How To Control Particle Size In Dry Granulation?

1.What Is Dry Granulation In Pharmaceutical Industry?

Dry Granulation-Sourced:lfatabletpresses

The granule with great uniformity and flow is the essential part for the manufacturing of tablets and capsules. Granulation is the part which can help make the qualified granule for your later medicine products manufacturing. There are wet granulation and dry granulation for you to choose.

Dry granulation is the technique which made granules with no adding of liquid. Without the adding of liquid or binder, dry granulation makes no change to medicine products property. Dry granulation makes great improvement for the products flow, characteristic, density, size and so on for the later smooth and qualified tablet manufacturing work.

2.What Industry DoesDry Granulation Be Applied Commonly?

Dry granulation can be applied to many industries. Here are the common industries you may find the dry granulation application.

Pharmaceutical industry

Pharmaceutical Industry-Sourced:support

Pharmaceutical industry is the industry where dry granulation applied most frequently. There are tablets and capsules which all need the even, uniform and stable granule products. For nutraceutical products, the dry granulation can also be applied for the various oral dosage.

Plastic industry

Plastic Industry-Sourced:storker

There is the great need of various plastic parts in plastic industry. The plastic parts of suitable and precise size are essential. Dry granulation makes the great job of pruning and making the even and uniform plastic products.

Food industry

Food Industry-Sourced:hanningfield

Food industry is also the industry which needs the even and uniform particle and granules. There are various types of instant mix, flavoring products and so on which all need the high and qualified granule for the best work of the products.

Agricultural industry

In agricultural industry, there is the strict work in making great powder for fertilizer, pesticide and other agricultural powder. Dry granulation is also the common manufacturing method which applied in agricultural industry.

3.How To Control Particle Size In Dry Granulation?

In dry granulation, the rule for the qualified work is the uniform and even particle size. So how to control particle size in dry granulation.

Adjusting the tablet pressing pressure

Adjusting The Tablet Pressing Pressure-Sourced:usvalidation

Tablet pressing is one of the key steps in dry granulation. The pressing pressure directly affects the compactness of the granules and the difficulty of subsequent crushing. If the pressure is too low, the material forms loosely packed tablets, which may generate more fine powder during subsequent crushing and granulation, increasing the proportion of small particles.

Increasing the tablet pressing pressure results in higher hardness and density of the tablets, potentially increasing the proportion of large granules. For example, when producing medicines with high granule strength requirements, increasing the pressing pressure can yield more large granules with better strength. However, it is important to note that excessive pressure may lead to excessively hard granules, which could affect the drug's dissolution performance.

Controlling the press roll speed

Controlling The Press Roll Speed-Sourced:sciencedirect

The speed of the press roll affects the time the material is compressed between the rolls. With a higher speed, the material is compressed for a shorter time, resulting in relatively loose tablets, which may lead to an increase in the proportion of small particles and fine powder in the granules. A slower speed allows for more thorough compression, leading to firmer tablets and potentially an increased proportion of large granules.

For softer materials that are easy to form, the press roll speed can be increased to improve production efficiency while adjusting the particle size distribution in the subsequent granulation steps. For difficult-to-form materials, reducing the speed ensures thorough compression and proper formation of the granules.

Adjusting the crushing and granulation parameters

Adjusting The Crushing And Granulation Parameters-Sourced:matconibc

Choosing the right crusher type and parameters

Different types of crushers produce varying effects on granule fragmentation. For instance, a hammer crusher has a stronger impact force and is suitable for crushing harder tablets, but it may generate more fine powder. A roller crusher, on the other hand, is gentler and better at controlling the particle size and distribution.

In addition, the speed and gap of the hammer or roller in the crusher also affect the crushing outcome. Increasing the speed or reducing the gap results in more thorough crushing and an increased fine powder ratio. Conversely, reducing the speed or increasing the gap leads to a higher proportion of large granules.

