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Agglomeration and granulation in pharma

Forming powders into functional particles

A fundamental understanding of these two processes is crucial for correctly identifying their respective applications.

What is agglomeration?

Agglomeration forms porous, loosely bound particle clusters that reduce dust, increase instant properties and improve wettability. Unlike dense granules, agglomerates are typically designed for better dispersibility and user‑friendly handling.

What is granulation in pharma?

Granulation in pharma creates compact, mechanically stable granules with controlled density and flow properties. These granules are optimized for downstream operations such as tableting, encapsulation and continuous production.

Together, both processes aim to tailor particle design so that powders behave predictably and meet the functional requirements of pharmaceutical formulations.

Why agglomeration and granulation are essential in pharma

In solid dosage manufacturing, particle size control plays a central role in achieving stable, reproducible process conditions. The benefits include:

  • Consistent flowability and reduced segregation

  • Improved compressibility for robust tablet formation

  • Defined particle size distribution for uniform dosing

  • Reduced dust formation and safer material handling

  • Tailored porosity and solubility

  • Increased stability of sensitive ingredients

These advantages make agglomeration and granulation in pharma indispensable steps in the development and production of high‑quality oral solid dosage forms.

How agglomeration and granulation fit into the pharmaceutical process chain

Both processes are closely linked to fluid bed technology and downstream steps:

  • As agglomeration improves handling, reduces dust generation, and increases solubility, it is ideal for intermediates and instantized powders.
  • Granulation in pharma produces dense, uniform granules with good flow and processing properties. These are crucial for stable and reproducible tableting or encapsulation, as well as for consistent quality and performance of the dosage form.

By combining both technologies, Glatt enables a wide range of particle engineering options and ensures that every formulation possesses the properties required for efficient, high-quality pharmaceutical production.

Selecting the optimal process – material, product requirements and efficiency

The choice between agglomeration and granulation in pharma depends on:

  • the desired particle properties of the final product
  • the characteristics of the raw materials
  • the target dosage form and downstream equipment
  • process efficiency (time, energy, yield)
  • scalability and reproducibility

Glatt works with you to define all relevant target parameters in advance to ensure that every process is technically and economically optimized – from the laboratory scale to commercial operation.Depending on formulation, material characteristics and application area, the following processes are applied:

Spray Agglomeration

In spray agglomeration using the fluidized bed process, fine powders are converted into porous, easily dispersible agglomerates. A sprayed liquid forms temporary bridges between the particles, which are then dried and solidified. The result of spray agglomeration: improved instant properties, excellent wettability, and reduced dust generation.

Spray granulation

In fluidized-bed spray granulation, compact granules are formed by spraying a solution, suspension, or melt onto seed particles. Layer by layer, the droplets solidify into stable granules with defined size and density. This process is ideal for producing free-flowing, low-dust granules with a controlled structure and high mechanical properties.

High-shear granulation

High-shear systems produce dense granules through rapid mixing, wetting, and solidification. High-shear granulation in pharma is particularly suitable for formulations that require defined compressibility and high mechanical strength for subsequent tableting.

Microencapsulation via spray granulation

Liquids or sensitive actives can be embedded into a solid matrix structure. Microencapsulation enables controlled release, enhanced stability and safe handling of volatile, sensitive or hygroscopic substances.

Looking for the right process for your formulation?

Our experts support you in selecting the optimal agglomeration or granulation pharma technology for your material and application. Contact us to discuss your requirements!