Continuous granulation and drying system for r&d

Develop precise pharmaceutical granules with this compact system, tailored for small-scale continuous granulation and drying, ensuring consistent quality and seamless scalability from research to production without the need for extensive scale-up.

Processes Continuous Granulation and Drying

The ConsiGma® GD 25/80 from GEA is a continuous twin-screw granulator and dryer, designed for pharmaceutical R&D. It allows precise control over granule quality across small-scale production, seamlessly integrating into your workflow to develop continuous granulation processes. Using a single-stage continuous operation, it facilitates granulation and drying, streamlining the production of pharmaceutical granules, coated, controlled-release, hygroscopic, and friable tablets. With a starting capacity from just a few hundred grams, it ensures efficient use of active pharmaceutical ingredients, reducing material waste. The system’s twin-screw granulator is complemented by a compact dryer, enabling full integration into small-scale R&D operations without additional space requirements. The equipment is designed for flexibility, offering options like Brabender or Ktron feeders and solvent compatibility, ensuring adaptability to various formulations and process conditions. Its compact footprint and fast R&D capabilities reduce time to market and ensure rapid process development, with no need for scale-up between the GD 25/80 to GD or GC lines. Designed to comply with industry standards, it provides a valuable solution for pharmaceutical manufacturers seeking to optimize early-stage drug development.

Benefits

  • Minimizes raw material usage, enhancing cost-efficiency during R&D.
  • Eliminates scale-up challenges, ensuring smooth transition to full-scale production.
  • Accelerates process development, reducing time-to-market for new pharmaceuticals.
  • Integrates seamlessly into existing R&D setups, optimizing space and resources.
  • Facilitates precise quality control of small batches, improving product consistency.

General


Applications
Continuous granulation processes,Coating materials,Pharmaceutical tablets,Pharmaceuticals
End products
Coated tablets,Friable tablets,Hygroscopic tablets,Melt granulated products,Controlled-release tablets,Pharmaceutical granules
Steps before
Powder Blending,Liquid Addition
Steps after
Drying,Tablet Coating,Compression,LOD Measurement
Input ingredients
powder,liquid,API,solvent
Output ingredients
granules,dry granules,high-quality granules
Market info
GEA is known for its expertise in engineering innovative and sustainable equipment and solutions, focusing on sectors such as food, beverages, pharmaceuticals, and energy, with a reputation for quality, efficiency, and advanced technological applications in industrial processing.

Technical Specifications


Granulation Technology
Continuous twin-screw
Dryer Type
Standalone
Granulator Type
Twin-screw
Batch/Continuous Operation
Continuous
R,D Scale
Small-scale
Product Quantity Capacity
A few 100 grams to a few kilograms
Powder Feeder
1 unit
Liquid Addition System
1 unit
Dryer Segment
1 unit
Automation
Not specified
Material Compatibility
Solvent compatible option available

Operating Characteristics


Working mechanism
Twin-screw granulation
Integrated steps
Granulation and Drying
Batch vs. continuous operation
Inline Continuous
Automation level
PLC
Energy efficiency
0.5–2 kWh/kg moisture
Cleaning method
CIP / Manual

Material Compatibility


Density/particle size
0.5–2.5 g/cm³ / 50–1000 µm

Physical Characteristics


Machine footprint
Compact
Twin-screw granulator size
Small-scale
Discharge method
Continuous
Powder feeder
Standalone
Dryer segment size
Small-scale
Unit size
GD 25/80

Custom Options


Standalone or Integrated System
Standalone GD 25 with/without dryer segment
Feeder Type
Brabender or Ktron Feeder
Solvent Compatibility
Yes
Second Liquid Addition
Available
Lighthouse Probe® for LOD Measurement
Available
Melt Granulation Set-up
Available