Gerteis – The Perfect Partner for Dry Granulation Systems

GERTEIS® sets a world standard for advanced dry-roller compactor systems with its unique dry granulation technology. Deep understanding and experience of dry granulation systems combined with patented compaction technologies make this Swiss-based manufacturer an acknowledged leader.

This expertise carries real benefits for customers. For instance, Gerteis specialists can evaluate an application, quickly establishing the roller compaction parameters needed for an optimal dry granulation process.

Customers are constantly looking to achieve lower cost per tablet and consistent performance. The GERTEIS® roller compactors can achieve this through their continuously operated system that eliminates costly down- and up-scaling procedures and ensures consistent product quality compared to batch processing. Excellent control over granulation parameters helps to achieve consistent performance. GERTEIS® works closely with its customers to find ideally tailored process solutions.

Compaction Technology

GERTEIS® customers are constantly striving to develop new methods of reducing costs and environmental impact by using the dry compaction method to produce granules from powdered and micronized products. The control of the compaction and granulation process is of vital importance and aligns with the need for flawless process stability.

GERTEIS® equipment can maintain maximum process stability and reproducibility throughout its full range of roll pressures. To realize these standards, GERTEIS® developed the PACTOR® high performance line.

A fully computerized, sensor controlled unit with solid design and state-of-the-art solutions help you attain the best granulating results, stable processing sequences, and complete validation and replication.

During new product development, this unit will adapt to all your requirements, enable you to readily tailor processes and markedly reduce start-up-time. The PACTOR® line from GERTEIS®, with technology that is patented world-wide, provides optimal conditions to process products precisely and with very wide range of density and fluidity.

The product is transported from the hopper through the horizontal feed screw to the tilted tamping screw. Then, the pre-densified powder will be engaged by the press rolls and pressed into a ribbon according to the desired roller gap, roller speed and hydraulic press-force. The ribbon is then granulated to granules according to the selected granulator rotor conditions and the chosen screen type and mesh size. The machine is controlled by sensors which monitor and maintain all motor speeds, roller gap width and press force.

Roller Compaction

Roller compaction is becoming an increasingly important agglomeration technology for the production of granules, as the pharmaceutical industry looks at ways in which it can introduce lean manufacturing to reduce its R&D and manufacturing costs.

Not every formulation can be granulated on a conventional roller compactor. However, the GERTEIS® roller compactor has several unique patented roller compaction technologies that allow for a far greater range of formulations to be dry granulated successfully, compared with conventional roller compactors. The GERTEIS® roller compactor offers the following advantages:

• Unique patented angled roller feed system for more consistent flow of materials to the rollers
• Patented force control with in-process moveable roller, producing constant density ribbon
• Larger diameter rollers, producing longer dwell times in the nip area
• Superior punch and die roller design providing constant density over whole ribbon width, all but eliminating fines and consequent need for recirculation
• Superior granulating oscillating mill, to ensure clean cutting action of the ribbon for more consistent granule size distribution

Advanced Dry Granulation Technology

The PACTOR® line is the premium GERTEIS® roller compactor with output capacity of up to 400kg per hour. However, as a fully continuous granulation process, amounts from as little of 10grams can also be dry granulated, making the PACTOR® line suitable for development, pilot scale and production environments. Complete harmonization with the other roller compactors within the PACTOR® range is assured with identical roller diameters. The result is that scale-up is straightforward, avoiding common problems associated with batch-based processes, reducing material and API costs, and saving time to get the product to market quicker.

Unique PACTOR® Roller Compaction Features

• Angled compaction rollers to allow feed consistency and constant ribbon density, free floating gap design and in-process force control producing a constant density ribbon
• Large diameter rollers to produce a longer dwell time in the nip area
• Superior punch and die roller design to provide a constant density over the ribbon width and virtually eliminate fines (no recirculation required!)
• Three stage milling process with the granulating oscillating mill with adjustable screen clearance, to produce a consistent and controllable particle size distribution
• Full instrumentation with critical quality process parameter data-acquisition
• Full machine calibration
• Containment performance down to 0.1μg/m³ time weighted average

Customized Technology

The key to GERTEIS® success lies in its professionalism and uncompromising goal of satisfying your special requirements. Beyond the regular line of standard granulation equipment GERTEIS® supplies high-quality machines specially designed to meet individual needs. The PACTOR® and the POLYGRAN® roller compactor are fully compliant with FDA/GMP rules.

GERTEIS® values dialogue with its clients. This means jointly formulating customers’ wishes, analysing their requirements, and working together to find suitable process solutions. The simple design of the PACTOR® and the POLYGRAN® line allows a rapid changeover of products and process configuration. Milling gap, roller gap and scrapers are re-set quickly and precisely. The press rollers are readily changed and easily cleaned and, depending on the application, the press rollers and/or granulator rotor can be cooled or heated.

Optional features allow sampling of the ribbon and/or granulate at any time without interrupting the ongoing process. The PACTOR® and the POLYGRAN® line offers continuous batch documentation, totally flexible operations, and absolutely reliable, consistently reproducible production parameters.

GERTEIS® is constantly developing new technologies to accommodate your current and future needs for dry granulation.

To learn more about Gerteis’ roller compactor systems, and the potential benefits to your business please contact Gerteis directly