RES-2PN 2x12mm Pharma twin-screw laboratory extruder with a specialized feeder
RES-2PN 2x12mm-Pharma laboratory extruder
Scalability from lab to pharmaceutical production. Laboratory Pharmaceutical Extruders are a valuable research and development tool for performing research that will eventually be scaled up to production. In addition to preventing the use of valuable production resources, significant material cost savings can be achieved by making small batches of the product. The key to applying scale of operation is the flexibility of the laboratory pharmaceutical extruder. Versatile lab extruder allows processes to be tested and modified for best results before scaling up to production. A key factor in successful scaling is ensuring that the material has exactly the same experience in lab extruders as it does in production pharmaceutical extruders. Zamak Mercator Laboratory Extruders are fully customizable and can be equipped with specialized process control instrumentation to continuously measure and record parameters for accurate process mapping. The technical parameters of our pharmaceutical extruders are high. Our pharmaceutical extruders are compact, versatile, yet stable and precise. They have built-in digital control with a touch panel operator, they can work in the Ethernet network. They do not require connection to an external computer to work, they can be controlled wirelessly from a tablet. Laboratory pharmaceutical extruders RES-2PN 2x12mm-Pharma Zamak Mercator turn out to be a very profitable investment in equipment designed for research on hot extrusion of complex mixtures of active drugs.
Technical data of the device
|Extruder Extruder Screw Diameter:||2 x 12 mm||Replaceable cylinder working surfaces:||Yes |
|Extruder screws length:||40 - 48 L/D||Horizontally split cylinder:||Yes |
|Segmented construction of extruder screws:||Yes ||Top dosing and measuring ports [every 4D, side ports every 8D]:||Yes |
|Co-rotating operation of the extruder screws:||Yes ||Volumetric and gravimetric dosing systems:||Yes |
|Counter-rotating operation of the extruder screws:||Yes ||Zonal cylinder cooling system:||Yes |
|Maximum torque per extruder screw:||9 Nm||Water-cooled charging zone with its own closed-circuit cooler:||Yes |
|Maximum rotation of the extruder screws:||600 - 1200 obr/min||Automatic configuration change from concurrent to counter-rotating:||Yes |
|Drive unit power available:||2.2 kW||Co-rotating extruder screws:||Yes |
|Maximum power density:||10.92 Nm/cm3||Counter-rotating screws of the extruder:||[option] |
|Maximum working temperature of the plasticizing system - nitrided steel:||400/450 ℃||Real-time PLC and Ethernet controller:||Yes |
|Maximum operating temperature of the plasticizing system - acid-resistant steel:||270 ℃||Cylinder inserts and screws nitrided extruder:||[option] |
|Cylinder cooling system - air independent for each zone every 4D:||Yes ||Cylinder inserts and hardened acid-proof screws:||[option] |
|Feeding zone cooling system - pressurized water with its own cooler and pump:||Yes ||Cylinder inserts made in HIPP technology:||[option] |
|Temperature measurement and control for each cylinder zone and head:||Yes ||Side feeders:||[option] |
|Measurement of the torque of the extruder screws:||Yes ||Degassing system:||[option] |
|Measurement of the axial force acting on the extruder screws:||Yes ||Dosing of liquids to be filled with a peristaltic pump:||[option] |
|Material pressure and temperature measurement:||Yes ||High-pressure dosing of fluids into the cylinder by a gear pump:||[option] |
|Measurement of the drive load:||Yes ||Dosing gases into the cylinder under pressure:||[option] |
|Recording and archiving of measurement data and recipes:||Yes ||Wifi and tablet control:||[option] |
|Measurement of consumed electricity:||Option ||Remote supervision and service diagnosis:||[option] |
Important performance characteristics
Precise measurement of the axial force acting on the screws
No need to disassemble the dispensers to open the cylinder and see the process progress
Modular construction models Series -RES-2P Vertex 2x16 / 2x20 / 2x24 mm
Non-modular models Series -RES-2P Vertex2x12 / 2x16 / 2x20 / 2x24 mm
Many models and equipment options available
Replaceable inserts forming the working surface of the cylinder
Wireless remote control
Replaceable cylinder liners
Integration of gravimetric and volumetric dispensers for granules of powders, liquids and gases
The possibility of thermal calibration of the cylinder
Digital control and communication system
High speed heating and cooling of the cylinder for all zones
Possibility to measure temperatures and melt pressure in each zone
Freely configurable cylinder ports
The possibility of using concurrent and counter-rotating worms with a segmented structure
The cylinder heating and cooling system ensures accurate and reliable temperature control of each zone
Modular side conveyor system
Laboratory twin screw extruders easy and convenient access of horizontally split cylinder 2 x 12mm lab extruder
Możliwość personalizacji układu uplastyczniającego
Systemy dozowników grawimetrycznych i wolumetrycznych dla granulek, proszków, cieczy i gazów
Spersonalizowane systemy mocowania dozowników
Spersonalizowane programy użytkowe
Systemy bocznych w połączeniu z dozownikami grawimetrycznymi i wolumetrycznymi
Laboratory extruders for extruding new pharmaceutical products RES-2PN 2x12mm-Pharma
Laboratory pharmaceutical extruders are small versions of production extruders. However, there are many differences between laboratory and production extruders. Laboratory extruders are more extensively equipped with functions that allow testing many materials, which makes them very versatile devices. They have functionalities that facilitate and accelerate the research process. Laboratory pharmaceutical extruders are equipped with a rich set of precise measuring sensors .
