High Shear Wet Granulation Scale-Up Using Basic Principles

This poster explores a scale-up approach for high shear wet granulation by controlling impeller tip speed and matching the total number of impeller revolutions across different equipment scales. A development-scale batch was prepared using a Collette Gral 300 granulator at 185 rpm, with a 5-minute binder spray and 3-minute wet massing phase, yielding 925 impeller revolutions during spraying. Scale-up was then conducted on a Freund GMX-1200 high shear granulator with batch sizes of 132 kg and 352 kg, each divided into two sublots. To maintain equivalent tip speed, the GMX-1200 impeller was operated at 103 rpm, requiring a longer 9-minute spray to reach the same 925 revolutions. Process parameters for all batches are detailed in Figure 2 (downloadable below). This method highlights how adjusting impeller speed and total revolutions can effectively guide granulation scale-up between different equipment sizes while maintaining consistent process performance.