Pellets offer many aditional 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.
NEW Innovations
Tomorrow's technology today
- PharmaConnect™ which enables diverse GEA development equipment to be docked into a single ‘plug and play’ module with full cGMP compliance.
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.
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