Extruder Spheronizer: The Complete FAQ Guide in 2024

Imagine converting fine powders or sticky granules into uniform, spherical pellets that will not only make a product look and feel better but also make it work better. Be you in the pharmaceutical field of sustained-release medications or food production. With consistent granules for mixing, cosmetics in perfect beads, there's most probably a hand from the extruder spheronizer technology at work.

But what is actually going on inside these machines? How is the raw material taken through the process to end with the exact spheres, ready to be packaged or formulated?

Here in this guide, we dig the science behind an extruder spheronizer; therefore, the reasons it has become one of the cornerstones in many industrial practices. This guide takes on a transparent manner, the way that these two interact with one another: basic and critical steps when forming the pellet, fundamental parts to keep maintained, safety information, and more of the critical things making the modern palletization process on solid grounds.

Add a header to begin generating the table of contents

1.What is an extruder spheronizer?

Extruder Spheronizer- Picture Courtesy: Umang Pharmatech

An extruder spheronizer is a specialized device employed for converting wetted powders into uniform, dense spheres or pellets of controlled shape and size. The extrusion spheronization process includes making the wet mass into cylinders through the extrusion and then breaking and rounding into spheres within the spheronizer and subsequently drying.

Although commonly applied in the pharmaceutical industry for the production of solid oral dosage forms, it also finds its application in agrochemicals, catalysts, and specialty chemicals to manufacture consistent, precisely shaped pellets with specific characteristics.

2.Which industries use extruder spheronizer?

Application industries- Picture Courtesy: Bora Pharmaceuticals

Extruder spheronizer are not specific to pharmaceutical industries but a game-changer in many industries for precision and consistency of pellet size and shape. Some of the industries that apply this innovative technology are as follows:

Pharmaceutical Industry

Pharmaceutical Industry

With a revolution in pharmaceutical manufacturing extruder spheronizer produces quality drug delivery pellets. Small pellets could capture up to 90% of active pharmaceutical ingredients and therefore can enhance the effect of therapy together with the compliance rate of patients by making dosing infrequent.The process starts by mixing the API, excipients, and solvents into a homogeneous mass which is then extruded in cylindrical shapes and then spheronized into uniform pellets. This gives a very smooth surface ideal for altering drug release profiles.

Food Industry

Fish feed pallets

The production of pellets of the same size is important to the food industry, as offered by extruder spheronizer. Imagine adding this technology to breakfast cereals, snack foods, pet foods, and even infant or supplementary foods. The extruder spheronizer improves bulk density, so ingredients such as flavors and sweeteners for instant soups and drink mixes can be handled more easily.

Agrochemical Industry

Biomass Fuel Pallets- Picture Courtesy: Biomass Energy Techniques Inc.

Suppose you are a farmer spraying fertilizers all over a large field. You want uniformity and less dust all over a large area for convenience and effectiveness. Extruder spheronizer come to your rescue. It provides perfectly uniform pellets, made for nutrient-rich fertilizers, pesticides, or soil conditioners, which could be spread and handled without any issues.

Catalyst Industry

Alumina based Catalyst Pellets- Picture Courtesy: Xiangrun

Extruder spheronizer are a vital role player in the catalyst industry. It produces catalyst pellets in an entirely uniform and spherical shape that maximizes reaction efficiency. Such pellets pack well inside reactors compared to any other irregularly shaped pellets.

Cosmetic Industry

Microbeads in exfoliating scrub- Picture Courtesy: Britannica

The extruder spheronizer plays an especially important role in cosmetic manufacture to ensure pellets and beads are uniform and perform the function intended within the product. Consider a cleansing exfoliating scrub – all those tiny microbeads so smooth, gentle yet really rubbing away at dead skin. Extruder spheronizer makes it possible.

Household and Industrial Cleaning Industry

Uniform granules for detergent powder

It is very important in the household and industrial cleaning industry to have the use of extruder spheronizer to generate spherical detergent granules that may help improve cleaning efficiency. Consider powdered laundry detergent that instantly dissolves in cold water, such as powdered laundry detergent; these uniform granules prevent clumping or even improve solubility for a better wash.

3.What are the benefits of extruder spheronizer?

Benefits of extruder spheronizer- Picture Courtesy: LCI

Extruder spheronizer offer many benefits for various industries, including the following:

Uniformity	They produce pellets of uniform size and shape with active ingredients well distributed throughout the formulation. This uniformity contributes to better performance and stability in the product.
Flowability	Spheronized pellets exhibit better flow properties, and there is minimal chance of clumping or segregation during handling and processing, which is a crucial requirement in manufacturing.
Improved Dissolution	The pellet is in the form of a sphere; hence it can be more easily broken down in the liquid solution, thereby it increases its solubility and improves efficiency in operations such as detergents and medicines.
Increased Surface Area	The spherical form allows a maximum contact area of reactants or solvent with surface area, and this reaction is made very efficient with catalytic operation.
Controlled Release	Extrusion-spheronization is highly transformative for sustained-release formulations, offering exact control over pellet composition and release rate. Uniform, spherical pellets allow for higher drug loading with consistent delivery, reducing dosing frequency and enhancing therapeutic stability. With customizable excipients, this method meets diverse patient needs, improving both efficacy and compliance. Isn't it remarkable how this innovation can elevate treatment and adherence?
Less Dust Produced	Spheronization reduces the fine particles of the powder, so handling is done with less dust and there is a reduction in dusting and exposure to toxic dust in a working place.
Flexibility	Extruder spheronizer can be used to process wide ranges of products, including powders and granules and even liquid, hence they are applied in most industries.
Efficiency and Cost Savings	Extruder spheronizer can improve processing efficiency as well as product quality and therefore can reduce the production costs in the long run.

4.How does an extruder spheronizer work and what are the basic principles of its working?

Principle of Extruder Spheronizer- Picture Courtesy: Glatt

The extruder spheronizer works on four basic steps that cumulatively create the perfect spheres in a uniform shape. Let's find out how this happens:

Mixing	Imagine the combination of all the ingredients such as the active compound, binders, and water in a high-shear granulator. This will give a wet, cohesive mass that retains the shape but can flow by slipping into the next process.
Extrusion	This mixture then enters the extruder, where it is pushed through a screen, which forms spaghetti-like cylinders of the same diameter.
Spheronization	Real magic happens in the spheronizer. The cylinders fall onto a fast-rotating friction plate; they bounce around in the bowl and hit each other, which gradually rounds them into perfect spheres. Pellets are formed here in minutes and the process is accurate.
Drying/ Coating	Finally, these uniform spheres are either dried for stability or coated, ready to be used in applications where the consistency of shape and size is most important, like pharmaceuticals or catalysts.

5.Why extruder spheronizer are ideal for spherical granules and pellets?

Pellets

Pellets- Picture Courtesy: Shutter stock

Extruder spheronizer aid in the manufacturing of completely spherical granules and pellets. Here's the reason, though: you can really pack in much more active ingredients without reaching the oversized pellets, and with high-potency products, it works great perfectly.

In addition to this, if you really want to mix two or more active agents, then this is something extruder spheronizer do without very much hassle, offering a ratio accuracy in each one that comes out.

This process also allows you to refine the properties of the particles so that you get high-density, low-moisture, and very smooth surfaces. The pellets come out dust-free with uniform shape and size making them highly reliable and easy to handle in any process.

6.What materials are suitable for being used in an extruder spheronizer?

Spheronization

Materials that can be processed in an extruder spheronizer include:

Material	Example
Natural Extracts	Silymarin from milk thistle
Bacterial Cultures	Lactobacillus casei for probiotics
Pharmaceutical Drugs	Furosemide, Quinine sulfate, metformin hydrochloride
Poorly Soluble Drugs	Hydrochlorothiazide, Piroxicam
High Drug Load Formulations	5-aminosalicylic acid (5-ASA)
Taste-Masked Compounds	Quinine sulfate, Metformin
Sustained-Release Compounds	Naringin
Dehydrated Agricultural Products	Canola meal
Pulsatile Release Drugs	Omeprazole with osmotic pressure-activated membranes
Bioadhesive Pellets	Hexylaminolevulinate for photodynamic therapy
Enteric-Coated Probiotics	live Lactobacillus casei for oral probiotic delivery.

All these can be formulated into pellet types varying by changing the excipients and process parameters to specific release profiles and stability.

7.What are the main parts and elements of an extruder spheronizer?

Components of extruder spheronizer

Okay let's talk about the main parts of an extruder spheronizer and what they do with regards to quality pellets!

Feeder

Feeder

Feeder

Just like the front door. The feeder makes sure to feed the powder blend; that is, the raw materials that include the actives and excipients; at a steady rate and in constant amounts into the system. The constant flow of the feeder is meant to make the entire procedure uniform.

Extruder

Extruder

The extruder is as if the heart of the machine. The screw, at its rotation, applies assorted mechanical forces; it blends, compresses, and transforms the mixture into the continuous extrudate when allowing it to pass through the system. That's where everything magical with texture and consistency begins.

Die or Screen

Screen

Die/ Screen

The die at the end of the extruder gives shape to the extrudate in the form of cylindrical strands. It is almost like a sculptor shaping clay. The diameter of the die determines the size of the extrudate and is a precursor to the next step.

Spheronizer

Spheronizer- Picture Courtesy: Intimac

Imagine the spheronizer as a pellet-rounding artist. It takes the extrudate and, through friction and impact, turns it into perfectly spherical pellets. The rotating friction plate and stationary bowl create a dynamic environment where the magic of rounding happens!

Dryer

Dryer

Drying of Pellets- Picture Courtesy: DG Pro-Tec

After spheronization, the pellets move to the dryer. It's like a spa for the pellets, removing the moisture, which increases their stability and durability. The better the drying of a pellet, the better quality and shelf life!

Coater (optional)

Coater

Spray Gun for Coating of Pellets- Picture Courtesy: Durr

Finally, when needed, the coater adds a protective coating to the pellets. It is just applying sunscreen; coatings may mask flavor, control release of the active ingredients, or protect pellets from moisture and light.

Each of these parts is critical in the process of extrusion-spheronization, working in harmony with each other in producing pellets that are uniform in appearance and quality for any kind of application. What feature do you find the most interesting?

8.How are extruder spheronizer categorized into different types?

Extruder Spheronizer

Single-Stage Extrusion-Spheronization Systems

Single Stage Extruder Spheronizer- Picture Courtesy: Dorsa Tech

These are like the multitaskers of the group—extrusion and spheronization happen in a single chamber. Imagine a "one-pot" setup. This setup is rare, and it usually is made for materials that require least handling between the two of these steps. For the specific material, it's perfect since it minimizes movement, but it isn't ideal for everything.

Dual-Stage Integrated Systems

Dual Stage Extruder Spheronizer- Picture Courtesy: VJ Instruments

Now, imagine that two connected units operate perfectly together. The extruder feeds directly into the spheronizer. This is a seamless handover without material transfer and exposure to the outside world. Such an operation is conducive to mass production.

One saves handling time and even potential contamination. Imagine seamless efficiency where direct extrusion flows directly into direct spheronization, never stopping for one second.

Continuous Extrusion-Spheronization Systems

Continuous Extruder Spheronizer- Picture Courtesy: Caleva

Imagine a pellet conveyor belt. In these kinds of systems, there's always a feed of material going into the system and the system never stops! That's the powerhouse setup-ideal for high-volume production. The pellets are all in size and shape because of the process that never stops, therefore quality control is maintained. It's like the marathon runner of the group, steady and efficient.

9.What variables affect the quality and appearance of the granules obtained from Extruder Spheronizer?

Granules- Picture Courtesy: Avada Construction

Let's talk about each one of these variables that affects the quality and appearance of granules from an Extruder Spheronizer. Let's say we're fine-tuning this equipment together to make the perfect granules. Here's what we would focus on:

Optimization of Formulation Parameters	Adjusting the Concentration of Binder. Controlling Moisture Content. Selecting Appropriate Excipients and Particle Size
Fine-Tuning Process Settings	Setting Ideal Extrusion Speed and Screen Size. Adjusting Spheronization Speed and Time. Choosing the Right Spheronizer Plate Design
Controlling Environmental Conditions	Regulating Temperature and Humidity.
Material Properties Assay	Improving Plasticity and Deformability. Achieving Right Cohesiveness and Friability.

