regularly carry out comprehensive disinfection treatment for the whole dryer system, adopting high temperature steam and chemical disinfectant to thoroughly disinfect all parts of the equipment to ensure the sterility of the equipment and prepare for the next production.
Amoxicillin aseptic airflow dryer performance characteristics
(1)Good product quality
Asepsis guarantee: the equipment is equipped with air filter, the air into the dryer is strictly filtered to remove the microorganisms, dust and other impurities, to prevent the material from being contaminated, to ensure the sterility of amoxicillin products, in line with the strict requirements of the production of drugs.
Stable quality: the material is suspended during the drying process, the heat is uniform, to avoid the local overheating caused by the material deterioration or destruction of the active ingredients and other problems, so as to ensure the stability of the quality of amoxicillin products and the consistency of the efficacy of the product.
Material damage is small: due to the short drying time, temperature control precision, and the material in the airflow is suspended in a state of dispersion, collision and friction between each other is small, so it can zui greatly reduce the damage to the amoxicillin particles of the material, to maintain its original physical properties and particle size distribution.
(2)High drying efficiency
Rapid drying: air dryer using high temperature and high speed hot airflow and material full contact, so that the moisture in the material in a very short period of time to evaporate quickly, drying time is usually only 0.5 ~ 2 seconds, greatly improving the production efficiency.
Continuous operation: it can realize continuous feeding and discharging, and the residence time of the material in the dryer is short and stable, which can meet the demand of large-volume amoxicillin production and is suitable for industrialized large-scale production.
(3)Energy saving and environmental protection
High energy utilization rate: after the hot air flow is fully exchanged with the material in the drying process, the rest of the heat can be recycled and reused in an appropriate way, such as preheating the cold air entering the dryer or used for the heating of other process links, thus improving the comprehensive utilization rate of energy and reducing the production energy consumption and cost.
Low emission: the equipment is usually equipped with effective dust removal devices, such as cyclone dust collector, cloth bag dust collector, etc., to collect and treat the dust generated in the drying process, reducing the pollution of dust emission to the environment, and also avoiding the waste of materials, in line with the requirements of environmental protection). High degree of automation
Automatic control: adopting advanced control system, such as DCS control system, it can precisely control the key parameters in the drying process, such as temperature, airflow speed, feeding speed, etc. It automatically adjusts and stabilizes the operation state according to the preset parameters to ensure the consistency and stability of the drying effect, and to reduce the influence of human factors on the quality of products.
Online monitoring: equipped with online monitoring device, real-time monitoring of material humidity, temperature, dust concentration in the airflow and other parameters, and the data will be displayed intuitively on the operating interface, the operator can always understand the dynamic information of the drying process, in order to find and deal with the abnormalities in a timely manner.
Fault diagnosis and early warning: with fault diagnosis function, it can automatically detect the operating condition of the equipment, when there is a fault or abnormality, the system will promptly issue an alarm and prompt the cause of the fault, so as to facilitate the maintenance personnel to quickly locate and solve the problem, reduce the downtime of the equipment and improve the production efficiency.
(5)Compact structure of equipment
Small footprint: the main components of the air dryer, such as drying tube, heater, fan, cyclone separator, etc. are usually used in compact design and reasonable layout, the overall structure is relatively simple, compared with some other drying equipment, its footprint is significantly smaller, can effectively save space in the plant, reduce the cost of construction investment.
Convenient installation and maintenance: the structure of the equipment is relatively simple, the number of parts is less, the installation process is easier and faster, which can shorten the installation and commissioning cycle of the equipment. At the same time, in the daily maintenance and overhaul, maintenance personnel can easily check, clean, repair and replace various components, reducing the difficulty of equipment maintenance and maintenance costs.
Amoxicillin aseptic airflow dryer technology improvement
(1) Material handling technology upgrade
Pre-dispersing technology: Add efficient pre-dispersing equipments, such as ultrasonic disperser or high-speed rotating dispersing disk, near the feeding port. These equipments can effectively disperse the agglomerated amoxicillin materials before entering the drying tube, disperse the large particles into smaller particles, so that the contact area between the material particles and the hot airflow is zui maximized, thus improving the drying efficiency.
Particle size control technology: Combined with screening and crushing equipment, the particle size of amoxicillin material is precisely controlled before drying. By screening out the appropriate particle size range of materials into the dryer, at the same time will not meet the requirements of the large particles of material for crushing, to ensure that the size of the material into the dryer is uniform, and is conducive to improving the drying effect and product quality.