Lab extruders are ideal for short delivery and response times for low volume batches or pilot trials. They can be tailored to suit all applications.
They are designed to enable the efficient development of new products and the testing of new extrusion processes can be critical for a manufacturing company or research laboratoriesLaboratory extruders can be used to reduce the time to market of new pharmaceutical products.
Pharmaceutical extrusion laboratory extruders can test active drugs (APIs) Different formulations can be tested to find out how they behave during extrusion The amount of extruded samples is usually sufficient to be easily made for testing and evaluation of a newly developed product.
Continuous research and development ensure continuous improvement and optimization of final products. Final products require quality control. This is most easily done on a laboratory scale.
Universal laboratory extruders designed for small batches of product, with the possibility of a quick change of the research process, can be effectively used in the training process. They allow you to effectively use time and maximize the effectiveness of training.Laboratory extruders are ideal devices for practical acquisition of new knowledge and experience.
Construction elements of the pharmaceutical extruder:
Feeding tank (gravimetric or volumetric feeding).
Extruder cylinder with precise temperature control (heating and/or cooling).
Die forming the extruded product (different die configurations available).
Additional equipment of the pharmaceutical extruder:
Process analysis technology - saves all measurement data.
Vacuum pumps for degassing the plasticizing system of the extruder.
Pumps for feeding fluids into the extruder barrel.
Pharmaceutical granulators for cutting extruded material.
Calendering rollers for forming tapes or films.
The pharmaceutical extruder provides measurement and monitoring of the following parameters in the extrusion process using standard instrumentation:
Axial force acting on the screws
Temperature of the extruder barrel zones
Torque of the extruder screws
Rotational speed of the extruder screws
Ambient relative humidity
Vent vacuum level (if applicable)
By monitoring these parameters, it is possible to effectively conduct research on the extrusion process. The condition must be met that the measurements made are reliable and the operation of the regulators is reliable and repeatable. In this way, the research process can be maintained and optimized and can be characterized by important aspects. can be determined by these parameters.
The extruder instrumentation mentioned above allows the operator to control the extruder in an optimal way. Some critical quality attributes can be combined using the parameters of the extrusion system with values monitored by the extruder instrumentation. It is important that changes in the operating parameters of the extruder are reliable.
Zamak Mercator laboratory extruders are modular in design to facilitate configuration changes. In particular, the configuration of the extruder screws has a significant impact on the extrusion process and can be designed to achieve high or low shear.
Parameters defining the screws of the pharmaceutical extruder:
(Di) is the internal diameter of the extruder screw and (D0) is the diameter of the extruder barrel The ratio D0/D is very important and indicates the available free volume of the extruder screws The length of the extruder barrel is given as a multiple of the diameter of the extruder barrel [Do] This means that an extruder of length 40 L/D has a length equal to 40 times the outer diameter of the extruder screws. For scaling purposes, it is important to keep the functional length and D0/D ratio constant.
Advantages of pharmaceutical hot extrusion [HME].In the pharmaceutical industry, hot melt extrusion has been used for a variety of purposes, such as:
Increasing the rate of dissolution and bioavailability of the drug
Controlling or modifying drug release
Masking the taste of the product
Stabilizing the interface of the active substance API
Parenteral storage and topical drug delivery systems
Modification or addition of a functional group
Controlled degradation and cross-linking of polymers to produce a product with a controlled molecular weight distribution
Reactive blending which involves the extrusion of two or more compatible polymer blends leading to the formation of a polymer-polymer complex
Increasing the dissolution rate and bioavailability of APIs that are poorly soluble in water are important challenges in the development of dosage forms. One approach is to form a solid dispersion solution of the drug with hydrophilic excipients. thermodynamic barrier to dissolution Once formulated, hot extrusion is a reliable and robust process offering cost-effectiveness advantagesCompared to other solid solution manufacturing processes, the extrusion process is much less complex The production of such dosage forms requires only a few steps and avoids the use of organic solvents.
