Should I use extrusion and spheronization or pellet layering to manufacture spheroids for pharmaceutical and nutraceutical active ingredient or drug delivery?
The main reason the process of extrusion and spheronization a much more widely used technique than layering is the ability to produce quantities of products quickly.
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In development and testing of formulation, new iterations of small batches (from about 30 g) of product samples for testing can be produced in about 30 minutes or so. With layering often several hours are required to make a sample batches for trials. Progress is slow with layering, and development can be prolonged.
This fast v’s slow situation in product development is then carried through to the production operations. A small commercial manufacturing operation can often produce between 50 and 150 kg per hour of dry pellets ready for packing using Extrusion and Spheronization. With the layering process a single batch of 20 to 30 kg might require up to 20 hours of the slow layering process to finish this smaller batch. If significant quantities of pellets are required by layering then a significant amount of capital equipment and space will be needed.