As a core process in pharmaceutical manufacturing, dry granulation has provided significant cost and time-saving benefits to the industry. When producing tablets or capsules, dry granulation streamlines the production process by reducing the number of steps it takes to create a finished product while also improving product quality. Let’s take a closer look at how this process works and why it is so important in the pharmaceutical industry.
What Is Dry Granulation?
Dry granulation is a pharmaceutical manufacturing process where active ingredients are agglomerated into larger particles using pressure. This process can be done with roll compaction for low-dose products and direct compression for high-dose products. Compaction pressures up to 50,000 lb/in2 (345 MPa) are used to produce microscopic agglomerates that increase particle size while maintaining uniformity and flowability. This method reduces dust while also decreasing segregation potential due to increased surface area contact points within the powder blend. In addition, uniform particle sizes reduce variability in tablet weight and improve dissolution rates.
Dry granulation offers several advantages over wet granulation processes including faster processing time, reduced energy costs, improved material handling, and less wear on equipment components such as rolls, screens, and dies. Additionally, there is minimal waste generated compared to wet granulations since most of the product remains in its solid state throughout the entire process. This further reduces energy costs associated with drying operations as well as eliminates potential environmental impacts from wastewater disposal or liquid hazardous waste generation. Finally, dry granulated materials tend to have better flow characteristics making them easier to compress into tablets and capsules during downstream processing operations.
In summary, dry granulation offers numerous benefits for pharmaceutical production operations such as faster processing times, reduced energy costs, improved material handling capabilities, and less waste generation compared to wet processes. It can also help improve tablet weight uniformity and dissolution rates due to more consistent particle sizes that result from this type of processing technique. With its many advantages over traditional wet granulation methods, dry granulation should be considered an essential tool for any pharmaceutical manufacturer looking to reduce costs while still delivering high-quality products that meet customer expectations.
