Drug Pellet formation may appear as semicircular granules to an unaided eye. But is it the same plain, old, bitter tastings medicinal stuff, nay! It indeed a marvelous of modern pharmaceutical research. We at Vision Pharmaceutical put literally our heart and soul with critical Thinking brains and expert hands into making drug palletization a reality and its wider availablity to local as well as international consumers.

Vision Pharmaceutical with its focused and result oriented R&D makes the formation of nearly spherical particles into final, pellitized product possible undergoing the process of fine particulating ,tumble drying, addition of binders and additives in various pellitization equipment.

Our unique pellitization techniques make us not only on par with any standardized international pellet manufacturers but give us un upper hand in economically competitive market as well. Drug Pellets manufacturing an art in itself and undergoes stages of production under uber scientific principles. What factors work deep down in these processing and how complicated it  ,let us have a look.

At first moist content of dried particles is reduced to form an effective air water interface. Make a granulation of particles possible with the help of both physical and applied forces. Physical forces impart tensile strength and liquid bridging among particles, changing capillary and surface tension of granules.

At Vision Pharmaceutical purpose built fully automated manufacturing unit makes tumbling motion of the particles possible and applied forces.   That arise as a result bring individual wetted particles close to each other and uniform distribution of active ingredients. This mechanism makes it possible to initiate pellitization process and subsequent growth of individual pellets under the following factors.

1. Nucleation

Nucleation the Formation of nuclei and the process of particles formation from the continuos phase via interaction within the physical environment. In this stage liquid bridges created making formation of three dimensional water-air-liquid bonding possible, this give particles specific physical appearance and properties. Vision Pharmaceuticals makes sure that particles size must kept smaller for better bonding strength.

2. Coalescence:

The second stage is coalescence, its a transition stage. This region affected by growth factors of coalescence and drug layering. Very important indeed so it needs to be closely supervised and Our R&D strives to make the process up to date. Coalescence brings discreet changes to size and no of particles but not to their mass.

3. Layering

Layering is a third and final factor in manufacturing process of pellet formation. It is a continuous phase where both size and properties of particulate matter changes with drug layering. Vision Pharmaceutical advanced, fully automated production facility. Makes its possible to layer single or multiple active drugs on a single granule. Masking of bitter tastings drugs with addition of layers of Tasteless additives also ensured in this process.

All these Physical and Chemical processes work simultaneously in delicate ways to make scientifically quantified, tasteless, single/multi ingredient active drug pellets a reality and Vision as a pioneer in the science of pellitization.

Vision Pharmaceutical has one of a kind, state of art production machinery. That unique in its own way and utilise every modern pellitization Techniques, a quality unmatched in local market as well as neighbouring India. A Vision Pharmaceutical fully automated plant, R&D and Quality control department work in synchronisation to produce products with unmatched quality, economy, efficacy and Heartfelt satisfaction from our end consumers.

Vision Pharmaceutical utilises every modern standardised technique and pharmaceutical manufacturing procedures to produce drug pellets of unmatched quality.

We herby Discuss Vision Pharma’s pellitization Techniques in detail.

Extrusion Spheronization:

This technique widely used in modern pellitization worldwide. Vision Pharmaceutical utilises it as a major pellitization procedure in its operations. Our unique extrusions Spheronization takes place in three steps.

. Feed preparation

. Pellets production

. Pellets curing

Feed preparation, the first step and it initiated by mixing of drug-excipients with desired additives such as solution of binding agents. Then the second and most important step follows, and the process of agglomeration, where desired size of pellets are formed in pellitizater. The final step curing of wet pellets by thermal drying. Vision Pharmaceutical also utilises technique of simple stockpiling for some drug pellets.

The pellitization begins with the dispensing of powder feed material with binding solutions to the granulator to form a plasticized wet mass. This mass allowed to the screening chamber of extruder. Here pressure blades provide enough Compression to wet mass against the exterior of the screen. The extruder material discharged into discharge unit through scrapper blade and then finally into Spheronizer. Pellitizer disk  rolls the extruded with high speed in the direction of the roller and a rolling movement of helical like structure takes place. This makes the extrudes smooth in short amount of time. Due to intense rolling action and finally uniformed and spherical pellets discharged at the discharge unit.

More about Pellitization Technique

Pellitization Technique needs careful evaluation and continuous monitoring.  Vision Pharmaceutical’s production and quality control departments keep a keen eye. Monitors and document the whole process according to strict guidelines at every step of production. We ensure that every step thoroughly followed and not even a slight mistake is tolerated. We at Vision ensure that.

. In order to produce pellets of uniform size and shape the whole procedure of spheronization properly optimized.

. Extrudate should be in proper wet condition before entering spheronizer. So that it can be spheronized smoothly and no further breakdown occur.

. Different types of extruders are used for different formulations in order to achieve uniform pellitization.

. Amount of binders strictly controlled to avoid hardness and irregular shapes of pellets.

. Formation of big lumps of pellets  avoided at every cost.

