VJ Instruments'

Lab-Scale Extruder & Spheronizer Combo

Lab-Scale Extruder and Spheronizer Combo is a seamlessly integrated system poised to redefine granulation in formulation research and product development. The Extruder component, featuring four interchangeable heads, facilitates versatile low-pressure granulation techniques on a bench-top scale, accommodating batches as small as 200 grams. Its adaptability and indicative results make it a cost-effective and efficient solution for evaluating diverse formulations.

Complementing the Extruder, the Spheronizer component offers precise control over spheronization processes, featuring a substantial 230 mm diameter friction plate capable of producing spheres ranging from 0.5 mm to 10.0 mm. With user-friendly features such as easy disassembly, GMP design, variable plate speeds, and a dedicated stainless steel control panel, this dynamic duo empowers researchers and product developers to seamlessly progress from extrusion to spheronization, unlocking new possibilities for innovation in pharmaceuticals, chemicals, and the food industry. The VJ Instruments Extruder and Spheronizer Combo stand as a cohesive and powerful platform, representing a significant leap forward in granulation technology.

Lab-Scale Extruder & Spheronizer Combo in Action

Explore the synergy of the Lab-Scale Screw Extruder & Spheronizer Combo in Action. Discover the versatility of the extruder with interchangeable heads for low-pressure granulation and witness its effortless operation on a bench-top scale. Then, delve into the spheronizer’s role with a substantial friction plate, transforming cylindrical granules into uniform spheres. The section provides a concise journey into the precise and innovative workings of this dynamic duo, unlocking new possibilities in granulation for pharmaceuticals, chemicals, and the food industry.

Application

Lab-Scale Extruder

A versatile Low pressure granulator tool from VJ Instruments. The VJ Instruments Multi Granulator is a bench- top device that allows formulation researchers and new product developers to readily evaluate the best of Four different types of low pressure granulation techniques— dome, cone, radial, and axial extrusion— and determine which one suits their product. The Multi Granulator’s size and unique design allow it to evaluate batches as low as 200 grams, saving time and money, yet generating product that is indicative of a full scale production system. Four types of extrusion—dome, Cone, axial, and radial—can be evaluated by simply changing the extrusion head. VJ Instruments offers four types of low pressure extruders.

Operation
The Multi Granulator is easy to setup and assemble with any of the four extrusion configurations for immediate use. A wet mixture is separately prepared manually or in a small mixer. The extruder is fitted with the appropriate die (or screen). The prepared wet material is manually fed through the feed hopper. The wet mass is transported to the extrusion area by a single feed screw. The wet material is gently wiped through the die (screen) yielding well formed extrudates.

Features

Single screw extruder with variable speed (10-90 rpm) Easily converts into a dome, cone, radial, or axial extruder
Capable of extruding granules from 0.3 mm to 8.0 mm diameter. Axial from 2.0 mm to 8.0 mm diameter; Radial from 0.6 mm to 1.2 mm diameter; Dome & Cone from 0.3 mm to 2.0 mm diameter
GMP design with SS 316 contact parts
Die is SS 316 ๏ 1.0hp 230VAC /3/60 variable speed drive for extrusion screw
Sanitary clamps allow for quick disassembly, cleaning, and conversion to any of the three extrusion configurations. No tools required.
Separate stainless steel control panel with motor starter

Application
Chemical / Agrochemical
✓ Herbicides / Insecticides / Fungicides
✓ Catalysts
✓ Flavors
✓ Neutraceuticals
Pharmaceuticals / Food
✓ Controlled Release Pellets
✓ Multi-Particulate Systems
✓ Sustained Release Polymer Coated Pellets
✓ Enteric Coated Pellets

Lab-Scale Spheronizer

The VJ Instruments Spheronizer is a bench top device that provides
researchers and new product developers a means to easily
evaluate the effectiveness of spheronization on their extruded
products. The size and unique features allow it to evaluate
batch sizes as small as one litre, while generating product
indicative of a full scale production system. The lab spheronizer
is designed to convert moist cylindrical extruded granules into
smooth, uniform spheres in a variety of applications.

