Mixing, Extrusion and Spheronization for Chemical R&D

Developing a promising catalyst, adsorbent, Metal Organic Framework (MOF) or advanced material is only part of the challenge. Before meaningful performance testing, scale-up studies or process evaluation can begin, researchers often need to transform powders into robust, representative extrudates, granules or beads.

Many chemical formulations contain abrasive, difficult-to-process or high-value materials, making formulation development both technically challenging and expensive. Caleva's laboratory mixing, extrusion and spheronization solutions are designed to help scientists produce representative samples using minimal material, enabling rapid formulation optimisation, process evaluation and more confident scale-up decisions.

Whether you are developing catalysts, adsorbents, MOFs, zeolites, carbon capture materials, advanced ceramics or battery materials, Caleva provides flexible laboratory scale equipment to investigate processing parameters, extrudate geometry, granule robustness and quality before moving to larger scale production.

Working with abrasive chemicals, catalysts, MOFs, adsorbents or zeolites?

Many chemical formulations can accelerate wear of conventional laboratory equipment shortening service life, increasing maintenance requirements, and compromising process consistency and data accuracy. Explore the Caleva Chemical Kit, specifically designed for demanding chemical formulations.

Featured Research

Caleva equipment used in published MOF pelletisation research

Researchers at Zhejiang University used a Caleva Multi Lab to produce mechanically robust Metal Organic Framework pellets for greenhouse gas capture and separation studies, published in Nature Communications. The work demonstrated how advanced powder materials can be transformed into beads suitable for continuous process evaluation while preserving adsorption performance.

Reported outcomes:

Industrially relevant bead production
Excellent mechanical stability
Preservation of adsorption performance
Continuous process suitability
99.91% SF₆ recovery
99.91% SF₆ purity

Why Shape Advanced Materials?

Many advanced materials demonstrate exceptional laboratory performance in powder form but require shaping before meaningful process evaluation can begin. Caleva's extrusion and spheronization systems help researchers bridge the gap between material discovery and industrial application by producing representative extrudates and granules using minimal quantities of valuable material.

Benefits of Wet Mass Extrusion and Spheronization

Wet mass extrusion and spheronization is a proven process for producing robust, uniform extrudates and spherical beads. Compared with alternative shaping methods, screw extrusion provides excellent control over extrudate outcomes, allowing formulation scientists to optimise extrudate quality, geometry and processing parameters in their formulation development.

Consistent Product Geometry: Produce extrudate and beads or granules with a more uniform size and shape, improving repeatability during formulation development and downstream processing.
High Mechanical Strength: Create robust extrudates and beads with low friability, reducing dust generation and material losses during handling, drying and transportation.
Improve Flowability and Handling: Convert difficult powders into representative test samples of free-flowing extrudates or pellets that are easier to process, transport and evaluate.
Increase Surface Area: Interchangeable die faces allow cylindrical, trilobe and quadrilobe geometries to be evaluated to optimise surface area and performance.
Formulation Flexibility: Multiple powders and functional materials can be combined into the same extrudate or bead.
Enhanced Catalysis: Wet, cohesive and abrasive formulations can be processed effectively using appropriate screw, barrel and die configurations, allowing representative samples to be produced for further testing and scale-up.

Whether developing catalysts, adsorbents, MOF extrudates or other advanced chemical formulations, wet mass extrusion and spheronization provides a reliable and repeatable method to create representative laboratory scale samples. Caleva's range of extrusion and spheronization equipment enables researchers to investigate their processing variables with confidence.

Caleva Equipment in the Chemical Industry

Designed for formulation development and process optimisation, our bench-top systems enable you to investigate the influence of processing parameters, die geometry and material characteristics before scale-up.

Engineered for abrasive materials

Many chemical formulations contain abrasive materials that can accelerate wear of conventional extrusion equipment. Caleva's chemical extruder for the Multi Lab system utilises a hardened 17-4 PH stainless steel screw and grooved extrusion barrel, providing improved durability and flow characteristics when processing catalysts, ceramics, zeolites and other demanding formulations.

