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 dies are available to enable you to change the diameter, shape and density of your extrudate which could be advantageous to your project. The die plates on the extruder are easily interchanged with other die plates.

The Extruder attachment is designed to work with small batches and forms an important part of proof of concept and scale up projects

Benefits of the Extruder:

  • Can process expensive/scarce materials in small batches to prevent waste.
  • Due to it's easy disassembly and reassembly, cleaning the attachment and running the next iteration is a short and time efficient process. (Learn more)
  • Different die plate options are available to allow you to vary the density of your extrudate.
  • The CML is supplied with an additional screw variant to enhance your chances of development success.
  • The CML is supplied as standard with 2 die variants to broaden your research parameters.





What are the hole diameters of the dies being used in the video?

  • 0.5 x 0.5 mm (Top left)
  • 1 x 1 mm (Top middle)
  • 3 x 12 mm (Top right)
  • Trilobe (Bottom left)
  • Quadlobe (Bottom middle)
  • 3 x 3 mm (Bottom right)


For more information on the Caleva Multi lab or the Caleva extrusion range, visit the CML Page, or talk to us directly via the Contact Us page.

If you found this article interesting or helpful, please take the time to share it on LinkedIn.





Talk To Caleva

How to Reduce Your Formulation Development Time

Discover how to cut your formulation development time in half with the Caleva Multi Lab and its wide range of variable density dies. Read More

Do I Need a Screen Extruder or a Screw Extruder?

At Caleva, we offer a variety of extruders to meet your needs, from laboratory scale extruders for research and development purposes, to pilot scale extruders and larger models for batch production environments. Read More

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 machi... Read More

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, c... 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 screws ... 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 help you find the best options for your formulation. We offer die plates that are excellent for most uses, like... 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

Using the Caleva Multi Lab it is possible to extrude of small quantities of catalytic material, whilst increasing the surface area to volume ratio of the extrudate produced. 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

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

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

Trilobe and quadrilobe extruder dies with catalyst adsorption

Can trilobe and quadrilobe extruder dies provide benefits when working with catalysts or products for gas adsorption? Read More

Can the results from very small batches be repeated during scale up?

This range of Variable Density extruders is designed to allow scale up starting from the initial development with the product saving, time saving and flexible Caleva Multi Lab (CML). Moving forward to the manufacture of larger trial batches (kilos rather than grams) the bench top VDE™ would be the p... Read More

Increase the Surface Area to Volume Ratio in the Extruded Material

Can the equipment design help to increase the surface area to volume ratio (SA/V) in the extruded material (extrudate)? Read More

Modify the density, pore size and porosity of the extruded material

The Caleva CML extruder attachment is the smallest in the family of screw driven extruders that can offer the operator the ability to extrude the material at high, medium high, medium low, or low density. By management of the extrudate density physical properties of the extruded material can be infl... Read More

Can I modify the density of extrudate produced during extrusion?

During the formulation development process, challenges related to final product performance have to be examined, exposed and overcome. This is not always easy or straight-forward. However, if you have more options that you can investigate then there is likely to be an increased probability of a succ... Read More

Is there a correctly sized extruder die to get the size of pellets you need?

There is no simple answer to this question as it depends on the characteristics of your formulation and the size of the pellets you require. 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

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