Twin-Screw Melt Granulation for Oral Solid Pharmaceutical Products
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Updated: Nov 3, 2025

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Published on: January 27, 2021
Seth P Forster1, Erin Dippold1, Tiffany Chiang1
1Pharmaceutical Commercialization Technology, MMD, Merck & Co., Inc., Kenilworth, NJ 07033, USA.
Abstract:
This article highlights the advantages of pharmaceutical continuous melt granulation by twin-screw extrusion. The different melt granulation process options and excipients are described and compared, and a case is made for expanded use of twin-screw melt granulation since it is a flexible and continuous process. Methods for binder selection are profiled with a focus on rheology and physical stability impacts. For twin-screw melt granulation, the mechanism of granulation and process impact on granule properties are described. Pharmaceutical applications of melt granulation ranging from immediate release of soluble and insoluble APIs, taste-masking, and sustained release formulation are reviewed, demonstrating the range of possibilities afforded by twin-screw melt granulation.
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