. This type of pellitization process  more labor intensive but result in very ideal uniform shaped also spherical pellets.

Another common pellitization technique employed by Vision Pharmaceutical layering technique. This production technique predominantly used for taste masked and control release formulations. This technique of two types, solution layering and powder layering.

In solution layering powder feed material and other components dissolved in solvent. Then this solution or suspension sprayed on the starter core and spread evenly on the surface. Spraying follow by drying phase, in this phase dissolved material get crystallized and solid bridges formed between drug and polymers. Vision Pharmaceutical controls drying method very strictly because drying can affect structural and functional properties of pellets. Various techniques employed by Vision Pharmaceutical’s production unit to increase dissolution properties of pellets.

In powder layering the seeds charged into the pellitizer and on its surface. Then the binder liquid and powder feed material sprayed tangentially. The uniform distribution of powder over the seed surface ensured by rolling movement confirming its spherical shape. It involves uniform deposition of fine drug particles plus excipients on the surface of starting core with the help of binding liquid.

Vision Pharmaceutical never use conventional coating pan ( used by many pellet’s manufacturers even today) due to its limitations, like poor degree of mixing and very inefficient drying. We employ procedures that deliver the powder in such a manner and rate that in equilibrium with the binder liquid application rate throughout the process. We at Vision make sure that no over wetting and dust generation occur as it will reduce the overall quality and yield of products.

Fluidized Bed Processor:

Also called Wurster process, it performs multiple function like coating, drying, granulations and pellitization. Vision Pharmaceutical prepares control release formulations by this technique particularly.

It involves successive deposition of several layers of the coating material. A spray nozzle fitted in the base plate with concurrent air flow and pressurised stream of specific spray pattern. The particles accelerated within the Wruster tube and coating material continuosly sprayed through the spray case. The process continues till appropriate build up on the surface of particles takes place.

Vision Pharmaceutical controls critical parameters in order to avoid powder adherence to side of hopper and if the bed temperature high and there a risk of powder lost to exhaust system. binders consistently used during solution Layering to impart strenght to the pellets.

Our Quality Control parameter ensured that our consumers get best form of sustained released, and taste masked drug pellets.

Vision Pharmaceutical with its unique and state of the art production and quality control techniques takes pride in unparalleled satisfaction of its end consumers through highest standard product portfolio and goal oriented business module. Here Quality control procedures followed at every stage  of production line and final product bring under strict scrutiny.

Vision Pharmaceutical manufacture drug Pellets through its automated plant and evaluate them through various standardized technique. Only pellets that pass through these evaluation measures allowed distribution to market.

Pellet Shape:

We at Vision Pharmaceutical strive to keep our pellets shape uniform and in accordance with international standards. Prime requirements for successful coating spherical and smooth shape of pellets. Both microscopic and non microscopic methods are used to determine Pellets’ shape. Pellet Shape affects its geometric properties, flow and compaction. It possible to determine whether the pellet spherical or asymmetrical. Spherical shaped pellets have minimum surface volume per unit area. The minimum face value is 6 for spherical shape Pellets, if the value exceeds 6 then the pellet is considered asymmetrical.

Size Distribution:

Pellet size equally important factor in addition to shape. Pellet size determined by sieve shaking method and microscopy. Vision Pharmaceutical commonly use sieve shaking method for evaluation of pellet size but microscopic measurements also used whenever need arises.

Surface Morphology:

Surface morphology is another very important parameter in pellets manufacturing. Scanning as well as analysis of cross section of pellets can use to determine surface morphology. Microscopic properties of pellets, structure of pellets’ surface, density and frictional force between the pellets are parameters of utmost importance. Vision Pharmaceutical ensures to impart optimal morphological properties to its manufactured pellets in order to give these ,ideal compression, and disintegration properties.

Tensile strength:

Tensile strength is very important property of drug pellets. In order to evaluate the tensile strength of pellets, Vision Pharmaceutical uses tensile apparatus. Pellets strained under five kg load cell until failure occur. Then tensile strength of that particular drug pellets calculated by using various formula specifically devised by our quality control department.

Crushing strength:

The crushing strength is the measure of load needed to break the pellet. We at Vision Pharmaceutical use material testing machine to measure crushing strenght of various drug Pellets. This process repeated at every step of production line and at end product along with other quality control tests.

Specific Surface Area:

Surface per unit volume called specific surface area. Size and shape of pellets directly affected by this physical property alone. For film coating of pellets, knowledge of specific area is extremely important, but even for uncoated pellets  it has got some importance. As this property directly influence drug release profile, so Vision Pharmaceutical production unit carefully monitor specific surface area of every individual batch of single or multi ingredient drug Pellets evaluation.

Disintegration Time:

Disintegration time very important characteristic for immediate release pellets. It can influence actual drug availability in vitro and peak plasma concentrations at various time intervals. Vision Pharmaceutical uses latest Disintegration Apparatus to measure disintegration time of every batch of drug Pellets.