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Fast disintegrating pellets: Formulation and evaluation.

Suhad Anabousi1, Hani Naseef1, Moammal Qurt1

  • 1Department of Pharmacy, Faculty of Pharmacy, Nursing and Health Professions, Birzeit University, West Bank,, State of Palestine, 14, Palestinian Territory.

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|November 10, 2025
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Summary

This study developed rapidly disintegrating microcrystalline cellulose (MCC)-based pellets using extrusion-spheronization. Optimized formulations with mannitol, polyethylene glycol 400, polyplasdone, and croscarmellose sodium achieved fast disintegration within 2 minutes.

Keywords:
Extrusion-spheronizationFast disintegrating pelletsPelletscombinationmicrocrystalline cellulosesuper disintegrant

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Area of Science:

  • Pharmaceutical Technology
  • Drug Delivery Systems
  • Materials Science

Background:

  • Extrusion-spheronization is a common pellet production method using microcrystalline cellulose (MCC).
  • Traditional MCC pellets exhibit poor disintegration and extended drug release.
  • This research addresses the limitations of conventional MCC pellets.

Purpose of the Study:

  • To develop rapidly disintegrating MCC-based pellets.
  • To optimize extrusion-spheronization parameters for enhanced pellet properties.
  • To investigate the impact of formulation excipients on disintegration time.

Main Methods:

  • Pellet formulations were prepared using extrusion-spheronization with MCC, mannitol, polyethylene glycol 400 (PEG 400), polyplasdone (PPXL), and croscarmellose sodium (CCS).
  • Process parameters including extrusion and spheronization speeds were optimized.
  • Physical characteristics and disintegration time (DT) of the pellets were evaluated.

Main Results:

  • Optimal extrusion speed was determined to be 500 RPM.
  • A spheronization speed profile starting at 3000 RPM and reducing to 1000 RPM improved pellet sphericity and reduced fines.
  • Increased PEG 400 content to 20%, with 15% CCS and 5% PPXL, significantly reduced disintegration time.

Conclusions:

  • Fast-disintegrating MCC-based pellets were successfully produced via extrusion-spheronization.
  • The combination of mannitol, PEG 400, CCS, and PPXL created a porous matrix enhancing water uptake and rapid pellet disintegration (within 2 minutes).
  • This formulation strategy overcomes the limitations of traditional MCC pellets, offering improved disintegration profiles.