Processes APIs and Solid Dosage Forms

The ZSK Pharma Twin Screw Extruders from Coperion are engineered to enhance the continuous processing of active pharmaceutical ingredients (APIs) and solid dosage forms. Featuring a modular design, these extruders provide flexibility in processing with adjustable barrel and screw configurations, ensuring precise mixing and controlled temperatures to prevent API degradation. Ideal for producing controlled-release tablets, sustained-release capsules, and transdermal drug delivery patches, they are instrumental in pharmaceutical applications requiring high levels of dispersion and encapsulation. The ZSK Pharma Extruders offer specific torque of up to 18 Nm/cm³, accommodating high throughput while maintaining product integrity. Integrated with PLC control systems that comply with CFR Part 11, they facilitate seamless automation and easy scale-up from R&D to full-scale production. Constructed in GMP-compliant stainless steel with FDA-compliant lubricants, these extruders ensure reliability and safety. The self-cleaning twin screws and compact design allow for quick operation, reduced maintenance, and minimal space requirements, supported by Coperion’s extensive engineering expertise and after-sales service network.

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Processes Diverse Food and Pet Food Products

Coperion’s ZSK Mv PLUS Twin Screw Food Extruder offers versatile processing for food and pet food manufacturers by allowing continuous extrusion of products such as plant-based proteins, snacks, and confectioneries. The equipment features co-rotating screws with a self-wiping profile, ensuring high conveying efficiency and self-cleaning. Its modular design supports varied applications by adjusting free screw volume, speed, and torque, accommodating both laboratory and production-scale operations. Capable of processing various solids, powders, and granules, it enhances operational efficiency with speeds up to 1,800 rpm. The ZSK Mv PLUS operates with a specific torque of 11.3 Nm/cm³, delivering up to 40% increased throughput compared to previous models. Constructed from stainless steel, it ensures hygienic and easy-to-clean surfaces, reducing downtime. Additionally, it supports hybrid versions, enabling the production of both dry texturized vegetable proteins and high moisture meat analogues with customization options and engineering support available to meet unique production needs.

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Cools and Texturizes Plant-Based Proteins

The Modular Cooling Die from Brabender offers unparalleled flexibility for plant-based food production. Designed for R&D labs and food manufacturers, it enables precise control over the cooling and texturization of protein-rich products like soy-based meat alternatives and vegan patties. The die features independent temperature control across three heating/cooling zones, allowing tailored processing for varied textures. It supports real-time material measurement through six strategic openings, enhancing process monitoring and quality control. This modular design accommodates easy adaptation for different product dimensions, meeting specific production needs. Ideal for laboratory-scale and pilot-scale operations, it integrates seamlessly into existing extrusion setups, offering customizable nozzle dimensions for diverse plant protein applications.

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Scales and Mixes for R&D Extrusion Tasks

Three-Tec’s ZE 5-12 Hybrid Laboratory Extruder delivers innovative extrusion solutions for R&D and laboratory environments. This compact device integrates both 5 mm and 12 mm screw diameters, enabling swift scalability without compromising performance. It excels in processing pharmaceuticals, nutraceuticals, fine chemicals, and polymers into products like extended-release capsules and biodegradable plastic resins. The extruder’s water and air cooling system, along with its single control panel, facilitates precise operation and efficient scale-up. Designed for versatility, it operates with maximum pressures of up to 250 bar, handling diverse material types, including powders and granules. The equipment’s flexible L/D ratios and heating zones ensure adaptation to various research applications, while its robust construction supports compliance with industry standards, offering reliability and ease of maintenance.

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Forms and Tests Small Batch Extrusions

The laboratory extruders from The Bonnot Company address the specific needs of research and development environments by providing precise control over material extrusion. These CE-compliant units utilize the company’s proprietary twin packer technology to ensure positive material ingestion. Tailored for multiple applications, they are equipped for temperature control and pressure monitoring, making them ideal for handling diverse materials such as bulk molding compounds, carbon, and food. With outputs ranging from 5 to 150 pounds per hour, these extruders are versatile for bench-top and pilot-scale operations. Each model, from the 1 Series to the 2 Series, integrates seamlessly into existing production lines with optional touchscreen controls, high torque gear motors, and quick-release connections for efficient maintenance. Housed in stainless steel, these extruders ensure durability and chemical resistance, meeting rigorous testing protocols across industries like chemical processing, food manufacturing, and polymer development. Optional features provide customization and data collection capabilities, supporting complex research projects and scale-up processes.

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Processes and Loads Sealants and Mastics Efficiently

The RS 6 Series LB and RS 8 Series LB Live Bottom Extruders from The Bonnot Company are engineered to streamline batch processing workflows, tackling the challenge of efficiently handling entire loads of diverse materials—ranging from sealants and mastics to industrial rubber and food products. This equipment stands out with dual-drive technology that independently controls feeding and extrusion, providing unparalleled precision in material handling.

