Extruder And Spheronizer

The Typical Method Of Producing Pellets

Agglomeration via extrusion and spheronization is one of the oldest methods of producing pellets.

Moistening the powder mixture, extruding cylinder-shaped agglomerates, shattering and shaping the extrudate to round pellets via spheronization, and drying the end product are the four production phases.

A liquid is used to knead the dry, combined powdered active ingredients into a dough. This dough was then fed through an extruder. The strength of the elongated extrusion threads produced is determined by the diameter of the apertures in the extrusion plate or extrusion basket. The produced pellets are larger than 600 micrometres for technical reasons.

The Extruder Spheronizer is widely used in the pelletization, granulation, and granulation of spherical particles and granules.

Particularly effective are the sustained release oral solid dosage kinds.

The Extruder Spheronizer Is used In Four Primary Steps:

the formation of the moist mass (granulation)
Making cylinders out of the wet mass (extruder)
Dissolving the extrudate and forming the fragments into spheres (spheronizer)
Pellets are dried.

The process of making pellets with an extruder spheronizer begins with blending and wet mixing the materials.

Extrudates are produced by an extruder with defined die sizes.

The spheronizer then moulds them into spheroids (beads or pellets) with uniform size and desirable flow characteristics.

The pellets are subsequently processed to make capsules or tablets.

Typically, the extrusion process aids in the densification of the wet mix to saturation point.

Spheronization, on the other hand, is primarily a shaping procedure that maintains the hydro-textural state.

At the same time, the drying process completes the textural aspects of the product by densifying them by induced shrinkage.

The ratio of liquid to solid material, as well as the size of the extruder holes, have a major impact on the quality of the extrudates. The pellet hardness is ensured by the final drying.

Even if the ball-shaped extrudate is imperfect, the surface evenness creates favourable circumstances for future coating. Extruded pellets with a sufficient amount of microcrystalline cellulose are useful for various medicinal applications.

Most pharmaceutical applications require pellets with medium particle sizes ranging from 600 to 2,000 micrometres. Pellets in other sectors might reach several millimetres in size. Exactly what you require.

Extruder Types

i. Screw Extruder

A screw extruder generates the pressure required to propel the material.

Material will flow through equal apertures, generating identical strands, known as extrudates, depending on the design.

It makes use of screw-fed machinery that consists of single or twin helical screws revolving in a barrel.

As a result, the damp mass material is transferred from a feeder hopper to the die portion.

A thin steel plate with many holes serves as the die.

They can also be positioned axially or radially to the screw feed.

As a result, they are known as axial or radial screw extruders.

ii. Extruders That Are Fed By Gravity

It is made up of rotary gear and rotary cylinder extruders.

It typically changes mainly in the design of the associated with a number cylinders.

iii. Extruder Using A Rotary Cylinder

One of the counter-rotating cylinders in this type of extruder is empty and holed.

The second cylinder, on the other hand, is solid and serves as a pressure roller.

Feed the material to be extruded into the portion between the two cylinders.

Pressure builds up in the perforations, compressing the wet material and pushing the extrudate to the cylinder’s interior.

To reduce the temperature increase in the extrudate, chilled water is circulated throughout the pressure cylinder.

iv. Extruder With Rotary Gears

It is made up of two hollow contra-rotating gear cylinders.

Using counter-bored dies as dies and drilling into the cylinders between the teeth.

The raw material is drawn in by the toothed cylinders and fed into the hopper by gravity.

The materials are forced into the cylinders by pressure through the nozzles, where the extrudate is chopped by scrappers.

The product is crushed as it goes through the nozzles, resulting in a dense extrudate.

To make a variety of pellet sizes, adjust the diameter of the holes from 1 to 10 mm.

Spheronizing Equipment

What Exactly Is Spheronization?

Spheronization is the process of shaping extrudates (extruder output) into little rounded or spherical grains.

Why Should You Consider Spheronization?

The output of this procedure can be valuable in a variety of ways:

Product performance and functionality can be enhanced or altered to satisfy a variety of needs.

Plant procedures might be simplified to decrease costs or improve operational security.

The method is well-known and frequently employed in the pharmaceutical, nutraceutical, catalytic, petrochemical, materials science, and other industries. Its application is becoming more widely accepted in other fields of industrial material handling.

Spheronization has numerous benefits. They will not all be applicable to all consumers or sectors.

What Essential Tools Are Needed For The Spheronization Process?

Spheronization is divided into four major steps:

A mixer or granulator is needed for mixing or granulating.
An extruder is necessary for extrusion.
Spheronization: you need a spheronizer.
Using a coater and a dryer may be necessary for drying and, maybe, coating.

Spheronization’s Primary Applications And Benefits Are:

material clumps with a consistent and controlled size
the creation of tiny particles having a large surface area to volume ratio
the improvement of flow properties
generating the ideal coating form
To make it easier to combine incompatible products
To make powder or granular materials appear prettier
enhancing the capacity to replicate the identical physical characteristics of packing beds and columns
To increase the granules’ hardness and friability
To make the granules more dense
To increase dose control precision
To enhance the handling of materials at high speed
To reduce the risk of dust
To make handling challenging material easier
To make things easier and go more quickly

Why Should You Choose SENIEER?

Senieer, a global manufacturer and provider of pharmaceutical equipment, including tablet coating machines, offers a ONE-STOP SOLUTION. Senieer is the leading global partner for pharmaceutical, food, chemical, and cosmetics firms. For almost 34 years, Senieer has primarily focused on solid dosage forms in China. Dependable integrated process solutions. We produce equipment in compliance with international standards such as GMP, cGMP, and the US FDA.

Members of the Senieer technical team enhance one-stop solution services for large-scale projects, from consulting through design. We fully fulfill your approach and requirements for resolving all of your concerns.