Innovations


Immediate Release Pellets

Umang offers technology of state of the art equipments and complete range of Products for "Pharmaceutical pellets" and "Mouth dissolving films", UMANG is the innovator and industry standard for complete Pellet processing solutions, and offers a range of solutions for IMMEDIATE RELEASE of pellets / tablets by Fluid bed wurster coating or fluid bed processor or by extrusion and spheronization or drug layering technology for immediate release solid dose applications. Our machines and technology produce attractive and stable on even the most challenging formulations.

An extensive selection of machines and formulations provides the user with the ability to impart many beneficial features to a solid oral dosage formulation. Benefits include:

  • Reduced developmental process time
  • One stop solution for Machines and technology.
  • Stable formulation.
  • Open DMF for all products open for registration.
  • Lesser loss of drug due to optimised formulations.
  • Complete documentation and analytical data.

Umang also offers customized solutions for customers where we develop products, supply them commercially and also match innovator profile wherever desired by the customer.

Umang's ongoing research on pelletization solutions and processes has produced many solutions and options for our customers for Personal care we have a complete range of spheres, for edible complete decoration range, for Neutraceutical complete range of encapsualted pellets, Herbal and Ayurvedic complete range of ready to fill pellets. Additional advances in our immediate release tablet film coating technology include high gloss and pearlescence for products where desired, which not only give a more elegant appearance to your solid oral dosage form, but provide unique opportunities for branding and tablet / capsule identification.

Controlled Release Pellets

Controlled release technology, also known as sustained-release, sustained-action, extended-release, Controlled-release or Controlledd-release, Time-release, modified release, or continuous-release, is a mechanism used in pill tablets or capsules to dissolve slowly and release a drug over time. The advantages of sustained-release tablets or capsules are that they can often be taken less frequently than instant-release formulations of the same drug, and that they keep steadier levels of the drug in the bloodstream.

Today, most Controlled-release drugs are formulated so that the active ingredient is embedded in a matrix of insoluble substance(s) (various: some acrylics, even chitin; these substances are often patented) such that the dissolving drug must find its way out through the holes in the matrix. Some drugs are enclosed in polymer-based tablets with a laser-drilled hole on one side and a porous membrane on the other side. Stomach acids push through the porous membrane, thereby pushing the drug out through the laser-drilled hole. In time, the entire drug dose releases into the system while the polymer container remains intact, to be later excreted through normal digestion.

In some SR formulations, the drug dissolves into the matrix, and the matrix physically swells to form a gel, allowing the drug to exit through the gel's outer surface.

Micro-encapsulation is also regarded as a more complete technology to produce complex dissolution profiles. Through coating an active pharmaceutical ingredient around an inert core, and layering it with insoluble substances to form a microsphere you are able to obtain more consistent and replicable dissolution rates in a convenient format you can mix and match with other instant release pharmaceutical ingredients in to any two piece gelatin capsule.

There are certain considerations for the formation of Controlled-release formulation:

  • If the active compound has a long half-life (over 6 hours), it is sustained on its own.
  • If the pharmacological activity of the active compound is not related to its blood levels, time releasing has no purpose.
  • If the absorption of the active compound involves an active transport, the development of a time-release product may be problematic.
  • Finally, if the active compound has a short half-life, it would require a large amount to maintain a prolonged effective dose. In this case, a broad therapeutic window is necessary to avoid toxicity; otherwise, the risk is unwarranted and another mode of administration would be recommended.
Sustained Release Pellets

Sustained release technology, also known as sustained-action, extended-release, Controlled-release or Controlledd-release, Time-release, modified release, or continuous-release, is a mechanism used in pill tablets or capsules to dissolve slowly and release a drug over time. The advantages of sustained-release tablets or capsules are that they can often be taken less frequently than instant-release formulations of the same drug, and that they keep steadier levels of the drug in the bloodstream.

Today, most Sustained-release drugs are formulated so that the active ingredient is embedded in a matrix of insoluble substance(s) (various: some acrylics, even chitin; these substances are often patented) such that the dissolving drug must find its way out through the holes in the matrix. Some drugs are enclosed in polymer-based tablets with a laser-drilled hole on one side and a porous membrane on the other side. Stomach acids push through the porous membrane, thereby pushing the drug out through the laser-drilled hole. In time, the entire drug dose releases into the system while the polymer container remains intact, to be later excreted through normal digestion.

In some SR formulations, the drug dissolves into the matrix, and the matrix physically swells to form a gel, allowing the drug to exit through the gel's outer surface.

