Granulation
Techniques
Amol P. Suryawanshi1*, Dattatraya
M. Shinkar1, R.B. Saudagar2
1Department of Pharmaceutics,
R. G. Sapkal College of Pharmacy, Anjaneri,
Nashik.
2Department of Pharmaceutical
Chemistry, R. G. Sapkal College of Pharmacy, Anjaneri, Nashik.
*Corresponding Author E-mail: amol2304@gmail.com
Granulation is one of the most important unit operation in the production of pharmaceutical oral dosage
forms. Granulation is defined as the size enlargement process in which fine and
smaller particle are aggregated to form strong and stable particles called
granules. Granulation process improves flow compressibility and content uniformity
of powders this technique helps to achieve improved yields with tablet defects , high productivity along with reduced down time the
present review mainly focused on
granulation techniques and the advantages and disadvantages of the process.
KEYWORDS: Granulation,
Pharmaceutical dosage forms, improved yields.
INTRODUCTION:
Active pharmaceutical compounds (drugs)
are use for the treatment of a disease or for prophylactic purpose. An Active
Pharmaceutical ingredient may exist in solid, liquid or semisolid form. They
are rarely prescribed to the patients as such i.e. without adding excipients, since the desired effect may not be obtained.
Earlier, it was thought that excipients are inert in
nature but, in recent time it is well known that excipients
can greatly modify the intended effect of a drug. The API and excipients are suitably processed in pharmaceutical
industry to convert them into dosage forms such as tablet, capsule, suspension,
solution, etc. The selection of excipients and
processing of drug excipients mixture is as important
as API itself 1.
Granules:
Granules is defined as primary powder
particles get adhere and form larger multi-particles entities having size range
from 0.2 and 4.0 nm and mainly depend upon the use of granules.
Mostly during the production of tablets
and capsules, when the granules will be made as an intermediate product and
have a typical size range between 0.2 to 0.5 mm, whereas larger granules are
used as a dosage form in their own right. Granulation generally commences after
initial dry mixing of the necessary powdered ingredients so that a uniform
distribution of each ingredient through the mix is achieved 2.
Reasons for granulation:
1. To prevent segregation of the constituents of the
powder mix:
Segregation or de-mixing
is due to the differences in the size or density of the components of the mix,
the smaller particles or denser particles concentrating at the base of a
container with the large particle or more dense particles above them. In order
to have an ideal granulation all the constituents of the mix are in correct
proportion in each
granule and segregation of the ingredients will not occur. It is necessary to
control the particle size distribution of the granules because although the
individual components might not segregate themselves, if there is a wide size
distribution, the granules will get segregated by themselves. If this occurs in
the hoppers of machines like sachet-filling, capsule- filling or tablet
machines, products obtained will have large weight variations. The reason
behind this is that these machines fill by volume rather than weight and if
different regions in the hopper contain granules of different sizes (thereby
bulk density), a given volume in each region will have variation in weight of
granules. This leads to an unacceptable distribution of the drug content within
the batch of finished product even if the drug has been evenly distributed,
weight by weight, through the granules 3.
2. To improve the flow properties of the mix:
Large number of powders,
because of their small size and irregular shape or surface characters, are
cohesive and do not flow well. Poor flow often results in a wide weight
variation within the final product due to variable fill of tablet dies, etc.
The granules will be larger and more diametric when produced from such a
cohesive system3.
3. Improvisation of the compaction
characters of the mixture:
The primary powder particles are
difficult to compress even though a readily compactable adhesive has been
included in the mix but granules of the same formulation are often more easily
compacted and produce stronger tablets. Mostly the solute migration which
occurs during the post granulation drying stage results in a binder rich outer
layer to the granules. This leads to the direct binder-binder bonding that
helps in the consolidation of the weak bonding materials 3.
4. Other reasons:
·
Granulation
process is helpful to minimizing the hazards associated with toxic dust
particles during handling, transporting of powders, thus precaution should be
taken.
·
Granules are
generally occupy less volume per unit weight and more denser
than the powder mix, thus more convenient for storage and shipment.
·
Granulation
technique helps adhesion and cake formation of hygroscopic materials. This
occurs because the granules will be able to absorb some moisture and still
retain the flow-ability because of their size 3.