10.How does the process of an extruder spheronizer compare to other methods of granulation?

Extrusion Spheronization- Picture Courtesy: Dorsa Tech

The Extruder Spheronizer process is unique compared to other approaches such as high-shear, fluidized bed, and roller compaction granulation. Here's how it compares:

Extruder Spheronizer	Other Techniques
Shape and Uniformity
Imagine you are choosing a granulation method for a project and weighing the pros and cons of an extruder spheronizer against other granulation techniques. The extruder spheronizer is unique in giving very spherical and uniform granules, ideal if you need precise shapes, as in controlled-release formulations.	Other techniques, like high shear or fluidized bed granulation, may yield granules, but not usually so regularly shaped; roller compaction gives dense sheets milled, so the granule shape varies.
Granule Density and Strength
However, if strength is the major consideration, then an extruder spheronizer could be the best option as it yields strong, cohesive granules that could withstand the stress of processing.	High shear and roller compaction yield dense granules, but the lighter particles from fluidized bed granulation may not be as robust.
Moisture Content
The process of extruder spheronization requires excellent care in controlling moisture content-too much or too little impacts the quality of the granule.	Fluid bed granulation allows in-process drying to control moisture, and the process may result in a more porous granule.
Scalability and Control
Of course, with regard to scalability, the extruder spheronizer process can be controlled quite well over particle size and shape and therefore allows for production at larger scale.	High-shear and roller compaction granulators also scale up well, but fluid bed granulators require precise regulation of airflow and temperature control.

When you are making a formulation that will require spherical particles of uniform size; for example, a modified-release drug or an encapsulated ingredient, you may be able to cut directly to the extruder spheronizer, but from a standpoint of versatility alone you may get more flexibility with either high-shear or fluid bed methods.

Every procedure has its own advantages, so knowing them helps to properly pick the right tool for your granulation needs.

11.What routine maintenance should be performed on extruder spheronizer to put it into optimal operation?

Maintenance of Extruder Spheronizer- Picture Courtesy: LCI

An extruder spheronizer should be kept constantly maintained for it to go at its best. Follow this short guide for what you must do as far as routine maintenance goes, which will be described step by step:

Cleaning, Daily

Begin the morning by cleaning the extruder spheronizer on a day-to-day basis. You must clear left-over materials to prevent re-contamination and easy, smooth running.

Lubrication

Check the proper lubrication of moving parts according to the manufacturer. Proper lubrication will provide less wear and tear or friction in the operation mechanism, ensuring it runs more economically.

Components Inspection

Critical parts like the die, screen, and blades are always checked for signs of wear or damage. Any worn parts are replaced to prevent operational problems.

Calibration Checks

All settings and controls must be calibrated to the right standards. This will ensure accuracy in the granulation process.

Cleaning Filters

If your device has filters, clean or replace them when necessary to avoid blockages that may cause problems with airflow and performance.

Monitor the operational parameters

One has to monitor KPI's such as temperature and pressure during operation. Regular monitoring can catch up any potential issue before it goes out of proportions.

Documentation

Maintain a maintenance log in order to monitor all activities performed on the machine. This helps in identifying patterns and helps in planning ahead for maintenance.

By including these routine maintenance activities in your operation, you can get the best out of your extruder spheronizer in terms of performance and longevity. Which area of maintenance would you like to explore further?

12.What are some common problems with extruder spheronizer, and how do these problems get solved?

Extruder Die-Picture Courtesy: IDAH

Common problems associated with extruder spheronizer severely affect the quality of the granules produced as well as overall efficiency. Have you experienced any of these issues? Let's look at some common problems and their solutions together:

Problem	Solution
Granule Quality Are you experiencing irregular shapes or sizes in your granules?	Did you check the moisture content and binder concentration in your formulation? You might just need to fine-tune the extrusion speed and spheronization parameters. Don't forget to examine the uniformity of the raw materials!
Blockages in the Die or Screen Is the extruder spheronizer giving you a hard time, either in slow throughput or operational upsets?	Regular cleaning and screening of the die and screen can help prevent blockages. Material feed rate should be adjusted and the particle size of feed material should meet specifications in order to reduce blockages.
Excessive Heat Generation Do you notice higher temperatures that can affect material quality?	Monitor and control the temperature during operation. You should check your cooling mechanisms and ensure that the device has adequate ventilation to keep temperatures in check.
Varied Moisture Content Are your granules moister in some parts of the batch than in other parts?	Achieve precise measurement when blending and granulating. Inconsistency is the root problem - keep a leash on those moisture contents!
Dust Generation Is dust creating too much of a nuisance and risk?	Adopt dust control measures and ventilate your workplace. Even a proper material handling process to transfer can help you have less dust.
Low Throughput or Production Rate Are your production rates not up to par?	Check your operating conditions, feed rate, and spheronization time. Ensure your equipment is calibrated and your formulation is optimized for extrusion.
Preventive Wear and Tear Are parts being worn out sooner than you thought they would?	Check and maintain parts. Using better raw materials and following the manufacturer's maintenance schedule can help extend the life of your equipment.

Do you have a particular problem you'd like to explore in more depth? By actively engaging with these issues and solutions, you can troubleshoot and improve the performance of your extruder spheronizer.

13.What precautionary measures should be taken while handling the extruder spheronizer?

Preventive Measures- Picture Courtesy: LLumin

Precautions that should be taken in handling an extruder spheronizer include safeguarding the quality of granulation and protecting the worker.

Personal Protective Equipment

Put on personal protective equipment: This would include the gloves, goggles, and lab coats as a safety measure against the chemicals and particles.

Proper Training

The operator is trained to use the extruder spheronizer because of its unique function and safety aspects. Therefore, the occurrence of accidents when the machine is known will be decreased.

Equipment Inspection

Every part of the equipment is inspected before starting it. Determine if there are loose connections or improper alignments and whether it has a safety feature that is functioning well.

Ventilation

Work in an area well-ventilated to keep the dust and fumes away, particularly when powders or volatile compounds are involved.

Never overload equipment

Overloading causes apparatus breakdowns, and there may be irregular granulation.

Emergency Procedure

The emergency shutdown procedures and the location for stop on the equipment are also known. The area also has to be labeled on signs as safe.

Monitoring Parameters

The parameters running in the process like critical temperature and moisture content also have to be continuously kept under check to prevent or lessen undesirable occurrences that can spoil the quality and safety of the product.

Material Transportation

The granules along with raw materials need transportation through the right methods or equipment that can reduce possibilities of spillage or any accidents.

Maintenance routine

Always maintain equipment regularly as scheduled by the equipment manufacturer. This means, the equipment is allowed to work efficiently and effectively during a period of time.

Conclusion

Extruder spheronizer are mainly the tools that help generate top-quality uniform pellets within industries dealing with pharmaceuticals, foods, and so forth. This is because the process of size and shape control of pellets is achieved in a precise manner for obtaining a better quality of performance and also to smoothen out the manufacturing process. Which part of your work can have possibilities with extruder spheronizer? Ask Allpack in exploring extruder spheronizer machines to start the production success together!

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machines from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

Extruder Spheronizer: The Complete FAQ Guide in 2024 Read More »

What Are Common Types of Pharma Granulators?

Granulator

What Are Common Types of Pharma Granulators?

To manufacture pharmaceutical formulations, you can’t ignore granulation. Why is it required? This is an essential step used to make powders free-flowing, dust-free, and flexible to handle. You can find several types of pharma granulators in the market. The wiser step is to identify the right machine for the specific materials.

Nevertheless, operating granulators is easy to do but it poses some technical challenges. What are those factors and how to deal with them? What are the common types of pharma granulators? How do they work? I know ample queries are knocking on your mind! Isn’t it? Let’s read the article to clear up the confusion. In this article, our experts have suggested important classifications and all essential points that will definitely help you in processing and selecting the machine. Come on! Explore the world of pharma granulators.

Add a header to begin generating the table of contents

1.What are pharma granulators?

Allpack High Speed Mixer Granulator

A pharma granulator is a device that helps in the transformation of small and irregular particles of powder to well-defined agglomerated which is commonly known as ‘granules. Basically, pharma granulators are set up soon after attempting the dry mixing that includes the combination of excipients with active pharmaceutical ingredients (APIs).

This equipment is used to enlarge the particle size by implementing agglomeration and is required specifically for making capsules, pills, and tablets.

It is employed in manufacturing procedures of pharmaceutical products to make consistent and uniform particle sizes for every ingredient added to the mixture. The suitable particle size in pharma mainly ranges between 0.2 to 4.0 mm, it is suitable to offer an intermediate particle size of 0.2 to 5.0mm which is commonly used for making capsules or tablets.

Methods of Pharma Granulators

Before going towards types of commonly used pharma granulators, you should understand the major method of pharma granulation used for manufacturing products. There are basically two major categories of granulation used and opting for them is dependent on the type of formulation and materials. For example:

Dry granulation

Dry granulation-Picture Courtesy: LFA Tablet Presses

This is the common type of granulation that does not involve any compressing substance or heat inclusion for compression. It just needed greater pressure for powder aggregation. There are two main processes involved in dry granulation.

Slugging

A slug is formed by offering heavy-duty machine such as tablet presses.

Roller Compaction

The powder is compressed between two heavy rollers that form a thin layer of sheet or flake which is broken down by the help of milling equipment and provides uniform particle sizes.

Both methods are used due to several benefits as they simply reduce the need for any substance that ensures binding as well as drying, thus eliminating cost and time.

Wet Granulation

Wet granulation

This method involves the granulation of the wet mass of the powders by taking the help of granulating fluid that must be volatile in nature and can be evaporated once the finest particle size is achieved with the help of drying.

The granulation liquid is mainly used are isopropanol and ethanol or may be used in combined form. Wet granulation is beneficial in many ways as it tends to produce sophisticated processes without dust emission and improves the flow properties of the particles without losing the quality of the powders. The process ultimately provides you with consistent gives-out particles that are suitable for tableting and further processing.

Dimensions of Pharma Granulators

There are two dimensions followed in the designing of the pharma granulators. For example:

Vertical Mixer Granulator

Vertical Granulator- Picture Courtesy: Gebrüder Lödige

In this type of granulator, the mixing and granulation process takes place vertically. The machine is designed with a vertical chamber ensuring the entire process in a vertical manner that allows mixing, wetting, blending, and agglomeration in the same pattern. The machine has a compact structure with minimum edges hence lesser chances for cross-contamination and easy to clean option for pharma businesses.

Horizontal Granulator

Horizontal Granulator

Here, the granulator machine design such as rotating impellers, mixers, and granulation are fixed in a horizontal fashion. The machine is suitable for effectively handling large production batches to provide consistent results.

2.Why do you need pharma granulators?

Pharma granulators are required in pharma due to several significant reasons. Have a look at the below points:

Improving Powder Flowability

Excellent flow properties- picture courtesy: VAVA pantry

This is well understood that raw powder has poor flow characteristics and is unable to be incorporated into the manufacturing process. By using pharma granulators, you can obtain a powder with an excellent flow ratio and easy to handle. Because it ensures that powder particles are transformed into better and consistent granules and easier to process them.

Improved Compaction

Improved compactness- Picture courtesy: Pharmtech

When making tablets, the key factor is to assess disintegration time, strength, dissolution rate, etc. for that the powder material must be consistent with an equal proportion of particle size and should have excellent compressibility during the making of tablets. Remember, if tablets are perfectly formed they will produce the desirable effects. By pharma granulator, promises to yield powder with suitable compressibility and can assure that it can be pressed better.

No Dust Formation

No Dust Formation

Generally, powder produces dust during handling and can be caused by various unwanted factors such as loss of product, poor quality of final formulation, and health-related problems. By using pharm granulators, such problems are avoided, and it ensures that the powder is subtle and dust-free therefore beneficial for you and for the final dosage form.

