Extruder And Spheronizer Machine Manufacturer
☑ Benchtop to high-capacity pelletization machines
☑ 20+ years of leading industry experience
☑ Turnkey solutions customized to your layout
☑ Combines multiple processes into a single unit
☑ Tightly controlled particle sizes
☑ Suitable for full production line integration
Extruder And Spheronizer Machine Applications
In pharmaceutical applications, our extruder and spheronizer machines produce pelletized dosages for controlled drug release, multi-particulate capsules, and taste-masked APIs. They’re also widely used in food and confectionary, chemical, nutraceutical, and agricultural manufacturing for products like fertilizers, pesticides, probiotics, desiccants, flavors, and more.
What Is An Extruder And Spheronizer Machine?
An extruder and spheronizer machine is used to turn granules or powder into high-density, uniform pellets. This has many benefits. It makes the material easier to handle, gives it a more attractive appearance, and improves dosing accuracy.
At SaintyCo, we specialize in extruder and spheronizer machines for producing pharmaceutical pellets. Our systems are primarily designed for wet blends, where a binder solution, lubricant, or water is added to dry powders or granules. This forms a moist material with the right rheology for extrusion and spheronization (also known as marumerization). However, we also offer machines that can handle meltable formulations or dry powders with thermal plasticity, suitable for a range of industries from nutraceutical to petrochemical.
Pelletizing granules or powder using a SaintyCo extruder and spheronizer reduces the material’s friability. The pellets are less likely to crumble or create fines due to their increased hardness. This minimizes dust, resulting in a safer and cleaner work environment with a reduced contamination risk.
Our extruder and spheronizers also help you reduce handling losses, blockages, and bridging in hoppers by giving the material fast-flow characteristics. This is ideal for large-scale, automated, and continuous operations, and essential for products that rely on precise dosing accuracy.
Types Of Extruder And Spheronizer Machine
SaintyCo extruder and spheronizer machines come in a variety of models, with several unique designs to suit different use cases.
Used in the case of materials with increased malleability at higher temperatures.
Our standard setup operates at or below room temperature, best for products sensitive to heat.
Runs non-stop with automatic feeding and discharge, for large-scale production.
Batch-based systems give you greater flexibility over the process in smaller runs or pilots.
Extremely efficient for high-throughputs, with dual counter-rotating rollers.
Our mechanically simple options rely on gravity for material flow, great for reduced complexity.
High pressure forces material through the die plate for particularly dense formulations.
A perforated basket or mesh screen turns wet masses into uniform cylindrical extrudates.
Extruder And Spheronizer Machine Setups
Here at SaintyCo, we engineer extruder and spheronizer machines for all sorts of facilities. From small, stand-alone solutions to mass-production models, our machines cover a range of capacities.
Our most compact units are ideal for lab-scale production, research, and development.
Our streamlined systems combine two key functionalities and integrate into your production line.
An all-in-one unit and enclosed design save space and improve contamination control.
We can build to your exact spec. Contact us for a custom-engineered solution.
Key Machine Features And Benefits
SaintyCo extruder and spheronizer machines are optimized to be operator friendly, efficient, and cost-effective.
Switch extrusion screens without tools for fast and simple changeovers.
Innovative, space-saving designs to fit even the smallest of facilities.
Compatible with CIP and SIP options for less downtime during cleaning between batches.
Compliant with stringent standards like CE, FDA, GMP, and cGMP for safety and efficacy.
Expertly engineered for higher yields than other pelletization methods.
Less material loss is achieved through closed loop and high-efficiency systems.
Produces uniform spheres of consistent size, ideal for high-quality products.
Our systems are adaptable and work with many materials, formulations, and products.
Components Of An Extruder And Spheronizer Machine
Every element of our extruder and spheronizer machines has been carefully refined by world-class engineers. Here’s a closer look at each key stage of the process.
The product is funneled from the storage bin using gravimetric or more-accruate volumetric feeders. Liquid feeders operate with fluid displacement, mass flow velocity flow, or differential pressure meters.
Many SaintyCo extruder and spheronizer machines include a granulation system to reduce oversized agglomerates and ensure the blend can be compacted smoothly, reducing torque on the extruder.
At this critical stage, the extruder presses the moistened material through a die plate or perforated screen. The extrudate forms in multiple cylinders of an equal diameter, which breaks off under its own weight.