Features

Bench top device ideal for a laboratory environment
Easy disassembly of process parts
230 mm diameter friction plate
Capable of producing 0.5 mm to 10.0 mm spheres
Friction plates available with groove spaces of 1-8 mm
Friction plates available in various grid patterns
Variable plate speeds between 600- 1800 rpm
GMP design with SS 316 product contact parts 304SS jacketed bowl for heating/ cooling 1.0hp 230VAC /3 / 60 motor to drive friction plate
Separate stainless steel control panel with motor starter and inverter

Operation
The Spheronizer can be easily assembled with the desired friction plate for spheronization. Moist granules, from
an extruder or mixer, are fed into the spinning friction plate and thrown against the inside of the Spheronization,
forming a “twisting rope”. Collisions of the particles with the wall, friction plate, and other particles result in plastic
deformation of the granules, forming spheres. The final shape of particles is time and formulation dependent.
Once the desired particle shape is achieved, the batch is discharged through a manual plug valve and discharge
chute, collected, and dried.

Technical Specification

Extruder Combo Machine Specifications

Sr. No.	Specification	Details
1	Model No	VJEX – Combo
2	Certificates	GMP, ISO, CE
3	Type	Single Screw
4	Production Capacity	2-6 kg/hr depends on formulation.
5	Perforated mesh hole diameter	Ø 1 mm standard. Optional with additional cost: Ø 0.5 mm Ø0.6 mm Ø 0.8 mm Ø 1.2 mm Ø 1.5 mm
6	Product	Any Aqua base or solvent base formulation.
7	RPM of screw	10 to 150 rpm
8	Hopper Discharge	Auto discharge by gravity
9	Electric Accessories	230 V 1 Phase 50 Hz / 440 V 3 Phase 50 Hz
10	MOC Contact Parts	SS 316
11	MOC Non-Contact Parts	SS 304
12	Hardware	Standard Make (Bearing shaft seal of SKF etc or equivalent)
13	Finish	Non Contact Area Matt Finish Contact area Matt Finish Machine part- Machine Finish
14	HMI (Touch Screen)	Delta
15	Drive Motor	Crompton or equivalent
16	Reduction Gear Box	Standard Make.
17	Documents	User Manual, Warranty Certificate.
18	Electric Consumption	1.0 Kw
19	Dimension (LXWXH) in mm	425 mm (L) X 500 mm (W) X 575 mm (H)
20	Weight	48 kg
21	Control Panel	22 kg 300 mm (L) X 375 mm (W) X 475 mm (H)

Spheronizer Combo Machine Specifications

Sr. No.	Specification	Details
1	Model No	VJSP – Combo
2	Certificates	GMP, ISO, CE
3	Chequered Plater	3.0 mm Pitch (Std) Optional with extra cost: 1.0 mm to 8.0 Pitch
4	Production Capacity	100 to 500 gm per batch (2-6 kg/hr depends on formulation.)
5	Product	Any Aqua base or solvent base formulation.
6	RPM	100 to 1400 rpm
7	Electric Accessories	230 V 1 Phase 50 Hz / 440 V 3 Phase 50 Hz
8	Air purged inlet	Through Fan
9	MOC Contact Parts	SS 316
10	MOC Non-Contact Parts	SS 304
11	Hardware	Standard Make (Bearing shaft seal of SKF etc or equivalent)
12	Finish	Non Contact Area Matt Finish Contact area Matt Finish Machine part- Machine Finish
13	Drive Motor	Crompton or equivalent
14	HMI (Touch Screen)	Delta
15	Documents	User Manual
16	Electric Consumption	1 Kw
17	Dimension (LXWXH) in mm	360 mm (L) X 425 mm (W) X 500 mm (H)
18	Weight	48 Kg

Note: Capacities mentioned above depend on samples used and may vary accordingly. VJ Instruments product development is a continuous process so specifications may change without prior notification.

Safety Features

Emergency stop switch
Auto stop feature when process time completes

Certifications

01.

CE Certificate

We prioritize quality and safety and proudly display our CE certification which meets EU standards for health, safety, and environmental protection. Our team is dedicated to ongoing training and education for continued compliance and customer satisfaction. Choose us as your trusted partner for quality products and services.

02.

GMP Certificate

Our product/facility meets high safety standards and has earned the internationally recognized GMP certification for excellence. We’re dedicated to quality and safety in everything we do, so you can trust us for safe and high-quality products.

03.

ISO Certificate

Our company is ISO certified and values quality and customer satisfaction above all else. We aim to exceed customer expectations with top-notch service and products, making your business with us a great experience.

04.

