Process Simulation of Twin-Screw Granulator: Effect of Screw Configuration on Size Distribution

Abstract

The effect of screw configuration on granule size distribution (GSD) using gPROMS FormulatedProduct (gFP) software to perform optimization, estimation of complex processes, and analyses is evaluated. Twin-screw granulation modeling was used to investigate the contribution of screw configuration and liquid-to-solid (L/S) ratio on GSD. Lactose and Avicel were the granulating materials. Twelve different configurations were investigated under three feed rates as consistent with literature and at various L/S ratios. Results indicate that kneading elements promote the recovery of 100–1000 µm granules while reducing the production of oversized granules. Higher feed rates support the production of fines and agglomerates, while a low feed rate produces 100–1000 µm granules.