Category Archive: Products

Why Does Your Product Need Dry Granulation?

At Alexanderwerk, we partner with leaders across a range of industries, including pharmaceutical and chemical. Our expertise in dry granulation enables us to provide our customers with solutions for even the most complex powder handling processes. While we are headquartered in Germany, we efficiently serve our customers in Canada, the USA, and Mexico from our 17,000 square-foot facility in Pennsylvania. Offering extended services such as commissioning, calibration, training, and repair services, we consistently help our global customer base reap the many benefits of dry granulation.

The Process

To produce granules, there are two types of granulation processes: wet and dry. Wet granulation requires the addition of a liquid binder to form the granules, joining each individual particle together in a process known as agglomeration. Typically, wet granulation also necessitates a drying process to reduce the moisture within the granules. This can slow down the granulation process and may have a negative impact on the quality of the granules.

Dry granulation, on the other hand, does not require the manufacturer to add a liquid binder. This method utilizes a two-step process; first compacting and then milling the initial powder to create granules with the desired particle size distribution, and density. Most often, manufacturers will utilize roller compaction equipment, which functions by compressing the initial powder between two counter-rotating rollers. 

The dry granulation process

While dry granulation is advantageous across an array of industries, there are some sectors that rely on it particularly heavily. These include:

  • The chemical industry
  • The pharmaceutical industry 
  • The food and beverage industry

When or Why Is Dry Granulation Required?

Due to the fact that it does not require a liquid binding agent, dry granulation is highly beneficial for applications that utilize active pharmaceutical ingredients (APIs). This is because the addition of liquid and a heated drying process may reduce the efficacy of certain APIs. Furthermore, there are many products in the food and chemical industries that are also very heat sensitive. There are two types of material in particular that require the dry granulation process.

Moisture Sensitive Materials

Certain bulk materials, e.g  APIs in the pharma industry, react negatively when they come in contact with moisture. This means that the API is at risk of losing vital chemical properties, thus rendering it ineffective. As these types of materials will not function after undergoing wet granulation, manufacturers must opt for dry granulation instead.

Temperature Sensitive Materials

Once a material has undergone the first step of the wet granulation process, the manufacturer must then put the material through a drying process. Even if a material can handle exposure to moisture, it must also be able to withstand high temperatures if it is to maintain its efficacy after it is dried. If the API in question is sensitive to temperatures, dry granulation is required.

Overall, regardless of the initial properties of the powder blend, the goal of dry granulation is to increase both the particle size and the bulk density of the powder. Both of these outcomes serve to improve the flow of distributed material, thus increasing the efficiency of the manufacturing process.

However, increased efficiency is just one of the advantages of dry granulation. A manufacturer or pharma CDMO may opt for dry granulation due to the fact that dry granulation machinery is smaller and requires minimal amounts of floor space. This process is also very flexible, as it functions well for both large and small volume runs. Additionally, dry granulation is significantly less likely to result in any type of alteration in drug morphology when compared to wet granulation.

Other advantages of dry granulation may include:

  • Improved blending and a fixed blend uniformity
  • Improved tablet disintegration time
  • Dense compaction
  • Reduced friability
  • Dust reduction
  • Reduction of material volume during handling and storage

Partner With Alexanderwerk for Your Dry Granulation Needs

Dry granulation is an efficient and reliable process with a variety of advantages. At Alexanderwerk, our specialists are well-versed in this process, and we work closely with our customers to find the appropriate solution and ensure optimal results for each unique application. Learn more about our dry granulation equipment, or contact us to discuss your project and schedule a consultation.

 

Let’s talk and collaborate with us helping solve your most difficult granulation challenges.

Alexanderwerk Inc Lab2

WP120 and WP200 Pharma in Alexanderwerk Inc’s Chem Lab

Wp120 Pharma in Alexanderwerk Inc lab

WP120 Pharma in Alexanderwerk Inc’s Pharma Lab

Equipment Spotlight: The Alexanderwerk WP120 for Pharmaceutical Roller Compaction

WP120 Pharma

As a global leader in compaction and granulation, Alexanderwerk develops industry-leading machinery for the pharmaceutical industry. We also provide testing facilities that provide our customers with state-of-the-art machinery in a quality-controlled environment.

Our new process testing suites allow our clients to expand their current production capabilities or test out our technology. Among the testing machinery and equipment we have available for onsite pharmaceutical roller compaction is the WP120. This blog post will go into detail about the WP120’s design features and capabilities.

