Knowledge Base

Extruder dies | all sizes | variable density | quadrilobe | trilobe

In the process of extrusion, having different dies available to process your product is key to increasing your chances of development success.  This is why we offer a large range of dies to allow us to work with you to find the dies that best fit your formulation needs.

We offer die plates that are excellent for most uses, like our 1 x 1 mm die, however sometimes a more specialist die may be...

A better way to granulate with your viscous and sticky materials

Our new High Viscosity Mixing Blades, designed for making those sticky, viscous, difficult, granulations much simpler.  Our design team have been working tirelessly to come up with a solution to a constantly asked question. 

Extrusion of catalyst and petrochemical materials

An opportunity in laboratory extrusion with catalyst material.  We have recently had some considerable success with one of our customers working with the extrusion of small quantities of catalytic material.

Extruding catalyst materials for petrochemical and adsorption products

In collaboration with some of its users, Caleva have recently been successful in extruding of small quantities of catalytic material using the Caleva Multi Lab (the first steps of blending and mixing can also be completed in the same multilevel base machine) whilst increasing the surface area/volume ratio of the extrudate produced.

The Caleva Multi Lab is faster and easier to clean

The Caleva Multi Lab (CML) is faster and easier to clean than any comparable bench-top extrusion & spheronization equipment

The best results in the minimum time for your formulation development

 

Guide to the optimum diameter to length ratio of extrudate fragments

Is there a guide to the optimum Length to Diameter ratio of the extrudate fragments?

In the calculations used to demonstrate the data it is assumed that the extrudate is an infinitely long strand. In this case the length of the extrudate has no influence on the data shown. In reality, extrudate is not infinitely long and as the individual strands of the extrudate produced become shorter, the...

How long should I granulate my materials?

Variable Mix Time Test

It is well-known that a minimum amount of mixing is required to ensure consistent and repeatable product characteristics. What is often less considered is the possibility of over-mixing the product so that the characteristics of the resulting formulation undergo a change.

How do I ensure consistency during scale up?

Consistency Measurement

A direct consistency measurement of a small sample (generally around 40 g) taken from a process as it is ongoing.  This allows for accurate comparisons to be made quickly, accurately, and repeatable way.

Formulation development - determine optimum powder to binder ratio

Multiple Addition Test

Binder liquid is added to a dry powder mix and the consistency is measured as the mixing and addition of binder progresses.

What type of pharmaceutical or catalyst extruder do I need?

All extrusion processes require the generation of pressure within the material to be extruded. When materials are put under pressure heat is generated. This cannot be avoided but different extrusion types generate different amounts of heat. There are basically three different types of extruder and the one chosen may have far reaching implications on production operations. It is important that...

What pharmaceutical products or drugs can I make in pellet form?

A list of suggested uses for pellets in pharmaceutical applications. 

We are working closely with many partners in a wide variety of industries as well as pharmaceutical. The industries where we are helping our customers to make pellets and extrudates are listed below. 

 

What is the smallest particle that I can coat in the Mini Coater Dryer

The Caleva MCD was originally designed for coating of very small batches of tablets. The original Mini Coater Drier was very efficient at this. However, as a response to several user comments and requests a new version was designed to allow users to also coat small samples of pellets over a range of industries.  The original improved design specification that users were requesting was that...

What characteristics should my extrudate have?

Extrusion and spheronization is not always completely straightforward.  A formulation required for spheronization needs to go through the following processes and achieve the following properties.

What are the standard processes in the manufacture of pellets?

Wet Granulation - Granules are formed by the addition of a granulation liquid onto a bed of powder under the influence of an impeller. This is typically carried out using a high-shear granulator or a simpler planetary mixer.

Should I use spheronization or layering to manufacture pellets?

There are two main ways to make small pellets for drug delivery:

  1. Drug layering onto inert starter (or seed) pellets that are bought commercially
  2. Extrusion and spheronization binding the active material in the substrate of the pellet from the beginning

There is no right or wrong way to make pellets. The most appropriate method for your particular application will depend on what you are trying...

Coating large tablets in the Mini Coater Drier

Our general tablet coater literature describes the coating capability of a tablet size of up to 10 mm. However, this refers to a diameter rather than a capsule style design in length. The Mini Coater Drier is incredibly versatile and really the limiting factor is generally a weight issue as opposed to size. It’s important to consider weight/batch size to ensure a good coating motion within the...

Formulation development of catalyst materials zeolite and bentonite?

We always offer our potential users the opportunity to test their formulation with us in our lab. This is to ensure that installing our machines would be the right decision for their formulation development, and/or their production environment.

This short article has been written from notes that Dr Steve Robinson made during trials with catalysts sent to us by a customer and we achieved some...

Do I need to coat my pellets to prevent disintegration or dissolution?

We have been asked by a manufacturer (interested in looking at the development of Omeprazole formulations) if it was really necessary to coat these pellets with an enteric coating. 

Do all extruders and spheronizers have the same level of performance?

Product yields (the percentage of the spheroids produced in a batch that are within the size range required) will never be 100%.

However, it is possible to achieve yields of greater than 98% if the formulation, process parameters and the equipment used are optimised. 

Formulation and process parameters are outside the control of Caleva, but the quality of the equipment used is our direct...