No More Constituent Segregation

No separation of constituents- Picture Courtesy: westend61

This is a state-of-the-art technique that helps in avoiding the segregation of mixed excipients and active pharmaceutical ingredients once combined. This is because they’re properly amalgamated to one another and packed for an extended period of time and are effective for making pharmaceuticals without any risk of separation.

No Toxicity Hazard

User safety- Picture Courtesy: Burst Pharmacy

Have ever thought about what happens when toxic powder blows? Of course, the dust blowing can be inhaled and may damage the workers’ health and safety of the environment. Pharma granulators are worthwhile and save you in many ways. The granulation of harsh and toxic substances can subside the risk of toxic dust and ensure easy and safe handling.

3.What Are Common Types of Pharma Granulators?

There is a huge list of pharma granulators. We have talked about some of the commonly used in pharmaceutical industries. For example:

High Shear Mixer Granulator

AIPAK High Shear Mixer Granulator

This is a highly developed equipment used for developing the shape of granules. It is also known as a wet granulator or vertical granulator due to its working and design. As it offers several benefits therefore it is commonly used in pharma preparation and other industries such as foods, and nutraceuticals. The machine is capable of making ingredients into large and consistent granules.

Working Of High Shear Mixer Granulator- Picture Courtesy: Fluid Air

This is a compact vessel with a chopper which helps in the mixing of the powder and side by side pulverized it. The machine works by adding powder with binding liquids via a spray nozzle, so it forms a liquid-solid bridging resulting in a perfect granule. The entire process takes place under high-shear forces such as mixing, wetting, and granulation. The mixing is continued till you get a desirable shape of granules.

Fluidized Bed Granulator

Fluidize Bed Granulator- Picture Courtesy Pharmaceuticals

A fluidized bed granulator is used to convert loose powder substances into compact granules which is required to attain compaction and improve flow properties.

How it is done is somewhat technical, it basically works on the basis of fluidizing the powdery particles. This means fluidized air is blown into the granulator which moistens the powders. Thus, it is now in a solid mass state, which is then lifted upward with the help of high air pressure. The particle in the air is exactly the phase where powders act as suspended fluid particles.

At this phase, powder particles and hot gases help in the drying of particles by vaporizing them. That’s why this granulator is suitable for heat-sensitive as well as non-heat-sensitive materials and is considered suitable equipment for pharmaceutical granulation.

Rotary Granulator

Rotary granulator

The machine design is based on a rotating vessel with multiple series of blades. You can enter the raw powder inside the machine where the rotary baffles start to break them into small particle sizes that promote agglomeration and finally granules with the help of centrifugal force.

Rotary granulator- picture courtesy: US Validation Service

The rotary drum moves and mixes the ingredients and binders and the action of the rotary forces the granules formation is accessible. This is a well-suitable process and is mainly implemented by large production industries for subtle and consistent granule formation to deal with large production batches.

Oscillating /Vibratory/ Swing Granulator

Oscillating Granulator- Picture Courtesy: Pharma Machinery

This is the straightforward equipment used in pharmaceuticals for the breakdown of powdery lumps and assures to formation of uniform particle sizes with consistent blending and grading. The device is considered a good option for general and moisture or heat-sensitive substances to improve flowability and compressibility rate. You can handle wet as well as dry granulation methods by using the machine.

It mainly works by oscillation of the rotating impellers or blades to make a reduction in the particle sizes. The blade movement in the machine mainly follows the principle of oscillation that lies between clockwise and anticlockwise movement. It is also designed with sifters that allow careful screening of the particles and you can obtain the effective texture of the particles with uniform sizes thus it is useful for pharma formulations.

Extruders

Extruder- Picture Courtesy: Hosokawa Micron

Extruders are the type of granulator used to make powders suitable for pharmaceutical preparations by treating them under high force, pressure, and controlled temperature. They are mainly incorporated with binders and additives so the final product is released from the die with a consistent and defined shape.

The working of the extruder is based on the screw which is either single screw or twin-screw extruder. The machine design is composed of a hopper, barrel, screw, and cutting die with the temperature-controlled unit that allows material transformation with prominent uniformity.

Roller Compactor or Dry Granulator

Roller Compactor Or Dry Granulator- Picture Courtesy: Increnovo

This granulator is composed of a set of counter-rotating discs that are closely moving to press the powder. As a result, a thin compressed ribbon sheet is formed that is further subjected to the milling process to form granules. The high pressure of rollers allows the formation of agglomerates, so it ensures a desirable particle size.

A roller compactor granulator is a common types of pharma granulator used for dry granulation that make particles with solid densification and particle uniformity for solid dosage form i.e. tablets, and capsules. This is a beneficial machine as it is simple to operate and can give greater productivity. It is not only energy efficient but also suitable for pharmaceutical items that are heat sensitive.

Basket Granulator

Basket Granulator

This machine is featured with basket shape chamber that facilitates mixing and granulation of raw powder. Within the basket, multiple rotary impellers allow the reduction of particles by finely chopping or cutting process. There are fixed sieves attached within the chamber to ensure the finest filtering of granules to process uniform-sized particles to maintain batch-to-batch precision effectively.

This machine is available in various sizes such as benchtop, medium, and large size, hence suitable for batches with variable production demands.

Conclusion

In summary, pharma granulators are mainly used to enlarge the size of particles which is suitable for manufacturing solid dosage formulations such as tablets and capsules. By this process, fine or coarse particles are transformed into large agglomerates that are simply known as ‘granules. Whether it is dry granulation or wet; you will be required various pharma granulators that are available in the market. What is your choice? We hope after reading a blog on ‘what are the types of pharma granulators’ you will be clear about the types. But if you want to know more or looking to purchase one of them. We would suggest contacting us to avail guidance and an excellent series of pharma granulators right now.

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machines from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

What Are Common Types of Pharma Granulators? Read More »

What Are The Advantages Of Wet Granulation?

Granulator

What Are The Advantages Of Wet Granulation?

Whether is it pharmaceutical industry, food industry or cosmetic industry, the use of powders and granules is a routine practice. Now, these powders are not always used in their fine form instead they are turned into granules for effective processing. Similarly, wet granulation is said to be the best method employed for granulating powders in various areas. But have you ever tried to know the reasons behind? If not! Then we are here to explain What Are The Advantages Of Wet Granulation.

Wet granulation is one of the oldest and simplest ways of granulation. It offers myriad of techniques to deal with all kinds of granulation. Moreover, the materials which it processes remain safe throughout operation, hence, their essence could be well retained with this method of granulation. So, stay tuned and keep reading to know further about wet granulation!

Add a header to begin generating the table of contents

1.What Is Wet Granulation?

Wet granulation- Picture Courtesy: pharmaexcipients.com

Wet granulation is a technique popularly used in pharmaceutical industry for the formation of large entities from powder called granules. In this method, liquid binders are used as principal agents to make coalescence of active ingredients and excipients. When liquid binders are added, the fine particles of powder form agglomeration. This mixture is turned into uniform granules which are then dried to desired level.

Granules produced through wet granulation are uniform in structure and have good flow properties due to which they are helpful in the manufacturing of solid dosage form such as capsules and tablets. Moreover, wet granulation has several types for granulation as a result of which now it can be used for products made in industries like pet food, chemical, and detergent industry.

2.What Are The Advantages Of Wet Granulation?

Wet granulation is the most widely used method for granulation despite the presence of other methods like dry granulation. The only reason is its numerous benefits which are associated with your long term ease and profit. So, let's know some of the important advantages of wet granulation!

Structural Uniformity

Uniform granules- Picture Courtesy: blogger.googleusercontent.com

Granules produced by wet granulation are highly uniform in their structure with round appearance. It is due to the homogeneous distribution of binder and particles which give you desired size of granules, enabling manufacturers to ensure content uniformity in the end product.

Better Flowability

Throughout wet granulation, you will get the granules with high density and consistent spherical shape. Both these factors leads to the smooth flowing of granules during tablets formation and other formulations.

Dust-free Particles

Pharmaceutical powders- Picture Courtesy: gea.com

Hygiene and environmental safety is one of the primary concerns of pharmaceuticals practitioners. While it is not possible when dealing with dry granulation due to excessive dust, dry granulation offers you dust-free particles. These granules are strongly made with presence of moisture which prevent the emergence of dust, protecting both the product and users involved.

Facilitate Compression

Uniformly compressed tablets- Picture Courtesy: gea.com

Air entrapment is one of the greatest challenges to tablets compression that is common in dry granulation. However, this problem can be easily solved by switching to wet granulation. It will not only reduce the risk of air entrapment to zero but will also facilitate compression by requiring low compression force.

Improved Bioavailability

There are large number of hydrophobic APIs which have low bioavailability thereby limiting therapeutic effect. Such ingredients require liquid binders and advanced granulation methods such as spray drying and hot melt extrusion. In this way, wet granulation is the only way to create these granules with porous surface, enhancing their dissolution rate and curing outcomes for patients.

Easier Coating

Coated pills presentation idea- Picture Courtesy: pharmacentral.com

Most of the times, drugs require coating due to unpalatable taste, odor, and the need for its slow release. Therefore, it becomes necessary to mask their original properties by applying coating. This step cannot be carried out in dry granulation due to its limitation to expose liquid, while as, wet granulation is best suitable for such post processing of granules.

3.Is There Any Alternative To Wet Granulation?

Dry granulation- Picture Courtesy: Fitzpatrick

The answer to your question is yes! There are certain other methods which can be used as alternative to wet granulation. However, among them the most prominent one is dry granulation.

Dry granulation, as the name indicates, is a technique in which powders are turned into granules without any exposure to liquid. It simply involves the compression of active ingredients and excipients into strips or slugs (large tablets). Similarly, these compressed strips and slugs are crushed to form granules.

Despite having simple procedure and cost-effective way of granulation, dry granulation is rarely used in pharmaceutical industry as compared to wet granulation. The reason is because it has certain limitations by using special binders, creation of dust during operation, compression issues, and nonuniform structure of granules.

4.What Is The Process Of Wet Granulation?

The process of wet granulation is a bit lengthy by involving certain equipment. It follows few steps to form granules. These are enlisted below for your understanding:

Process of wet granulation- Picture Courtesy: sciencedirect.com

Ingredients Weighing

First, you need to collect the various ingredients required for formulation. It will include active ingredients and excipients along with binders. Weigh them properly before mixing to ensure a uniform formulation.

Powder Mixing

The second step involves proper mixing of the powder ingredients taken. It must be carried out appropriately.

Binder Addition

Now, the liquid binder is introduced to powder mixture in form of spray. Depending upon the latest techniques being introduced in wet granulation, the binder may be added to powder in different ways like steam, foam, or melted solvent.

Agglomeration

As the liquid binder get in contact with powder, the process of nucleation takes place and multiple tiny powder particles gather to form agglomerates.

Consolidation

At this point, the formed granules are further strengthen and consolidated by the continuous agitation of agitator. Similarly, this is a critical phase to determine the tensile strength, disintegration rate, and hardness of granules.

Granules Formation

Now, the consolidated large agglomerates are broken down to form uniform granules. This is the stage where the size of granules is finalized.

Granules Drying

As granules passed through wet granulation process, they are subjected to drying to remove out excess moisture content and reach a desired level.

5.What Equipment Are Needed For Wet Granulation?

In order to carry out wet granulation, you will need two types of equipment: one for granulation and the other for drying. In this question, we have discussed the tools required for both manual and automatic way of wet granulation:

Equipment for Manual Practice

Sieve

Sieve

Mesh sieve- Picture Courtesy: Schneider GmbH

Sieve is a kind of utensil having a perforated sheet surrounded by metallic frame. It is primary tool being used by practitioners when conducting wet granulation manually. The wet mixture is placed in a sieve after which it is rubbed. This continuous rubbing of agglomeration result in the formation of granules which fall from the lower side of the sieve.

Drying Tray

Granules drying tray- Picture Courtesy: LABCONCO

As wet granulation produce wet granules, they should be dried before further processing. In this way, hygienic drying trays are needed to safely make these granules dry.

