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Troubleshoot Extrusion Spheronization
Troubleshoot the extrusion and spheronization parameters. Investigate the three necessary parameters that could disrupt the extrusion spheronization process. Mix the dry powder product with a liquid to form an even wetted mass. Choose the mixer that is suitable for your product, such as planetary, high shear or continuous. It is imperative that the mixed powder with liquid is even, or the extrusion spheronization process will result in a bad product.
Conduct the extrusion process. The extrusion process requires that the wet mass's pressure is raised enough for it to undergo plastic deformation and flow through a die or the cylindrical hole in the extruder screen. In addition, the next process of spheronization requires that the extrusion be able to break into short lengths to form into spheres, but not wet that the spheres become to long or oversized. If the extrusion does not form into spheres, adjust the pressure for the extrusion to be successful.
Conduct the spheronization process. The extrusion process will fragment into short cylindrical lengths. The spheronization will form round pellets. The spheronization process uses a spheronizer, which is composed of a wheel with a friction machine on the top surface and a spinner on the vertical axis. Drop the wet extrusions into the spinning wheel which forms the pellets. If the wet extrusions do not form into pellets, there could be a problem with the spheronizer. Adjust the wheel speed to make sure it is spinning fast enough. It should only take about two to four minutes to make round pellets. Read the spheronizer user manual to find the problem with the device. Most spheronizer manufacturers will perform maintenance on these devices.