Granulation method:
Granulation may be defined as a size
enlargement process which converts small particles into physically stronger and
larger agglomerates. Granulation method can be broadly classified into
three types1:
·
Wet granulation
·
Dry granulation
·
Granulation
incorporating bound moisture 1
Ideal characteristics of granules:
The ideal characteristics of granules
include spherical shape, smaller particle size distribution with sufficient
fines to fill void spaces between granules, adequate moisture (between 1-2%),
good flow, good compressibility and sufficient hardness.
The effectiveness of granulation depends
on the following properties4.
·
Particle size of the drug and excipients
·
Type of binder (strong or weak)
·
Volume of binder (less or more)
·
Wet massing time (less or more)
·
Amount of shear applied
·
Drying rate (Hydrate formation and
polymorphism
[A] Wet granulation:
It is the most widely used agglomeration
process in the pharmaceutical industry. This process involves the mixing of the
powder with the granulating liquid, wet sizing and drying 5-7 .
a Important steps involved in the wet granulation
b Mixing
of the drug(s) and excipients
c Preparation
of binder solution
d Mixing
of binder solution with powder mixture to form wet mass.
e Drying of moist granules
f Mixing
of screened granules with disintegrant, glidant, and lubricant.
Advantages:
a. Permits mechanical handling of powders
without loss of quality of blend.
b. The flow properties of powder are improved
by increasing particle size and sphericity.
c. Increases and improves the uniformity of
powder density.
d. Improves cohesion during and after
compaction.
e. Air entrapment is reduced.
f. Reduces the level of dust and cross
contamination.
g. Allows for the addition of a liquid phase to
powders.
h. The hydrophobic surfaces are made
hydrophilic.
The granulation effectiveness depends
on the following properties8 :
· Particle size of the drug as well as excipients
· Type of the binder (strong or weak)
· Volume of binder (less or more)
· Wet massing time (less or more)
· Amount of shear applied
· Drying rate (hydrate formation and polymorphism)
Types of Wet Granulation:
i. High shear mixture granulation
ii. Fluid bed granulation
iii. Extrusion- Spheronization
iv. Spray drying
i. High Shear Mixture Granulation:
It has been widely used in various
pharmaceutical industries for blending and granulation (Figure 2) 9-12.
Wet aggregation in a high shear mixer
involves 3 stages:
·
Dry powder mixing
(for 2-5 minutes)
·
Liquid binder
addition(1-2 minutes)
·
Wet massing
Figure 1: Flow chart for wet granulation process
Advantage of this
technique is that even very highly cohesive material can also
granulated.
Figure no.2: High Shear Granulator
ii. Fluidized bed granulation:
Fluidized bed processing is a air suspension technique in which binder solution is
sprayed on to the fluidized powder bed to get finer, free flowing and
homogenous granules. This fluidized bed processor contains air handling unit,
product container, air distributor, spay nozzle, disengagement area, process
filters, exhaust blower/fan, control system, and solution delivery systems 13-18 .
There are two different modes of fluid
bed granulating
a) Wet
stage: In wet stage granulation, the particles require a significant amount of
moisture or granulating solution before they become tacky enough to stick to
each other. The granulating solution is applied t a rate higher than the
evaporating rate until the particles build up enough moisture to granulate.
b) Dry
stage granulation: In dry stage granulation, the particles require only a
slight wetting to become tacky and stick to each other. The granulating
solution is applied at a rate less than or equal to its evaporation rate. Thus,
the particles remain “dry” through the entire process. The particle formation
in fluidized bed granulation is influenced by numerous parameters like
1 Moisture
content in solids
2 Liquid
spray flow rate
3 Airflow
rates
4 Atomization
pressure
Granulation in fluidized state can be
achieved either by batch process or continuous process. For granulation in
batch process, the dry starting product is placed in the product container,
where it is mixed vigorously in the heated gas stream, held in the suspension
and granulated by spraying with a suitable bonding material. The product is
finally dried to the required end moisture content. Continuous granulators are
sub-divide into several granulation zones, which are operated at different speeds
and temperatures. E.g., Granulation in first and second
sections, drying in the third section and cooling at the end of the process
chamber.
Batch process:
Bottom Spray Top spray
Continuous process:
Bottom Spr Top spray
Figure No.
3: Fluidized bed granulation-continuous process
Advantages:
1. Reduces
dust formation during processing.
