Melt granulation as an alternative technique in solid dosage forms manufacture

Conventional granulation methods are associated with significant disadvantages which have led to increased interest and investment in the development of alternative techniques. Melt granulation is an alternative technique with significant potential for the application in production of solid dosage forms. Melt granulation involves the use of binders with relatively low melting point (50 to 100°C) that act as a molten binding liquid in agglomeration process. Considering that solvent is not required, drying phase is avoided, and number of processing steps and costs is reduced in comparison with the traditional wet granulation process. Process is suitable for moisture-sensitive drugs, and by selecting the suitable binder, it can be used to prepare modified or immediate release dosage forms, with improved bioavailability of poorly water soluble drugs, as well as to achieve taste masking. Melt granulation can be performed in the equipment commonly used for wet granulation, such as high shear mixers, fluid bed granulators, and extruders. Numerous formulation variables, process parameters, and equipment-related factors can affect the agglomeration mechanism and characteristics of the granules obtained. Well controlled melt granulation process requires thorough knowledge and understanding of the influence of these factors. Therefore, this research area still requires an intense and often multidisciplinary research.