What Is Granulator Used for?
Granular drugs are not new to people, usually sick cold time will have their shadow. The granulator, such as the dry granulator, plays a key role in the production of granular drugs. It is understood that the dry granulation machine can achieve the requirements of one-step granulation, will be complex processing links integrated together, and complete closed processing, so that the processed granule medicine in the appearance has been improved, and easy to store and transport.
A dry granulator machine is especially beneficial in pharmaceutical production because it controls key physical properties of the drug, such as solubility, porosity, and surface area. According to industry experts, “Dry granulation technology enhances the quality and functionality of medications, meeting the fast-paced needs of modern healthcare.”
How Does a Dry Granulator Work?
Dry granulation is a novel granulation method developed following the second-generation “one-step granulation” technique. As an environmentally friendly granulation process, it can directly compress powder into granules. Widely applied in pharmaceutical production, dry granulators are particularly suitable for processing materials that are prone to decomposition or clumping when exposed to moisture or heat. The granules produced by dry granulators can be directly compressed into tablets or filled into capsules.
Compared with wet granulation, dry granulation requires fewer equipment, lower maintenance costs, reduced floor space, and lower production processing expenses. Additionally, the dry granulation process features a simpler workflow compared to wet granulation, thereby reducing the complexity of GMP certification procedures.
Common Problems in Dry Granulation and Their Solutions
Although dry granulators have many advantages in pharmaceutical production, such as less equipment, low cost, and simple process, there are still some common problems reported by users in actual application, which often affect production efficiency and the quality of the final product. In order to help companies apply dry granulation technology more efficiently, the following summarizes the three most common problems in the dry granulation process and their corresponding solutions to provide a reference for optimizing production.
Excessive Particle Hardness
This is usually caused by excessive compression force applied during granulation. When granules are too hard, they lose compressibility, leading to problems during tableting (such as increased equipment vibration and wear) and poor flowability during capsule filling, resulting in inconsistent dosage. To address this, manufacturers should optimize roller pressure and compaction settings to produce granules with an ideal balance of hardness and compressibility.
Inconsistent Particle Size Distribution
This problem is usually caused by inadequate mixing, uncontrolled feed rate, or excessive fines content. To address the problem of uniform granule distribution during compression, operators can use high-speed agitators to ensure adequate mixing, limit fines content (usually below 80 mesh), and use forced feed mechanisms to prevent material stratification and segregation during tableting.
Roller Wear and Leakage
In dry granulators, rollers utilize internal cooling systems to prevent overheating. Over time, dynamic seals between rotating rollers and static coolant pipes may fail, causing coolant leakage, especially under high pressure. Additionally, prolonged high-load operations can lead to roller surface wear, degrading granulation quality. To mitigate these issues, manufacturers are adopting improved roller designs that spray coolant directly onto roller surfaces for better temperature control and reduced leakage risks. Using high-quality materials and precision manufacturing processes can extend roller lifespan, while regular maintenance and timely component replacement help ensure long-term stable operation.
Conclusion
As the market for granular pharmaceuticals continues to grow, the dry granulation sector is poised for significant expansion. To remain competitive, equipment manufacturers must prioritize innovation—enhancing machine design, material selection, and automated control systems—to meet the demands of modern pharmaceutical production.
For more information or to explore our range of pharmaceutical granulation equipment, contact your trusted pharmaceutical machinery partner, SED Pharma.