2. Improves
housekeeping and worker safety.
3. Suitable
for subsequent coating and controlled release products.
4. Reduces
product loss.
Disadvantages:
1. Cleaning isolabour-intensive and time consuming.
2. Assuring
reproducibility is troublesome.
iii. Extrusion- Spheronization:
This is used
as a method to produce multi-particulates for controlled release application. A
multiple step process which involves 5 steps those are capable of making
uniform sized spherical particles. The equipment used for spheronization
is given in the figure 3. Steps
·
Dry mixing of materials of achieves homogeneous dispersion.
·
Wet granulation of the resulting mixture to form wet mass.
·
The extrusion of wet mass to form rod shaped particles.
·
The rounding of the particles in spheronizer.
·
Drying of the round particles.
These dried
particles are then screened I order to achieve a targeted mean size
distribution 19.
Advantages:
·
More than two active agents can be easily combined in any ratio in the
same unit.
·
Various physical characteristics of the ingredients and excipients can also be modified but using this technique.
·
It helps in producing the particles with high bulk density, low hygroscopicity, high spherocity,
dust free, narrow particle size distribution and smoother surface.
Disadvantages:
·
This process is more laborious and time consuming as compared to other
granulation techniques 20.
iv.
Spray Drying:
This process has been divided in three stages:
·
Atomization of a liquid feed into fine droplets.
·
The mixing of spray droplets with a heated gas streams allows the liquid
to evaporate and leave behind the dried solids.
·
The dried powder is separated from the gas stream 9.
Advantages:
It is a very
rapid and continuous process.
·
It helps in the overall cost reduction by avoiding the labour intensive drying and the granulation steps.
·
It helps in minimal product handling and operator exposure to dust.
·
It is suitable for heat sensitive product.
Limitation of wet granulation:
a. The greatest disadvantage of wet
granulation is its cost. It is an expensive process because of labor, time,
equipment, energy and space requirements.
b. Loss of material during various
stages of processing.
c. Stability may be major concern for
moisture sensitive or thermo labile drugs.
d. Multiple processing steps add
complexity and make validation and control difficult.
e. An inherent limitation of wet
granulation is that any incompatibility between formulation components is
aggravated.
Figure no.4:
Different steps involved in the Extrusion- Spheronization
process
Figure no.5 Method for spray drying of
granules.
Figure no.6: Dry granulator.
Figure no.7:flow
chart of dry granulation
2. Dry Granulation or Compression
Granulation:
This technique involves the compaction
of the components of a tablet formulation by means of a tablet press or with
the help of specially designed machinery which is followed by milling and
screening before the final compression into a tablet. This process is used for
drugs which are sensitive to heat, moisture or both of which precludes wet
granulation. In this dry method, the primary particles are aggregated at high
pressure as is shown in the figure given below.
It is done by two processes; either a
heavy duty tabletting press produces a large tablet
or the powder is squeezed between the two rollers and a sheet of material is produced.
In both the cases these intermediate products are broken using a suitable
milling technique to produce a granular material which is usually sieved in
order to separate the desired size fraction21-23.
.
3.Novel granulation techniques:
1. Pneumatic Dry Granulation
(PDG):
The PDG Technology:24
·
Is based on a
pneumatic dry granulation process, a novel dry method for automatic or
semi-automatic production of granules,
·
Enables flexible modification of drug load,
disintegration time and tablet hardness
·
Can achieve:
i.
High drug
loading, even with ‘difficult’ APIs and combinations
ii.
Taste masking
iii. Excellent stability,
·
Is compatible
with other technologies, such as sustained release, fast release, coating,
·
Is suitable for
heat labile and moisture sensitive drugs, and
·
Is the subject of
a number of patent applications.
The PDG Technology™ produces
porous granules with excellent compressibility and flowability
characteristics
Granulate Any API:
The pneumatic dry granulation
process can granulate virtually any pharmaceutical solid dosage ingredient. The
granulated material has exceptionally good flowability
and compressibility properties. PDG Technology has been used with superior
results in developing fast-release, controlled-release, fixed-dose, and orally
disintegrating tablets. The technology is applicable to practically any solid
dosage pharmaceutical product.
