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Pharmaceutical Powder Compaction Equipment

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

The click and puff of inhalers is a universal signal for respiratory conditions. Inhalers quickly grew into preferred drug delivery systems for asthma and COPD. Dry inhaler powder formulation produces a more stable drug than liquid dosage forms. Moreover, inhaler ingredients are more resistant to bacterial growth.

Dry inhaler powder

Used in the pharmaceutical industry to produce tablets and capsules, among others, pharmaceutical granules are made to enhance the uniformity and flow of powder, increase the density of the blend and reduce dust and, therefore, toxic exposure. The choice of the granulation process, whether it is wet, dry, or direct compression, as well as the selection of appropriate pharmaceutical granulation equipment, depends on the specific drug being formulated.

Pharmaceutical granules

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Brochure_lb_bohle_BRC

The fizz of effervescent tablets is commonly associated with a vitamin C boost. But the soluble pill is an excellent drug delivery method for pediatric and geriatric patients. Sometimes referred to as carbon tablets, manufacturing effervescent tablets binds biocarbonate and citric acid that produce the smooth hiss as they dissolve in liquid.

Effervescent tablets

It is strange how two tablets can belong to the same but at the same time to a different category depending on how the tablet itself is classified. For example, chewable tablets and effervescent tablets have two different routes of administration but both belong to the category of uncoated tablets. Uncoated tablets are prepared by compression of granules in which no coating is added after compression. They may be single-layer or multi-layer tablets.

Uncoated tablets

Wide production range, from less than 1kg/h up to 400 kg/h

Rotary sieve can be changed quickly according to process requirements

Uniform output through precise compaction force including ribbon thickness

Hygienic design and Washer nozzles allow WIP (Washing In Place)

Minimal product loss

A granulator is a high-speed knife mill designed to cut down large components of feedstock and reduce them to smaller particle sizes. Selecting the right scissor geometry and configuration allows granulators to process plastic bottles, organic fibers, films, wires, cables, and other difficult materials. Agglomeration granulators combine fine particles into larger granules by creating bonds between them. Bonds are formed by compressing fine particles or through the use of a binding agent.

Granulators

Pharmaceutical

Compaction Machines

Compaction machines and technologies crush or compress materials and make them denser. Compaction can be used to simply save space or to shape materials into a desired form or format. Tablets, pellets, or briquets are formed by compactors but powder presses also help form cosmetic eyeshadow or face powder.

Compaction

Connect directly with world leading manufacturers of Compaction equipment and find technology to build or improve your production line.

Compaction - Making.com

Compaction Machines - Making.com

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

Pharmaceutical powders provide longer shelf life and better stability than liquid dosage forms. But the processing of pharmaceutical powders is crucial for growing segments besides pharmacy. Functional foods and cosmetics formulated with active ingredients and excipients depend on powdered forms to fulfill their promises.

Pharmaceutical powder

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

Among all dosage forms in use today, tablets constitute the most common one. They are pharmaceutical solid dosage forms containing active ingredients and excipients such as diluents, binders, glidants, and lubricants. Using tablet making equipment, these solid dosage forms are made by compression of granules or powder blends and then shaped by molding.

Tablets

Granulation

When making tablets, pharmaceutical manufacturers need to use a mechanical process, like a rolling press for compaction, to produce granules from powders

Continuous roller compactor for dry granulation of pharmaceuticals - Making.com

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Enhanced feed flow control reduces fine material in the final product

Increased throughput of up to 250 kg/h

Advanced control interface for precise product quality management

Patented granulation technology for higher efficiency

Designed for maximum OEB5 containment, ensuring safety

Granules

Process

Continuous

Industrial

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

solid

Pharmaceutical production often demands highly controlled granulation processes to ensure product consistency and quality. Traditional methods may not

Pharmaceutical roller compactor for granulation - Making.com

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Brochure_Bonals_BE40

The wave of liquid soaps and detergents in the 1950s revolutionized home and personal care. Cheap and convenient, these off-the-shelf products fit perfectly into the lifestyle of the time. A few decades later, though, plastic waste put the sustainability of hygiene products into question. Refill tablet production technology answers that by eliminating single-use plastic. Instead of picking up a new bottle every time, end-users complete the formulation process in a multi-use container and with a simple instruction: just add water.