With customized feed beds and multiple temperature zones, including screw temperature control, the Live Bottom Extruder ensures consistent output and optimal material properties. It processes applications such as butyl sealant strips, automotive mastics, and cereal bars, supporting capacities from 1,000 to 4,500 lbs/hour, depending on the model. The extruder’s design incorporates high torque motors and a hydraulic batch loading system for seamless integration into your production line.

The RS Series features jacketed barrels for enhanced temperature regulation, while its flexible configuration—right or left-hand orientation—accommodates various facility layouts. The extruders are suitable for chemical, food, rubber, and sealant industries, offering robust construction with optional material and corrosion-resistant finishes. Simplified maintenance and customizable options ensure these extruders meet specific operational demands and production goals efficiently.

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Efficiently Blends and Mixes Industrial Materials

The 12 Series PM Single and PM Twin Pugmill Mixers from The Bonnot Company are designed for industrial material blending, utilizing twin shaft technology with variable pitch knives for enhanced mixing intensity. These mixers are pivotal in processes requiring high-torque operation and precise control. The equipment supports a diverse range of applications, including bulk molding compounds, food products, and rubber processing, ideal for producing durable components like EPDM rubber seals and eco-friendly firelogs.

With the capability to mix solids, powders, and slurries continuously, the mixers ensure seamless integration into existing production lines. Their bolt-through design minimizes maintenance costs, while the adjustable slide gate controls mixing cycles and throughput. The jacketed feed beds facilitate temperature management, enhancing the handling of heat-sensitive materials like guar gum thickeners.

Engineered for rigorous industrial environments, these pugmill mixers also offer integrated controls for automation, adjustable output rates, and optimal alignment with downstream extrusion and processing equipment. Optional customization allows accommodation of specific line layouts and operational needs, ensuring versatility and precision in material processing tasks.

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Processes and Forms Diverse Industrial Materials

The Terrier Extruder from The Bonnot Company is engineered for high-volume material processing, offering robust solutions for industries such as chemical, food, and rubber manufacturing. This extruder employs a high torque drive and a robust gearbox to handle challenging materials with ease. It utilizes a segmented cast screw segment system and heavy-duty thrust bearings, enabling years of cost-effective and low-maintenance operation. Known for its versatility, the Terrier Extruder effectively processes a wide range of applications, from forming silicone sealants and clay bricks to producing activated carbon pellets and cookie dough. Its large hopper design, with optional counter rotating packer, enhances feeding efficiency, especially for difficult materials. With processing capabilities ranging from 5 to over 3500 lbs/hour, and power options up to 75 HP, it integrates seamlessly into continuous production lines, supporting high-volume and automatic operations. Customizable with jacketed components for temperature-sensitive processes, it offers flexible adaptation for specific industry needs.

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Enhances Material Ingestion and Extrusion

The Twin Packer Single Screw Extruder from The Bonnot Company solves the challenge of efficiently handling difficult materials prone to bridging in feed sections. With a versatile design, it serves applications from chemical catalyst production to pet treat formation. Its working principle involves customizable screw geometries and independent gear motor drives, optimizing material flow and process control. Models like the 1 Series TP to the 8 Series TP offer throughput capacities ranging from 5 to over 3500 lbs/hour, accommodating various production scales. The extruder integrates seamlessly into existing lines with its continuous operation and variable speed capabilities, while ensuring energy efficiency through high torque gear motor technology. Custom engineering options include configurable screw lengths, diameters, and material protection features, making it suitable for diverse industrial environments. Its robust design includes jacketed barrels for temperature control, ensuring consistent processing conditions. Additionally, The Bonnot Company provides engineering support to tailor the extruder to specific operational needs, ensuring seamless integration and performance in demanding industrial settings.

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Controls Material Feed for Extrusion and Processing

The Twin Shaft Feeders from The Bonnot Company are designed to provide a controlled material feed for extrusion and processing applications. What sets these feeders apart is their variable pitch knives, allowing for customizable residence time and feed rate adjustments, essential for continuous or variable-pitch operations. Ideal for industries such as chemical, food processing, and rubber, they handle a variety of product types including solids, powders, and granules. Typical applications include feeding bulk molding compounds, carbon materials, and rubber extrusions, leading to end-products like molded plastic parts and automotive catalytic converters. The feeders integrate seamlessly into production lines, featuring direct connect gear motors and sealed gear cases for durability, while offering custom bases and orientation to fit existing setups. With processing capabilities tailored through integrated controls, these feeders ensure optimized flow and material consistency, critical for maintaining downstream processing efficiency.

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