The spheronization process, also known as marumerization, is where the extrudate is gradually broken down and rounded into spheroids by centrifugal force, bouncing between the rotating disk and bowl walls.
Moisture is removed from freshly formed pellets using modules like fluid bed or vacuum dryers. We also offer integrated pellet coating systems for adding functional or aesthetic outer layers.
Our extruder and spheronizers are centrally controlled by a PLC using the latest software. You can live monitor performance, adjust parameters, view data logs for audit trails, and diagnose errors via the intuitive HMI.
Screw Extruders
SaintyCo screw extruder and spheronizer machines can be further classified into axial, dome, and radial, with axial and dome being the preferred options for pellet quality. Our machines also come in single-screw and twin-screw designs, which can be configured to be either co-rotating or counter-rotating.
Spheronizer Friction Plate Patterns
At SaintyCo, we have a selection of plate textures to match different products and material characteristics, and optimize the spheronization process. Our cross-hatch (waffle-iron) plates are most popular, where the surface is a grid of truncated pyramids. Our radial groove plates have indents that radiate from the center. We also offer plates with a striated edge pattern.
Useful Resources
Download our comprehensive product catalog to browse our various extruder and spheronizer models at your leisure.
We’ve created a handy document with all our extruder and spheronizer machines’ technical specifications.
Take a look at how our extruder and spheronization machines work, with a guided video showing each stage of the process.
Why Should You Partner With SaintyCo?
SaintyCo is a leading manufacturer and supplier of high-quality extruder and spheronizer machines in China. All our designs are engineered in-house, so we govern the whole process from conception to delivery. This gives us the flexibility to create tailor-made solutions that meet your extrusion and spheronization needs precisely. We’ve got a proven track record of hundreds of happy, long-term clients on an international scale. If you choose us for your extruder and spheronizer order, you’ll see why they keep coming back.
Top Extruder And Spheronizer Machines
We manufacture a vast array of extruder and spheronizer machines to meet the needs of our diverse client base. These are some of the top-selling categories according to our recent orders.
Our compact, benchtop design is popular for R&D applications in laboratories to support formulation development and testing. It’s also a great option for university facilities and teaching students in the pharmaceutical field.
Our aseptic machines are built specifically for sterile environments that process products like injectable and inhalable drugs. They feature containment systems like pressure control, sealed enclosures, and dust extraction.
Our best-selling machines use the wet granulation method because of its suitability for a wide range of materials. Adding a liquid binder also helps to reduce dust formation and improve overall pellet quality.
For moisture-sensitive and thermo-sensitive materials, where purity must be maintained and a liquid binder would not be appropriate, our dry granulation, extrusion, and spherification systems are perfect.
Centralized Control Systems
You can choose the automation level of your extruder and spheronizer machine depending on your budget and production goals.
Our semi-automated extruder and spheronizers are an affordable entry-point for startups, small businesses, R&D labs, or facilities with limited automation infrastructure.
They’re small, easy to clean, and perfect for pilot-scale production. Manual loading, discharge, and transfer is required.
Our advanced extruder and spheronizers automate the entire process, requiring little to no operator intervention. The PLC continuously manages activity and performance, which can be reviewed and adjusted using the user-friendly HMI.
These machines are suitable for 24/7 industrial production.
More About Our Extruder And Spheronizer Machines
Get more information including technical data and after-sales details. Plus, look at pictures of our extruder and spheronizer machines in place.
- Data Sheet
- After-Sales Service
- Gallery
| Bench-Top Models | Mid-Range Models | Full-Scale Models | |
| Throughput | 15g-6 kg | 30-80 kg | 100-200+ kg |
| Pellet Size | 0.4-3.0 mm | 0.4-5.0 mm | 0.4-8.0 mm |
| Spheronizer Plate Diameter | 200 mm | 300 mm | 400-700 mm |
| Return ratio | >90% | >95% | >99% |
| Power Supply | 220V | 220V/380V | 380V/415V |
| Construction Material | SS316L/SS304 | SS316L/SS304 | SS316L/SS304 |
| Extruder Screw Speed | 10-40 rpm | 80-220 rpm | 800-1,000+ rpm |
| Machine Weight | 50 kg | 680 kg | 1100 kg |
| Certification | GMP, ISO, CE | GMP, ISO, CE | GMP, ISO, CE |
| Cleaning System | Manual tool-free dismantling | Optional CIP | CIP integration |
Not only do we offer some of the best extruder and spheronizer machines on the market, but we also top the charts when it comes to service. Whether you’re a new or returning customer, you’ll get dedicated support from highly trained staff throughout every step of your order.
