R&D | Pilot Scale basket granules | extrudes | Pellets

R&D | Pilot Scale basket granules | extrudes | Pellets


Basket extruder is the new extruder range that builds on the proven Umang technology and its benefits. Similar design of Pressing blades and meshes ensures that process and validation so there is no difference to the extrusion from machine to machine. This design is the lowest extrusion pressure for your product.

The outstanding feature of the basket extruder /granulator range is the integrated and CIP optimized design. Connections, cabling and supplies are completely integrated, covered and sealed so the outside of the machine is smooth and very easy to clean. The innovative discharge blade design and optimized seals inside the extrusion assembly allow for CIP. As a result of this the our Basket extruder is highly flexible, quick product changeover increases productivity and cost effectiveness.

The Basket extruder ranges from 25 to 1000 Kgs/ batch, the design operation with platform and dust-free discharging via a linked mill directly into an IBC. The Basket extruder can be stand-alone or linked to aspheroinizer or a fluid bed dryer and continuous vibratory dryer to form an integrated system.

Standard Features for Basket Extruder :

  • Standard meshes from 500 - 1500 mcrons.
  • Bottom driven Blades and cams rotating in counter directions : no seals in direct contact with the product
  • Perfect cGMP-design: smooth covering, no external tubing and piping allowing easy cleaning
  • External blade for pushing the material out to a spheroinizer or a fluid bed dryer bowl.
  • Variable perforation meshes ideal for perfect discharge of difficult products
  • 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.

Optional Features for Basket Extruder :

  • Explosion proof design
  • Automatic cleaning (WIP/CIP) of entire system
  • 21 CFR part 11 certified controls.
  • ADVANCE PROCESS + for easy and automated plant control
  • Jacketed / insulated bowl
  • Total containment through up- and downstream split valves and flexible isolation systems.
  • Integration with mill and/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 Basket Extruder:

Model UBRE -75 UBRE -300 UBRE – 450 UBRE – 600
Batch Cap./Kgs. 1-5 kgs / hr 100-150 kgs / hr 300-500 kgs / hr 1000-1200 kgs / hr


  • Standard meshes from 500 - 1500 microns.
  • Bottom driven Blades and cams rotating in counter directions.
  • System components easily accessible for cleaning and maintenance.
  • External blade for pushing the material out to a Spheronizer or a fluid bed dryer bowl.
  • Variable speed of extruder (20 - 100 rpm). Standard set up 1mm mesh.
  • Fully integrated with Allen Bradley controls & touch screen.
  • Scrapping attachment for extrudes to be collected at one exit point.
  • Extrusion various mesh size (0.5 / 0.6 / 0.8 / 1.0 / 1.2 / special size).

  • 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

FormulationDevelopment

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.


AnalyticalDevelopment

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

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

What are the particle size constraints ?
There are no constraints we design the machine as per your product requirements .

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

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

Do you offer the machine 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 ?
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.

Content

Contact me