Refill tablets

Powder aspiration system

Quick change over, less than10 minutes

Easy adjustment of compression speed

Minimal powder waste

Small and medium batch capacity  

Chemical tablet formulas allow granules to break away under the conditions you would have designed them for. Powder presses distribute particles from the stock material evenly onto molds and subject the it to pressure to produce a dense block. Powder tablets often include a precise mixture of products and presses combine the correct dosage to form multi-layered slabs ready for packaging.

Powder presses

A tablet press consists of two essential tools, namely dies and punches. It compresses powder or granules into a desired solid substance of uniform size and weight. After filling the dies with powder or granules, upper and lower punches are pressed together within the die hole to form tablets. Then the upper punches come back to their original position while the lower punches help the ejection of the tablet from the dies.

Tablet presses

Chemical

Cosmetic

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

Detergents are cleaning agents that help remove dirt and grease from porous and non-porous surfaces. Industrial production of detergents began after World War I. Still, it was after the 1950s and 1960s that the detergent industry grew exponentially due in part to the development of new detergent manufacturing equipment.

Detergents

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Pressing

Hundreds of different refill tablets, of various shapes or sizes, are on the market today. To get a range of soap, shampoo or lotion tablets, the powdered

Eccentric press for refill tablets - Making.com

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Dry Granulator - BRC

Chewable tablets are suitable for patients who have difficulty swallowing. Chewable tablet formulation masks the natural flavors of pharma drugs and alters their aftertaste. But besides the taste, chewable tablets favor the bioavailability of pharmaceutical ingredients.

Chewable tablets

When taking a tablet, it is usually the job of our stomach to break down the medication to make it ready to be absorbed into the bloodstream. However, some drugs are not meant to be dissolved in the stomach because the acidic pH of the stomach can disintegrate the drug, making it no longer effective. Using tablet coating equipment that applies a polymer barrier to the tablet makes it possible to protect it from stomach acidity.

Enteric Coated Tablets

Microtablets range between 1 and 4 millimeters, making the dosage form an excellent delivery system in polypharmacy. The size of the products makes them easier pills to swallow, but microtablets production brings a unique set of complexities.

Microtablets

Multilayer tablets are a popular fixed-dose combination (FDC) offering a range of release profiles for effective drug delivery. Multilayer tablet technology solves challenges to API consistency, allowing manufacturers to develop formulations from incompatible ingredients while optimizing the release profile for immediate release and controlled release.

Multi-layer tablets

Less maintenance, no oil change required

Improved compressibility and minimal material loss from using electromechanical roller drive

Flexible sieve setup, can be fitted with conical or oscillating sieve

Quick assembly/ disassembly of the system allows easy installation – less than 10 minutes

Standard washer nozzles allow WIP (Washing In Place)

In pharmaceutical industries, where large-volume production is the norm, compactors or granulators are used to turn powdered materials into granules. As

Dry granulator for pharmaceutical powders - Making.com

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factsheet-qbcon1

Wet granulator and dryer - QbCon1

Throughputs of 0.5 to 2.5 kg/h range

Simple and safe scale-up from R&D to production scale

Can operate continuously and uninterrupted for a long time (more than 8 hours)

Gentle and uniform drying of granules with short residence time

Small footprint

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Pharmaceutical laboratories need compact equipment to handle and produce small amounts of granules from a mixture of wet and dry elements for R&amp;D

Continuous wet granulator and dryer for R&D - Making.com

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<h3>Reduce particle sizes before manufacturing pharmaceutical powders</h3>
Variable particle sizes of pharmaceutical powders develop significant challenges in the manufacturing process. Polydisperse materials have poor mixing characteristics and may lead to clumping instead of particle cohesion. Therefore, powder characterization is an important part of the production process.

Mill your powders before mixing the formula to <a href="https://www.ramauniversity.ac.in/online-study-material/pharmacy/bpharma/iiisemester/pharmaceuticalengineering/lecture-2.pdf" target="_blank" rel="noopener">ensure a homogeneous</a> particle size distribution. The ball mill produces impact and attrition between the material and the moving balls and is suitable for wet and dry grinding processes. Although it downsizes particles to very fine grades, it does not very well handle soft, fibrous materials. A hammer mill adapts better for these kinds of powders.

