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Pelletizing

Forming spherical pellets with defined properties

Pelletizing is a proven process for particle formation. Finely powdered materials are converted into compact, spherical granules – known as pellets.

What is pelletizing?

Pelletizing is the transformation of small powder particles into dense, spherical pellets. Through controlled moistening, shaping, and rounding steps, powders become mechanically stable particles with smooth surfaces and precisely defined size, shape, and functional properties.

This clear definition of what pelletizing is highlights the importance of this process: Compared to irregular granules, pellets offer superior flowability, improved handling, and reproducible further processing.

Why pelletizing is used in pharmaceutical production

Pellets are widely used in the pharmaceutical industry because pelletizing significantly improves both product performance and process efficiency. The key benefits include:

  • Improved flow properties and consistent material handling

  • Safe storage with reduced dust formation

  • Easier transport and dosing

  • High mechanical stability during further processing

  • Flexibility in coating, encapsulation, or tableting

Therefore, pelletizing is a key technology for multi-component dosage forms such as capsules, sachets, and MUPS tablets.

Pelletizing with Glatt – technology variants and benefits

What raw materials do you work with, and what requirements do you have for your pellets? Glatt offers a wide range of pelletizing technology options tailored to material properties, formulation goals, and production concepts – to meet your specific needs. All pelletizing variants are designed to deliver compact, spherical pellets with high reproducibility.

The resulting pellets are:

  • Stable in storage
  • Easy to transport
  • Simple to dose
  • Well-suited for further processing

Depending on material characteristics and application objectives, we offer a wide range of extrusion pelletizing technology:

Extrusion and spheronization

Extrusion and spheronization are established pelletizing processes for producing highly spherical pellets from moist slurries or granulates. The material is extruded through a die and subsequently rounded in a spheronizer. This method delivers dense pellets with narrow size distributions and excellent mechanical stability.

Layering

Layering is a pelletizing approach in which active ingredients or excipients are applied onto starter cores. Using liquid or powder layering techniques, pellets with defined drug load and functional layers can be produced. Layering enables precise control of pellet composition and is often combined with subsequent coating steps.

Pelletizing via spray granulation

In spray‑granulation‑based pelletizing technology, liquids, suspensions or melts are sprayed into a fluidized bed, where compact pellets are formed layer by layer. This pelletizing process allows the direct production of spherical pellets without the need for starter cores and offers high flexibility in formulation design.

Direct pelletizing

Direct pelletizing combines mixing, wetting and shaping in a single step. Powders are transformed directly into spherical pellets through controlled agitation and moisture addition. This pelletizing technology is particularly suitable for streamlined processes with reduced processing steps and efficient scale‑up.

Looking for the right pelletizing solution for your product?

Our experts support you in selecting the optimal pelletizing technology based on your formulation, process requirements and production goals. Contact us!