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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 fluid bed coating and fluid bed granulation processes.

New Innovations :
Machine + : One machine for granulation, blending and extrusion and spheronization. (batch sizes from 100 gms to 20 Kgs./ batch or more high throughput available on request)

The centre of the Umang Pharmaceutical Systems services has developed small scale and R&D approach is Machine+. This innovative system provides a unique benefit to the Pharmaceutical Development industry, integrating a single Control Unit with a wide range of Process Modules like high shear mixing from 100 gms./batch capacity to 20 kgs./ batch, pelletizing, extrusion and spheronization.

Pharmaceutical Pellets offer many additional features compared to conventional tablets. Umang Pharmaceutical Systems is able to offer all the typically used pelletization processes like mixing cum extrusion, screw extrusion, radial extrusion, pressure extrusion, basket extrusion, radial extrusion, cone extrusion, dome extrusion, die roller extrusion, etc. and assist with the selection of the process that best suits your needs and products, we at Umang pharmaceutical services have around 100 pellet products that we manufacture for sale to our customers, we not only give the machines, but the pellet technology and products with technology transfer too.

Extrusion and Spheronization :
Pelletization by extrusion and spheronizing extrudates into round pellets.

The UMANG 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 / cone extruder / pressure extruder / basket extruder. The extrusions are fragmented and formed into pellets in the spheronizer.

We have single and twin spheroidization options possible in the integrated system, for high throughput systems we recommend single extruder and twin spheronizers with twin bucket assembly for feeding the spheronizers.

Features:
  • Continuous process one bucket is filling at one time and the other is discharging the product into the other spheroinizer.
  • Fast throughput process
  • Easy to up-scale from a lab scale to production scale
  • Stand alone units but also fully integrated systems available called the Integerated Pelletization series.
  • Very high drug loads possible due to special extruder design we have typically achieved 95% drug loads using various extrusion systems we make.
  • Integration with up-stream equipments like high shear mixers and downstream equipments like fluid bed dryers / processors / coaters is possible.
  • We also assist with a Pellet line : where we install the complete line for customers from powder mixing to blending and packaging.


  • Applications:
  • Forming of extrudes / pellets between 0.4 mm and 3 mm diameter.
  • Capacity up to 600 kg/hr


  • Benefits:
  • Fast process.
  • Robust process.
  • Uniform pellet size.


  • Liquid layering of pellets :
    Layering a drug onto starter pellets

    The multi-functional fluid bed rotor and fluid bed 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 the active material, and dried simultaneously.

    Features:
  • Continuous process.
  • Fast throughput process
  • Easy to up-scale from a lab scale to production scale
  • Very high drug loads possible due to special extruder design we have typically achieved 95% drug loads using various fluid bed processing systems we make.
  • Integration with up-stream equipments like high shear mixers and extrusion and spher'oidization is possible.
  • We also assist with a Pellet line : where we install the complete line for customers from powder mixing to blending and packaging.


  • Applications:
  • Forming of extrudes / pellets between 0.1 mm and 3 mm diameter.
  • Capacity up to 600 kg/batch


  • Benefits:
  • Fast process.
  • Robust process.
  • Uniform coating.


  • 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, UMANGs technology has automated sensors to control the liquid spray and powder spray on the starter core, this eliminates manual handling of the process and makes it robust and . The layered pellets are then dried and taken for further coating processes like sustained release, enteric coating, etc.

    Features:
  • Continuous process.
  • Fast throughput process around 1 / 10th of a fluid bed coating process.
  • Easy to up-scale from a lab scale to production scale.
  • Very high drug loads possible due to special extruder design we have typically achieved 600% drug loads using various configurations in the equipment.
  • Integration with up-stream equipments like high shear mixers and downstream equipments like fluid bed dryers / processors / coaters is possible.
  • We also assist with a Pellet line : where we install the complete line for customers from powder mixing to blending and packaging.


  • Applications:
  • Forming of layered pellets between 0.2 mm and 3 mm diameter.
  • Capacity up to 240 kg/batch


  • Benefits:
  • Fast process typical batch time for 100% loading 30 minutes.
  • Robust process.
  • Uniform pellet size.


  • Melt granulation pelletization by HOT MELT EXTRUDER :
    Pelletization by heating and massing a powder mixture

    Melt extrusion is performed in the HOT MELT EXTRUSION. 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 machine which is twin screw hot melt, UMANG has a dozen of systems in operation for hot melt granulation, cooling and cutting of the granules into desired form and shape.

    Features:
  • Very fast process
  • True One-Pot operation
  • Special polymer liners to minimize sticking
  • Controlled heating.


  • Applications:
  • Forming of pellets between 0.5 and 5 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.


  • Fluid Bed Rotor Pelletization :
    Granulating and spheronizing a powder mixture to make micro spheres

    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 FLUID BED ROTOR

    Applications:
  • Forming of pellets between 0.1 and 0.5 mm diameter. Possible to acheive extremely round pellets. Capacity up to 150 kg/batch.
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