Hot melt Granulation and Coating

Hot melt coating and granulation are both advanced techniques used in the pharmaceutical industry for improving the properties of drugs, such as their bioavailability, stability, and controlled release. The evolution of hot melt processing in the pharmaceutical and nutraceutical industry reflects a broader trend towards more efficient and environmentally friendly manufacturing system versus other traditional coating methods.

Hot melt is a technique that applies a thin layer of molten material, like polymers or waxes, to a particle. The melted coating material solidifies upon cooling inside of the Fluid Bed. Unlike traditional wet granulation, no solvents are needed, making this process ideal for moisture-sensitive drugs and shorter processing time. It's commonly used in pharmaceuticals to mask unpleasant tastes, control drug release, and improve stability of final product. It's also used in food, nutraceuticals and other industries for similar purposes.

Your challenges

Unpleasant tastes: Need to mask bitter or unpleasant tasting medications for patient (specially children) compliance?
Moisture/oxygen/light sensitivity: Proceeding moisture/oxygen/light sensitive products?
Controlled release: Processing products which needs controlled/gradually release over time?
Losing time by long processing times? Excessive never-ending drying time?
Need to reduced production costs? How to mitigate OPEX and energy usage?
Want to be more sustainable? Compliance with Global Warming and decarbonization?
Invest on Sustainable equipment? Compliance with local authorities?

Our solution

Protection of APIs: APIs that are sensitive to moisture, oxygen, or light can be protected by hot melt coatings, thereby enhancing the stability and shelf life of the drug product. Carnauba Wax is also highly effective, particularly for moisture-sensitive APIs. Stearic acid is hydrophobic and can act as a moisture barrier.
Solvent-Free Process: Traditional coating methods often require solvents, which can be harmful, require special handling, and need additional drying steps. Hot melt coatings eliminate the need for solvents, making the process safer and more environmentally friendly.
Rapid Processing: Hot melt coating processes are generally faster because they do not require long drying times associated with solvent evaporation. This improves manufacturing efficiency and throughput. It can lead to up to 85% shorter processing times

Moisture or heat sensitivity: APIs or excipients that are sensitive to moisture or high temperatures, can benefit from hot melt coatings since the process does not involve water or other solvents, neither high temperature in the fluid bed.
Uniform Coating: Hot melt coatings provide a uniform and consistent layer, which can be critical for ensuring dose uniformity and the controlled release profile of the drug.
Process Control: Precise control of temperature and other process parameters is essential to ensure consistent coating quality and performance.
Controlled release: In pharmaceuticals, hot melt coatings can be formulated for controlled release, allowing the medication to be released gradually over time. This improves drug delivery and patient outcomes.
Beeswax: is a highly effective excipient for hot melt coating in the pharmaceutical industry, especially in fluid bed systems. Its natural, biocompatible properties, combined with its excellent barrier and film-forming abilities, make it ideal for controlled release, taste masking, and moisture protection applications.
Energy efficient: Together with the Ventilus USP process times are significantly reduced compared to other Fluid Bed on the market. In addition to this, there is no need to heat up the inlet air at higher temperatures as heat loss it is been recuperated.

What you can expect

Compared to some alternative coating methods, hot melt coating offers a faster and more cost-effective solution due to its efficient application process and shorter curing times.
Rotojet: One nozzle principle minimizes the spray loss
Orbiter: Controlled product movement improves yield and product quality
Sepajet: Unique filter design for long standing times
Reduced cleaning times
Innojet Hot Melt Device: Fast solution preparation and cleaning IHD5, IHD50 and IHD300
Coating agents made from renewable plant-based raw materials
No chemical additives

Suitable Products

Innojet

VENTILUS® Multipurpose lab unit

Applications

Maximum output (liters)

1–5

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Innojet

VENTILUS® Mobile pilot plant

Applications

Maximum output (liters)

4–25

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Innojet

VENTILUS® Production scale solutions

Applications

Maximum output (liters)

7.5–1,500

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You are facing one of the challenges above?

Then hotmelt coating could be the solution for you. Contact us for more information.

Do you want to keep up to date with other game changer in terms of Sustainability? Discover Innojet’s unique Heat Recovery System.

Our Laboratory InnoTech can help you to find the right customised Innojet Solution. Moreover, our InnoTech supports you e.g. with demonstrations and optimization as well as with improvement of existing processes.