High torque-capacity, high free-volume geometry and uniform barrel heating ensure consistency is maintained under all operating conditions. Quality is maintained at high output or by low bulk density materials with optional features such as through-shaft cooling and side feeding.
2. Cooling Conveyor
Nip rolls transfer the product to the conveyor for cooling. A closed loop water system can be specified to aid cooling.
3. Product Flaking
Product is flaked before discharge.
4. Product Discharge & Collection
In addition to the extruder, a complete process line comprises ingredient mixing and feeding before the extruder and cooling, with flaking and grinding after it.
Baker Perkins works with a number of partner companies who can supply all the pieces of equipment required to put together a full process line. Each one specializes in their particular technology so customers are assured of excellent performance throughout the process. Working with partners ensures that the capacities of the individual units are matched and that mechanical and electrical interfaces are optimized before the equipment arrives on site.
- Industrial Extrusion
In the pharmaceutical industry, continuous processing techniques are being developed to give productivity and product quality improvements over the traditional batch processing alternatives.
Constructed according to the specific requirements of the pharmaceutical industry, the MP-PH is available in a range of sizes, from bench-top models suitable for processing batches of a few hundred grams to large scale production units with capacities of several hundred kilograms per hour.
The 'clamshell' barrel design allows access to all contact parts for cleaning and maintenance. CIP facilities are also available. The versatility of the MP-PH series allows a wide variety of raw materials to be processed under a variety of processing conditions.
The Baker Perkins MP-PH series of twin screw extruders can be used for continuous production of solid dosage formulations by either continuous granulation, extrusion spheronisation or melt extrusion techniques.
The MP-PH twin screw mixer extruder is the ideal choice for improving productivity and product quality through continuous processing in the pharmaceutical industry.
Baker Perkins offers comprehensive support on all machines from our sales and service centres in the UK and USA. A full range of replacement parts plus engineering service and equipment upgrade packages ensure that your machine is kept running at optimum efficiency throughout its life.
Continuous processing techniques
Continuous processing gives productivity and product quality improvements over the traditional batch processing alternatives. It can also cut costs.Baker Perkins MP-PH extruders can be used for continuous production of solid dosage formulations by either the continuous granulation, extrusion spheronisation or melt extrusion techniques.
Cost saving potential
Continuous processing overcomes many drawbacks of batch processing which require time, effort and investment. Continuous processing reduces many process stages to one. This lowers investment, energy, labour and space requirements. Waste shrinks to negligible levels. Cleaning and maintenance are rapid and easy.
Continuous v. Batch
In a continuous production process, raw materials are fed accurately and continuously into the automated system. Tests and measurements of pre-defined product and / or process characteristics can be carried out continually. These checks are accomplished without interrupting the manufacturing process, and without stopping the equipment or the process. Batch to batch variation is eliminated. Process control is improved. In contrast, batch processing is based on a long series of reactions or events. This can result in time-consuming production procedures, with the need for expensive storage of reaction intermediates.
In a continuous process, rejected product can be handled by live automated feedback, and adjustment to the process parameters and recycling loops. This enables the re-use of some or all reject materials. Rejected material can be minimized by discarding small amounts of product rather than complete batches.
- Pharmaceutical Processes
Production of controlled release formulations by extrusion spheronisation usually involves an energy intensive drying stage. When the active ingredient is sufficiently thermally stable to permit compounding into a molten binder then production by this route eliminates the drying stage.
The MP-PH range of closely intermashing co-rotating twin screw extruders has been specially designed to meet the specialist needs of the pharmaceutical industry. Constructed in wear resistant stainless steel, according to cGMP guidelines, the MP-PH is suitable for the melt extrusion of many pharmaceutical compounds. The mixer is electrically heated to promote melting of the binder without excessive mechanical energy input. The molten mass can be extruded onto a cooling band or roller to form a flaked product. This can then be ground to a free flowing powder for tableting or filling to capsules.
Wet granulation is a common technique for preparation of free flowing porous granules which are readily compressed into tablets.
Continuous wet granulation combines solid components and binding liquids inside the twin screw mixer extruder. The granules formed can be dried in a continuous dryer. The MP-PH range of closely intermeshing co-rotating screw extruders is suitable for the wet granulation of many pharmaceutical compounds.
Production of spheroids by extrusion spheronisation is widely used in the manufacture of controlled release dosage forms. The particles formed are smooth surfaced, round and exhibit a narrow and reproducible size distribution. The density and friability of such particles are also well defined. These characteristics result in the particles being easily and uniformly coated and lead to well defined dissolution profiles. In addition to the the pharmacokinetic properties of the microspheres, the regular beads exhibit excellent flow properties and are able to be accurately filled into hard gelatin capsules.
High drug loadings are necessary to achieve sustained blood levels of active pharmaceutical over an extended time period. Drug loadings of 60-85% in a polymeric matrix are possible with the use of extrusion spheronisation techniques.
The use of a twin screw extruder allows combination of the wet massing and extrusion stages into a single unit. The dry powder blend is fed to the extruder where it is mixed with a liquid binder. The resulting wet mass is then extruded through a die plate to form 'noodles' before spheronisation.
Brochure: Industrial Extrusion
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