Granulation plays a crucial role in the production of tablets, capsules, and other solid dosage forms. As the pharmaceutical industry advances, so do the techniques we use to ensure the highest quality products.
Let’s explore some cutting-edge granulation methods that are shaping our field:
1. Hot Melt Granulation Technique
This method involves using a meltable binder (as Polymer), which solidifies upon cooling, to form granules.
Key Advantages: Solvent-free, rapid processing, suitable for moisture-sensitive materials.
Process:
• Heat the binder to a temperature above its melting point
• Mix the molten binder with the powder blend
• Cool the mixture to allow solidification of granules
2️. Foam Binder Granulation Technique
Utilizes foam as a binder for more uniform distribution.
Key Advantages: Reduces binder usage, improves homogeneity, minimizes dust.
Process:
• Create a foam using a liquid binder and a foaming agent as SLS
• Introduce the foam into the powder blend
• Mix to form granules
3️. Steam Granulation Technique
Utilizes steam as a granulating agent.
Key Advantages: Solvent-free, faster than traditional wet granulation, enhances dissolution rates.
Process:
• Introduce steam condensed into the powder mixture
• Dry the formed granules
4️. Moisture Activated Dry Granulation (MADG) Technique
Combines dry and wet granulation principles.
Key Advantages: Low moisture levels, suitable for moisture-sensitive formulations, minimal drying required.
Process:
• Add a small amount of liquid to activate a binder
• Mixing
• Dry the granules without heating to remove excess moisture by sieving and expose it to filtered air
5️. Freeze Granulation Technique
Involves freezing droplets of slurry to form granules.
Key Advantages: Preserves sensitive materials, ensures uniform granule size, minimal thermal degradation.
Process:
• Create a slurry of the powder and binder
• Spray the slurry into a freezing chamber
• Collect and dry the frozen granules
6️. Reverse Wet Granulation
A modified process where the binder solution is prepared first.
Key Advantages: Better granule size control, reduced risk of over-wetting, suitable for high-dose formulations.
Process:
• Prepare a binder solution or slurry
• Add powder to the binder solution gradually
• Mix until granules form
7️. Pneumatic Dry Granulation Technique
Uses air pressure to compact powder into granules without liquid binders.
Key Advantages: No liquid binders needed, suitable for moisture-sensitive compounds, produces granules of the desired size with minimal fines.
Process:
• Compact the powder into sheets using a roller compactor
• Milling or sieving to form granules
• Fine particles are captured by the pneumatic system and recycled through the roller compactor
Each method offers distinct benefits tailored to various formulation needs.
Read also:
- Fluid Bed Granulation Process
- Granulation End Point Determination
- CPP & CQA of Different Stages of Drug Product Manufacturing
Resource Person: Jamal Jameel
