Pellets possess a high degree of mechanical stability and a dense, regular surface. Due to the regular spherical shape and the narrow particle size distribution pellets are ideally suited for further film encapsulation and products providing a high degree of uniformity.

IPC produces pellets using different technical processes - depending on product requirements:

  • The pure pellet is created from a solution using spray granulation
  • A wide variety of active ingredients can be easily made available in pellet form by embedding in a carrier material: matrix pellet
  • Multifunctional products can be manufactured using the layering process: layered pellet
Direct Pelletizing

Manufacture of pellets directly from powder.

  • Round Pellets
  • Defined surface
  • Ideal flowability and dosability
  • Narrow particle size distribution
  • Low abrasion

Pellets can be automatically dosed and filled into capsules or compressed to form tablets using a suitable formulation. The even shape and surface provide ideal conditions for application of a precise film, in order to achieve controlled release.

Process principle

Powder is mixed and moistened and the powder bed set into centrifugal motion ( fluid bed pelletizing in the rotor). The impact and acceleration forces that occur in this process result in the formation of agglomerates, which become rounded out into uniform and dense pellets and are then dried.

Verfahrensprinzip Pelletierung
Pelletizing by layering

Pellet built up layer-by-layer - around a given starter core.

  • Round pellets
  • Ideal dosability
  • Low hygroscopicity
  • Dense, even surface
  • Narrow grain size distribution
  • Low wear
  • Layer-by-layer structure
  • Different active ingredients possible

Active ingredients can be applied as a powder or a solution on a layer-by-layer basis onto a carrier, and so unite wide-ranging different functions in a single pellet.

Process principle suspension and solution layering

A starter core or a pellet is presented as the starting material. The pellet is then built up to the required size and active incredient content on a layer-by-layer basis by spray application of the layering substance.
Suitable layering substances are micronized powders, suspensions or solutions.

Another possibility of suspension layering is the manufacture of pure pellets by spraygranulation.

Verfahrensprinzip Suspensionslayering
Pelletizing by Extrusion and Spheronization

An all-rounder for wet granules and extrudates.

Pelletierung durch Verrunden
  • Round, even shape
  • Ideal flowability and dosability
  • Compact structure
  • Low hygroscopicity
  • High bulk density
  • Dense surface
  • Narrow particle size distribution
  • Low abrasion

Round pellets are characterized by optimum dosability. The regular shape and the dense surface are required for a functional coating.

Principle of spheronizing of a wet-granulated product

Verfahrensprinzip Verrunden von Granulaten

Principle of spheronizing an extruded product

Irregular particles can be spheronized with the help of a pelletizer/spheronizer. The moist granulates or extrudates are fed onto the rotating pelletizing plate. The surface is smoothed due to the intensive rolling movement and spherical pellets are produced. (Spheronizing in the pelletizer)

Verrunden von Extrudaten