Micro-encapsulation is also regarded as a more complete technology to produce complex dissolution profiles. Through coating an active pharmaceutical ingredient around an inert core, and layering it with insoluble substances to form a microsphere you are able to obtain more consistent and replicable dissolution rates in a convenient format you can mix and match with other instant release pharmaceutical ingredients in to any two piece gelatin capsule. There are certain considerations for the formation of Sustained-release formulation:

  • If the active compound has a long half-life (over 6 hours), it is sustained on its own.
  • If the pharmacological activity of the active compound is not related to its blood levels, time releasing has no purpose.
  • If the absorption of the active compound involves an active transport, the development of a time-release product may be problematic.
  • Finally, if the active compound has a short half-life, it would require a large amount to maintain a prolonged effective dose. In this case, a broad therapeutic window is necessary to avoid toxicity; otherwise, the risk is unwarranted and another mode of administration would be recommended.
Delayed Release Pellets

Pellet (or bead) technology allows a variety of different drug delivery profiles to be achieved by coating drug and excipient with various polymers. The drug cores are generally spheroidal in shape and have a diameter in the range of 300-1,700 ¼m. Two types of process are used to generate the spheroidal pblog. The first of these processes, which allows potencies up to 90%, utilizes extrusion and spheroidisation to form a drug core with a polymer coat.

The second process is known as drug layering by Wurster and drug layering by a drug layering system, where the drug pblog are fixed to the outside of a seed core (typically a sugar sphere). This process provides a very tight size distribution of pellets. Drug potencies up to 60% are possible. For both of the processes above, the desired drug release profile is achieved by coating pblog with the appropriate polymer.

Enteric Coating Pellets

An enteric coating is a barrier applied to oral medication that controls the location in the digestive system, where it is absorbed. Enteric refers to the small intestine, therefore enteric coatings prevent release of medication before it reaches the small intestine.

Most enteric coatings work by presenting a surface that is stable at the highly acidic pH found in the stomach, but breaks down rapidly at a less acidic (relatively more basic) pH. For example, they will not dissolve in the acidic juices of the stomach (pH ~3), but they will in the alkaline (pH 7-9) environment present in the small intestine. Materials used for enteric coatings include fatty acids, waxes, shellac, plastics, and plant fibers.

Drugs that have an irritant effect on the stomach, such as aspirin, can be coated with a substance that will dissolve only in the small intestine. Likewise, certain groups of azoles (esomeprazole, omeprazole, [[pan and all grouped azoles) are acid-unstable. For such types of drugs, enteric coating added to the formulation tends to avoid the stomach's acidic exposure, delivering them instead to a basic pH environment (intestine's pH 5.5 and above) where they do not degrade, and give their desired action.

Recently, some companies have begun to utilize enteric coatings on fish oil (omega-3 fatty acids) supplements. The coating prevents the fish oil capsules from being digested in the stomach, which has been known to cause a fishy reflux (fish burps). Sometimes the abbreviation "EC" is added beside the name of the drug to indicate that it has an enteric coating.

Hot Melt Extrusion

Incorporation of a drug in a polymer matrix is often used to sustain drug release. To producethese sustained-release matrices, hot-meltextrusion (HME) is becoming a widely-used technology in the pharmaceutical industry. Its major advantage over conventional techniques for manufacturing of sustained-release matrices (e.g. compression) is the continuity of the hot stage extrusion technique as the different process steps (mixing, melting, homogenizing and shaping) are carried out on a single machine.

This offers many opportunities for automation of the production process, allows a high throughput,limits material loss and yields matrices with excellent homogeneity. UMANG not only focuses on the machine but also on the principles of operation, process technology, equipment and different drug delivery systems manufactured via HME.

Several polymers can be processed via HME to function as release-controlling matrix: synthetic cellulose derivatives (ethyl cellulose, hydroxypropylmethyl cellulose, celluloseacetobutyrate.), methacrylates, polyethylene oxides, polyvinylacetate, polyvinylacetate, poly(lactide co-glycolide), starch, lipids, waxes (possibly in combination with a plasticizer to optimize the thermoplastic properties of the polymer). The design of the extrusion screw have a transfer screw, mixing elements, extrusion screws ensure a homogeneous drug distribution in the tablet matrix.

Oral Dissolving Films

Fast oral dissolving films have become popular as a new delivery system because they are easy to administer and sudden-onset of drug action is possible as the films are taken through the sublingual route. Since the sublingual mucosa is relatively permeable because of thin membrane and is highly perfused, rapid drug absorption and instant bio-availability is possible and this leads to quick-onset of drug action.

Since the drug is directly absorbed into the systemic circulation, degradation in the gastrointestinal (GI) tract and first pass effect can be avoided. Moreover, better patient compliance is expected, because this system does not require being swallowed as in the case of conventional tablet, and therefore beneficial in patients with dysphagia or difficulty in swallowing.

The use of muco-adhesive polymers in the films will enable them to adhere to the sublingual mucosa for better retention and drug absorption. Drugs well absorbed through the buccal or sublingual mucosa can be formulated as fast oral dissolving films for sublingual use.

