When dry granulation moves into serious production, capacity alone is not enough.
You need controlled feeding. Stable compaction. Consistent ribbons. Clean granulation. And a system that can adapt when the formulation changes.
That is exactly where FALCON FLOCS 250 × 230 comes in.
With Ø250 mm × 230 mm compaction rolls and an indicative production range of 50–250 kg/hr*, FLOCS is designed for pharmaceutical manufacturers looking for a robust, configurable dry-granulation platform.
From Powder to Granules. In One Controlled Flow.
Feed. Compact. Break. Granulate. Collect.
The FLOCS process is built around a simple idea:
Keep the material moving. Keep the process controlled.
Powder is fed through an integral screw-feeding system into the roll nip. The feeder assists with controlled material delivery and pre-densification before the powder is compacted between the counter-rotating rolls.
The resulting flakes can then move directly into an online two-stage granulator/crusher arrangement for controlled size reduction.
250 × 230 mm Rolls. Built for Production.
The heart of FLOCS is its compaction zone.
Roll Size: Ø250 × 230 mm
Roll Speed: 0–12 RPM
Vertical Feed Screw: 0–40 RPM
Indicative Output: 50–250 kg/hr*
Different formulations behave differently under pressure.
That is why FLOCS can be configured with multiple roll-surface options:
Corrugated | Plain | Knurled | Briquetted
The right roll surface can be selected based on powder characteristics and the required ribbon behaviour.
Control the Gap. Control the Ribbon.
With the hydraulic roll-adjustment option, FLOCS provides an adjustable roll gap of approximately:
0.5 mm to 5.0 mm
The hydraulic system is designed to maintain controlled pressure on the rolls and support consistent flake formation during operation.
Because in roll compaction:
Small changes in the gap can create big changes in the granule.
Compaction Is Only Half the Job.
A good ribbon is useful only when it becomes the right granule.
FLOCS can therefore be combined with an online two-stage granulator/crusher.
The first stage reduces the compacted flakes.
The second stage processes the material through a selected screen to achieve the required granule size.
The result:
Compaction + Granulation in one connected process
with easier material handling and less dependence on disconnected downstream equipment.
Built Around the Process. Not Around a Fixed Machine.
FLOCS can be configured with:
PLC/HMI Touch Control
Hydraulic roll adjustment
Roll-gap sensing
Vacuum deaeration
Powder level sensing
Automatic Powder Transfer System
Water-jacketed rolls
IPC collection bin
Online sifting
Enhanced electronic compliance package
This allows the machine to be engineered around the actual product and validation requirement, rather than forcing every application into one standard configuration.
The Real Question Is Not “How Many Kg per Hour?”
The better question is:
Can the machine repeatedly produce the granule quality you need at the throughput you want?
That depends on:
Powder Behaviour + Feed Rate + Roll Speed + Roll Gap + Compaction Pressure + Screen Size
FLOCS 250 × 230 gives pharmaceutical manufacturers a production-scale platform to work with those variables in a controlled way.
FALCON FLOCS 250 × 230
Bigger Compaction Zone. Better Process Flexibility. One Connected Dry-Granulation System.
For pharmaceutical manufacturers looking to scale dry granulation without losing process control, FLOCS is built to keep the process moving.
FALCON MACHINERIES
You Desire, We Deliver.
*Actual output depends on product characteristics, formulation, bulk density, processing parameters and required final granule properties.