MSME Certificate

MSME Certified companies comply with the MSMED Act guidelines and are certified by the government of India. By partnering with an MSME Certified company, you ensure reliable products and services while supporting economic growth.

Frequently Asked Questions

We understand that you may have questions about our Lab-Scale Extruder Spheronizer Combo, its applications, and how it can benefit your specific needs. Here are some common questions and answers to provide you with quick and helpful information:

What is an extruder machine and how does it work?

An extruder machine is a processing device used to shape materials by forcing them through a die. Commonly used in industries like pharmaceuticals, food, and plastics, it mixes, melts, and forms materials into consistent shapes, ensuring high-quality output in continuous production lines.

What industries use pellets making machines?

Pellets making machines are widely used in pharmaceuticals for controlled drug delivery, in the chemical industry for catalyst formation, and in agriculture for producing feed or fertilizer pellets. Manufacturers like VJ Instruments offer specialized machines tailored to meet different industry standards and production needs.

What are the benefits of using extruders machines in pharmaceutical production?

In pharmaceutical manufacturing, extruders machines help produce uniform granules or pellets, improving dosage accuracy and product consistency. They offer precise control, high efficiency, and compatibility with downstream processes like spheronization or coating.

Where can I find reliable extruder machine manufacturers in India?

India has several reputable manufacturers of extruder machines, specializing in pharmaceutical, food, and plastic industries. Companies like VJ Instruments offer high-quality, customizable extruder machines that comply with international standards and cater to various production needs.

How does a mini lab extruder differ from industrial extruder machines?

Unlike large industrial extruders, a mini lab extruder is designed for low-volume output and flexibility in experimentation. It offers precise control over process parameters, making it suitable for formulation development, pilot testing, and quality control in a lab environment.

What is an extruder and how is it used in manufacturing?

An extruder is a machine that processes raw materials by forcing them through a shaped die to create uniform products like pellets, granules, or profiles. It’s widely used in industries such as pharmaceuticals, plastics, and food processing for continuous and efficient production.

What are the advantages of using a screw extruder machine?

Screw extruder machines offer precise control over temperature and pressure, ensuring consistent product quality. They support a variety of materials and are efficient in mixing, melting, and shaping, making them ideal for high-volume industrial production.

What should I consider when choosing single screw extruder manufacturers?

When selecting single screw extruder manufacturers, consider factors such as machine quality, compliance with industry standards (like GMP and ISO), customization options, production capacity, and reliable customer service to ensure long-term performance.

What factors influence the price of a pellet machine in India?

The price of a pellet machine in India depends on factors like machine capacity, type (flat die or ring die), automation level, and additional features such as GMP compliance and material construction. Customized solutions may also affect the cost.

What key features should I look for in an extruder for lab?

When selecting an extruder for lab, prioritize features like adjustable screw speed and temperature control, interchangeable screw and barrel designs, ease of cleaning, and accurate torque measurement. These ensure precise control over shear, residence time, and temperature, enabling reproducible results across diverse materials and formulations.

What is the primary function of the Lab-Scale Extruder & Spheronizer Combo?

The combo is designed for seamless integration of extrusion and spheronization processes, offering researchers and developers a comprehensive tool for granulation in formulation research.

What batch sizes can be accommodated by the lab-scale extruder?

The extruder is capable of accommodating batches as small as 200 grams, providing a cost-effective solution for formulation evaluation.

Can the extruder handle different low-pressure granulation techniques?

Yes, the extruder is equipped with interchangeable heads for dome, cone, axial, and radial extrusion, allowing users to explore and evaluate various granulation techniques.

What is the diameter range for the spheres produced by the spheronizer?

The spheronizer is capable of producing spheres with diameters ranging from 0.5 mm to 10.0 mm, providing flexibility for diverse applications.

Are there specific applications for the Lab-Scale Extruder & Spheronizer Combo in the pharmaceutical industry?

Yes, the combo is widely used for the formulation of controlled-release pellets, multi-particulate systems, and the production of enteric-coated and sustained-release polymer-coated pellets.

How user-friendly is the combo for researchers and product developers?

The combo is designed for ease of use with features like easy disassembly, variable plate speeds, and a dedicated control panel, providing researchers with precise control and efficiency in their granulation processes.

Can the Lab-Scale Extruder & Spheronizer Combo be utilized in the food industry?

Absolutely, the combo is suitable for crafting flavors with controlled release properties and formulating nutraceutical granules for enhanced nutritional delivery.