The Twin Dome Granulator (TDG) is a high-capacity twin screw extruder engineered for efficient, low-pressure extrusion of wet granulated materials. It features a hemispherical dome die that ensures uniform extrusion pressure and shear, resulting in cylindrical extrudates with consistent size and quality. The TDG extruder is ideal for applications across industries like agricultural chemicals, pharmaceuticals, industrial chemicals, and food processing.
Working Principle
Wet Mix Feeding:
The wet mix is prepared using a kneader, pug mixer, or high shear granulator. The prepared material is fed into the extruder either manually or through a feeder.
Screw Transport & Extrusion:
Twin screws convey the wet mix through the extrusion zone, pushing the material toward the dome-shaped die. The twin screw mechanism ensures a smooth and consistent flow without back-mixing.
Extrudate Formation:
As the material is pushed through the die, cylindrical extrudates are formed. These extrudates naturally break off by gravity and are collected for further processing like spheronization, drying, or coating.
Key Features & Benefits
- Low Pressure Extrusion: This feature minimizes heat generation during extrusion, preserving the quality of heat-sensitive materials.
- Plug Flow Transport: The material follows a first-in, first-out (FIFO) process, ensuring that no back-mixing occurs, which maintains the consistency of the product.
- Clamshell Extrusion Chamber: The chamber design allows easy cleaning and access to internal components, reducing downtime for maintenance.
- Hydraulic Clamping System: The hydraulic system simplifies the disassembly and maintenance process, ensuring ease of service.
- Low Hold-Up Volume: Reduces material waste, improving the overall yield and efficiency of the extruder.
- High Yield & Repeatability: Consistent results are guaranteed across production cycles, making it easy to scale production.
- Improved Particle Size Distribution & Flowability: Ensures better product flow and improved performance in downstream processes.
- Easy Scale-Up: The extruder supports process development and smooth scaling from laboratory experiments to full-scale production.
Application Areas
The TDG extruder finds use in a variety of industries, particularly where precise granulation and consistent extrudates are critical. These industries include:
Agricultural Chemicals
The TDG is ideal for low-pressure extrusion of Water Dispersible Granules (WDG) and Water Soluble Granules (WSG). It is commonly used for products like:
- Herbicides (e.g., Atrazine, Metribuzin, Glyphosate)
- Insecticides, Fungicides, Biocides
- Other agricultural chemicals (e.g., Diuron, Sulfentrazone, Ametryn)
Pharmaceuticals
The TDG works with spheronization systems to produce controlled-release pellets. It is used to create:
- Controlled, delayed, and sustained-release pellets
- Immediate-release pellets (e.g., for sachets)
- Multi-particulate and multi-unit erosion matrix systems
Industrial Chemicals
In the industrial sector, the TDG extruder is used for products such as:
- Catalysts (e.g., Zeolites)
- Pyrotechnics
- Specialty detergents
- Absorbents
- Detergent additives (e.g., enzymes)
- Sodium benzoate
Other Industries
The TDG also finds applications in several other industries, including:
- Animal Health: Antibiotics, feed enzymes
- Nutraceuticals: Active intermediates
- Tobacco: Granular formulations
- Food & Beverage: Granulation of flavors, preservatives, colorants, and enzymes
Working with the TDG Extruder
The TDG twin-screw granulator consists of several key components that contribute to its effective and efficient operation:
- Drive Motor: Powers the screw mechanism, ensuring smooth extrusion.
- Feeding Hopper: Receives and feeds the wet granulated material into the machine.
- Extrusion Screw: The twin screws transport the material into the extrusion zone.
- Perforated Plate: Defines the diameter and shape of the extrudates. This can be adjusted for different sizes of extrudates.
The wet mass enters the extrusion zone where the twin screws transport it through the perforated plate, forming cylindrical extrudates. These extrudates break off either by gravity or via a rotary cutter and are collected for subsequent processing.
Conclusion
The Twin Dome Granulator (TDG) is a reliable and efficient twin-screw extruder ideal for producing high-quality extrudates in industries like agricultural chemicals, pharmaceuticals, industrial chemicals, and food processing. With its patented dome-shaped die, low pressure extrusion, and easy maintenance features, the TDG provides a scalable solution that improves granulation quality and enhances downstream processing.
Director
Darshan Rao represents the new generation of leadership at Shree Bhagwati. As Director, he is committed to driving innovation, operational excellence, and growth across all facets of the company. With a focus on fostering strong relationships with stakeholders, partners, and clients, he leads a team of dedicated professionals in delivering high-quality manufacturing solutions.
One of his key strengths lies in pressure management—a crucial quality in the fast-paced and dynamic manufacturing industry. He firmly believes in turning challenges into opportunities and using adversity as a catalyst for growth and innovation.
To embark on this journey together, he invites you to join hands with Shree Bhagwati in pursuit of excellence, embracing innovation, and setting new benchmarks in manufacturing. Together, let us create a success story defined by integrity, ingenuity, and an unwavering commitment to quality.