The fine diameters of pharmaceutical powders achieve high penetrability, making them effective delivery systems for intra-respiratory solutions. Their small particles have a faster <a href="https://www.researchgate.net/profile/Rasha-Suliman/publication/331917546_A_Recent_Progresses_and_Manufacturing_Techniques_in_Pharmaceutical_Powders_and_Granulation/links/5c932716299bf111693b7467/A-Recent-Progresses-and-Manufacturing-Techniques-in-Pharmaceutical-Powders-and-Granulation.pdf">dissolution rate and better bioavailability</a>.

However, unless distributed in mono-dose formats, dosing can be inaccurate. Powders typically also have an offensive aftertaste compared to other oral medicines.

Processing of pharmaceutical powders improves the bioavailability of active ingredients

<h3>Contain pharmaceutical powders in sealed packaging</h3>
Non-potent drugs manufactured into pharmaceutical powders are dispensed as bulk products. Medicated powders such as antacids or topical anti-infectives <a href="https://www.pharmapproach.com/classification-of-pharmaceutical-powders/" target="_blank" rel="noopener">may be stored in containers</a>, but they must ensure airtight closure.

Headache powder, laxative powders, and other products formulated from potent ingredients are prepackaged into single-dose portions. Divided powders, as they are called, reduce the risk of overdosing, so dosing and weighing systems are indispensable for production.

Innovative equipment for pharmaceutical powder

Let's Make Pharmaceutical Powders

Find production technology for processing and packing pharmaceutical powders and connect with leading machine and equipment manufacturers worldwide.

Find production technology for making , and connect directly with leading machine manufacturers worldwide.

Find Pharmaceutical powder making equipment - Making.com

Pharmaceutical Powders Processing - Making.com

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Pharmaceutical laboratories need compact equipment to handle and produce small amounts of granules from a mixture of wet and dry elements for R&amp;D applications. Furthermore, the granulation process requires short residence times in drying the products to easily identify and remove the defects without discarding the entire batch.


<h2>Automatic feeding, granulating, and quick drying of pharmaceutical  products</h2>
The QbCon 1 from L.B. Bohle is a continuous wet granulating and drying system for pharmaceutical laboratory scale applications. The system performs three processes: feeding, granulating, and drying. It features a twin screw granulator with a hinged barrel for easy access to its parts. The unit comes with a multi-position feeder and interchangeable ports, ensuring accurate gravimetric feeding of dry powder and using a pulsation-free pressurized feeder for granulation liquid.

The wet granules are gently dried by a moving fluid bed that provides short residence times and consistent product output. Its narrow residence time distribution allows easy traceability from the initial product to the final tablet or vice versa. The drying process parameters, such as airflow, temperature, and conveying speed, can be controlled and adjusted according to product requirements. The system allows for sampling wet and dry granulations without interrupting the ongoing processes. The system also has an innovative filter cleaning system to prevent clogging for longer hours of operation. The unit also features a complete WIP (Wash-in-Place) cleaning.

Continuous wet granulator and dryer for R&D

Continuous wet granulation and drying have been widely discussed in pharmaceutical research and development (R&amp;D) and industry. Daniel Emanuele from

Scientifically tested continuous drying for your tablets - Making.com

Scientifically tested continuous drying for your tablets

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Grete-Liina Roosve

In pharmaceutical industries, where large-volume production is the norm, compactors or granulators are used to turn powdered materials into granules. As hydraulic systems are commonly utilized in these granulators, the compressibility is affected by the properties of the oil used. Certain oils can be compressed more than others and their properties degrade over time and are affected by temperature fluctuations.


<h2>Compacting dry powder into granules using an electromechanical roller drive</h2>
The Dry Granulator BRC 100 from L.B. Bohle, is a compacting system that turns powdered materials into granules for pharmaceutical industry applications. The system utilizes an electromechanical roller drive to provide precise control, consistent compressibility, and minimal material loss compared to hydraulic systems that rely on oil properties to drive the rollers.