Equipment for Industrial Practice

Wet Granulation Machine

Allpack- HLSG Series High Speed Wet Mixing Granulator

Wet granulation machine is the core machine required for wet granulation on industrial level. It manifests robust and hygienic structure which is made up of several components including a stainless steel tank, stirring blade, cutter, and binder spraying tool.

The machine is automatic in technology by following simple operational procedure along with providing a safe environment for granules formation. All the steps of wet granulation including mixing, agglomeration, consolidation, and attrition are carried out simultaneously in one machine. Moreover, the growing advancements has introduced many types of wet granulation machines to cope up with granulation complexities.

Pharmaceutical Drying Machine

Allpack- FG Series Fluid Bed Dryer

Pharmaceutical drying machine is a spectacular equipment employed to facilitate the drying of wet granules. It is a comprehensive solution to reduce the moisture content of granules by necessary level while taking care of the granules properties.

It simply works by circulating hot air around the wet granules which in turn start evaporating the moisture. Resultantly, in a very short period of time, granules are dried. The machine is widely applicable to pharmaceutical, nutraceucal, food, and chemical industry for wet granulation.

6.What Are The Advancements In Wet Granulation?

Wet granulation is popularly undertaken in pharmaceutical industry. Therefore, to enhance the drugs sustainability, bioavailability, and essence, certain advancements have been made in wet granulation to produce granules with more strong characteristics. These advanced methods or techniques are enumerated below:

Steam Granulation

Steam granulation- Picture Courtesy: researchgate.net

This is one of the first advanced techniques of wet granulation in which steam technology is used instead of conventional liquid binders. The steam is replaced with liquid and it performs the function of binding by agglomerating the powder ingredients.

Use:It is suitable for creating spherical granules with quick drying properties due to its gaseous nature that absorb instantly into powder.

Limitation:Steam granulation method is undesirable for heat-sensitive drugs and drugs requiring high tensile strength.

Moisture Activated Dry Granulation (MADG)

Moisture activated granulation- Picture Courtesy: semanticscholar.org

Moisture activated dry granulation is another type of wet granulation with its distinct method where first the mixture of active ingredients, excipients, and liquid binder is prepared. Then silicon dioxide or microcrystalline cellulose is added to the same preparation for moisture absorption.

Use:This method is useful in a way that it reduces the chances of lump creation.

Limitation:It is not suitable for hydroscopic drugs.

Thermal Adhesion Granulation (TAG)

This method of wet granulation utilizes a bit unconventional way for granulation by using low amount of pharmaceutically accepted liquid binder for mixing with powder and excipients. However, to fill this gap of using less amount of solvent, heat is used to expedite the granulation process.

Use:Thermal adhesion granulation is admired for its self drying process and creation of granules with high tensile strength.

Limitation:This technique cannot be used for thermolabile ingredients.

Melt Granulation

Melt granulation is a size enlargement process where solid binders are used instead of liquid binders. These binders get melted with relatively low temperature and therefore form agglomeration in combination with powder and excipients for creating granules. This method of wet granulation eliminate the use of water thereby ending additional drying process.

Use:It is best suitable for moisture sensitive drugs.

Limitation:Like many other techniques of wet granulation, it has also a limitation for the processing of heat sensitive drugs.

Foam Granulation

Foam granulation & wet granulation- Picture Courtesy: pharmtech.com

Foam granulation is yet another notable way of applying wet granulation. As the title illustrates, it transform the solvent in form of foam which is then introduced over powder ingredients. Resultantly, the powder ingredients quickly surround the foam and uniform granules are produced.

Use:This process of foam granulation is beneficial for water sensitive drugs. Moreover, it is quick in granules formation and use a little amount of binder.

Limitation:Requiring high energy and additional resources, this is comparatively an expensive method.

Freeze Granulation

Freeze granulation- Picture Courtesy: researchgate.net

Freeze granulation is among other innovative methods of wet granulation being practiced on industrial level. Under ultra-low temperature environment, powder suspension is sprayed over nitrogen as a result of which the freeze droplets are produced. These freeze drops are then pass through sublimation where ice is freeze dried and only granules are left.

Use:For making granules with controlled density and homogeneous property, freeze granulation is perfect.

Limitation:In this process, use of organic binders is preferred over water due to which it may form granules with low bioavailability.

Reverse Wet Granulation

Reverse wet granulation is referred to as the latest technique of wet granulation that involves two steps for granules formation. In the first step, active powder ingredients are mixed with solvent which is then processed through granulator. These granules are now ready for another phase where the excipients are added and final granulation stage is achieved.

Use:This recent advancement is good for making granules with controlled breakage, flow, and even dissolution especially for tablets formulation.

Limitation:Compared to other methods, reverse wet granulation produces granules with low intragranular porosity.

7.Are There Any Drawbacks Of Wet Granulation?

Despite having many advantages, there are certain limitations of wet granulations including:

Moisture sensitive ingredients- Picture Courtesy: caleva.com

Complex Process

Wet granulation has lengthy process which become more complicated without use of machines. Even with machines, you will have to intervene in the process for granules administration and drying etc.

Expensive

This process of wet granulation require multiple machines, extensive energy, and capital sources. Together, these expenses may not be bearable for medium to low level businesses.

Product Degradation

As wet granulation entirely depends upon the use of liquid binders, there is possibility that it may degrade the product quality and essence due to constant exposure to humidity and heat.

8.Factors Affecting Wet Granulation?

While practicing wet granulation, it is important to consider some of the essential factors or else you may face challenges in form of inappropriate granules formation. In this way, prominent factors which may affect wet granulation are as follows:

Pharmacist examining powder for granulation- Picture Courtesy: ct5prr2.findtwep.de

Amount Of Water

The first and foremost thing that may affect wet granulation process is the amount of water being used for granules formation. It is important to take note of the characteristics of various ingredients taken for granulation and use water in accordance with them. Otherwise, excessive water can cause lumps that may badly affect the properties of final granules.

Choice of Binder

Binders are very critical components in wet granulation without which granules of uniform properties cannot be created. Therefore, selecting right binder for your formulation will determine the cohesive and adhesive forces of your granules.

Temperature Intensity

Another factor that has influence on wet granulation is temperature intensity. It is evident that drying is compulsory step in wet granulation which is mostly done through heat. However, most of the drugs ingredients are susceptible to heat, so, temperature must be kept under control to reduce the possible damage to drug essence.

Apart from this, different methods within wet granulation like foam granulation or moisture additive dry granulation can be used.

Conclusion

So, we are going to conclude this blogspot with a hope that you have got the idea about wet granulation and able to answer the question What Are The Advantages Of Wet Granulation? The importance of wet granulation can be realized in almost every industry dealing with powder encompassing pharmaceutical, spices, detergent, and chemical industry. Most importantly, its scope is extending in drugs industry day by day due to the growing advancements to facilitate easy solid dosage formation. Paying heed to critical factors and adopting further relevant modification can enhance its worth. If you are eager to learn more just contact us!

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machines from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

What Are The Advantages Of Wet Granulation? Read More »

Wet Granulation Vs Dry Granulation

Granulator

Wet Granulation Vs Dry Granulation

Granulation is one of the important things being practiced in medical industry to make solid dosage form such as capsules, tablets, and pills. It paves the way for precise creation of granules by processing powders. That's why the industry in constantly engaged in trailblazing new methods and techniques to fulfill this inevitable step. In this way, two methods are globally recognized which are different from each other naming Wet Granulation Vs Dry Granulation.

You might be hearing it for the first time or may be familiar to these terminologies. However, most of the time medical practitioners and manufacturers get confused in them and start asking questions about their relation. So, this piece of writing has been designed to answer you that Wet Granulation Vs Dry Granulation are two totally different methods being employed for the creation of granules in many ways. So, let's delve deep into this review!

Add a header to begin generating the table of contents

1.What Is Wet Granulation Vs Dry Granulation?

Wet Granulation

Wet granulation process- Picture Courtesy: foodfeedfinechemicals.glatt.com

Wet granulation is the most popular method used for the formulation of granules from powder which are commonly used for creating solid dosage form such as tablets, capsules, and other food products. It uses fluids for mixing with the powder to make an agglomeration of ingredients. The powder when mixed with binder form adhesion. Similarly, this wet mixture is processed by certain tools to produce granules of desired size.

The formed granules are further meant to be dried depending upon the needs of material. This method of wet granulation is suitable for powders which are strong and able to withstand heat as well as humidity. Although, it requires more time and energy to make granules, however, its finished granules are highly spherical and perfect.

Wet granulation can be achieved by using three components:

Powder:Powder is the first material required for wet granulation. Depending upon formulation needs, powder can be excipients, active ingredients, or mixture of both.

Fluids:Fuids are the prerequisites for wet granulation which involve the volatile and nontoxic liquids used as binding agents for amassing powders.

Sieve:Sieve is a metallic container with perforation through which the agglomerated mixture is processed and turned into homogeneous granules. It must be noted that different machines can be used instead of sieve which is employed for manual practice only.

Dry Granulation

Dry granulation- Picture Courtesy: senieer.com

Dry granulation is another notable method of granulation which is completed without using any liquid or heat. It simply involves the compaction of powders into slugs or strips which are then broken into small pieces called granules. That's why, it is considered the most convenient way for granulation as it uses compact rollers and tablet presses for granulation.

This technique is suitable for powders which are either temperature sensitive or moisture sensitive. Thus, you will find its use in both pharmaceutical as well as food sectors.

Dry granulation only requires two elements for the accomplishment of granulation including:

Powder:The use of powder is common to both in wet granulation and dry granulation as principal ingredient.

Granulating Device:It refers to the tools or machines needed for granulation. Now, it can be roller compactor for making flakes or standard tablet press for making slugs.

2.Wet Granulation Vs Dry Granulation? Equipment Required?

When applying wet granulation vs dry granulation into your production, you will require relevant equipment for it. Similarly, machines used for both of these machines vary from each other. So, let's have a look towards these machines separately!

Wet Granulation

Depending upon the way, manual or automatic, you adopt for wet granulation, you will require the following equipment.

Sieve

Sieve

Test sieve- Picture Courtesy: walcoom.com

Sieve is one of the basic and important tools being used for carrying out manual wet granulation. It is a sort of container with flat layer of perforation. It can be simply used by putting the wet agglomeration of powder inside the sieve. Similarly, the constant rubbing of wet mixture result in their contact with perforation, consequently, it turns out of the sieve in form of granules.

Wet Granulation Machine

GHL Series High Speed Mixer/Granulator

Wet granulation machine is a sophisticated machine which is used to make granules by wet granulation. It is an automatic machine which is used on industrial level to deal with large volume of granules. The structure of machine is durable and composed of several components which vary from one type of machine to another.

However, the machine follows simple working procedure where powder is loaded into the working chamber. The attached agitator keeps the powder moving and fluid is constantly sprayed over the powder. Simultaneously, the chopper blade keeps cutting the wet mixture and precise granules are formed.

Wet granulation machine can be found in the following types:

High shear granulator
Low shear granulator
Steam granulator
Foam granulator
Freeze granulator

Pharmaceutical Dryer

Allpack- FG Series Fluid Bed Dryer

Pharmaceutical dryer is an equipment which is tailored to dry the granules formed by the wet granulation method. They are useful in reducing the moisture content of granules to make them suitable for further processing.

Among many other types, fluid bed dryer is an important one which provides an enclosed environment for the drying of granules. It uses both hot and cold air for the simultaneous drying and cooling of granules. Hence, it provides you with finished product as per your demands.

Some of the other prominent types of pharmaceutical dryer include:

Centrifuge Atomizing Pharmaceutical Dryer
Mesh-belt Pharmaceutical Dryer
Vibration Fluidized Bed Dryer
Double Cone Rotary Vacuum Dryer
Boiling Pharmaceutical Dryer
Fluidized Bed Dryer
Square And Round Static Vacuum Dryer
Hot Air Circulating Pharmaceutical Dryer

Dry Granulation

In order to apply dry granulation method, you will need to use one of the two machines which are as follows:

Roller Compactor

Pharma roller compactor- Picture Courtesy: pharmaexcipients.com

Roller compactor is a type of machine used for dry granulation. It uses compaction method for the granulation of powders. The machine is composed of a stainless steel body with roller compactors as principal component where the actual process of dry granulation occurs.

