High torque-capacity, high free-volume geometry and uniform barrel heating ensure consistency is maintained under all operating conditions. Quality is maintained at high output or by low bulk density materials with optional features such as through-shaft cooling and side feeding.
2. Cooling Conveyor
Nip rolls transfer the product to the conveyor for cooling. A closed loop water system can be specified to aid cooling.
3. Product Flaking
Product is flaked before discharge.
4. Product Discharge & Collection
In addition to the extruder, a complete process line comprises ingredient mixing and feeding before the extruder and cooling, with flaking and grinding after it.
Baker Perkins works with a number of partner companies who can supply all the pieces of equipment required to put together a full process line. Each one specializes in their particular technology so customers are assured of excellent performance throughout the process. Working with partners ensures that the capacities of the individual units are matched and that mechanical and electrical interfaces are optimized before the equipment arrives on site.
In the pharmaceutical industry, continuous processing techniques give productivity and product quality improvements over traditional batch processing alternatives.
Baker Perkins' MPX extruder range has been specially designed to meet the specialist needs of the pharmaceutical industry. Constructed in wear-resistant stainless steel, according to cGMP guidelines, the MPX is suitable for the extrusion of many pharmaceutical compounds. Extruders are available in a range of sizes, from bench-top models - suitable for processing batches of a few hundred grams - to large scale production units with capacities of several hundred kilograms per hour.
Baker Perkins' MPX twin screw extruders can be used for continuous production of solid dosage formulations by either continuous granulation, extrusion spheronisation or melt extrusion techniques:
Wet granulation is a common technique for preparation of free-flowing porous granules, which are readily compressed into tablets.
The MPX range is suitable for the wet granulation of many pharmaceutical compounds.Continuous wet granulation combines solid components and binding liquids inside the extruder. The granules formed can then be dried in a continuous dryer.
Production of spheroids by extrusion spheronisation is widely used in the manufacture of controlled-release dosage forms.
The particles formed are smooth surfaced, round and exhibit a narrow and reproducible size distribution. The density and friability of such particles are also well defined. These characteristics result in the particles being easily and uniformly coated and lead to well defined dissolution profiles.
In addition to the the pharmacokinetic properties of the microspheres, the regular beads exhibit excellent flow properties and are able to be accurately filled into hard gelatin capsules.
High drug loadings are necessary to achieve sustained blood levels of active pharmaceutical over an extended time period. Drug loadings of 60-85% in a polymeric matrix are possible with the use of extrusion spheronisation techniques.
Using Baker Perkins' MPX twin screw extruder allows the combination of the wet massing and extrusion stages into a single unit. The dry powder blend is fed to the extruder, where it is mixed with a liquid binder. The resulting wet mass is then extruded through a die plate to form 'noodles' before spheronisation.
Production of controlled release formulations by extrusion spheronisation usually involves an energy-intensive drying stage. When the active ingredient is sufficiently thermally stable to permit compounding into a molten binder, then production by this route eliminates the drying stage.
The mixer is electrically heated to promote melting of the binder without excessive mechanical energy input. The molten mass can be extruded onto a cooling band or roller to form a flaked product. This can then be ground to a free-flowing powder for tableting or filling to capsules.
Brochure: Industrial Extrusion
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