R&D | Pilot Scale High Pressure Die and Knurling roller Extruder

R&D | Pilot Scale High Pressure Die and Knurling roller Extruder


Die roller extruder is the oldest extruder range that builds on the proven Umang technology and its benefits. We have a die roller and a pressing roller called as the knurling roller, the variety of designs ensures that process chosen for the product and process suits it application like high pressure extrusion.

The outstanding feature of the Die Roller extruder range is the integrated, covered and sealed so the outside of the machine is smooth and very easy to clean. As a result of this the our Die Roller extruder is highly flexible, quick product changeover increases productivity and cost effectiveness. Its unique design makes it suitable for hard material and difficult powders to be extruded.

The Die Roller extruder ranges from 5 to 600 Kgs/ hr. featuring through the wall design and movable head, allowing operation with platform and dust-free discharging via a linked mill directly into an IBC. The Die Roller extruder can be stand-alone or linked to a high shear mixer for down stream integration or aspheroinizer for up-stream integration.
The features of our Die Roller extruder are the following:


Standard Features for Die Roller Extruder :

  • Variable meshes from 800 - 7000 microns available.
  • Perfect cGMP-design: smooth covering, no external tubing and piping allowing easy cleaning
  • Completely integrated full opening side discharge: perfect discharge of difficult products
  • Through the wall installation: minimum space required in GMP area
  • User-friendly operator-machine interaction via graphical operator panel 12" Industrial PC software with PROCESS + range of software which helps interlinking all plant equipments to a single system.
  • Flexibility (processes and products) for wet granulation.
  • Feeders for feeding controlled rate of powder for extrusion.

Standard Features for Pressure Extruder :

  • Explosion proof design
  • 21 CFR part 11 certified controls.
  • ADVANCE PROCESS + for easy and automated granulation control
  • Jacketed / insulated extrusion chamber
  • Different processing dies available with different hole configurations suting your product and applications.
  • Total containment through up- and downstream split valves and flexible isolation systems.
  • Integration with mill and/or Spheronizer or fluid bed possible: perfect closed link for dust-free operation
  • Video monitoring of the process.
  • Product feeding both by gravity or vacuum loading system directly from the containers
  • Validation documentation and assistance based on GAMP

Technical Specifications for Die Roller Extruder:

Model UDRE-65 L UDRE-65 R UDRE-65 E UDRE-100 UDRE-130 UDRE-200 UDRE-270
Batch Cap./Kgs. 1-3 kgs/hr 5-15 kgs/hr 10-25 kgs/hr 50-90 kgs/hr 150-300 kgs/hr 300-700 kgs/hr 500-1500 kgs/hr

  • Standard Die roller extruder with NON SPILL type GMP feeder and hopper with safety grill.
  • Various mesh configuration with different perforation area / thickness for product suitability
  • System components easily accessible for cleaning and maintenance.
  • Fully integrated with Allen Bradley controls & touch screen.
  • Standard set up with 1mm Die roller.
  • Variable speed of extruder (20-100 rpm).
  • Stainless steel 316 GMP design with high polish finish.
  • Various sizes of Die roller (1.0 / 1.2 / 1.5 / 2.0 / 3.0 / 5.0 / 7.5mm / special size).
  • Jacketed / insulated extrusion chamber. Chilled water through knurling roller.

  • Agricultural chemicals
  • Fertilizers
  • Agrochemicals
  • Carbon black
  • Ceramics
  • Atomic tablets
  • Soya and food processing
  • Home and Personal care.
  • Cosmetics
  • Agglomeration
  • Particle size build up
  • Heat Sensitive materials
  • Pressure sensitive materials
  • Pharmaceuticals
  • Pigment
  • Toner, etc.

Umang Pharmatech : Pharmaceutical Test Station

The Umang Pharmaceutech Test Station is located in Vasai, THane, conveniently located very close to Mumbai airport, only forty five minutes from Mumbai International Airport. The Test Station's purpose is to assist our Pharmaceutical and Biopharmaceutical Industry customers with feasibility testing of their products on our equipment, and to be a partner with them in the process development as they move forward from the Research and Development stages to clinical production, and eventually into full-scale Manufacturing.

The station combines decades of design and development know-how in the pharmaceutical industry with the very latest in processing equipment to provide you with a unique opportunity for feasibility, development, and small-scale manufacturing of pharmaceutical products.

Your needs are critical and individual. The UMANG Pharmaceutical Test Station has been designed to meet those needs.