It processes powders in a way that the powder is passed through roller compactor which result in the formation of a strip. The same compacted powder strip is then converted into granules by milling. As, the process lack inclusion of water as well as temperature, so, it is beneficial for all kinds of sensitive powders.

Slugger

Slugger

Dry granulator machine- Picture Courtesy: yindamachinery.com

It is another machine used for dry granulation. Although, it is less frequently used than roller compactor, this machine can form slugs (large tablets) by mixing and then pressing powders. Therefore, it does not require any kind of fluid or temperature to carry out dry granulation.

The main structure of machine consists of feeding system, tablet pressing unit, granulation or crushing system, and dust collecting system. Thus, it carries out the process of dry granulation simultaneously.

3.Wet Granulation Vs Dry Granulation? Process?

The process of wet granulation and dry granulation entirely differs from one another. You will know their processes in the upcoming paragraphs:

Wet Granulation

The key steps involved in wet granulation are discussed below for your understanding:

Wet granulation process- Picture Courtesy: upload.wikimedia.org

Powder Loading

The process begins with loading the mixture of powder into wet granulation machine. As the powder is loaded, its wetting and nucleation process get started.

Liquid Spraying

Now, the liquid is sprayed over the mixture of powder which is in constant state of rotation by the agitator. This liquid spraying is the primary step for wetting your powder.

Granules Formation

As soon as the powder get sprayed with fluid, the tiny particles of powder start binding with each other. This process is referred to as coalescence where small particles come together to form a bigger one which is known as granule.

Breakage

As the granules formed by liquid spraying may vary in shape and size, a device naming chopper blade is located at the pot side which break down the granules to specific size. Hence, uniform wet granulation is achieved.

Dry Granulation

Dry granulation process entails few necessary steps including:

Dry granulation process- Picture Courtesy: eijppr.com

Mixture Preparation

Firstly, the active pharmaceutical ingredients and excipients are taken and appropriately weighed. They are then well mixed without adding any liquid. However, certain solid binders may be added to adjust the flow properties of powders.

Compaction

Once mixed, the powder will be compacted through force. Now, in dry granulation process two such compaction method may be used:

Slugging method:It adopts the technique of entering powder into the die cavity after which the powder is pressed between two flat metallic punches which form the slugs or large tablets.

Rolling method:It is the mainstream method of dry granulation which involves feeding the powder to the counter rotating pinch rollers. When supplied with powder, the rotation of roller compactor result in the formation of strips or flakes.

Granulating

It is the final phase where formed slugs or flakes are crushed by using pulverizing or milling technique to achieve the desired size of granules.

4.Wet Granulation Vs Dry Granulation? Pros And Cons?

Both wet granulation and dry granulation have their positive as well as negative sides. Therefore, it is necessary to know both of them for deciding the best method for you. In this way, the pros and cons of these granulation methods are enumerated below:

Pros

Pros

Wet Granulation

More Potent

Dry granulation uses conventional excipients instead of special ones. These too involves the additives for coloring and preservation of active ingredients. Thus, unlike dry granulation drugs produced through this method is more potent in effect.

Uniform Structure

Different types of dry granulation granules- Picture Courtesy: foodfeedfinechemicals.glatt.com

The granules produced through wet granulation are of uniform size with spherical shape. These granules when further processed for making tablets, are greatly helpful in creating precise and perfect shaped tablets.

Better Compressibility

Wet granulation support does not allow air entrapment during compression due to their high density. Moreover, this procedure offers better compressibility by reducing the need for extra force and time.

Support Post-Processing

Coated tablets with different colors- Picture Courtesy: pediaa.com

Post processing such as coating is often needed for tablets to mask their unpleasant taste and smell. In this way, wet granulation support coating due to its perfectly finished granules which remain unchanged even after contacting further liquids.

Limits Dust

Manufacturers of pharmaceutical industries need to reduce the prevalence of dust to the possible limit which is only possible with wet granulation. Thus, the removal of cross contamination and protection of employees involved is ensured.

Dry Granulation

Simple Procedure

Dry granulation follows extremely convenient procedure for making granules with no specific need for air cooling and hot air-drying system. Thus, the process is simple which can be carried out by layman after understanding the basic steps.

Cost-effective

This method is well-known for its cost-effectiveness with low capital investments and operating cost. In addition to it, dry granulation equipment often has low maintenance requirements as compared to wet granulation.

Wide Application

Food granules- Picture Courtesy: piscespros.com

Dry granulation skip the involvement of liquid and temperature which are the basic limitations for most of the moisture and heat sensitive powders like medicine powder, abrasive powder, and certain Good powders. Therefore, it can perfectly deal with such sterile materials without affecting their quality.

High Efficiency

By lacking multiple machines and long operational procedure, dry granulation offers continuous production process. Thus, the output ratio is increased, and high volume of production is achieved in less time.

Cons

Cons

Wet Granulation

Complicated Process

Cycle of wet granulation- Picture Courtesy: researchgate

The process of wet granulation is more complex and complicated especially without the use of right equipment. It follows a long procedure with preparing the wet mixture while taking control of the amount taken. Similarly, the formation of granules and their drying through separate machines consume both time and energy.

Product Limitation

Wet granulation is not suitable for powders with moisture sensitivity. Although, such powders are not plenty in pharmaceutical industry but there are numerous materials available in sectors like food and chemical. Together, it shows the application of wet granulation to the limited sphere.

Expensive

Wet granulation require more capital in form of multiple machines which are too expensive. These machines also need stable electric supply; therefore, companies must have renewable energy sources. Hence, this method of granulation is not reliable for small scale and startup business.

Dry Granulation

Nonuniform Structure

Tablets produced through dry granulation have high tendency of softening or breaking, especially during transportation as they are porous. They hardly have uniform shape or beautiful appearance due to less adhesion and uneven distribution of colors.

Poor Compressibility

Broken tablet

Dry granulation causes problem during compression such as air entrapment and it needs much force for compression.

Use of Special Excipients

Unlike wet granulation, dry granulation requires special excipients for binding as it cannot use the regular liquid ones. This is the reason why tablets produced through dry granulation have potential side effects.

Dust Prevalence

The absence of liquid binders in dry granulation often leads to excessive dust during operation. It is harmful especially when dealing with hazardous substances.

5.Wet Granulation Vs Dry Granulation? Properties Of Granules?

The granules produced by wet granulation and dry granulation can be easily distinguished from each other due to their structural, potency, and apparent properties. These are as follows:

Wet Granulation

Wet granulation end product granule- Picture Courtesy: foodfeedfinechemicals.glatt.com

Granules formed through wet granulation method are:

More spherical in shape.
They are roughly textured, therefore, often have poor flowability.
These granules have low density due to which they cannot glide efficiently.
These granules are better for any type of formulation.
Such granulation forms a product that is difficult to disperse or segregate.

Dry Granulation

Dry granulation properties- Picture Courtesy: hmicronpowder.com

Dry granulation make granules which possess following properties:

They have irregular shape.
Granules produced by this way are denser and compact.
These granules support instant flow.
As granules produced through dry granulation are dry in nature, they are suitable for few types of formulation and do not support coating.

Such granules are dispersal and may lead to segregation of the components.

6.Which Is Widely Used? Wet Granulation Vs Dry Granulation?

Medical practitioner placing lid over wet granulation machine- Picture Courtesy: tabletpresses.com

When it comes to highlight the use of wet granulation and dry granulation, so, both have their relevance in respective domains due to the concerned benefits and drawbacks. However, wet granulation is widely preferred by pharmaceutical manufacturers due to its effectiveness, safety, and formulation of uniform granules.

Despite its complexity and long working procedure, wet granulation offers certain advantages which a concerned manufacturer can never overlook. It is good in using less binding agent, offering scalability, and maintain dust free environment to retain the integrity of tablets

In contrast, dry granulation is also popularly used by the owners of industries in food and chemical sector due to its simple working procedure. It is also favored for its usefulness for moisture sensitive materials as a result of which sterile powders are not exposed to intense heat and humidity.

7.Which Is Cost-effective? Wet Granulation Vs Dry Granulation?

Cost measuring icon- Picture Courtesy: choice.com.au

As we have explained above, wet granulation requires more equipment and its operation is based on certain steps which also take time. Similarly, the new advancements in the field have introduced new types of machines to deal with wet granulation in different ways. However, all this account for the expensive nature of wet granulation despite its popularity among industrialists.

On the other hand, dry granulation can be simply called a cost-effective and cheaper way to turn your powders into granules. It is because this method has limited and easy steps which do not require multiple cycles to done with granulation. Moreover, the use of a single machine also emphasizes the other associated aspects such as low consumption of energy, resources, and time.

8.Methods Used In Wet Granulation Vs Dry Granulation?

There are numerous methods which are used in wet granulation and dry granulation. These can be better understood under traditional methods and advanced methods.

Traditional Methods

Wet Granulation

Low Shear Granulation

Low shear granulation is one of the conventional and important methods being used for wet granulation. It involves the wetting of powder with fluid which is then processed by using low shear granulation mechanism. With low speed, low shear granulation is less costly and require less amount of binders. Therefore, it is good for pharmaceutical, food and fertilizer industries.

High Shear Granulation

It is another significant method of wet granulation which uses equipment having high shear mechanism in form of double blades, a rotary agitator and side chopper. Therefore, it is efficient in performance and is capable to produce uniform granules without generating dust. It is suitable for pharmaceutical, detergent, and and agrochemical industry.

Fluidized Bed Granulation

Fluidized Bed granulation process- Picture Courtesy: mdpi.com

It refers to a more comprehensive method where powder mixing, granulating, and drying is done simultaneously. The agglomeration is formed by spraying fluid after which granules are formed. The same granules are then dried by using hot air. This method is fully automatic with performing every step in a single machine.

Dry Granulation

Slugging

Slugging method- Picture Courtesy: ipharmachine.com

Slugging is seldom used method for dry granulation. It involves the preparation of dry powder formulation by mixing excipients along with active ingredients. It is also known as precompression or double compression in which the prepared mixture is compacted in form of slugs by using standard slugger tablet press. Similarly, these formed slugs are crushed into small granules for further processing.

Compaction

Compaction dry granulation method- Picture Courtesy: ipharmachine.com

It is the most widely used method for dry granulation. This method follows a simple procedure where no need of liquids is realized for wetting. Instead, a roller compactor is employed to make flakes or strips of powder through their pressing between punches. These formed strips are then broken down into desired size of granules.

Advanced Methods

Wet Granulation

Recently, many advancements have been made in the the wet granulation methods to facilitate its convenient application. So, let's enumerate these advanced methods one by one:

Steam Granulation

Steam granulation- Picture Courtesy: semanticscholar.org

Steam granulation is one of the advanced methods introduced in wet granulation. Unlike conventional method, it uses a technique of water steam to form granules. It does not need liquid as a binding agent instead this is done by the help of steam. In this way, the granules made by steam granulation are spherical and easily diffusible. However, it is not desirable for thermolabile drugs and powders.

Moisture Activated Dry Granulation

Moisture activated granulation- Picture Courtesy: semanticscholar.org

It refers to the advanced method where wet granulation is based on two steps. Firstly, by adding liquid binders to powder, agglomeration is formed. Afterwards, the same mixture is dried by adding silicon dioxide or microcrystalline cellulose to absorb excess moisture. In this way, the possibility of lumps become zero, but this method is technique is not good for hygroscopic drugs.

Thermal Adhesion Granulation

Thermal Adhesion Granulation- Picture Courtesy: semanticscholar.org

This is another advanced technique which uses both binder and solvent along with heat. The wet mixture is processed by the machine in a way that heat is used for the adhesion and dry of granules. Thus, no additional drying is required, and the finished granules have more tensile strength. However, the method has limitations of choosing among specific binders and it needs it needs specific equipment for heat generation.

