Breakthrough in drug coating dispersion: 62% faster production with advanced mixing technology.

Innovative combination of high shear mixing and magnetic agitation delivers stable suspensions, minimizes sedimentation, and enhances cleanability.

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From studies in the ZETA TechCenter to a fully automated production plant.

At the ZETA TechCenter, extensive studies were carried out on the production of a dispersion for coating orally administered drugs. An optimized process with a significantly reduced mixing time was developed. Based on these studies, a dispersion production plant was designed, built and automated, consisting of two mobile mixing tanks. These are equipped with the most advanced magnetic agitators, such as the ZETA high shear mixer.

The challenge

A key challenge in adapting their coating dispersion production process was the need to significantly reduce production time while ensuring the creation of a stable, homogeneous suspension. This required preventing common issues such as sedimentation, lump formation, and the unwanted adhesion of ferromagnetic pigments to the rotor of the magnetic agitator. Additionally, the cleanability of both the mixing vessel and the agitator head emerged as a key concern.

The solution

Feasibility studies were performed in the ZETA TechCenter in close collaboration with the customer. Several experimental configurations were tested for their applicability at production scale, and a combination of BMRT and High Shear Mixer was recommended. The newly developed process reduced overall production time by 62% (80 min instead of 210 min per batch).

Small tank with glass window, front view

Engineering, fabrication, qualification and automation of two mobile vessels including magnetic agitators.

Small mobile reactor with control cabinet

Numerous details were clarified in cooperation with the customer, and specific technical solutions were developed according to the customer's wishes.

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Thomas Maischberger

Corporate Head of Research & Development

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