Determining the granulator mesh size

Granulation involves screening and classifying the crushed particles. The mesh size directly determines the final particle distribution. Using a mesh with a larger aperture increases the proportion of large granules, while a smaller aperture yields more small granules and fine powder.

The appropriate mesh size can be selected according to the product's particle size requirements, and multi-stage screening can be used to precisely control the ratio of particles in different size ranges.

Optimizing the feeding speed

Optimizing The Feeding Speed-Sourced:chamunda

Feeding speed influences the filling volume and uniformity of compression within the equipment. If the feeding speed is too fast, the material will not be adequately compressed between the rolls, resulting in uneven tablet formation and unstable particle distribution, with more fine powder.

A slower feeding speed may reduce production efficiency. Feeding speed should be adjusted based on the equipment's performance and material characteristics to ensure uniform compression and the proper particle distribution.

Setting the continuity and stability of equipment operation

The continuity and stability of dry granulation equipment operation are crucial for consistent particle distribution. Frequent starts and stops or fluctuations during operation lead to inconsistent processing conditions at different stages, affecting the particle distribution. Therefore, it is essential to ensure the equipment runs smoothly, with regular maintenance and stable parameters to achieve a consistent particle distribution.

4.What Are The Advantage Of Dry Granulation?

Dry granulation is welcomed by many industries. So do you know the advantage of it?

Higher efficiency

Higher Efficiency-Sourced:mintzberg

Dry granulation applies the cutting-edge machine for the higher efficient granulating work. The dry granulating technique also applies no liquid for binding and saves the process in adding and drying. The high efficiency can save you a lot in manufacturing process and manufacturing time.

More versatile

Dry granulation is more versatile and it can make the consistent and various granulating work. You may apply it for medicine products, plastic products, agricultural products and many other products. It is also flexible in making manufacturing scale.

Better quality

Better Quality-Sourced:liberty-bd

For the products with low moisture content and high sensitive to heat, dry granulation is the great technique to prove the stable and qualified products feature. Dry granulation can have the quality and production scale proved at the same time.

Lower cost

Dry granulation makes the great work for various products with little cost in time and budget. Dry granulation is economic which has no adding of other binder. Besides, it is also more time-saving which is also the great sign for the lower cost.

5.What Are The Main Types Of Dry Granulation?

Dry granulation has more than one type. And here are the main types of your dry granulation technique.

Dry mixing

Dry Mixing-Sourced:yindamachinery

Dry mixing has the process of sifting, mixing, blending and final compressing. In dry mixing, you should also add active pharmaceutical ingredients, lubricants, excipients and so on. Dry mixing can make particle or granule with great uniformity, bulk density and flow property.

Slugging process

Slugging Process-Sourced:chinacanaan

Slugging process has the complex process of sifting, blending, compressing, milling, pruning, mixing and pressing. The slugging process is complex and time consuming. But it is high qualified and efficient. You may apply tablet pressing machine, sifter and other blender for its applying.

Compaction

Compaction-Sourced:AIPAK

Compaction is also the common dry granulation technique. It is similar to slugging process. With roller compacter, it can has powder and granule fit into roller for compressing. The flakes it make can then be sifted and milled for the manufacturing of granules. The last step of compaction is blending of granules with lubricants.

6.What Are The Equipment Applied For Dry Granulation Process?

In dry granulation process, there are equipment which provides the essential and great help. Here are the common equipment applied for dry granulation process.

Roll compaction machine

AIPAK Roll Compaction Machine

Roll compaction machine is the irreplaceable machine for dry granulating work. It can make your powder into granules by series of work like squeezing, crushing and granulating. The work of your roller compaction machine is qualified enough for the direct tablet pressing and capsule filling.

It is the typical and common products which can be applied for dry granulation work. For heat sensitive material, fragile material, agglomerated material, it makes the outstanding work. The high efficiency and low energy consume make it welcomed by many business. Its exposed extrusion system can help make the easy and reliable maintaining and cleaning.

7.What Are The Process Of Dry Granulation?

How does dry granulation work? Here are the process of dry granulation.