Melt Granulation

Melt granulation- Picture Courtesy: semanticscholar.org

Melt granulation involves the usage of binders with low melting temperature. During process, active ingredients, excipients, and binders are collectively loaded. The binder may be in solid form or melted liquid which is why this method is sometimes called thermoplastic granulation. This mixture is then heated according to the temperature of binder which ultimately result in the creation of uniform granules without using excessive water and heat.

Foam Granulation

Foam granulation- Picture Courtesy: researchgate.net

This inventive method is unique in its way. It simply turns the binder into foam and introduce the binder to powders in form of foam. Resultantly, the granules created are containing more nuclei and the particulates are uniformly distributed. That's why, this method is admired for its effectiveness for all kinds of drugs despite its expensive operation.

Freeze Granulation

Freeze granulation- Picture Courtesy: semanticscholar.org

Freeze granulation is one is the innovative methods used in wet granulation. It is undertaken in a way where powder suspension is poured into liquid nitrogen and the drops are frozen into granules. These granules are then dried by using freeze drying method during which ice is sublimated and only homogeneous granules are left. It is good for controlled granules density.

Reverse Wet Granulation

Reverse wet granulation is the recent advancement in wet granulation technique which follows two phases. First, the active powder ingredients are mixed with liquid binder in a granulator to form granules. Second, the formed granules are subjected to be mixed with powder excipients for final granulation in granulator. Hence, these granules are then dried and milled for sizing.

Dry Granulation

Pneumatic Dry Granulation

Pneumatic dry granulation- Picture Courtesy: researchgate.net

It is the only advanced technique being introduced in dry granulation. This method is effective to maintain the tablet hardness, flowability, and compression abilities. For this reason, the roller compactor or tablet press has an attached air classification system which separate the undesirable size of granules from the right-sized granules.

Similarly, the smaller granules are sent back for compaction and precise granules are processed for making end product. Hence, you can easily reduce the common errors associated with dry granulation by employing this technique.

Conclusion

The bottom line is that Wet Granulation Vs Dry Granulation are two distinct methods of granulation. Both these techniques vary from one another in numerous aspects as discussed above. Wet granulation is gaining more importance due to the advancements made in it. While as, dry granulation is still preferred by the companies in different fields. Besides, you may have established your own analysis after reading this blogpost. So, if you have any query or you want to adopt one of these two methods for your manufacturing and looking forward for relevant machines then you can simply approach us through our website.

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machines from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

Wet Granulation Vs Dry Granulation Read More »

Dry Granulation Process: The Ultimate Guide In 2024

Granulator

Dry Granulation Process: The Ultimate Guide In 2024

Do you know granulation is gaining traction in the manufacturing industry? With granulation, you can turn fine powder into compact granules within a short time. Two processes are most common in the granulation technique, one being the dry granulation process.

It is a straightforward and cost-effective process, needing less equipment to create a system. A dry granulation process is employed for the manufacturing of moisture and heat-sensitive drugs. It is an efficient process that increases the stability of drug components.

Now this blog “Dry Granulation Process: The Ultimate Guide In 2024” will answer all your questions about the dry granulation process. So, sit tight and read this guide.

Add a header to begin generating the table of contents

1.What is Meant by the Dry Granulation Process?

Dry Granulation Process

The granulation process is particle transformation and enlargement. It is the process by which fine powders are changed into spherical masses called granules. The dry granulation process is a subtype of the granulation process. It is the process in which granules are created without the help of any granulating fluid or binder.

The dry granulation process is typically used for powders that are sensitive to heat and water content. It generates dust-free and free-flowing granules. There is no change in the chemical composition of granules in the dry granulation process because a binder is not added during granulation. This process takes dry raw materials and compacts them in larger granules to lock in the ingredients proportion. It is the most widely used technique for forming oral solid dosage because it densifies powders.

2.Why Do You Need a Dry Granulation Process?

The dry granulation process is needed for different purposes because it decreases the surface area of sensitive ingredients, making them easier to transport and handle. It improves the homogeneity of ingredients and their flowability. Some of the reasons why dry granulation is a preferred technique are as follows:

Formation of Heat-Sensitive Drugs

Formation of Heat-Sensitive Drugs- Picture Courtesy: PharmTech

Some drugs deteriorate at high temperatures; therefore, the dry granulation process is a suitable solution to deal with this issue. It does not involve drying at elevated temperatures so, it formulates thermos-sensitive drugs easily.

Reduction in Moisture-Related Issues

Reduction in Moisture Related Issues

Moisture content in pharmaceutical formulation could leads to detrimental effects like promotion of microbial growth, change in physical properties, and increase in drug degradation. However, with dry granulation process, these problems are easily resolved, because there is no liquid addition during dry granulation steps.

Efficient Processing

Efficient Processing

Dry granulation process has integral role in efficient and smooth processing, as it increases the powder flowability. Powder clumping has serious consequences like bridging, arching, and segregation. These issues are prevented with dry granulation process.

Rapid Production

Rapid Production

There are a smaller number of steps in the dry granulation process, especially it bypasses the drying step, which decreases the production time leading to increased production efficiency. It decreases the granulation time and streamline the production performance.

Cost-effective Process

Cost-effective Process

The dry granulation process is a very cost-effective process because it has lower overhead cost. It does not require binder that saves the purchasing cost of binder. Moreover, there are fewer equipment involved in dry granulation process, resulting in lower operational expenses.

Increased Compressibility

Increased Compressibility- Picture Courtesy: Signos

Compressibility is important in tablet formation and dry granulation process create granules that are easier to compress. This results in sturdy and homogenous tablets.

High Stability

High Stability- Picture Courtesy: Good Housekeeping

The dry granulation process is essential in preserving the chemical stability of powder components. Due to zero use of binder or solvents, there is no loss of potency, hence it ascertains that drugs retain their therapeutic potential over the course of their life.

3.What are the Types of Dry Granulation Process?

There are two types of dry granulation processes, which are discussed below:

Slugging

Slugging- Picture Courtesy: Packaging Strategies

It is the earliest form of dry granulation process. slugging is the also referred to as precompression or double compression. In this process, the powders are uniformly mixed and then compacted into slugs (large tablets) using standard tablet press. After using mills, these slugs are converted into granules.

Process of Slugging- Picture Courtesy: Gerteis

The weight of the slugs differ in the slugging process as small particles do not flow efficiently in the tablet press die cavity. Hence, slugs formed as a result of slugging have non-uniform characteristics and cannot be effectively milled. Therefore, slugging is not frequently used in the dry granulation process.

Roller Compaction

Roller Compaction

It is one of the most commonly used methods in dry granulation. It is alterative method to slugging dry granulation process. This process is dependent upon the intermolecular bonding between particles. This bonding is created by the particle arrangement, deformation, and fragmentation during the roller compaction dry granulation process.

It produces a solid mass called ribbon, flakes or sheets by the compaction of powders. These ribbons are broken down into granules of smaller sizes using mills. In this way, powders agglomerate together to produce granules.

Roller Compaction- Picture Courtesy: Pharmaceutical Technology

In roller compaction dry granulation method, the powder mixture is compressed via high pressure forces to augment the size of granules. The powder blend is transported to the counter-rotating rollers that compact or squeeze the powder to generate the sheets. These sheets are breakable and split into flakes. These flakes are milled into granules after careful treatment.

The gap between roller is responsible for homogeneity and bulk density of the final granules.

4.Enumerate Industrial Applications of the Dry Granulation Process?

Due to the diverse uses of dry granulation process, it is executed in different industries to produce different types of products. Some of its applications are included below:

Pharmaceutical Industry

Dry Granulation Process in Pharmaceutical Industry- Picture Courtesy: diaTribe

First and foremost, dry granulation process is utilized in the pharmaceutical industry for producing the desired-sized particles because it boosts material flow. This process has improved robustness; thus, it manufactures tablets and capsules having unvarying weight and acceptable strength. It also has contributed in the formation of controlled release pills.

Nutraceutical Industry

Dry Granulation Process in Nutraceutical Industry- Picture Courtesy: ET HealthWorld

It is another important industry in which dry granulation process is used for creating different nutraceutical oral dosage form like vitamin and mineral supplement pills. Dry granulation process results in uniform distribution of drug ingredients. Nutraceutical granules have better processibility improving the manufacturing practices.

Food Industry

Dry Granulation Process in Food Industry

Yes, dry granulation process is a suitable method for forming different kinds of instant mixes, flavoring agents, and other important food particles. This procedure also produces different instant beverages and drinks like soups and juices. Dry granulation process also boosts the uniformity of spice blends and herb mixes.

Chemical Industry

Dry Granulation Process in Chemical Industry- Picture Courtesy: The STOCKMEIER Group

The dry granulation process also has a pivotal place in the chemical industry, as it increases the handling and storage characteristics making it the perfect approach for creating non-clump anticaking agents, food additives, fillers, and catalysts. It also improves the cleaning action of detergent powders.

Agriculture Industry

Dry Granulation Process in Agriculture Industry

In the agriculture industry, fertilizers, pesticides, and other insecticides powders are routinely processed. So, dry granulation process is a common practice in the agriculture industry. It also boosts the attributes of agriculture powders and decreases the quality deviations.

5.What are the Steps in Dry Granulation Process?

There are different steps involved in subtypes of dry granulation process. These steps are penned below:

Steps in Slugging Dry Granulation Process

Steps in Slugging Dry Granulation Process- Picture Courtesy: iPharmachine

First, the powder mixture is introduced in the tablet press machine for slugging.

Afterward, slugs are formed by compression powders using flat-faced punches in the die cavity. These slugs have a diameter of about 25 mm and a thickness of about 10-15 mm.

The screening or sieving of slugs is performed both before and after compression.

After screening, the slugs are divided into intended size particles using mills or oscillating granulators.

Finally, reduced particles are sieved to attain final granules.

Steps in the Roller Compaction Dry Granulation Process

Steps in Roller Compaction- Picture Courtesy: Pilotech

In this process, first raw material is loaded in the funnel that is equipped with agitator, feed auger, and tamp auger. These components transfer powder material to the rotating rollers.

When the powders reach the gap between counter-rotating rollers, a force is exerted on the powder for compression.

High compression force on the powders transforms them into ribbon-shaped mass.

These ribbons are transported to the sieve to separate out desired-sized particles.

Afterward, these particles are moved toward the mills to obtain required sized particles.

Fine granules having size less than required and sent back to the granulating funnel for second cycle of dry granulation.

6.What Equipment are Employed in Dry Granulation Process?

There are two main types of machines in the dry granulation process, for instance:

Slugger

Slugger

Slugger Machine- Picture Courtesy: Yinda Machinery

It is one of the oldest machines for granulation. It is a standard tablet machine for rotary press that is used for the compaction of powders. It employs mechanical force to convert powders into granules of even shapes and sizes and creates bolus or slugs. This machine forms large tablets and compacts powders that have lower flowability.

Working Principle

Working Principle of Slugging- Picture Courtesy: giexpre

It has two different die cavities that provide mechanical force for the compression of powders without the need for any solvent or heat. The powder is subjected into a feeding hopper and the auger helps in facilitating the compressing die. The powder is milled to form a slug known as pre-compression. The main compression is followed by exerting pressure on it with the help of an upper punch. Now, the lower die punch rises to eject the material.

Compaction Roller

Pharmaceutical Compaction Roller- Picture Courtesy: Fitzpatrick Company

Nowadays, the slugger machine for dry granulation is largely replaced by the roller compaction machine. This machine is the core part of the dry granulation line for solid dosage form. It has two pressure rollers with which a mixture of powders is transformed into a ribbon, sheet, or flake. It delicately compresses the powder blend without breaking it.

It has a hopper, feeding part, and compaction part. The roller compression pressure is adjusted using a hydraulic control system to create granules with unvarying crushing strength. It creates uniform and consistent-sized granules. The compaction roller is a cost-effective machine because it does not require wet massing and drying stages, saving energy and operational costs.

Working Principle

Working Principle of Compaction Roller- Picture Courtesy: L.B. BOHLE Coating

The bulk powder for compaction is transferred to the hopper via a powder handling system. The hopper is equipped with a screw feeder that moves the powders in space between pressure rollers. The counter-rotation of rollers brings the powders to the central area between rollers, which exerts pressure on the powders for compression. Then, the rotation of rollers pushes the enlarged mass outward of the machine.