Pneumatic Dry Granulation
Replaces Wet Granulation:
Today, wet granulation is the
most commonly used granulation method. Formulation teams will usually target a
direct compression or dry granulation formulation where possible but in
approximately 80% of the cases they end up with a wet granulation formulation
due to processing issues.
Wet granulation is also
unsuitable for moisture sensitive and heat sensitive drugs, it is more
expensive than dry granulation, it is relatively labour
intensive and can take a long time. There are a large number of process steps
and each step requires qualification, cleaning, and cleaning validation, high
material losses can be incurred because of the transfer between stages, there is
the need for long drying times. Scale up is usually an issue, and there are
considerable capital requirements. PDG Technology solves the above
problems. PDG Technology granules have
excellent properties compared to wet granulation, dry granulation and direct
compression.
Figure
8: PDG Technology and wet granulation comparison
At the same time, the granules
show both high compressibility and flowability. The
results can be archived without using exotic and expensive excipients7.
Advantages of PDG Technology:
The PDG Technology has a number
of advantages to support the above claims including the following:
·
Good granulation
results even at high drug loading have been achieved even with materials known
to be historically difficult to handle,
·
Faster speed of
manufacturing compared with wet granulation,
·
Lower cost of
manufacturing compared with wet granulation,
·
The system is
closed offering safety advantages due to low dust levels and potential for
sterile production or handling of toxic materials,
·
The end products
are very stable - shelf life may be enhanced,
·
Little or no
waste of material,
·
Scale-up is
straightforward,
·
The granules and
tablets produced show fast disintegration properties, offering the potential
for fast release dosage forms,
·
Release time can
be tailored to requirements.
Benefits to Pharmaceutical
Companies:
PDG Technology is the key
solution to challenges faced by pharmaceutical companies in development of
solid oral dosage forms. The technology replaces existing solid dosage form
development and manufacturing technologies, offering more rapid development and
better quality. The unique capabilities of the technology have been
demonstrated in number of evaluation studies with top-tier pharmaceutical
companies.
2. Freeze Granulation Technology:
This technique has been adopted
by Swedish Ceramic Institute (SCI) which enables preservation of the
homogeneity from suspension to dry granules. A powder suspension is sprayed
into liquid nitrogen, the granules are frozen instantaneously. In a subsequent
freeze-drying the granules are dried by using sublimation of the ice without
any segregation effects as in case of conventional drying in air. The resulting
granules will be spherical and free flowing with optimal homogeneity (Figure.9).
This technique helps in easy crushing to homogeneous and dense powder compacts
in processing operation 9.
Advantages:
·
Control of
granule density by the solid content of the suspension.
·
Serious oxidation
of non-oxides and metals is prevented by mild drying.
·
Granules have no
cavities.
·
There is low
material waste (high yield)
·
Small (50-100 ml
suspension) as well as large granule quantities can be produced to equal
quality.
·
The equipment is
easily cleaned and latex binder can be used for cleaning.
·
Recycling of the
organic solvents is possible.
Typical ceramic powders: Oxides
(aluminium oxides, silicon oxide), nitrides (Si3N4)
and carbides (SiC), but also nano
powders, diamonds and pharmaceuticals like proteins and enzymes.
3. Foamed Binder Technologies
(FBT):
Foamed binder technology from
The Dow Chemical Company can help you achieve faster, simpler, and safer wet
granulation processing25.Using familiar, proven METHOCEL polymers,
this technology greatly improves binder distribution in the formulation mix and
yields a remarkable array of processing advantages26.
Compared to conventional spray
processing, foamed binder technology can shorten processing times by reducing
water requirements. It can improve reproducibility through more uniform binder
distribution. Moreover, it eliminates spray nozzles and their many variables in
granulation processing equipment. Foam processing also offers better end point
determinations and reduced equipment clean-up time.
While foamed binder processing
offers many advantages, this technology doesn’t demand new equipment or radical
changes in processing techniques. You can very easily use it with familiar high
shear, low shear, or fluid bed granulation equipment, in both laboratory- and
production-scale settings.27 Our evaluations
also show it yields familiar metrics for particle size distributions, solid
dose physical properties, and dissolution profiles.
How foam binder granulation
works:
Foam granulation takes advantage
of the tremendous increase in the liquid surface area and volume of polymeric
binder foams to improve the distribution of the water/binder system throughout
the powder bed of a solid dose pharmaceutical formulation.