The WP120 Pharma by Alexanderwerk

Alexanderwerk’s WP120 Pharma was designed to meet the stringent standards and requirements in pharmaceutical research and development. It works well in applications involving small batches and provides completely controlled production conditions when processing special products. It features a roller diameter of 120 mm and a standard roller width of 40 mm. It also has an optional MiniBatch production module with a roller width of 25 mm for amounts ranging from 50 grams to 8Kg as well as an optional MicroBatch module for small mounts (1-5 gramm). The WP120 supports a maximum roller speed of 15 rpm and is highly adaptable to the specifications of varying applications. 

The WP120 is designed to process as little as 5 g up to a maximum of 40 kg/h into granules of different sizes. Due to its modular design, the process technology can be disassembled without the need for special tools, which allows for easy cleaning and replacement of rollers. 

The WP120 features a mobile, compact design and was created as a portable unit to provide the highest degree of flexibility for the compaction process. Additionally, it allows previously determined process parameters to be easily scaled up to larger production machines. Machines such as the WP120 can be used for a wide variety of pharmaceutical roller compaction applications to produce products such as:

  • Tablets
  • Nutraceuticals
  • Capsules
  • Instant powders
  • Life science products

Functions & Features

The WP120 features an advanced interface for comprehensive control of the compaction process. This interface enables the operator to precisely adjust parameters such as flake density, throughput, and compacting pressure. Another key feature of the WP120 is Alexanderwerk’s patented Diagonal-Design two-stage granulation unit, which provides gentle granulation and can achieve the final size of the granules based on previously defined tolerances.  Some additional features of the WP120 include:

  • cGMP design
  • Stainless steel construction
  • Throughput from 5 g to 40 kg/h
  • PLC control
  • Separation of the drives from the production area
  • Cantilever roller design ensures consistent compaction and granulation 
  • Fast clean up and roller exchange 
  • Feedback control loop for consistent processing
  • Reproducible scaleup and scale down capabilities
  • Compaction units are individualized with different roller combinations based on the application

The WP120 for pharmaceutical roller compaction has been updated with optional UL-rated controls in its interior. While previous models had been tailored for European markets, Alexanderwerk proudly supports reshoring initiatives in North American markets, as evident by our upgraded models. For additional information or questions regarding our machinery, please contact us today.

Alexanderwerk will exhibit at the Powder & Bulk Solids Conference and Exhibition 2021 taking place at the Donald E. Stephens Convention Center in Rosemont, Illinois (USA) from August 24 – 26, 2021.

Alexanderwerk will exhibit at the Powder & Bulk Solids Conference and Exhibition 2021 taking place at the Donald E. Stephens Convention Center in Rosemont, Illinois (USA) from August 24 – 26, 2021.

Powder Bulk Show 2021

Come on our and stop by at Booth #2505. Our regional sales managers Albin Friedrich and Matt Walczer are looking forward to collaborate with you. Besides being able to introduce you to our dry granulation technology with roller compactors you can talk to them about your material processing needs.  Don’t miss it and get the latest insights into Dry Granulation, Roller Compaction, Shredding, Grating and Milling!

For more information or personal appointments, please contact our colleagues from Alexanderwerk Inc. (contact person: Matt Walczer).

Direct link to the registration for the show – Visitor Registration.

Website of the organizers: PBS2021

#alexanderwerk #drygranulation #rollercompaction #pbs2021

Alexanderwerk Inc installs more efficient LED lighting

Alexanderwerk Inc installs LED lighting

Alexanderwerk’s dry roller compaction and granulation machines have a solid reputation for being energy efficient, reliable, and having very low overall life cycle costs. In addition to that, this technology is reported to use 10-15% of the energy of the alternative wet granulation technology. Our company prides itself with striving toward a goal of greater long term sustainability. Alexanderwerk has a long term sustainability strategy striving to lower the impact on our resources and the environment. At Alexanderwerk Inc we have already deployed a variety of sustainability measures:

  • None of our trash ends up in the landfill. Instead it is turned into energy by our waste and recycling company.
  • We recycle all cardboard, shipping materials, and of course all other standard recyclable materials.
  • We are pay close attention to minimizing waste water generation and capturing and then disposing of such in a responsible manner.
  • We feature a state of the art lab air treatment system that captures particulate so that it does not spread around our facility.
  • We follow Lean Manufacturing principles and are continually improving our value streams.
  • We strive to become a completely paperless organization.
  • We offer remote office work helping reduce commuting and thus lower carbon emissions.

