The integration of traditional Chinese and Western medicine products utilizing micronization technology has gained significant attention in the industry due to their enhanced absorption, reduced toxicity, and improved therapeutic effects. Among various crushing technologies, the fluidized bed ultrafine air flow crusher holds a critical position in the pharmaceutical, food, and heat-sensitive material industries, thanks to its excellent crushing performance, high product purity, and low processing temperature. However, conventional jet milling methods suffer from high energy consumption and inefficiency. To address these challenges, Chinese technical experts have developed a series of advanced, high-efficiency, and energy-saving jet crushing equipment through continuous innovation and technological upgrades.
One key improvement involves optimizing the nozzle arrangement within the crushing chamber. Traditional models use parallel nozzle configurations, but the new design employs a three-dimensional nozzle layout, where multiple nozzles are angled downward around the ring-shaped crushing chamber, while a central nozzle directs airflow upward. This three-dimensional configuration significantly increases the collision opportunities between particles, enhancing both powder fineness and production output. It also reduces material buildup during processing. According to practical tests, this design can boost production efficiency by 40% to 60% under the same fineness and energy consumption conditions.
Another major advancement is the implementation of full-scale positive pressure operation, which brings numerous benefits compared to traditional negative pressure systems. The entire process—from feeding to product collection—is fully enclosed, ensuring a clean environment with sterilized compressed air. This eliminates the need for draft fans, reducing noise pollution, energy use, and equipment costs. For example, a high-pressure induced draft fan operating at 5.5 kW/hour for 8 hours daily over 300 days consumes as much as 13,200 kWh annually. By eliminating the need for such fans, the new system not only saves energy but also improves operational stability and reduces vibration.
In a positive pressure system, the grading wheel can operate at lower speeds, resulting in less noise and longer equipment life. A case study involving vitamin C powder showed that under the same fineness requirements, the new model achieved a 200-mesh product (74 microns) with a grading wheel speed of just 1,000 rpm, compared to 7,000 rpm in the old system. Additionally, the new system can reach up to 6,250 mesh with a grading accuracy of 3–5 microns, allowing precise control over particle size distribution through frequency conversion devices.
The new models also simplify the classification process by using a single-stage cyclone separator instead of multi-stage systems, reducing resistance, energy consumption, and equipment investment. Furthermore, the high-precision horizontal grading system supports frequent product changes, making it ideal for pharmaceutical applications. The sealing method uses non-contact air seals, eliminating noise, vibration, and wear, ensuring long-term stable operation.
In terms of feeding and discharging, the new system introduces intelligent controls via PLC devices to ensure uniform material flow into the crusher. For materials prone to bridging, built-in pneumatic and manual anti-bridging mechanisms guarantee smooth discharge. The screw feeder air lock device replaces bulky star valves, offering a compact, efficient, and maintenance-free solution. This not only simplifies the process but also reduces space requirements and equipment costs.
Overall, these innovations make the new jet crushing systems more efficient, safer, and environmentally friendly, setting a new standard in the field of fine particle processing.
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