A simple foam generation
apparatus is used to incorporate air into a conventional water-soluble polymeric excipients binder such as METHOCEL hypromellose
(hydroxypropyl methylcellulose). The resulting foam
has a consistency like shaving cream. Hypromellose
polymers are ideal candidates for this technology because they are excellent
film formers and create exceptionally stable foams.
Figure
9: Freeze drying Granulation.
In a small-scale laboratory
setting or in a full-scale production setting, the foam generator can be
connected directly to high-shear, low-shear, or fluid bed granulation equipment.
28
Extremely efficient binder
delivery and particle coverage:
The key to the effectiveness of
foam binder performance is rapid and extremely efficient particle coverage.
Compared to sprayed liquid binders, foamed binders offer much higher surface
area, and they spread very rapidly and evenly over powder surfaces. The foamed
binders and the powder particles show excellent mutual flow through one
another.
The foam binder also shows a low
soak: spread ratio, so particle surfaces are quickly and completely covered. By
contrast, spraying is a cumulative process that begins with small liquid
droplets “dappling” particle surfaces until enough binder liquid accumulates to
initiate particle agglomeration. Spraying requires considerably more water and processing
time than a foamed binder to achieve particle agglomeration.
The foam binder technology also
eliminates the need for spray nozzles and all of their attendant variables,
such as nozzle configuration, distance from the moving powder bed, spray patterns,
clogging, droplet size, and droplet distribution. The dilute binder solutions
are easy to handle in processing. Overall, foam binder processing is easier,
faster, and allows safer handling of potent drug compounds29.
Figure
10: Foamed Binder.
4. Melt Granulation Technology:
This is technique with the help
of which granules are obtained through the addition of either a molten binder
or a solid binder which melts during the process. This method is also called
melt agglomeration and thermoplastic granulation 9,30,31.
Principles of melt
granulation:
This granulation process
consists of three different phases:
·
Wetting and
nucleation
·
Coalescence step
·
Attrition and
breakage
Wetting and nucleation stage:
In this stage, the binder comes
in contact with the powder bed and liquid bridges are formed which leads to the
formation of small agglomerates.
Two nucleation mechanisms used
are:
·
Immersion
·
Distribution
Immersion:
·
When the size of
molten binder droplets is greater than that of fine solid particles, it leads
to nucleation.
·
This process
proceeds by depositing fine solid particles onto the surfaces of molten binder
droplets.
Distribution:
·
The molten
binding liquid is distributed onto the surfaces of fine solid particles.
·
The collision of
the wetted particles leads to nuclei formation.
·
Smaller the
binder droplet size, low binder viscosity and high shearing forces are
favorable conditions for nucleation by distribution method.
Coalescence steps:
·
It involves the
nuclei that have residual surface liquid to promote successful fusion of
nuclei.
·
Plasticity to the
nuclei is imparted to the surface liquid which is necessary for the deformation
of nuclei surface for coalescence as well as promoting the rounding of
granulation.
Attrition- breakage step:
·
This is the
phenomenon of granulation fragmentation in that are solidified by tray cooling
to ambient temperature without the need for drying by a tumbling process.
·
Breakage plays an
essential role by affecting the properties of melt granulation during the
granulation phase.
Requirements of melt
granulation:
·
10-30% w/w of meltable binder with respect to that of fine particles is
generally used.
·
Meltable binder used in this has a melting point within a
range of 50-100°C.
·
For immediate
release dosage forms, hydrophilic molecules are used while for prolonged
release dosage forms, hydrophobic molecules are used.
·
Melting point of
fine particles used should be at least 20°C higher than that of the
maximum processing temperature.
Requirements for meltable binders:
·
It should be
solid at room temperature and has melting point ranging from 10 and 80°C.
·
These binders
should be physically and chemically stable.
·
HLB should ensure
the correct release of active substance.
There are two types of meltable
binders:-
·
Hydrophilic meltable binders
·
Hydrophobic meltable binders
Figure 11: Modes of distribution
Meltable binders:
1. Meltable
binders should be solid at room temperature and the melting point should lie
between 40 to 60° C.
2. The HLB value of the binder
should ensure correct release of the active ingredient.
Advantages:
·
No solvent is
used and the processing steps needed are fewer thereby eliminating the time
consuming drying steps.
