Back

Do I need a water jacket for cooling on a screw extruder?

The extruder attachment on the Caleva CML does not have a water jacket. Does it need one?

All extruders generate heat and screw extruders generate more than most other extruder types. For this reason, water jackets are generally an integral part of single or twin-screw extruders. 

  • Given the small batch sizes (10 to 100 g) that are optimum for the CML extruder, a well formulated extrudate will not generate excessive temperature over the course of a single extrusion as this phase of the entire process is completed in a relatively short time.
Extruder-assembly-for-Caleva-Multi-Lab

 

  • If the extrudate does not flow easily through the die this has the potential to generate excessive additional heat (this is formulation dependant). With some difficult formulations, excess heat can be generated even at this stage.
  • If this happens in these small experimental batches then this is a clear signal that the formulation would not likely be suitable when scaled to production or larger batches. If this happens to you, then you should consider modifying the trial formulation in some way to reduce excessive heat generation.
  • The use of a cooling water jacket could mean that this important information is not revealed to you during the development phase.
  • By using the Multi Lab, you can determine if the formulation under test is likely to be suitable for scale up. If excessive and unacceptable heat is generated at this early stage then the formulation is likely to be difficult to scale-up in an unmodified form.

To summarise:

A water jacket for cooling as a standard part with the screw extruder attachment on the CML is not recommended.

 

If you're interested in this system, you can contact us here.

Or for further reading on the Caleva Multi Lab, you can visit this page.

 

By Dr Steve Robinson
29 Oct 2020 in Formulation Development

Leave A Comment

Formulation development with Caleva

The process of spheronization consists of four key steps:- To optimize and achieve the right binder addition  & mixing time for your formulation Mixing or granulation - a mixer or granulator is required Extrusion - an extruder is required Spheronization - a spheronizer is required Drying and pos... Read More

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 t... Read More

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 manufactur... Read More

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 ... Read More

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... Read More

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 screw... Read More

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 impr... Read More

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 ... Read More

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. Read More

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... Read More

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. Read More

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 n... Read More

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. Read More

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. The consistency of the mix is measured at regular periods so that the relationship between the amount of liquid binder added to the mix and the consisten... Read More

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 t... Read More

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.    Read More

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. Read More

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. Read More

Should I use spheronization or layering to manufacture pellets?

There are two main ways to make small pellets for drug delivery: Drug layering onto inert starter (or seed) pellets that are bought commercially 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. ... Read More

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 ... Read More

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%. Read More

Developing a formulation with a tough waxy cosmetic material

We recently had a visitor from Asia who was trying to solve a problem with their cosmetic formulation. The investigator wished to have approximately 1 mm diameter pellets. The formulation presented was a tough, waxy material in irregular broken blocks that were up to about 10 mm in diameter and was ... Read More

Can I spheronize a granulation and skip the extrusion process?

In some circumstances it is possible to omit the extrusion stage, but the results may not be what you need. It is dependent on what you need to achieve with your result and what you want to do in the next phase of the project. Whether or not you decide to include the extrusion stage will depend on w... Read More

A better therapeutic effect with spheroids

In many cases the main reason for the use of pellets in the manufacture of products is for its controlled release properties. However there are reasons to believe that pellets or spheroids in any case can offer a superior therapeutic effect even when modified release is not the prime objective. Read More

Examples of the terminology used in spheronization and marumerization

Spheronization, marumerization, pelletization and micropelletization all mean the same thing. The manufacture of products in small spheres (spheroids) for use in pharmaceutical (pharma) and catalyst industries. Within each batch the spheroids are of regular shape and size and are quite dense. The pr... Read More

Do I need a water jacket for cooling on a screw extruder?

The extruder attachment on the Caleva CML does not have a water jacket. Does it need one? All extruders generate heat and screw extruders generate more than most other extruder types. For this reason, water jackets are generally an integral part of single or twin-screw extruders.  Given the small ba... Read More

How do I decide which laboratory extruder and spheronizer I need?

We are often asked for advice by researchers and teachers who want to acquire laboratory equipment for the development of both formulations and processes using the techniques of Extrusion and Spheronization in the laboratory.  All users are individual and have different requirements and there is not... Read More

Mixing and granulating small batches

The Caleva Multi-Lab (CML) is capable of performing 3 different processes: Mixing, Extrusion and Spheronization. This article is about the mixing and granulation phase of the process. The multi-lab works with a large range of materials from pharmaceutical materials and catalysts, to agricultural pro... Read More

Mix, Extrude & Spheronize in a single base - watch a video

Call Caleva's friendly team to talk about this unique solution for your applications, whatever your challenges are.   The Caleva Multi-Lab (CML) is often considered to be the flagship of Caleva lab equipment. Being able to perform 3 different processes rapidly in one machine with a footprint just sl... Read More

The Caleva Family of Laboratory Equipment

Whilst you may have heard of Caleva and any one of its flagship pieces of equipment, we'd like to introduce you to the family of Caleva laboratory equipment that you may find helpful for your application in your industry sector.  Choose one process or choose all of them.  Select further functions as... Read More

Caleva Multi Lab & Bone Regeneration study Medical University Gdańsk

Drug-loaded mesoporous silica/calcium phosphate composites for bone regeneration Adrian Szewczyk at Department of Physical Chemistry, Faculty of Pharmacy, Medical University of Gdańsk has kindly allowed us to introduce this paper that introduces a study of Drug-loaded mesoporous silica/calcium phosp... Read More

Caleva Mixer working in catalyst application for Ethylene and Propylene

Components were mixed with a specialist Caleva mixer to form a homogeneous paste Read More

How can I be sure that the trials and development work that I do will give me comparable results when I need to scale up to production sizes?

Scale up of the spheronization process is relatively well known and understood. All of the Caleva extrusion and spheronization equipment is designed with scale up in mind. Our range of screw extruders have the ability to modify the density of your extrudate when this is important. The smallest extru... Read More

Extrusion–spheronization a promising pelletization technique: In-depth review

Abstract This review article deals with various aspects of the extrusion–spheronization technique. The first part includes different steps in the production process of pellets such as granulation, extrusion, spheronization, and drying. In the second part, the parameters which can influence the quali... Read More

Catalyst Pellets cracked! The strange apple sauce method

Over the past couple of years I have worked with a huge number of chemical engineering teams, trying to crack the optimum base for a catalyst pellet. After hours of trials and research, I am pleased to say, we’ve done it! Read More

Caleva Mixer Torque Rheometer - The importance of mixing time for your formulation development and production

It is well established and understood that one of the most important factors in the development of a formulation for both tableting and making pellets by extrusion and spheronization is the amount of liquid binder added to the formulation. What is less widely acknowledged is the importance of mixing... Read More

The unique Caleva Multi Lab - Update - Now Available

Update: Now shipping as fast as we can make them! Read More