Surface modification technology: research on the surface modification of amoxicillin materials before drying methods, such as adding the appropriate amount of surfactant. Surfactant can change the surface properties of the material, reduce the affinity of the material and water, so that the water is easier to evaporate from the surface of the material, while also preventing the material from agglomerating in the drying process, improve drying efficiency and product quality.
(2)Improvement of heating technology
Precise temperature control technology: Adopt more advanced temperature sensors and controllers to realize high-precision control of the temperature of hot airflow. For example, the introduction of intelligent temperature control system can dynamically adjust the temperature of hot airflow according to the real-time drying state of amoxicillin material, and the error range can be controlled within ±1℃. This can avoid damage to the active ingredients of amoxicillin or incomplete drying due to temperature fluctuations.
High-efficiency heating method: Explore new heating methods, such as microwave-assisted heating. In the process of airflow drying, combined with microwave heating technology, the internal and surface of the material is heated at the same time, accelerating the evaporation of water. Compared with the traditional steam or electric heating, microwave heating can increase the drying efficiency by 30%~50%, and can dry the material more evenly, especially suitable for amoxicillin, a drug with high requirements for drying quality.
Heat recovery system: set up perfect heat recovery device to recover the waste heat in the exhaust gas after drying. For example, using heat exchanger to transfer the heat in the exhaust gas to the cold air entering the dryer, so that the cold air is preheated before entering the heater, which can reduce energy consumption. It is estimated that about 20%~30% of energy cost can be saved through effective heat recovery system.
(3) Airflow system optimization
Improvement of airflow distribution uniformity: Design more reasonable airflow guiding device in the drying tube, such as installing a deflector plate or changing the internal structure of the drying tube, so that the hot airflow can be distributed more uniformly in the drying tube. This can ensure that the amoxicillin material can be fully contacted with equal amount of hot airflow at all positions, avoiding localized overheating or uneven drying, and improving drying quality and efficiency.
Variable airflow speed adjustment: develop technology that can dynamically adjust the airflow speed according to the drying stage of the material. In the early stage of drying, when the moisture content of the material is high, the use of higher air velocity, so that the material is quickly dispersed and accelerate the evaporation of water; with the advancement of the drying process, the moisture of the material is reduced, the appropriate reduction in the air velocity, so that the material has enough time to complete the final drying of the zui, and at the same time to reduce the possibility of the material with the possibility of raising the product yield.
Low humidity air supply technology: introduce dehumidification equipment to deeply dehumidify the air entering the dryer. For example, using adsorption dehumidifier to reduce the relative humidity of the air to below 10%, providing low humidity hot airflow for amoxicillin drying, speeding up the evaporation of moisture and improving the drying efficiency.
(4) Aseptic protection technology enhancement
Upgrade of high-efficiency air filtration system: adopt higher-grade air filters, such as high-efficiency particulate air filter (HEPA), whose filtration efficiency can reach 99.97% or more, which can more effectively remove microorganisms, dust and other micro-particles in the air to ensure that the air entering the dryer is sterilized.
Aseptic treatment inside the equipment: develop new aseptic treatment technology inside the equipment, such as the use of ultraviolet light - ozone combined sterilization technology. After the equipment is cleaned, all corners inside the dryer are fully sterilized through UV irradiation and ozone release to kill the residual microorganisms, prolong the sterility keeping time of the equipment, and reduce the risk of the pharmaceuticals being contaminated.
Improvement of sealing technology: Strengthen the sealing design of the equipment, adopt high-quality sealing materials and sealing structure, such as double-channel sealing and vacuum sealing technology, prevent the outside air from entering the inside of the equipment, and ensure that the drying process is always in a sterile environment.
(5) Application of automation and intelligent technology
Model predictive control (MPC) technology: MPC technology is applied to the drying process control. By establishing the mathematical model of amoxicillin drying process, MPC can predict the future state of the drying process, adjust the control parameters in advance, such as temperature, airflow rate and feed rate, etc., to realize the zui optimal control of the drying process, and improve the drying efficiency and product quality.
Big data analysis and fault early warning: collect various data in the drying process, such as temperature, humidity, pressure, flow rate, etc., and mine the potential laws in the data through big data analysis technology. Using these laws to establish a failure warning model, when detecting abnormal signs of equipment or product quality decline trend, the alarm is issued in advance, so that operators can take timely measures to avoid production accidents and product quality problems.
Remote monitoring and maintenance technology: to realize remote monitoring and maintenance of the dryer, through the Internet technology, technicians can view the real-time operating status of the equipment, parameter settings and fault information in the remote control center, and can be operated remotely and maintenance guidance to improve the efficiency of equipment management and maintenance timeliness.
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