This setup offers less maintenance as it does not require oil changes and an oil cooling system. The system has a flexible sieve setup allowing for the use of either a conical sieve or an oscillating sieve to obtain the desired granule size of the product coming out from the rollers. The granulator comes standard with integrated WIP (Washing in Place) nozzles for effective and easy cleaning. The entire system can be assembled or disassembled quickly, which helps improve maintenance and installation.

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Dry granulator for pharmaceutical powders

Pharmaceutical innovations, particularly with highly potent active ingredients (HPAIs), are thriving largely in oncology medication. However, ensuring

Aim your safety standards high, while granulating dry - Making.com

Aim your safety standards high, while granulating dry

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Manufacturing pharmaceutical solids like tablets requires using a proper blender to blend dry powders into a homogenous mixture. Having a blender that can accommodate various blending container sizes allows easy adjustment of the production volume.


<h3>Blending homogenously dry powder batches using a stationary blending device</h3>
The Container Blenders PM from Bohle is a blending system for fine solids and powders in pharmaceutical applications. The system features a wide variety of blending containers with various capacities that can handle square or round containers. Each blending container can be used to mix powders effectively at a range between 20% to 85% of its total container volume for densities ranging from 0.2 to 1.2 kg/L. The blending process is done in a closed system; each container has an inner lid for filling.

The blending system rotates at 6 rpm with an option to increase the speed depending on process requirements. It can be equipped with a chopper that operates at a speed of approximately 750 rpm to break solid lumps and chop small amounts of ingredients.

Product changeover can be done quickly by simply exchanging the blending container. The entire system can also be used as a milling station for bin-to-bin product transfer.

Container blender for pharmaceuticals

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Whether you are making pharmaceuticals, chemicals, or nutraceuticals, you will need to blend your ingredients. Depending on your product and production

Discover the best mix for your blending application - Making.com

Discover the best mix for your blending application

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Producing the finest micro-emulsions and suspensions requires a mixing machine that generates extremely high shear.  Multi-staged rotor/stator dispersing machines work well for this purpose because of the high shear forces applied to the mixture at each rotor/stator stage.  A rotor /stator dispersing machine that also incorporates extremely fast rotation and resultant tip speeds for even greater shearing action will lead to the creation of super-fine emulsions and ensure the success of your process.
<h2>Top-of-the-line rotor/stator dispersion with utlra high shear for nano-scale particle emulsions and suspensions</h2>
The DISPAX-REACTOR® DRS from IKA is an inline ultra high shear dispersing machine used to achieve the finest micro-emulsions and suspensions. Extremely high shear rates (up to 190.000 1/s) combined with a fine generator geometry enable crushing of droplets and solids particles down to the nanoscale. The resulting product has long-term stability which reduces the need for emulsifying agents and thickeners. Because of the extremely high energy density, other dispersing aids can be reduced or possibly eliminated.

The DRS is usually equipped with a two-stage rotor-stator system (generators). The high tip speed of 40 m/s (10.000 fpm) often negates the need for a third stage. The ultra-fine dispersing machine, designed with the same high quality features as the ULTRA-TURRAX® UTL and the DISPAX-REACTOR® DR, is especially well suited for challenging pharmaceutical applications.  The units are designed for easy and reliable scalability and sizes are available with flow rates from 70 to 40.000 liters per hour.

Ultra-fine dispersing machine for emulsions and suspensions

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

The most important part of a capsule is its contents. But if the shell is not carefully made, the dosage ingredients inside lose effectiveness. From molding to sizing, capsule manufacturing equipment forms perfectly-matching husks ready for filling. The simplicity of encapsulation revolutionized pharmaceuticals since it was introduced in the 19<sup>th</sup> century. However, capsules are changing to increase delivery efficiency and reduce the dependency on gelatin.