7.What are Problems Associated with the Dry Granulation Process?

Although the dry granulation process is an advantageous technique, bringing several benefits to the production, still there are some problems arise occasionally in this method. These problems are discussed below:

Particle Hardness

Particle Hardness- Picture Courtesy: Syntegon

Cause

High compression pressure results in hard granules, creating problems in subsequent processes like milling and tablet compression.

Solution

This problem can be resolved using lower-pressure forces during roller compaction and slugging. Also, gently mill the granules to decrease their hardness.

Dust Generation

Dust Generation- Picture Courtesy: Multistation

Cause

Open systems and ineffective ventilation lead to high dust generation. Rough powder handling and manufacturing steps cause dust generation.

Solution

This issue is solved using enclosed systems and processing stages to reduce dust exposure. Also, setup, appropriate ventilation systems to manage dust levels.

Segregation of Particles

Segregation of Particles- Picture Courtesy: BulkInside

Cause

This could happen because of over mixing or diversity in the particle sizes. Similarly, density differences in the final blend results in segregation of particles.

Solution

To prevent this issue, optimize mixing time and limit the range of particle sizes. Decreasing density differences in the final blend resolves this issue.

Fines in Granules or Slugs

Fines in Granules or Slugs- Picture Courtesy: Industry Plaza

Cause

The utilization of unsuitable sieving mesh and high speed of mills could be the reason of fines in the final product.

Solution

Using right sized mesh screen and lowering the speed of dry mill prevent this defect.

Non-Uniformity in the Particle Size

Non-Uniformity in the Particle Size- Picture Courtesy: Justdial

Cause

It is due to inadequate mixing time and inadequate speed of the roller compaction.

Solution

It is recommended to improve the mixing time and alter the speed of roller compaction.

8.What are the Recent Advances in the Dry Granulation Process?

Pneumatic Dry Granulation Process- Picture Courtesy: Sudeep Nutrition

Recent advances in the dry granulation process include the pneumatic dry granulation process. It is a combination of roller compaction and proprietary air classification (pneumatic system). In this process, the first granules are created from fine powders employing mild compression force in the roller compaction. Then, smaller particles are separated from the required-sized granules in a classification chamber using a gas stream.

Entrained smaller particles are transported to the cyclone device and are either moved back to the roller compaction for reprocessing or stored in a container for later regranulation.

It can process higher drug loads and create good-flowing granules. Moreover, it rapidly processes materials, has lower operational costs, decreases material wastage, and lowers dust generation because it is a closed system.

Conclusion

The dry granulation process is a simple and cost-cutting technique, requiring little to less materials and equipment. It is a resourceful technique to manufacture heat and moisture-sensitive drugs. Moreover, the absence of granulating fluid in the dry granulation process simplifies the formulation and preserves the potency of drugs, reducing their drug degradation. Slugging and roller compaction are the main techniques in the dry granulation process while recent advances in this process include the pneumatic dry granulation process. Now, if you have more queries about the steps and equipment of the dry granulation process, you can contact the Allpack team now!

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machines from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

Dry Granulation Process: The Ultimate Guide In 2024 Read More »

What Is Granulator

Granulator

What Is Granulator

Do you know what is granulator? It is a common material processing machine which is widely used in various industries, this equipment is generally used to process powder materials, and it is very efficient. Of course, such a one-sided description is not enough to give you a good understanding of a granulator.

So, in this blog, you will see the complete introduction of granulator and learn more information of this machine, such as its advantages, applications, working principle, structure, classification and so on. If you are interested at granulator, please keep on reading this article.

Add a header to begin generating the table of contents

1.How can you define a granulator?

Granulator is a processing equipment which is used to make different materials into a specific shape, this machine is widely applied in various industries which include chemical, food, pharmaceutical, construction, mineral, ceramic, plastic and so on. It can form powders or fine granules into larger granules, or grind solid materials into small granules.

2.What are the advantages of granulator?

There are many worth mentioning advantages of granulator, here are some of them:

Uniform Granulation

A basic advantage of granulator is that this machine can provide uniform granulation, no matter what the raw material is, as long as you put it into the granulator, the machine can make it into particles of the same size, which can ensure the quality of the final product.

Increase Production Efficiency

When choosing a machine, the most important thing you should pay attention to is its production efficiency, the granulator is such a machine which has high speed. The machine can handle a large amount of raw materials in a short time, as a result, it can improve the efficiency of the whole production line.

Reduce Powder Flying

Generally speaking, powder material is easy to be lifted up by the air, however, when using a granulator, the powder has less chance of contacting with the air, so it is not easy to be lifted up. At the same time, the dust in the air can not enter the machine, which can ensure the cleanliness of the whole granulation process.

3. What are the applications of granulator?

Granulator can handle a variety of raw materials so that it is widely used in many industries, including food, pharmaceutical, chemical, plastic and metallurgical, etc.

Food Industry

In food industry, granulator is often applied in food processing, it is used to produce granular materials for food products such as beans, grains and so on. The granular food materials are easy to store and convenient for processing, which increase the production efficiency.

Pharmaceutical Industry

Pharmaceutical Industry-Photo Credit: Fabtech Technologies

Granulator is a ideal equipment for pharmaceutical industry, it can made drugs into granules, which can be pressed into tablets or used as brewing medicines. The granular medicines are simple to dissolve and absorb by your body, in addition, they have high stability.

Chemical Industry

Chemical Industry-Photo Credit: Mesto

In chemical industry, the chemical materials are processed into granules by granulator, therefore, they are more stable, can be stored for a longer time, and are convenient for transportation. Granulator improves the quality of chemical products.

Plastic Industry

In the plastics industry, the granulator is used to recycle plastics, it can process all kinds of waste plastics and make them into plastic granules, so as to achieve the purpose of plastic recycling.

Metallurgical Industry

Granulator plays a vital role in metallurgical production, it turns metals and minerals into granules, which are convenient for smelting. Why the metallurgical industry need to use granulator? The reason is that the granular materials are easier to burn, so the production efficiency and safety are increased.

4.How many types of granulators there are?

In terms of categories, granulators can be divided into dry granulators and wet granulators, according to these two categories, there are various other types of granulators, which will be listed next.

Dry Granulator

(1).Roller Granulator

Roller granulator belongs to dry granulator, it adopts compression to achieve its function, this machine performs granulation at a normal temperature, and does not require drying measures such as fuel oil and gas. By using a roller granulator, the dry material is extruded under pressure into hard chunks, then crushed and sieved into granules.

(2). Swing Granulator

Swing granulator is another kind of dry granulator, it can turn mixed powder material into granules, and can also crush lumpy solid material into granules. This machine can perform granulation effectively, it is widely used in chemical, pharmaceutical, food industries and laboratories, suitable for small scale production.

(3). Rotating Granulator

The rotary granulator is applied to turn mixed material into granules, it uses the oscillating action of the rotating drum to grind the wet powder raw material into granules through a wire sieve. This machine is very suitable for process materials which have high viscosity, commonly used in pharmaceutical, food, chemical, solid beverage and other industries.

Wet Granulator

(1). High Shear Granulator

High shear granulator is a typical wet granulator, it is equipped with a high speed rotor which is used to mix and shear raw material. This machine can provide effective granulation, in high shear granulator, the material is mixed, dried and sheared, finally made into uniform granules. This type of granulator is very common in various industries

(2). Drum Granulator

Drum granulator uses agglomerate wet granulation, it uses a certain amount of water or steam to wet the raw material, and then its cylinder begins to rotate, through the rotating motion, the materials are constantly extruded and collided, and agglomerated into granules.

(3).Fluidized Bed Granulator

Fluidized bed granulator is also a kind of wet granulator, it uses heat air and adhesive to achieve granulation. The material is placed on the fluidized bed and sprayed with adhesive solution, then aggregated, next, they are suspended under the action of hot air. When the materials are dried by hot air, the granulation process is finished.

5.Dry Granulator VS Wet Granulator

As is mentioned that there are two major categories of granulators, dry granulator and wet granulator, however, what are the difference between these two granulators? Let’s discuss together.

Dry Granulator VS Wet Granulator-Photo Credit: WANDA

Granulation Method: Dry granulator adopts dry granulation, which uses direct compression to squeeze bulk materials to obtain granules, during the granulation process, no liquid is required. However, wet granulator adopts wet granulation which uses liquid to mix the powder material, and then extrudes the material to obtain granules.
Suitable Requirement: Dry granulator is more suitable for making smaller sized granules while wet granulator is more suited for making larger sized granules.
Moisture Content: The granules which are made by wet granulator have higher moisture content than those made by dry granulator.
Cost:The granulation process of dry granulator is relatively simple, does not require drying, can save manpower and material resources, in other words, saves cost. However, the granules produced by the wet granulator need to be dried, which consumes more resources and increases the cost.

6.How does granulator work?

Since there are two major categories of granulator, when talking about the working principle of the granulators, there are different situations.

Working Principle of Dry Granulator

Working Principle of Dry Granulator-Photo Credit: Pharma Specialists

As the picture shows, at the beginning, the raw material is fed into the dry granulator through a hopper, and then there are two rollers which are used to compress the raw material, under pressure, the powder is compressed into tablets.

Next, the tablets are crushed into large particles, but this step is not over yet, the large particles have to be sieved through a screen, when they passing through the screen , they become smaller particles, and the granulation process is completed.

Working Principle of Wet Granulator

Working Principle of Wet Granulator-Photo Credit: TTP Group

The working process of wet granulator can be divided into mixing and granulation, the whole process is happened in a closed container. At first, the raw material is fed into the machine, and stirred by stirring paddle, during the stirring process, the material becomes semi-fluid, efficient mixed state.

At this moment, the adhesive solution is added, it is mixed with the material and forms a liquid bridge, the material becomes loose and agglomerated, next is the granulation process, the agglomerates are cut into fine and uniform granules by the cutter, and finally they are discharged, that’s the whole working process of wet granulator.

7.Can you tell the main parts of granulator?

The same as the working principle of granulator, in this part, it is still discussed in two cases: dry granulator and wet granulator.

Main Parts of Dry Granulator

Hopper: This is the entrance of the raw material, when you turn on the machine, you need to pour the material into the hopper.

Switch: There are two buttons which are used to turn on and turn off the machine.

Roller: A dry granulator is equipped with two rollers, which play a role in compression.

Mesh Screen: This part is to sieve the large granules and turn them into fine granules.

Discharge Port: The material which is processed will be discharged from this part.

Machine Body: The machine body is to support the whole machine, it contains a frame, pedestal rack and 4 movable wheels.

Main Parts of Wet Granulator

Main Parts of Wet Granulator- Photo Credit: Science Direct

Mixing Bowl: You can also call this part as the granulation chamber, here is the place where the whole granulation process takes place. In the mixing bowl, the raw material and adhesive solution are mixed and agglomerated.

Bowl Lid: This is the cover of the mixing bowl, when the machine begins working, you need to open the bowl lid and pour raw material into the mixing bowl. And during the granulation process, this part is closed so that the material will not contact with the air.

Liquid Inlet: As you know, adhesive solution is an important element in the granulation process of wet granulator, therefore, there is a small inlet on the bowl lid, it is called liquid inlet, is the entrance of adhesive solution.

Impeller: This part plays a role in stirring, you can regard it as a stirring paddle, during the granulation process, the impeller will constantly stir the material to let it completely mixed with the adhesive solution.

Chopper: When the material and adhesive solution are mixed and agglomerated, they need to be made of granules, and the chopper is such a component to do this operation, it cuts off the agglomerates so that they can become granules rapidly.

Granule Outlet: When the whole granulation process is finished, the granules are discharged through the granule outlet.

8.How to choose the right granulator?

Choosing the right granulator for your business can get twice the result with half the effort, but, what factors should you consider before buying a granulator? Let’s discuss together.

Figure out which type of granulator do you need.

Firstly, you should determine which type of granulator can meet your demand, do you think you need dry granulation or wet granulation? Think clearly whether you need to buy a dry granulator or a wet granulator, and then choose a specific type from the certain category.

