Extruder Cum Twin Spheronizer

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Umang Pelletization by extrusion and spheronizing extrudates into round pellets.

The UMANG Pelletizing System is a turnkey pellet production plant, which combines mixer/granulator, extruder and Spheronizer in a single, integrated process. Continuously wet powders pass through a low-shear radial extruder / cone extruder / pressure extruder / basket extruder. The extrusions are fragmented and formed into pellets in the spheronizer

We have single and twin spheroidization options possible in the integrated system, for high throughput systems we recommend single extruder and twin Spheronizers with twin bucket assembly for feeding the Spheronizers.


  • Continuous process one bucket is filling at one time and the other is discharging the product into the other spheroinizer.
  • Fast throughput process
  • Easy to up-scale from a lab scale to production scale
  • Stand alone units but also fully integrated systems available called the Integerated Pelletization series.
  • Very high drug loads possible due to special extruder design we have typically achieved 95% drug loads using various extrusion systems we make.
  • Integration with up-stream equipments like high shear mixers and downstream equipments like fluid bed dryers / processors / coaters is possible.
  • We also assist with a Pellet line : where we install the complete line for customers from powder mixing to blending and packaging.


  • Forming of extrudes / pellets between 0.4 mm and 3 mm diameter.
  • Capacity up to 600 kg/hr


  • Fast process.
  • Robust process.
  • Uniform pellet size.

More info

Technical Specifications for Extruder Cum Twin Spheronizer:

Models & Specs

(UTCE-70+SPH-500 Twin)
Batch processing: 40-50 Kgs./Hour [ Using 1.00 mm CONE MESH in extruder ]
(UTCE-110 + SPH-700Twin)
Batch processing: 100-150 Kgs./Hr [ Using 1.00 mm CONE MESH in extruder ]

  • Various Mesh size from 300 microns – 8000 microns depending on the product and customer application.
  • Various configurations of chequered plate like 1mm / 2mm / 3.25 mm / 6.5 mm plate configurations.
  • Various mesh sizes possible depending on the design of extrusion starting from 300 microns upto 7500 microns.
  • Jacketed / insulated bowl and extrusion chamber.
  • Total containment through up- and downstream split valves and flexible isolation systems.
  • Integration with a high shear mixer is also possible for uniform mixing of blends for further Extrusion and spheroinization operations.
  • 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.
  • Explosion proof design
  • Automatic cleaning (WIP/CIP) of entire system
  • 21 CFR part 11 certified controls.

  • 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


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.


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


  • 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

    Are the particles completely spherical after extrusion and spheronization?
    Yes, the shape is usually spherical, the major dependence of shape is the formulation development by the individual.

    Is extrusion Spheronization used for high drug load formulation only ?
    No, it is used for both types for low dose drugs as well as high loaded drugs in pellets .

    How is a narrow particle size of a extrusion and spheronization controlled ?
    Yes 98-99% can be achieved with a particular range with our guidance and formulation expertise.

    Do we provide a Integrated line from mixing to extrusion to spheronization te drying and fluid bed coating ?
    Yes, we do offer complete pellet processing lines.

    Do you provide twin Spheronizers ?
    Yes we provide single, twin and multiple Spheronizers coupled with extruders to give a continuous integrated processing plant.

    How often should I clean the machine, are internal parts completely accessible?
    Yes as per GMP design.

    How quick can we get the delivery for extruder cum twin Spheronizer  ?
    3-4 weeks depending on the size.

    Do you provide twin Spheronizers ?
    Yes we provide single, twin and multiple Spheronizers coupled with extruders to give a continuous integrated processing plant.

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