Flexible process development

Interchangeable die faces allow formulation scientists to investigate different catalyst geometries. Evaluate cylindrical, trilobe and quadrilobe die designs to optimise for pressure drop, external surface area, mass transfer and reactor performance.

Small batches. Lower development costs*.

Many chemical formulations rely on scarce and expensive materials. Caleva's bench-top equipment is designed for small batch processing, allowing proof-of-concept studies and process optimisation to be carried out while minimising material consumption, waste, laboratory space and development costs.

Reduced motor load

The optimised blade profile in the Chemical (Sigma) Mixer maintains effective mixing performance while reducing strain on the drive system, helping to minimise mechanical stress and support longer motor life^.

More efficient material transfer

Twin-flight pressing cams in the Chemical Screw Extruder create dedicated transportation and processing zones, promoting more consistent material flow and improving extrusion performance with challenging formulations^.

Modular equipment that grows with your project

Not every application requires spheronization. Caleva's modular Multi Lab platform allows researchers to configure their system with only the attachments required for their process, whether that is mixing and extrusion alone or a complete mixing, extrusion and spheronization workflow. Additional attachments can be added as project requirements evolve, protecting your investment and reducing unnecessary upfront costs.

*Formulation dependent

^Compared to standard Caleva mixer and extruder attachments

Chemical Extrusion Set Top Angle 1000px

Sigma Mixer Water Jacketed Bowl-1

Using the CML and MTR in combination we’re learning a lot about our catalyst material. The machines are easy to use, and we have achieved very accurate measurements, giving us precise repeatability. The MTR has been a massive advantage in our research and we’re doing things with the material we didn’t think were possible. The speed and ease of use have allowed us to conduct numerous experiments in a single day - we’ve accumulated vast amounts of data to inform our scale up.
IGTL Technology LTD

The quality of the first batches was great and we are positively surprised by the ease of use and time saved making the beads.
Department of Chemical Engineering Imperial College London

When transferring a new technology from R&D into production, process flexibility and equipment adaptability are key. Caleva was a true partner, working with us to find a creative solution to a difficult engineering problem.
Erik Koep Chief Executive Officer at Worn Again

In pig iron manufacturing, the physicochemical properties, such as particle-size distribution, wettability, and porosity, of raw powders often vary. This results in a large variation in the optimum water content for wet granulation of fine iron ore powders. We have demonstrated that the optimum water content for wet granulation of fine ore powders can be determined using the MTR, even when the raw ore powders varied.
Dr Nakamura Osaka Metropolitan University

Caleva were extremely nice and knowledgeable through presenting new technology and reliable products that achieve our client’s needs and satisfaction.
Qusay Kareem Knowledge House Engineering Supplies

MTR Pouring MCC Into Bowl

Published Papers

Read published papers featuring Caleva equipment in the chemical industry.

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MTR in the lab-5

Knowledge Base Articles

Read articles and real-life case studies featuring Caleva equipment in the chemical industry.

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Chemical Extrusion Set Top Angle

Chemical Kit

Engineered to address the challenges of processing tougher, more abrasive materials, the Chemical Kit combines specialist mixer and extruder components designed to minimise wear, extend component life, and deliver reliable, repeatable processing of challenging materials.

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Caleva - 002 SK S

Multi Lab Scientific (MLS)

R&D teams can find raw materials to be scarce or expensive during proof-of-concept resulting in high costs. The MLS uses small batch technology and accurate data processing to help reduce costs and increase return on investment.

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Caleva - 038-48

Shaped Dies

Caleva shaped dies are designed to increase the surface area of extrudate and can be engineered to increase the density. They are made from hard wearing 17-4ph Stainless Steel.

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Caleva MTR

Mixer Torque Rheometer

Replace the subjective 'hand squeeze' or 'snowball' test with precision data. Remove the guesswork, accelerate and enhance your R&D and maintain quality and protect yields in your production line.

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