But what about after you’ve received your order? SaintyCo is pleased to provide you with unparalleled after-sales services for the lifetime of your extruder and spheronizer machine. That includes troubleshooting, technical assistance, help with maintenance, and spare parts supply.
Testimonials
“We work with micron-level APIs so uniformity is incredibly important. We installed an extruder and spheronizer machine from SaintyCo in January. The output is always consistent regardless of the production run, and we’ve tested it with some long runs. The modular design is fantastic engineering. We need to swap friction plates depending on the batch – we use both waffle and radial groove. Being able to do that quickly and without tools really speeds up our processes.”
Markus BauerHead Of Procurement, AppVie“We use the SaintyCo extruder and spheronizer every day in production. It works very stable and the roundness of the pellets is much better than the machine we used before. At the beginning we had some question about settings but the support team replied very fast and helped us. They provided all documents for validation without trouble. Overall we are very happy with this extruder and marumerizer machine and the service from SaintyCo and will consider another one when we expand. ”
Piotr KowalskiOperations Director, Rutherford & Johnson
Here at SaintyCo, we work hard to ensure our lead times are kept at short as possible. Depending on the particular requirements of your order (including model, specs, volume, and location), lead times are generally anywhere from 4-8 weeks for standard products, or a few months for more complex orders.
We have a massive catalog of extruder and spheronizer machines, all of which come in at different costs. To get an accurate quote that includes any custom requests, manufacturing, and shipping, please send us your details. We aim to respond to all inquiries within 24 hours.
Yes, we specialize in machinery for the pharmaceutical industry so we offer various extruder and spheronizer machines designed for cleanroom environments. They use HEPA/ULPA filters, specialized extrusion heads, sealed systems, and other features to ensure compliance with ISO Class 4-8.
Related Products
Pharmaceutical Roller CompactorExplore another piece of equipment for dry material granulation.
Granulation LineTake care of the whole granulation process from start to finish.
Vacuum FeederEssential for the hygienic transfer of fine powders and light granules.
Clean Room FloorSterile flooring that holds even the largest extruder and spheronizers.
Optional Auxiliary Features
You can tweak SaintyCo extrusion and spheronizers with numerous add-on features that can improve process control and make the equipment more suited to your goals.
We can apply non-stick coatings to the inner wall of the spherification chamber wall and the friction plate. This makes cleaning easier and reduces the risk of the product sticking to surfaces during spheronization.
To reduce static dust accumulation, many models are available with a low-pressure airflow system which can be installed underneath the friction plate. This helps remove surface moisture. Another method for removing residual moisture by using a thermal jacket around the spheronizer bowl to heat the product during processing. A cooling jacket is ideal for increasing stability in temperature sensitive APIs.
If you’re interested in an application involving melt-extrusion (like taste-masking or sustained release granules) then we offer a hot extruder for thermoplastic materials. SaintyCo systems typically come with an intuitive PLC fitted with various features like an automatic cycle timer to reduce human error and ensure consistency.
Drying And Coating Systems
The spheronized pellets need to be dried before downstream processing which can be done by an integrated module or as another stage in your line. We offer tray drying modules and fluid bed dryers which gently dry pellets without damaging them.
Our machines can also be integrated with coating systems including fluidized spray coaters. The spheroid geometry of the pellets is the most economical shape to coat as it has a high surface area to volume ratio. This also increases solubility, or the dissolution rate, which in turn improves bioavailability of the drugs.
The core components of an extrusion and spheronizer machine are a) the extruder and b) the spheronizer, or marumerizer. However, many models include a granulator.
Yes. SaintyCo supplies extruder and spheronizers for mass production facilities with continuous, round-the-clock, fully-automated runs.
SaintyCo extruder and spheronizers are commonly integrated with supervisory control and data acquisition (SCADA) systems for centralized control.
With more than two decades of experience, the SaintyCo experts are well-equipped to answer your questions and provide advice on the right machinery for your desired use case.
Our machines are carefully packed in sturdy plywood crates with internal bracing to ensure their safe transit, whether by sea, air, rail, or road.