What material do you need to granulate?

And the second factor, you need to make it clear that what material do you want to process by using a granulator. This factor is very important, you need to know the particle size and property of your material, this can also help you choose the right type of granulator.

What is your granulation goal?

Of course, you also need to consider your granulation goal, in other words, what kind of particle size do you need to make the raw material into? When you set up your granulation goal, you can have a specific standard when choosing a granulator, instead of blindly searching.

What is your criteria for evaluating the granulator?

Last but not least, you need to set your own evaluation standards, what should your ideal granulator look like? Think about your requirements for the working speed, production output, ease of operation, maintenance and service life of the granulator.In this way, when choosing a granulator, your requirements will be more concrete, and it will be easier to choose a high quality machine.

Conclusion

Overall, granulator plays an important role in many production lines, therefore, learning the relevant knowledge of this machine can help you a lot. Well, after reading this blog, do you understand the basic information of granulator? Or, do you still feel curious about it? If you have some questions of granulator, you can contact and ask us.

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machines from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

What Is Granulator Read More »

Top 10 Global Granulator Machine Manufacturers:The Ultimate Guide In 2024

Granulator, Top 10

Top 10 Global Granulator Machine Manufacturers:The Ultimate Guide In 2024

As is well-known,granulator machines are important equipment in pharmaceutical and processing industry,like crusher and grinder,granulator machines can help people deal with material quickly and efficiently,therefore,they are widely used in industries.However,since they are popular,there are many manufacturers supply granulator machines,how can you choose a reliable one from them?

Don’t worry,here is the answer,in this blog,you will learn the top 10 global granulator machines manufacturers,you will learn their backgrounds,key products and advantages.It is helpful for you to choose a granulator machine manufacturer by reading this blog,don’t wait,just keep on reading!

Rank	Manufacturer	Headquarter
1	SERVOLiFT LLC	USA
2	Cumberland	USA
3	Freund-Vector	USA
4	GEA Group	USA
5	Allpack	China
6	Fluid Air	USA
7	Glatt	USA
8	GlobePharma	USA
9	Rapid Granulator	Sweden
10	XERTECS	Germany

logos

1.SERVOLiFT

CONTACT THIS COMPANY NOW

Headquarter: USA

Company Background & Information

SERVOLiFT LLC was founded in 1976,as an outstanding manufacturer in processing field,it provides various material handling and processing machines,such as blenders,lifters,washers,etc.The company mainly serves for chemical,food processing ,cosmetic and pharmaceutical industries,and it is highly recognized by these industries.

Key Products

High Shear Granulator Machine P 100 and 150
High Shear Granulator Machine PVAC – 10
High Shear Granulator P Machine 1 – 6

Recommend Reason

SERVOLiFT LLC provides complete service to customers,from consulting and designing to manufacturing,installing,training and maintenance,the company will always at your side.
SERVOLiFT LLC has served for many famous international companies and established cooperation with them,which means this company is very reliable,you can trust it in confidence.
SERVOLiFT LLC provides solutions and equipment for customers from the whole world,it supplies over 10,000 machines worldwide a year,which means the company has a certain strength and influence.

2. Cumberland

CONTACT THIS COMPANY NOW

Headquarter: USA

Company Background & Information

Cumberland was established in 1939,it is famous by providing high quality granulator machines and shredders,which are widely used in plastic processing,chemical industries.Now,Cumberland is one of the global leadership in granulator machine manufacturing area,it is renowned in industries.

Key Products

FX1000 Series Beside-the-Press Granulator Machine
T50 Series Central Granulator Machine
B Series Heavy Duty Granulator Machine

Recommend Reason

Cumberland establishes special research and development center,it designs,innovates and tests equipment at here,which improves its machines’quality,let them adapt to the changing market demands.
Cumberland has a team of responsible,professional and experienced employees,who have abundant knowledge,they always give customers the most effective solutions,help customers solve their problems.
Cumberland takes advantages of wide range of products,fast delivery,high quality customer services and cost effective solutions,these are the reason why this company is so popular.

3.Freund-Vector

CONTACT THIS COMPANY NOW

Headquarter:USA

Company Background & Information

Freund-Vector is a processing machine manufacturing company which was established in 1972,it manufactures and supplies equipment which are used for processing materials such as powder,granule,pill,tablet.The company offers granulator machine,coating machine,drying machine,tablet pressing machine and so on.

The equipment which are provided by Freund-Vector are widely used in pharmaceutical,food,chemical,metal and many other industries.

Key Products

GMX-LAB Micro Granulator Machine
GMXB-LAB Micro Granulator Machine
GMX-25Micro Granulator Machine

Recommend Reason

Freund-Vectorhas a bulk of dedicated employees who have much experience and deep knowledge,they work hard to design and produce high level processing machines for customers.
Freund-Vectortakes high importance of quality,it can guarantee its processing machines are high quality and have excellent performance,which can help a lot of industries.
Freund-Vector provides complete production lines,which are more useful than single equipment,and these products all have quality certification.

4. GEA Group

CONTACT THIS COMPANY NOW

Headquarter: USA

Company Background & Information

GEA

GEA Group was established in 1881,until now it has been over 100 years,the company provides all kinds of machines which are used in food,beverage and pharmaceutical industries.GEA Group provides advance technologies and high end equipment for customers,it is well-known in the world.

Key Products

High Shear Granulator Machine
Integrated Granulator Machine

Recommend Reason

GEA Group is a large scale company,it possesses 5 business divisions and 18,000 responsible employees in the world,therefore,the company can help more people who are located in different countries.
GEA Group provides equipment which are widely used in a variety of industries,which include diary,beverage,chemical,environment,food,marine industries,etc.No matter what industry you are in,you will have demand for the company’s equipment.
GEA Group establishes separated technical organizations and research center,which are beneficial for the management of the whole company,therefore,the company is quite reliable.

5.Allpack

CONTACT THIS COMPANY NOW

Headquarter: China

Company Background & Information

Allpack is a leading pharmaceutical and packaging machine manufacturer which is located in China,it has been founded for 12 years,it provides various types of processing machines,such as granulator machines,sifter machines,crusher machines,bin blenders,slicers,grinders,mixers and so on,which can solve many problems.

Key Products

GHL Series High Speed Granulator Machine
GK Series Dry Granulator Machine
HLSG Series High Speed Wet Mixing Granulator Machine

Recommend Reason

Allpack has abundant experience in design and manufacturing granulator machines,its machines are high speed,easy to operate and easy to maintain,also,they have excellent performance and long service time.
Allpack provides high quality customer services,it help customers in the whole cooperation period,it provides good pre-sales and after-sales services,gives customers efficient solutions,and helps customers’businesses.
Allpack ensure on-time delivery,it has its own logistic network,which can send machines to customers quickly,and before delivery,these machines will be tested strictly,so you can fully trust this company.

6. Fluid Air

CONTACT THIS COMPANY NOW

Headquarter: USA

Company Background & Information

Fluid Air is a branch of Spray System,Inc,it was established in 1983,the company focuses on material processing technologies and provides processing machines,it manufactures world class equipment and offer good service.
The company always cooperates with leaderships in pharmaceutical,nutraceutical,food,cosmetic and chemical industries,which establishes its leadership position.

Key Products

PHARMX PX150–PX1250 High Shear Granulator Machine
PHARMX PX25–PX100 High Shear Granulator Machine
PHARMX PX1 High Shear Granulator Machine

Recommend Reason

Fluid Air has locations in different countries in the world,therefore,the company can serve for more and more customers,if you want to buy its machine,it will be pretty convenient.
Fluid Air constantly improves its processing machines according to ISO 9001 Quality Management System Standard,and the company passes other quality certifications,which means its machines are all high quality.
Fluid Air insists of sustainable development,it devotes itself to help customers increase their production capacity with using less raw material,and its machines are durable,can serve for customers in a long-term.

7. Glatt

CONTACT THIS COMPANY NOW

Headquarter: USA

Company Background & Information

GLATT

Glatt was founded in 1949,it is a family-owned company,it is a full-direction manufacturer and supplier of processing technologies and equipment,from powder to tablet,the company can give all kinds of solutions.
Glatt always provides perfect and personalized customized solutions for customers,for the purpose to gain customers’ satisfactions.

Key Products

Glatt High Shear Granulator Machine
Glatt Granulation Line

Recommend Reason

Glatt is the pioneer of new technologies,it has abundant experience and expertise and it insists on innovation,constantly come up with new ideas in processing,this is the reason why Glatt offers world class equipment for customers.
Glatt has 15 divisions and sub-companies in the range of the whole world,its business range is so wide that people from different countries can enjoy the company’s service.
Glatt provides complete one-stop solutions for powder,granule and tablet processing,and then provides excellent processing machines for customers,it takes importance of service and communication,so its customers always choose to cooperate with this company in long-term.

8.GlobePharma

CONTACT THIS COMPANY NOW

Headquarter: USA

Company Background & Information

GlobePharma was created in 1993,its main business is to produce and supply granulator machines,milling machines,tablet pressing machines and so on.Besides providing machines,the company also provides training,maintenance,and other relevant services.
GlobePharma is a company which keeps on innovating and improving,it aims to meet customers’ expectations.

Key Products

High Shear Granulator Machine GP HSG 1-6
High Shear Granulator Machine GP HSG 5

Recommend Reason

As is mentioned,GlobePharma innovates constantly,it improves the quality of its processing machines,let them perform greater in industries,as a result,these machines are preferred by more and more people.
GlobePharma has a 30 years’history,in the past years,the company has accumulated much experience,it has discovered many technologies and has designed a large number of new models of machines,in other words,this company is worthy to trust.
GlobePharma offers comprehensive customer services,such as training,maintenance,repair of the machines,which help customers a lot,that is the reason why this company gains many rave reviews.

9.Rapid

CONTACT THIS COMPANY NOW

Headquarter: Sweden

Company Background & Information

RAPID

Rapid Granulator was established in 1942,it is a company which is specialized in designing and manufacturing granulator machines and shredders,it provides a variety of models of the two types of machines.The company conforms to sustainable development principle,so it always provides customers with recycled solutions.

Key Products

One CUT PRO Granulator Machine
200 Series Granulator Machine
400 Series Granulator Machine

Recommend Reason

Rapid Granulator is specialized in producing granulator machines and it has 80 years’experience,it applies the newest technologies into its machines so that they are high quality and durable.
The granulator machines which are manufactured by Rapid Granulator are designed compact and modern,they have high level appearances and perfect performances.
Although Rapid Granulator’s headquarter is located in Sweden,it has many distributors in countries of each continent,which means it can supply granulator machines and shredders to customers who are in different countries.

10.XERTECS

CONTACT THIS COMPANY NOW

Headquarter: Germany

Company Background & Information

XERTECS

XERTECS is a company that serves for pharmaceutical and chemical industries,its main business is to provide processing solutions and equipment for customers.

As the picture shows,this company is a brand under ACG Group,it is a new company in the industry,but because of its rapid development,now it is a leading manufacturer in this area.

Key Products

XERTECS High Shear Granulator Machine

Recommend Reason

XERTECSconforms to customer-centre principle,the company takes this principle as its core mission,therefore,it provides good customer service,helps customers improve their production efficiency and reduce their cost.
XERTECSpossesses a team of dedicated and responsible employees,who have strong service awareness,they try their best to provide the most effective solutions to customers.
XERTECSpossesses advance technologies and high flexibility,it keeps on innovation,aims to improve its processing equipment.
XERTECSis active in all over the world,it conducts its business in many countries,which means there are more people can gain its service and processing machines.

Conclusion

After reading this blog,do you have a deeper realization of the top 10 global granulator machine manufacturers?Which one do you think is the best?To be honest,these 10 manufacturers are all believable and renowned,each one of them will be beneficial to you.Hope you can find your satisfied manufacturer,and if you have other questions,welcome to contact us.

Don't forget to share this post!

CONTACT US

Tell us your raw material and project budget to get quotations within 24 hours.

WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Granulator Machine from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

Top 10 Global Granulator Machine Manufacturers:The Ultimate Guide In 2024 Read More »