·
There is uniform
dispersion of fine particles and it offers good stability at varying pH and
moisture.
·
They can be
applied safely in humans due to their non swellable
and water insoluble nature 9.
Table
1: List of Binders.
Hydrophilic meltable binders generally used
in the melt granulation technique |
Hydrophilic Meltable Binder Typical Melting
Range (°C) |
Gelucire50/13 |
44-50 |
Poloxamer
188 |
50.9 |
Polyethylene glycols : |
|
PEG 2000 |
42-53 |
PEG 3000 |
48-63 |
PEG 6000 |
49-63 |
PEG 8000 |
54-63 |
5. Steam Granulation:
• It is modification of wet
granulation. Here steam is used as a binder instead of water.
• In this method of
granulating particles involves the injection of the required amount of liquid
in the form of steam.
• This steam injection
method, which employs steam at a temperature of about 150° C., tends to produce
local overheating and excessive wetting of the particles in the vicinity of the
steam nozzles, thereby causing the formation of lumps in the granulated
product. 32
Advantage:
·
Higher
distribution uniformity,
·
Higher diffusion
rate into powders,
·
Steam granules
are more spherical,
·
Have large
surface area hence increased dissolution rate of the drug from granules,
·
Processing time
is shorter therefore more number of tablets are produced per batch,
·
Compared to the
use of organic solvent water vapor is environmentally friendly,
·
Lowers
dissolution rate so can be used for preparation of taste masked granules
without modifying availability of the
drug.
·
Compared to the
use of organic solvent water vapor is environmentally friendly,
·
Lowers
dissolution rate so can be used for preparation of taste masked granules
without modifying availability of the drug
·
· .Figure 12: Steam Granulation Technology
6. Moisture Activated Dry
Granulation (MADG)
• In this method moisture is
used to activate the granules formation but the granules drying step is not
necessary due to moisture absorbing material such as MCC33.
• The moisture-activated dry
granulation process consists of two steps, wet agglomeration of the powder
mixture followed by moisture absorption stages.
• A small amount of water
(1–4%) is added first to agglomerate the mixture of the API, a binder, and excipients. Moisture absorbing material such as MCC and
potato starch is then added to absorb any excessive moisture34.
• After mixing with a
lubricant, the resulting mixture can then be compressed directly into tablets.
Hence, this process offers the advantage of wet granulation is that eliminates
the need for a drying step.
• MCC, potato starch, or a
mixture of 50% of each was used as moisture absorbing material. FMC Biopolymer
has introduced two new excipient products to the Pharma market: Avicel HFE-102 and
Avicel PH-200 LM, which are based on already existing
excipients but have been generated to produce a
different entity with improved benefits35.
Avicel PH-200 LM, based on microcrystalline cellulose (MCC),
has been formulated to reduce the amount of water added to the granulation
process Avicel PH-200 LM is a step up from FMC
Biopolymer’s Avicel PH-200 which had a moisture level
of five per cent. The new product has a moisture level of no more than 1.5 per
cent and can absorb approximately three to four times as much
water from the granule. This advantage, along with enabling the use of
MADG, meant the use of Avicel PH-200 LM could
eliminate the extra steps of milling, drying and screening, thereby reducing
manufacturing costs and energy used. The process also produced a larger
particle size for optimal flow. This increases efficiencies to the
manufacturing process. It takes aspects of wet granulation but eliminates the
drawbacks of it. Also be useful for the use of active pharmaceutical
ingredients (APIs) which were sensitive to moisture.
Avicel HFE-102 is a new, proprietary co-spray dried MCC/mannitol high functionality binding excipient
for direct compression. The co-spray drying added extra benefits to the excipient as it changed its properties combining the high
compressibility of MCC and the low lubricant sensitivity of Mannitol.
Figure
12: Flow diagram of moisture activated dry
granulation process
The outcome was a harder, less
friable and faster disintegrating tablet36.
Advantage:
·
It utilizes very
little granulating fluid.
·
It decreases
drying time and produces granules with excellent flow ability.
·
Single production
equipment (high shear granulator)
·
No equipment
change
·
Lower tablet
capping
No over and under
granulation
7. Granulex®
Technology:
The Granurex®
precisely and consistently performs both coating and powder layering processes.