  • Product evaluation & testing
  • Demonstration
  • Training
  • Formulation development
  • Process optimization
  • Small-scale manufacturing

We offer the following process options:

  • Spray drying
  • High shear mixer
  • Extrusion and spheronization
  • Fluid bed coating and granulation.
  • Fluid bed rotor
  • Cone extrusion.
  • Die roller extrusion.
  • Continuous vibratory fluid bed dryer.
  • fluid-bed granulator - dryer

  • Analytical Capabilities

    • Specification development
    • Method development
    • In-process controls
    • Impurity profiling
    • Method validation
    • Stability testing and Degradation studies
    • Release of Intermediates and final product
    • Technology transfer to manufacturing sites
    • Support to regulatory filings
    • Pre-Fo HPLC (Shimadzu) AGilent, RI, Fluoresence Detectors
    • UV-Vis Spectrophotometer
    • Thereo Gravimetric Analyzer (TGA) (Shimadzu)
    • Moisture Analyzer
    • Granulators (Fluid Bed or High Shear)
    • Comminution Mill
    • Diffusion Blenders - V, Octagonal, Double Cone types
    • Multi-purpose equipment - Planetary Mixer, Granulator, Blender attachments
    • Tablet Coating - solid pan of various sizes
    • Pilot Plant for Dermatologicals
    • USP dissolution Apparatus with auto sampler
    • Vertical Cell Diffusion (Franz) Apparatus
    • Tablet: USP Hardness Tester, USP Disintegration Tester & USP Friability Tester
    • Stability Chambers (set to ICH Guidelines)
    • UV-Vis Spectrophotometer
    • FTIR
    • Brookefield Viscometer

    Formulation Development

    Our expertise in formulation development extends to the development of all conventional dosage forms. Our strategic alliances broaden the scope to consider many Novel Drug Delivery Systems (NDDS), including transdermal & liposomal delivery systems. We consider multiple approaches to improve the bioavailability of drugs. We have expertise in improving delivery of poorly soluble/ permeable drugs and the capability to screen potentially innovative drugs based on pharmacokinetic properties. We possess pelletization, drug-layering, particle-coating and other technologies to achieve extended release profiles for tablets or capsules.

    Analytical Development

    Our analytical development services include assay and RS method development and validation, dissolution method development and validation, stability studies as per ICH guidelines, polymorphic form characterization (DSC/TGA/XRD/Microscopy), cleaning validation studies and HPLC to UPLC method conversions.

    Generics and NCEs

    • Pre-formulation
    • Proof of Concept studies
    • Phase Appropriate CT Formulations
    • Formulation and Process Development
    • Scale-up and Technology Transfer
    • Life cycle management
    • Differentiated generics, 505 (b) (2)

    Dosage Forms

    • Pellets - Immediate Release, Modified Release
    • Granules - Immediate Release, Modified Release
    • MDF - Mouth Dissolving Film
    • Physico chemical evaluation

    Solubility studies:

    • pH dependent aqueous solubility
    • solubility in co-solvents
    • surfactant assisted solubility
    • equilibrium solubility
    • Intrinsic dissolution study in various pH conditions
    • Salt design/screening and selection
    • Dissociation constant redetermination
    • Partition coefficient and log P determination
    • Polymorphism studies
    • Particle size, surface area, bulk / tapped density determination
    • Particle size distribution
    • Bulk/tapped density determination
    • Binding constant determination
    • Drug-excipient compatibility studies

    Containers:

    • Closure integrity testing
    • Filter compatibility
    • Stress stability
    • Photo stability
    • Hold-time study

  • Integration with fluid bed possible: perfect closed link for dust-free operation
  • Video monitoring of the process
  • Liquid addition system (peristaltic pump / pressure vessel)
  • Product feeding both by gravity or vacuum loading system directly from the containers

    Do we offer high pressure extrudes ?
    Yes, die roller extruders.

    What type of material is suitable to process in a die roller extruder ?
    Non-sticky , powdered

    What are the particle size constraints in a die roller extruder ?
    There are no constraints we design the machine as per your product requirements .

    Will the process heat up my material excessively in a die roller extruder?
    No there is a uniform air distribution in the machine.

    How often should I clean the machine die roller extruder? Are the parts for die roller extruder easily available ?
    Yes the parts are easily accessible for product change over.

    Do you offer the machine die roller extruder in mild steel construction for industrial application ?
    Yes we do offer the same for procie sensitive products / segments .

    How quick can we get the delivery of the machine die roller extruder?
    3-4 weeks depending on the size.

    Do you provide a complete processing line ?
    Yes we do give machine from high shear mixing to extrusion , spheronization to fluid bed drying/coating as per product/process needs.

    Is the Extruder and powder feeder controlled by a inverter?
    Yes.

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