Granulations (Dry and Wet)
We specialize in powders for nutraceuticals and pharmaceuticals.
Compaction & Granulation
Compaction:
The primary goal of compaction is to increase the density of bulk materials. Small, fine particles are compressed into larger particles, and any air fractions in the material are removed, resulting in lower volumes.
Roller compaction is an efficient method where bulk material is compacted by two counter-rotating rollers. Depending on the material’s plastic deformability, this process can produce endless slugs or fine needle agglomerates, such as during the compaction of silicates. Afterward, the slugs are comminuted into granules of the desired shape. The result is bulk materials with higher densities and improved flow properties.
Granulation:
Granulation is used in nutraceutical applications to transform fine, poorly flowing powders into larger, more manageable particles called granulates. In the pharmaceutical industry, granulation is crucial for achieving good meterability of bulk materials, which allows for easier tablet formation in subsequent processes.
There are two main methods of granulation:
Wet Granulation
Weighing & Mixing: Ingredients (active and excipients) are mixed together to ensure uniformity.
- Binder Solution: A liquid binder (water or alcohol-based) is prepared.
- Adding Binder: The binder is gradually added to the powder mixture, causing particles to agglomerate into larger particles (granules).
- Wet Massing: The mixture is stirred or mixed to enhance granule formation.
- Granulation: The wet mass is processed through a granulator to form uniform granules.
- Drying: The granules are dried in our fluid bed dryer to remove excess moisture.
- Sieving: Dried granules are screened to achieve consistent size.
The process improves blend uniformity, helps powder fit into capsule because of increased density of powder, increase flowability, compressibility, and uniformity for tablet or capsule production.
- Poorly flowing powders that need improved flowability and density.
- Ingredients that require better compressibility for tablet formation.
- Poorly mixed ingredients that need improved uniformity and consistency.
- Heat-sensitive actives (with controlled moisture and drying processes).
- Granules that require coating, encapsulation, or improved size consistency.
- Compaction: Powders are compressed under high pressure to form a solid mass, typically using a roller compactor or tablet press. This step is crucial for creating the initial granules.
- Milling: The compacted mass is then broken down into granules using an integrated milling process. This step results in particles with a uniform size and shape.
- Screening: Granules are sifted (3 size sives) to remove fine particles and oversized granules, ensuring the desired particle size distribution.
- Recycling: Any fines or oversized granules are recirculated back to the compactor for further granulation using a pneumatic conveying system.