The pelletizing process for the production of pharmaceutical pellets - including extrusion and spheronization, production of pellets by powder layering and liquid layering and pelletization via melt and wet granulation processes.

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  • PharmaConnect™ Processor - batch sizes 100 g to 25 kg (or more)
    Granulating, Blending and Pelletizing
    The centre of the GEA Pharma Systems’ small scale and R&D approach is PharmaConnect™. This innovative system provides a unique benefit to the Pharmaceutical Development industry, integrating a single Control Unit with a diverse range of Process Modules ... learn more

Pharmaceutical Pellets offer many additional features compared to conventional tablets. GEA Pharma Systems is able to offer all the typically used pelletization processes and assist with the selection of the process that best suits your needs.

Extrusion and Spheronization

Pelletization by forming and spheronizing extrudates
The NICA™ Pelletizing System is a turnkey pellet production plant, which combines mixer/granulator, extruder and spheronizer in a single, integrated process. Continuously wet powders pass through a low-shear radial extruder. The extrusions are fragmented and formed into pellets in the spheronizer.

Features:

  • Continuous process
  • Fast process
  • Easy to up-scale
  • Stand alone units but also fully integrated systems available
  • Very high drug loads possible due to special extruder design
  • Integration with up-and downstream equipment possible.

Applications
Forming of pellets between 0.5 and 3 mm diameter.
Capacity up to 300 kg/hr

Benefits:

  • Fast
  • Robust (relatively insensitive to raw material particle size and moisture variations)
  • Predictable pellet size
    Wide range of operation

Liquid layering of pellets
Layering a drug onto starter pellets
The multi-functional fluid bed PRECISION COATER™ and top spray coater systems can all be used to make pellets by layering the active material onto an inert core. Non-pareil starter pellets are sprayed with a solution or suspension of theactive material, and dried simultaneously.

Powder layering of pellets
Layering a drug onto starter pellets
When the active ingredient is in powder form, pelletization can be achieved by spraying starter pellets with the active powder and at the same time a liquid binder solution. The layered pellets are then dried.

Melt granulation pelletization
Pelletization by heating and massing a powder mixture
Melt pelletization is performed in the Aeromatic-Fielder™ PMA™ Pellet Processor or the Collette™ ULTIMAPRO™. The active and binder powders are mixed and heated to a temperature above the melting point of the binder. Granulation and pelletization are then carried out in a single operation.

Features:

  • Very fast process
  • True One-Pot operation
  • Special polymer liners to minimise sticking
  • For melting a heated jacket or optional 'microwave energy' can be used

Applications
Forming of pellets between 0.5 and 2 mm diameter. By selection of the binder material it is possible to form sustained release forms without additional coating.
Capacity up to 150 kg/batch.

Wet granulation pelletization
Granulating and spheronizing a powder mixture
The active substance is mixed with 5-30% microcrystalline cellulose and the mixture granulated with water or an organic solvent. During the process the granules are compacted and spheronized. This operation can be performed using the Aeromatic-Fielder™ PMA™ Pellet Processor or the Collette™ ULTIMAPRO™.

Features:

  • Special polymer liners to minimise sticking
  • Special impeller for optimal pellet quality

Applications
Forming of pellets between 0.5 and 2 mm diameter. Possible to acheive extremely round pellets. Capacity up to 150 kg/batch.

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