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A novel lab-scale screen extruder for studying extrusion-spheronisation.

M Zhang¹, S Mascia, S L Rough

¹Department of Chemical Engineering and Biotechnology, New Museums Site, Pembroke Street, Cambridge CB2 3RA, UK.

International Journal of Pharmaceutics

|July 23, 2013

Summary

A new laboratory roller screen extruder (LRS) simulates industrial processes. This device aids in evaluating formulations for screen extrusion-spheronisation, producing acceptable pellets for capsule filling.

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Area of Science:

Pharmaceutical Engineering
Materials Science
Process Engineering

Background:

Industrial screen extrusion-spheronisation is crucial for pharmaceutical pellet production.
Replicating industrial conditions in a laboratory setting is challenging.
Understanding the mechanics of screen extrusion is vital for process optimization.

Purpose of the Study:

To develop and characterize a novel laboratory roller screen extruder (LRS).
To investigate the key parameters influencing extrusion performance.
To evaluate the LRS's capability in assessing formulations for industrial applications.

Main Methods:

The laboratory roller screen extruder (LRS) was designed to mimic industrial screen extruder geometry and shear rates.
A cohesive 45 wt% water/microcrystalline cellulose paste was used for commissioning.

Keywords:

Extrusion Granulation Paste Screen Spheronisation

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Key operating parameters (gap size, roller speed) were systematically varied.

Main Results:

Extrudate mass flow rate, screen force, and roller torque were controlled by gap size and roller speed.
Apparent shear rate, based on blade-screen clearance, emerged as a quantitative scale-up criterion.
Spheronisation yielded pellets with narrow size distribution and acceptable sphericity.

Conclusions:

The LRS effectively replicates critical aspects of industrial screen extrusion.
The developed LRS can be utilized for formulation assessment prior to industrial scale-up.
The findings support the use of LRS for predicting industrial screen extrusion-spheronisation performance.