Pressing powder

Pressing Powder-Sourced:lorenzato

You should first send your powder or material into machine. The punches will then get on the job to press machine into large slugs. And you can also adjust the size or thickness of your slug products.

Sifting slugs

Sifting Slugs-Sourced:3d-printer

Sifting is the important step for your dry granulation. Before pressing, you should make the careful sifting for the even mixing of your raw material. After the pressing work, you should also sift slugs for later smooth milling and breaking.

Break slugs

By applying the work of hammer or oscillating granulator, you can then degrade your slugs to your needed size. You should make clear the size of your later products for breaking for the benefits of your later milling work.

Mill slugs

Mill Slugs-Sourced:flodyn

Milling is the last step of your dry granulation. From milling, you can then have your products spherical shape which is so beneficial for your later tablet and capsule work. You also need the second sifting for the more even and uniform size.

8.What Is The Difference Between Dry Granulation And Wet Granulation?

What is the difference between dry granulation and wet granulation? Here is the comprehensive comparison between the two technique.

Dry Granulation VS Wet Granulation-Sourced:anishpharma

Points	Dry granulation	Wet granulation
Cost	Dry granulation is cheaper and more common in granulating work. It applies less source and simpler process.	Wet granulation costs more as it applies various different excipients and special machine and involves higher investment.
Pollution	In the process of dry granulation, there is large pollution and dust which may lead contamination for your manufacturing place.	Wet granulation makes less pollution in the granulating process.
Equipment applied	Dry granulation can be made with the common machine and equipment.	Wet granulation can only be made with the special machine like fluid bed dryer, high speed mixer  granulator and so on.
Products type	For products which has low content of moisture and high sensitive to heat, dry granulation is the great choice.	Wet granulation can have the active ingredients protected well in the granulating process.
Excipients applied	Dry granulation relies on the compaction for the granule forming.	Excipients are essential parts for wet granulation work. And you may find the use of it in wet granulation.
Feature change	Dry granulation involves little adding of other liquid or excipients and can save the natural feature of products easily.	Wet granulation requires the adding of liquid, lubricants or other products for the granules making.

9.What You Should Care In Dry Granulation?

Dry granulation can benefit you so much. Here are the things you should care in dry granulation for better products and smooth process.

Particle size distribution

Particle Size Distribution-Sourced:bulkinside

The size of particle and size change of particle can all lead the change of flow and compressing ability. Particle size distribution affect the product quality/ you should make the careful check about the machine condition and other technique parameter for the products quality.

Moisture control

Moisture can affect the granulating process greatly. The excess moisture may lead clumping and the lack of moisture may lead poor formation. You should make the careful control of manufacturing environment and temperature for the great products producing.

Binder selection

Binder Selection-Sourced:pyropower

The selection of your binder can also affect your products quality. The type and concentration of your binder make great difference for your granulating process. You should choose the suitable binder according to your different products type.

Granulating equipment

Granulating Equipment-Sourced:saintyco

For dry granulating, there are various granulating equipment for you to choose. To make the stable and smooth granulating work, you should make the careful scaling and calibrating for your machine and further manufacturing.

Process control

You should make strict control for every steps in your dry granulating process. The change of temperature, speed and other parameter can all lead change to your granule products. The real-time detect and control can help a lot for your manufacturing process.

Ingredients compatibility

Ingredients Compatibility-Sourced:pharmapproach

The compatibility of your granule products is also important. You should make sure the compatibility of active pharmaceutical ingredients and excipients. The wrong adding of ingredients may lead trouble for your work.

Granule quality

Granule Quality-Sourced:syntegon

Granule quality is the final and great show of your dry granulation work. Your granules should be strong and stable enough for the later manufacturing work. You may get more trial to get the best granule products.

Conclusion

How to control particle size in dry granulation? Do you have your own answer? For the other common problem in dry granulation, you may also get the solution here. Do you have any other problem or question? For your better granulating work, you should contact AIPAK for problem solving. Come on and contact AIPAK.