We also have cut films which can be cut into 1.5mm x 1.5mm size and then filled into capsules. different kind of drugs can be encapsulated in this form to have a innovative drug delivery system. The major applications are Mint Films, Oral Dissolving Films, Teeth Whitening Strips, Whitening Gel, etc.

Drug Layering

Centrifugal processing is single unit operation. The process involves the deposition of successive layers of an active compound onto nonpareil seeds resulting in the formation of uniform sized pellets. The operation is carried out using a plain rotating plate. During processing the starter seeds are wetted with a moistening liquid while rotating on the base plate. Dry powder dusted on nonpareils adheres, increasing their size and forming larger pellets.

Growth occurs by a process of binding of powder/ liquid binding and consolidation. After liquid addition and dusting creates the correct diameter pellets, then tumbling of the coalesced aggregates increases their sphericity.

Liquid Filled Beads

Our line of seamless capsule beads, developed and manufactured in Mumbai. India has a team of experts will provide you with tailor-made solutions from formulation through development and launch of your seamless liquid filled capsule products. We maintain leading edge capabilities with the most up-to-date manufacturing and quality control for seamless capsule technology.

Our product range is ideal for the Dietary Supplements and Pharmaceutical markets and includes all sizes, shapes, colors and forms of seamless capsules suitable for oral, topical, ophthalmic and vaginal administration. We also can help provide a color combination that suits both the product indication as well as patient preference.

The major applications are Yellow Beads, Pink Glitter, Color Beads, Blue Beads, Alginate Gel Beads, Agar Beads, Whitening Gel, Mint Beads, etc.

Homogenizer
Features :
  • Laboratory size Homogenizer.
  • Capacity 200gm “1000gm.
  • Glass Construction.
  • Heavy 18,000 RPM.
  • Forward & Reward mixing arrangement to have homogeneous mass.
Continuous Mixer

The Umang Granulator Instantly mixes and granulates dry powder ingredients in a continuous process. Pre-blended powders are dispersed on a high speed wheel and mixed with an atomized granulating fluid. Less than 100g of product is in the mixing stream at any one time, so scale-up depends only on process time.

The same machine can produce a few kilograms on a laboratory scale or volume production up to 500kg/hr. the unique compact design ensures that powder hold-up is minimal and cleaning is quick and easy. Discharge may be direct into the Umang's extruder.

The Umang's Granulator can also be used for dispersing and coating of powders and can be set up to discharge directly into a batch or continuous fluid bed dryer.

  • Instant processing
  • Contained operation
  • Simple, time-dependent scale-up
  • Small foot-print
  • Easy to clean

The unique modular concept of Umang's Pelletizing System facilitates optimized solutions to meet process needs exactly. Mixer/granulator, extruder and spheronizer modules are combined to create a complete integrated pellet production plant, or selected individually to suit specific requirements. Modules can be operated in either batch or continuous mode, for maximum flexibility of operation, and can be used stand-alone, or integrated with other up- or down-stream equipment such as fluid bed processing systems. Ideal for both product development and full-scale production applications, process scale-up of the Umang's Pelletizing System is easy “ it's simply a factor of processing time.

MODEL UCM-250 UCM-350 UCM-550
PUTPUT 100KG/HR 250KG/HR 500KG/HR
MOTOR (H.P.) 2 5 10
10 and 12 Bar Fluid Bed

Design and construction for total containment requires that the entire system is sealed to the environment. This applies during the entire processing cycle including the feed and discharge stages. UPPL provides traditional 2-bar vented systems as well as full 10-bar explosion containment systems.

These special 12-bar containment systems insure that no material must escape into the environment in the rare instance of an explosion up to 10-Bar pressures. These UPPL 10-Bar vertical granulators and fluid bed systems in conjunction with sieves and product handling components are sealed and resistant to 12-Bar pressure shocks throughout. This creates a granulation production line which is fully enclosed for Total Containment to protect the operator, system and facilities against potential hazards.

Micro Pellets

UPPL micro pelleting expertise has been developed through matching the unique requirements of our client base during our production of several hundred extrusion systems provided for pharmaceutical and agricultural applications. It is typical that the smaller the extrudates required below 500 microns are the more difficult it is to maintain low sheer, high capacity, and continued extruder operation without blinding. UPPL has overcome these difficulties with our unique Micro Pellet die designs available for our Cone, Radial and Die Roller extrusion systems.

Micro pelletization is a great innovation step how to make smaller pellets with higher drug loadings. Micro Pelletization is a round pellet for moist granulates and extruded products. With suitable additives, pellets can be made into tablets or used to fill capsules. The round shape is ideal for uniform coating. Pellets are good for automatic dosing.

Film Shapes

We can formulate shapes using a custom flavor or a proprietary flavor supplied by the customer. We also have a range of flavors available as standard products.

For example: Lichee, vanilla, strawberry, raspberry, mint, butterscotch, and mouth puckering lemon, just to name a few. Shapes with flavor contributes some special qualities to the flavor profile of your product.

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