In the pictures to the right, multiple coating and powder (ingredient) layers
demonstrate the accuracy and control of a Granurex®
rotor processor, including the creation of the nonpareil.
Key
feature:
Unique,
Efficient Granulation Processes: Granules
produced by the Granurex® are dense and spherical in
shape. The pictures and graphs shown below demonstrate how the Granurex® processes Ciprofloxacin from a 7μm poorly
flowing powder to 200μm granules with excellent flow characteristics. One
Pot Processing: A patented feature of the Granurex®
is its ability to dry product within the same processing chamber. This unique
drying method, combined with 12 bar construction, provides a true one-pot
system, ideal for manufacturing highly potent and expensive pharmaceutical
compounds.
Increased Batch Capacities:
The patented conical rotor plate
increases batch capacities when compared to traditional rotor processors. The
precision machined gap contains the product within the processing area and the
peripheral spray guns are embedded into the product, which provides accurate
coating with minimal spraying defects.
Maximum Process Flexibility:
Using micronized acetaminophen
as the base material, the Granurex® produced both a
100 μm granulation and a 200 μm
spherical bead. In both of the examples below, the APAP core material had the
same initial Mean Particle Size (X50) of 40 μm37.
8. TOPO
Technology:
HERMES PHARMA has developed a
unique technology for carrying out single pot granulation. This process
requires a very small quantity of liquid to start the chain reaction. Pure
water or water-ethanol mixtures are used.
TOPO Technology produces
granules for tablets which at least contains one solid crystalline, an organic
acid and one alkaline or alkaline earth metal carbonate that reacts with the
organic acid in aqueous solution to form carbon dioxide. As a result there are
no solvent residues in the finished products; granules have excellent hardness
and stability. TOPO Granulator was employed for producing effervescent tablets
following TOPO vacuum granulation technology, patented by Hermes Pharma. It involves granulation under vacuum to prevent
uncontrolled chain reaction 11.
9.Continuous Flow Technology:
This method does not require any
liquid to start the chain reaction. In this case granulation is carried out in
an inclined drum into which powder is fed at one end and granulate is removed
at the other. The process produces granule with surface protected by inactive
component that do not harm the sensitive API. CF technology can produce up to
12 tons of granules every day.
Advantages:
1. Sensitive APIs are
protected.
2. Granules and effervescent
become less sensitive to humidity and high temperature.
3. Granules form extremely
stable products.
4. No solvent residues in the
final products 9.
10. Thermal Adhesion
Granulation Process (TAGP)
It is applicable for preparing
direct tabletting formulations. TAGP is performed
under low moisture content or low content of pharmaceutically acceptable
solvent by subjecting a mixture containing one or more diluents and/or active
ingredients; a binder; and optionally a disintegrant
to heating at a temperature in the range from about 30ºC to about 130ºC in a
closed system under mixing by tumble rotation until the formation of granules.
This method utilizes less water or solvent than traditional wet granulation
method 38,39 It provides granules with good
flow properties and binding capacity to form tablets of low friability,
adequate hardness and have a high uptake capacity for active substances whose tabletting is poor.
In thermal adhesion granulation,
granules are formed during mixing of the moist powder under continuous tumble
rotation, as the heated powder mass flows within the container and agglomerates
with the aid of the binder Drying and milling to form
the desired granules are unnecessary in the present invention due to the low
amount of moisture introduced to the tableting
mixture40
Another major advantage of
granulating pharmaceutical products in a closed system is that it helps to
minimize the generation of dust during powder processing. This technique serves
to contain fine-powder active ingredients whose spread or loss from the system
is not desirable due to their cost or biological activity41
CONCLUSION:
These review works mainly focus
on the comparison of granulation and novel granulation techniques to produce
granule. Each technique has its own advantage and disadvantages. Which method
is chosen depends on the ingredients individual characteristics and ability to
properly flow, compresses, eject, and disintegrate. Choosing a method requires
thorough investigation of each ingredient in the formula, the combination of
ingredients, and how they work with each other. Then the proper granulation
process can be applied.
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Received on 02.12.2015 Accepted
on 08.12.2015
© Asian Pharma Press All
Right Reserved
Asian J. Res. Pharm. Sci.
5(4): Oct.-Dec. 2015; Page 203-215
DOI: 10.5958/2231-5659.2015.00030.2