Spheronization Equipment
Caleva design and manufacture a range Extruders and Spheronizers (marumerizers) from laboratory development to full scale production.
Typical Spheronization Process:
Spheronization is a rapid, economical and well understood method for making pharmaceutical spheroids. Since extrusion is a necessary first step, this process is often referred to as the "extrusion & spheronization" process. The usual steps in the extrusion-spheronization process are described as follows:
- The powdered pharmaceutical ingredients are mixed and blended.
- Liquid binders are added to the mix to create a semi-wet plastic mass with the proper consistency for extrusion. The venerable "hand squeeze test" can be used to gauge the consistency of the wet mass, however, the Caleva Mixer Torque Rheometer (MTR) can be used to more accurately and consistently quantify the properties of the mix.
- The wet mass is extruded to form a "spaghetti-like" extrudate. The diameter of the extrudate will be the approximate size of the final spheres.
- The extrudate is put into a spheronizer which converts the extrudate into small spheres.
- The spheres are dried and, if necessary, coated.
Advantages of spheronization
- Manufacture of modified, or controlled release formulations.
- Mixing of otherwise incompatible formulations.
- To enable uniform coating and accurate free flow filling into capsules. This application requires consistent smooth surface particles, with a narrow size distribution.
- Aesthetics. Small spheres can be an important marketing and product feature for pharmaceutical, food and cosmetic products.
- Elimination of dust. Spheroids can reduce risks due to toxic, environmental, and explosive hazards.
- To improve processing consistency and productivity by using consistent free-flowing spheres.
- To reduce product settlement in transport and handling.