Hot extrusion also has advantages over solid solution/dispersion forming methods using solvent methods:
There is no need to handle flammable solvents
No residual solvents
Possibility of continuous processing
Fewer process steps
High product density
Pharmaceutical extrusion equipment takes up little space
The extrusion process does not require water
In addition to oral medicinal preparations, the hot extrusion technique can be used to produce parenteral depots such as implants and stents, and topical delivery systems such as dermal or transdermal patches. For these applications, the extrusion process is often combined with a shaping or injection molding step.
A look into the future of HME pharmaceutical hot extrusion.
The value of 'continuous processing' in the pharmaceutical industry is recognized Hot extrusion (HME) is a manufacturing process widely used in the plastics industry and has considerable potential as a continuous pharmaceutical process.
New chemical entities that exhibit poor bioavailability due to solubility problems are prime candidates for hot extrusion. This technology can be used to disperse such drugs in a given matrix at the molecular level by forming a solid solution. Combined with the use of dispersed, amorphous and molecularly dissolved systems, it can be apply a range of other formulation techniques using a melt extrusion approach. HME has also been shown to provide many different advantages in the production of thin films for both drug delivery and wound care. Hot extrusion technologies can offer numerous advantages over traditional methods. Shorter and more efficient lead times to the final product.Environmental benefits of eliminating solvents in processing (including recyclability) Increased drug delivery efficiency to the patient makes hot extrusion an exciting challenge for pharmaceutical scientists.
A wide range of dosage forms and applications from oral to topical can be prepared Solid dispersions or solid dissolutions of drug embedded in carrier matrices can allow for sustained release and improved dissolution rates A wide range of functional excipients are available Potential drug and matrix degradation may be hampered by high process temperatures and shear forces. However, these challenges can be overcome through formulation and equipment design and engineering approaches. Selection of low melt media or use of compatible plasticizers can reduce
Zamak Mercator is a manufacturer of pharmaceutical twin-screw extruders with screw diameters of 2 x 12 mm and 2 x 16 mm.
Pharmaceutical research twin-screw extruders designed for larger tasks [applications] with screw diameters: 2 x 20 mm and 2 x 24 mm.
The extruders can work as co-rotating and, after changing the operating mode, as counter-rotating with the L/D range up to 48, with a modular and non-modular structure.
The key factor determining the quality and credibility of research on the pharmaceutical extrusion process is the control and reliable measurement of the melt temperature in each zone of the extruder.
The cylinder of the pharmaceutical extruder is divided along the longitudinal axis in order to obtain the possibility of optical control of the process of plasticizing and mixing the melt.
The extruder cylinder is equipped with ports for side feeders and ports in the top of the cylinder for dispensing liquids or gases. The heaters are arranged so that the heat is evenly distributed in each heating and cooling zone of the pharmaceutical extruder cylinder.
The temperature measuring sensors are arranged in such a way as to ensure reliable temperature measurement and limit measurement interference from heaters operating at a higher temperature than the plasticizing system.
In order to avoid uncontrolled temperature rises, each zone of the cylinder is equipped with an efficient and fast cooling system that cooperates with the heating system of the pharmaceutical extruder cylinder.
Precise temperature control of the plasticizing system of the extruder is ensured by a multi-zone temperature controller designed by our company.
The temperature control system has the ability to calibrate and shape the heating and cooling characteristics of the plasticizing system by the researcher.
We have designed cylinders with exchangeable inserts constituting the working surface of the extruder cylinder. In practice, this means that we can adapt the extruder to work with other materials in a short time by replacing the cylinder inserts. Interchangeable inserts allow for quick and relatively cheap regeneration of the plasticizing system. In principle, inserts can be made of any material and technology that is suitable for this purpose. A set of screws is easy to replace with another. You can conduct research on virtually all materials in the medical and pharmaceutical industries.
The Vertex II geared extruders replace two extruders, expanding your research capabilities.Our extruders are equipped with torque dividing gears that can work as co-rotating and counter-rotating, the direction of rotation is changed automatically from the operator's panel.
Zamak Mercator research extruders can be equipped with a precise tensometric measurement of the force acting on the screws lengthwise, this mechanism additionally extends the possibilities of conducting research.
The Vertex II geared extruders replace two extruders, expanding your research capabilities. Our extruders are equipped with torque dividing gears that can work as co-rotating and counter-rotating, the direction of rotation is changed automatically from the operator's panel.
We have made every effort to ensure that the information about our products is factually correct. Please treat the technical data of the devices as indicative, because we constantly improve our products, adapting them to changing technologies.
The presented offer is informative and does not constitute an offer within the meaning of the Civil Code