Development of a novel vertical high shear kneader and its performance in wet kneading of pharmaceutical powders.

A novel multi-functional vertical high shear kneader has been developed. Wet kneading of pharmaceutical powders was conducted under various blade components and operating conditions. Compression properties of wet kneaded mass was analyzed and dispersion of hinder liquid (water) among the mass was investigated by assaying tracer aqueous pigment. Pellets were produced through a dome type extrusion granulator with continuous extrusion pressure measurement device and a fluidized bed drier, and then the physical properties were measured. Quantitative relationship between the pellet's physical properties and the binder dispersion condition as well as the compression properties could be obtained. It was found that the newly developed kneader was very effective to uniformly disperse binder as well as impart high shear stress to the wet mass without generating obvious adhesion onto the vessel wall. It was also pointed out that the extrusion pressure could determine the physical strength of pellet. This method proposes a new methodology for continuous monitoring of kneading condition as well as predicting pellet's physical properties.