Knowledge Base

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 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%.

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 unable to be spheronized into the required size or shape.

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 what you want to achieve with your project. 

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.

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 products produced by these processes can be called spheroids, spheres, micro-spheres, pellets,...

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...

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 a single system that will fit all needs.

Find out what you need to consider.

 

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 products.

The granulator/mixer

The mixer attachment blades thoroughly mix the liquid binder with the...

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 slightly larger than an A3 piece of paper, makes the CML a welcome addition to any lab space that...

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 you need them.  This adaptable and future proof suite of equipment will allow you to obtain...

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 phosphate composites for bone regeneration.  

 

Caleva Mixer working in catalyst application for Ethylene and Propylene

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

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 extruder we offer is the Caleva Multi Lab (CML) with an extruder attachment designed to work with...

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 quality of pellets including formulation (moisture content, granulating liquid, excipients, and...

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!

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 and the mixing regime used. The concept of “granulation end point” is recognised but there is...

The unique Caleva Multi Lab - Update - Now Available

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