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Caleva Variable Density Extruder



The Caleva Variable Density Extruder

Variable Density Extrusion For the Laboratory


Only the Caleva VDE Variable Density Extruder™ can offer a selection of extruder die apertures and bore lengths for both radial and axial extrusion methods.

With aperture diameters from 0.4 – 2.0mm and bore lengths from 0.5 – 8.0mm, the optimal length to diameter ratio (L:D ratio) can be selected to produce the ideal density extrusions to suit your application.

The unique ability of the VDE™ to produce extrusions using either the Axial or Radial methods, coupled with the range of die L:D ratios allows for quick and easy laboratory evaluation of various densities and formulations. There is nothing else available that offers this degree of flexibility and ease of use in a single piece of equipment.

The VDE™ from Caleva, for the development of pellets by Extrusion and Spheronization. The most flexible and productive laboratory extruder available. The only bench-top extruder with variable die diameter and depth with both radial and axial extrusion!

Low load Performance

customers who are considering the Caleva Variable Density Extruder (VDE) are
asking more and more frequently about the use of the VDE for very small batches when
used in the axial mode. In order to respond to these questions a series of small batches
were extruded through the VDE and the percentage recovery was measured

Customers who are considering the Caleva Variable Density Extruder frequently ask about using the VDE for very small batches when processing in axial mode. In order to respond to these questions a series of small batches were extruded through the VDE and the percentage recovered (yield) was measured.

Batch Weight (grams) Extrudate Weight (grams) Lost Product (grams) Yield(%)
400 331 69 82.7 %
200 161 39 80.5 %
100 73.8 26.2 73.8 %
50 30.2 19.8 60.4 %
25 14.0 11.0 56.0 %
15 5.20 8.8 34.6 %
Methodology: A mix of microcrystalline cellulose (Avicel® pH 101) was mixed for five minutes in a planetary mixer with water at a ratio of 1:1.1. The resulting mix was stored in bulk overnight in a refrigerator. The next day, different batch sizes were run one at a time through the Variable Density Extruder. The extruder was cleaned and dried between each extrusion run. In each case, the extruder was run in the axial configuration at 70 RPM and the product was fed a slow rate, slightly starving the extruder.

The objective of this trial was to determine the smallest batche that can be successfully extruded through the Caleva VDE, and it is clear here that it's possible to process batches as small as 15 grams. As in any screw extrusion system, smaller batches result in lower yields, however, a 50 gram batch results in 30 grams of useable extrudate.  This is considered exceptional for an extruder of this size.

 

 A short YouTube video showing the Caleva VDE™ in operation can be found here.

  • Ability to control the density of the extrudate.
  • Radial and axial extrusion in a single bench-top unit.
  • High flexibility according to requirements of the formulation.
  • Reduce patient dosing frequency by increasing product density.
  • A wide range of apertures and depths are available.
  • Comparative trials have shown significant yield benefits.
  • Trials produced average usable yield with a higher density result.
  • Toolless assembly and disassembly for cleaning.
  • All product contact components are manufactured in 316 stainless steel, and cGMP compliant polymers.
  • Product can be heated or cooled as required.
  • Heat of extrusion can be partially or completely removed, depending on formulation and configuration.
  • Operating parameters are directly controlled by the user.
  • Extrusion rates up to 27kg/hr* on a radial screen and 20kg/hr* on an axial screen.
  • All product contact components are manufactured in316 stainless steel, and cGMP compliant polymers.
  • Safety interlocked.
  • Operating parameters are directly controlled by the user via front panel controls.
  • Jacketed screw casing allows the product to be heated or cooled as required. Heat of extrusion can be partially or completely removed, depending on formulation and configuration.

Utilities:

  • 110 volt, single phase, 60 HZ.
  • Liquid heating/cooling medium.

*Figures given here are for comparison purposes only. The actual production rate will depend on the machine’s configuration and the material being extruded.

THERE IS A BROAD RANGE OF EXTRUDER APERTURES AND DEPTHS AVAILABLE:

 

  • Diameters between 0.4 and 2.0mm.
  • Depths between 0.5mm and 8mm.

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