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Model 40 Gear Extruder

Caleva Extruder 40

The Caleva Model 40 Extruder is a floor standing,  gear–type extruder. The Model 40 gear–type extruder is designed to produce extrudate from wet granulated pharmaceutical formulations, without imparting excessive energy (which can result in unwanted heat gain and potential damage to either the process, the product, or both) into the wet granulate being extruded.


The Model 40 gear–type extruder is currently employed in the pharmaceutical industry in combination with Caleva Spheronizers to produce hundreds of thousands of kilograms of extrudate and spheronized end product.The gear–type extruder(s) is the next generation of what is commonly known as a roll–type extruder. 


The Caleva Model 40 gear–type extruder is very different from the Caleva Model 20 and Model 35 screen – type extruders. The Caleva Model 20 and Model 35 screen–type extruders employ the combination of a single, vertically oriented extrusion screen in combination with a pair of diametrically opposed, solid cylindrical rollers, to physically transform the wet granulate into extrudate.The wet granulate is fed into the interior cavity of the extrusion screen, at the same time that the rollers are rotating around the internal circumference of the extrusion screen.  The wet granulate that lies just ahead of each roller, is pushed into the gap between the outside diameter of each roller and the inside diameter of the extrusion screen and then through the holes ( the dies ) in the extrusion screen. As the wet granulate passes through the holes ( the dies )in the extrusion screen, individual, discreet, spaghetti – like extrudate form and exit to the exterior of the extrusion screen.  The direction of flow of the material is inside – to – outside in relationship to the extrusion screen.


The Caleva Model 40 gear–type extruder operates much differently than the Caleva Model 20 and Model 35 screen–type extruders. Instead of employing a single, vertically oriented, screen to extrude the wet granulate, the Model 40 gear–type extruder utilizes a pair of horizontally oriented, opposed, intermeshed, hollow extrusion gears to physically convert the wet granulate into individual, discreet extrudate. Each extrusion gear contains a set of rectangular–shaped inserts. Each insert contains a quantity and pattern of holes (dies) that have been individually drilled. The drilled inserts are physically located at the root (the valley) between each gear tooth on each extrusion gear.  The pair of extrusion gears is horizontally mounted onto a pair of parallel horizontal drive shafts.  The drive shafts are connected to a drive train.  The drive train sits inside a casing and shroud. The wet granulate is fed into the axial center point between the pair of extrusion gears.  When in operation, the drive shafts transmits the power that causes the left–hand extrusion gear to rotate clockwise (CW) and downward, and the right–hand extrusion gear to rotate counter clockwise (CCW) and downward.  The wet granulate being fed, finds its way into the open space between the equip–spaced gear teeth on each extrusion gear.  As the pair of gears rotate / intermesh, the top of each gear tooth on the opposing gear, fills the space containing the wet granulate in the other gear. In doing so, the wet granulate is pushed through the the dies in the insert.  As this happens, the wet granulate physically transforms into individual, discreet extrudate.

Each extrusion gear has a hollow interior, the extrudate falls into this hollow interior and then travels along the horizontal length of each gear, until the extrudate discharges at the open end of each extrusion gear.  The direction of flow of the material is outside–to-inside in relationship to the pair of extrusion gears. 


If the durability / strength of extrudate is such that it precludes the individual extrudate from breaking free, into individual, non–continuous lengths, or if the next unit operation requires that the individual extrudate be of approximately the same equal length, then an optional cutter blade assembly can be fitted inside the extrusion gears to cut the individual extradites into near – equal lengths prior to collection.


The extrudate is collected for further processing (usually spheronization is the next unit operation). The Caleva Model 40 gear–type extruder can make use of extrusion gears, that contain drilled hole inserts, that can be as much as four (4) times thicker than the drilled hole vertically oriented extrusion screen on the Caleva Model 20 and Model 35 screen–type extruders.  This difference in thickness can have a direct impact on the density of the extrudate.  Gear–type extruders produce a higher density extrudate than the screen–type extruders. The Caleva Model 40 floor standing gear–type extruder is designed for use in laboratory and in pilot plant environments.  For higher production requirements, the Caleva Model 100 floor standing, gear –type extruder is required.


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  • Gear – Type Continuous Production Extruder
  • Portable, Floor Standing Configuration
  • Simple, Easy Operation
  • Manual Feed Loading
  • Utilizes Individual, Paired, Hollow, Horizontal Extrusion Gears
  • Interchangeable, Replaceable, Drilled, Rectangular Inserts In The Extrusion Gears
  • Low Energy Input
  • Yields High Density Extrudate
  • Front Mounted and Integrated Manually Operated Controls and LED Display
  • Pre – Wired with External Power Cord
  • ( 2 ) Swivel Wheels ( Lockable )
  • ( 2 ) Non – Swivel Wheels ( Non – Lockable )
  • Suitable for Use in Laboratory and Pilot Plant Environments
  • Compact Design Requires Limited L x W x H Floor Space
  • Suitable for Use in Combination with Caleva Model 380 and Model 500 Spheronizers
Feed Configuration:  Manual Loading
Nominal Overall Dimensions:  1,000 mm W  x  480 mm D  x  1,000 mm H
Nominal Assembled Weight: 230 kg
Nominal Processing Rate:  Up to 40 kg per hour ( product dependent, confirming test work required )
Nominal Extrusion Gear Speed:  30 – 90 RPM 
Drive Arrangement:  2.2 kw AC motor
Method of Extrusion:  Paired,  hollow, horizontal, extrusion gears containing interchangeable, replaceable, drilled rectangular inserts
Cabinet: 304 SS
Contact Parts 316 SS
Control: Front mounted LED display of extrusion gear RPM,
manually adjustable speed Control, push button ON / OFF,  power indicator light and emergency E – STOP push button included
Insert Hole Size Range:   0.8 mm up to 2.00 mm hole ( die ) diameters
Electrical Utility: 230 v / 3 Ph / 60 Hz, or 460 V / 3 Ph / 60 Hz, or 480 v / 3 Ph / 60 Hz
  • Interchangeable, replaceable, drilled, rectangular insert sets.
  • Various drilled hole (die) diameters (0.8 mm up to 2.00 mm ) for the inserts.
  • Automated feed system.
  • Can be fully integrated with twin spheronizers (Caleva Model 500 and Model 700).
  • Installation, start up and training.
  • Product contact material certificates.
  • Installation Qualification ( IQ ) / Operational Qualification ( OQ ) Document Package.
  • Customized controls and displays.
  • Factory Acceptance Test (FAT) and Site Acceptance Test (SAT).