Capsules

<p class="filterable-grid__description">Liquid dosage forms are designed for easy absorption. The body quickly carries the active ingredients through the system and triggers the required response. But the greatest advantage of this medicinal type is its flexibility in formulation and dispensation. From lotions and syrups to drops and sprays, liquid solutions can be adapted to different administration routes including parenteral, topical, and oral. The fundamental liquid dosage manufacturing process involves dissolving or suspending solutes in a fluid. But that is not enough. A precise blend of excipients is needed to make the medicine go down.</p>

Liquid dosage forms

To serve the industry across diverse production scales, IKA replicated Magic Lab’s success on a larger scale, ensuring consistent milling outcomes

In the pharmaceutical industry, change often moves at a snail’s pace due to stringent regulations, but it does happen. Traditionally, API manufacturers

Wet milling: The revolution in the API production - Making.com

Wet milling: The revolution in the API production

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Deborah

Powder containment is the cornerstone of chemical and pharmaceutical manufacturing. Floating particles do not only represent efficiency loss but serious hazards too. Lack of tightness during the powder discharge process leads to cross-contamination and operational health risks.


<h3>Dock transfer systems squarely in place</h3>
The ASBV active/passive valve interface by Andocksysteme locks into position, minimizing exposure of material during powder discharge. The system has two split valves – one active, one passive – that can be easily and reliably centred on each other at a tolerance of ± 14 mm.

Once the units are docked, the valve discs open simultaneously, preventing exposure of the products during transfers. The dust-tight environment achieves contamination values lower than 1µg/m3.

The ASBV solution is fitted with EPDM seals and are optional with a wide range of materials, such as PTFE, offering top-range chemical resistance. All seals are made from FDA-approved materials and can handle a wide range of temperatures as well as explosion-proof executions.

Washing the ASBV interface is simple as the system can be connected to a WIP loop to flush out residual powders. These containment solutions serve applications with an exceptional performance and are easy to be integrated. Moreover, high quality parts and reduced complexity drives simple maintenance.

High containment split butterfly valve

The rise of high-potency ingredients (HPAPI) is taking medication into unchartered territory. Since the turn of the century, the pharmaceutical industry

Closing the containment loop in HPAPI manufacturing - Making.com

Closing the containment loop in HPAPI manufacturing

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Nathanael

Conventional dryers are inefficient and can lead to significant mechanical and thermal stress on sensitive products. Non-uniform mixing can lead to lump formation and increased processing time. Vacuum dryer with eccentric agitator is designed to dry wet flowing powders from filtration and centrifuging processes.


<h2>Vacuum dry efficiently in an agitated paddle dryer</h2>
Planex® system from Italvacuum is a special horizontal vacuum paddle dryer with an eccentric agitator which revolves around its own axis while rotating tangentially to the drying chamber. It is ideal for drying wet feeds from filtration and centrifuging processes. Planex® is ideal for the production of active pharmaceutical ingredients (API), fine chemicals and intermediates. The efficient agitator action ensures perfect mixing and consumes three times less energy than conventional dryers. It also reduces the mechanical and thermal stress on the products which is important for delicate and temperature-sensitive applications. The tangential movement of the agitator prevents lump formation. Suitable for both crystalline and amorphous products, Planex® has a short cleaning downtime and complies with US FDA standards and cGMP regulations.

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Horizontal vacuum dryer with eccentric agitator

Without friction, we would not be able to walk, jot down notes, or slice a pie. Friction resists the relative motion of two objects that come in contact,

Lowering heat stresses on API by reducing friction - Making.com

Lowering heat stresses on API by reducing friction

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Irina Lescika

Find production technology for the compaction of pharmaceutical powders, and connect directly with leading machine manufacturers worldwide.

Pharmaceutical Powder Compaction

Pharmaceutical Powder Compaction - Making.com

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Pharmaceutical Powder Compaction Equipment

Which pharmaceutical powder compaction technology do you need?

Continuous roller compactor for dry granulation of pharmaceuticals

Pharmaceutical roller compactor for granulation

Eccentric press for refill tablets

Dry granulator for pharmaceutical powders

Continuous wet granulator and dryer for R&D

There is currently no equipment listed with your specified properties, but we are sure we can help you. Try us!Contact us

What are you making?

Let's talk about your project!

Which pharmaceutical powder compaction technology do you need?

Continuous roller compactor for dry granulation of pharmaceuticals

Pharmaceutical roller compactor for granulation

Eccentric press for refill tablets

Dry granulator for pharmaceutical powders

Continuous wet granulator and dryer for R&#038;D

There is currently no equipment listed with your specified properties, but we are sure we can help you. Try us!Contact us

What are you making?

Let's talk about your project!

Continuous wet granulator and dryer for R&D