Alexanderwerk Inc just recently audited its own energy usage. One major energy consuming line item was identified to be the fluorescent and HID lighting in office and warehouse. On average the newly installed LED lighting consumes an impressive 1/3 energy of the originally installed fluorescent and HID lighting. In addition to conserving energy the employees as well as visiting customers can now enjoy a much brighter and natural light like atmosphere – and we have become more environmentally friendly as well.

Photo: Krista Stapf, Estimator from PECO ally Centrica and Ralf Weiser, VP of Operations

CIPM 2021 (Spring) – China International Pharmaceutical Machinery Expo 2021 in Qingdao (P.R. China)

Alexanderwerk will be present at the CIPM 2021 Spring Fair (May 10 – 12, 2021) in Qingdao, Shandong Province (P.R. China) – where the famous beer (Tsingtao) is brewed.

Our local specialists from Alexanderwerk Shanghai Ltd. will be happy to meet you on the Alexanderwerk booth and introduce you to our world-leading dry granulation and compaction technologies.

Visit us on our booth … and enjoy becoming a part of the Alexanderwerk family!

AW show booth side view AW show booth 3D view

Meet us on the 60th (2021 Spring) National Pharmaceutical Machinery Exposition & China International Pharmaceutical Machinery Exposition (CIPM) 2021 in QingDao!

Show hours:

5/10  9:00 am ~ 5:00 pm
5/11  9:00 am ~ 5:00 pm
5/12  9:00 am ~ 4:00 pm

Venue:

Qingdao Cosmopolitan Exposition
No. 3399 SanSha Road
New West Coast District
Qingdao, Shandong
P.R. China

Official event website:   www.cipm-expo.com

Test Laboratories

Montgomeryville, October 2019:   Alexanderwerk, Inc. has just completed a half million dollar renovation to the test laboratories and process suites in our US headquarters in Montgomeryville, PA.  The purpose of these spaces is to make us a better partner to our current and potential customers by offering services and capabilities that will assist them in their work.

If you need help deciding if roller compaction can make a difference in your manufacturing processes call us to discuss what product testing in our new lab suites could offer you.  If you want to learn how to maximize the benefit of this technology in you company – ship us your products and spend some time in the lab with our experts.  There are no projects too small or problems too difficult for us to tackle.  It makes no difference if you work in the pharmaceutical world or in food manufacturing or other industries.  We have the machines and the expertise to help you.  The equipment lineup will change from time to time to keep the best mix of capabilities to meet your goals.
 Read more on our testing capabilities

Contact us today to discuss your needs. 

Phone:  (215) 442-0270; e-mail: generalinfo@alexanderwerkinc.com

We are eager to be of service and honored to be your partner!

Upcoming seminar at TechCeuticals – “The Manufacturing Process and Troubleshooting”

From June 4th through June 6th, 2019, a training session covering “The Manufacturing Process and Troubleshooting” will take place at the TechCeuticals Laboratory in Cleveland, OH.

Albin Friedrich (National Sales Manager USA) will assist Michael Tousey of TechCeuticals in the education of Dry Granulation technology as used in tablet manufacturing. Albin Friedrich will also perform a detailed training into the theory of dry granulation. A hands on demonstration using the Alexanderwerk WP 120 roller compactor currently available at the TechCeuticals development center will complete the introduction to Dry Granulation.

Visit www.techceuticals.com for information, or contact us in order to get a discount for this great seminar!

Seminar location: Techceuticals Lab, 2917 E. 79th Street, Cleveland, OH 44104 United States

 

SHIN-ETSU GRANULATION SEMINAR 27TH & 28TH JUNE, 2018

Alexanderwerk actively supports the Granulation Seminar in Wiesbaden, Germany.

In the pharmaceutical industry, granulation is a key processing step in the production of many solid dosage drugs (OSD).

Given the importance of granulation in the production of oral solid dosage forms, this seminar will focus on different granulation processes in detail. The two-day seminar will be held at the ShinEtsu PFMD Lab in Wiesbaden, and will include presentations and practical demonstrations of various technologies.

The participants will be able to get hands-on expierence of dry granulation on the WP 120 Pharma of Alexanderwerk during the seminar!

Further information and registration for the seminar can be found on the seminar page of ShinEtsu!

CASE STUDY: ALEXANDERWERK WP 200 PHARMA

Increasing your efficiency and drive down your costs with Alexanderwerk Roller Compactors!

A new Alexanderwerk customer was (more…)