Knowledge Base

Does the Caleva Mixer/Granulator/Blender allow me to mix and test small batches of product?

We are frequently asked for information about the ability of the small mixer/granulator/blender, a must have tool for any laboratory needing to complete these processes quickly with small sample sizes. Recent trials provide new information about the capability of the Caleva mixer/granulator/blender (MGB) and its ability to act as a stand alone mixer when mixing powder samples of different...

Book a live online demonstration with Caleva

Are you interested in one of our products and would like to see it in action?

We provide free R&D system demonstrations live online via video conference wherever you are in the world.

Scott Humphries or Steve Mate (or both) will explain and demonstrate advanced equipment features and allow you to see the processes that you'd like to see and that are relevant to your work. It will be an ideal time...

Increase Surface Area of your product with Trilobe and Quadrilobe Dies

An opportunity to shape and form catalyst materials/particles

Caleva have had some considerable success with working with the extrusion 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 Multi Lab base machine)

Caleva Study on the Importance of Granulation

Our customer, a major pharmaceutical, biotech & nutraceutical manufacturer with an extensive portfolio of products. For reasons of confidentiality we do not name them.

One of our Production Extruder & Spheronizer Systems for manufacturing on a large-scale was used in trials by the manufacturer, but the pellets produced were not acceptable. As the product was already registered, the...

Production Capacity Estimates for Extrusion and Spheronization Systems

We are often asked about the production capacity of our extrusion and spheronization systems. To provide this information there needs to be an understanding of the process parameters that will be used and that have been determined at the development stage. With that information, the advice that we give can be both meaningful and useful in the planning stages.If you have proven your concept at...

A Brief Non-Technical Guide To Spheronization (Marumerization*)

What is Spheronization?

Spheronization is the process where extrudates (the output from an extruder) are shaped into small rounded or spherical granules. In practice these usually vary in size from 0.4 to about 3.0 mm. The use of these spheroids can be relevant for a wide variety of industries.

Why Consider Spheronization?

The products produced from this process can be useful in several ways:

Shaped Catalyst Body Preparation with MTR and Caleva Screw Extruder

 Shaped Catalyst Body Preparation. Zeolite HZSM-5 (ACS Materials, M38) was mixed as a dry powder with alumina (Sasol, Catapal D (Boehmite)) and the required amount of Milli-Q water to ensure an optimum solid-to-liquid ratio for extrusion (measured using a Mixer Torque Rheometer, Caleva). The paste, containing a ratio of 70:30 wt % zeolite:binder, was extruded using a Mini-Screw Extruder...

Caleva explain the basic Mixer Torque Rheometer concepts - Video

The MTR can process from 10g to 25 g of your material, depending on the formulation, meaning barely any material is wasted in experiments.  The machine will very quickly tell you the ideal amount of liquid to add.  The user may have a start point in mind but this may result in a formulation that is too wet or too dry.  The iterations may be repeated, but this can be wasteful in terms of...

Extrusion of small batches

The Caleva Multi-Lab (CML) can Mix/Granulate, Extrude and Spheronize all in one base unit.

This article is about the Extruder attachment that comes with the CML.

The Multi-lab is capable of working with a variety of materials from catalysts and pharmaceuticals, to agricultural products.

The Extruder

The extrusion attachment on the CML is in the form of a single screw extruder.  A variety of...

Possible issues with extrusion of small samples - how to resolve them

It is not possible to extrude and spheronize everything.  Extrusion and spheronization can be used on a wide range of products and formulations.  However, if you are having trouble extruding your formulations with the Caleva Multi Lab (CML) then please read this article.

Caleva offers extruder screws of different designs for use with the CML.  If you are having issues with the CML then the...

Opportunities for Mixer Torque Rheometry

Wet granulations are a useful precursor to many solid dosage formulations and as such are widely used in the pharmaceutical industry. Because of the diverse nature of pharmaceutical materials, granulation is often employed as an intermediate process to enhance flow and compaction properties and improve the final product performance. The properties of a wet granule have a critical effect on the...

How much product should be used in the MTR and how accurate is it?

How much product do you use?  The answer is that this is always product specific. This is demonstrated in this article.  In these experiments the MTR is used in the multiple addition mode whereby increasing binder content is automatically added to different masses of product.  The Caleva Mixer Torque Rheometer. The only way to quantify the rheology of a wet mass.  The MTR has, for many years,...

Can temperature during granulation influence formulation consistency?

The temperature of the mix during granulation processes is generally considered to be of minor significance in both formulation development and in large batch granulation despite the fact that in some locations ambient temperature can change significantly during the course of a working day.The MTR manual states that the bowl should be allowed to return to room temperature after washing. The...

A Tool For Preformulation Assessment Of Excipients

 

Excipients from different batches or vendors may be variable in quality and it is often necessary to perform pre-formulation assessment for each batch of excipient received. In some cases, excipients from different vendors require comparative assessment of their equivalent functionality. In this type of assessment, the MTR can be an invaluable tool to evaluate the potential performance of...

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