Developed for natural rubber/plastic applications approximately 100 years ago, the process has produced some of the most advanced drug delivery systems through twin-screw extrusion. After around 25 years of use in the pharmaceutical environment, it has become apparent why twin-screw extrusion processing has significant advantages over other manufacturing techniques.
The good properties of the extrusion process make it easy to scale up and process optimization, while also offering the benefits of continuous manufacturing. Interestingly, the development of twin-screw extrusion for pharmaceutical products has followed a similar path that plastics processing pioneers have taken before. Almost every plastic is processed at some point in the manufacturing process on a twin-screw extruder, which is used to mix materials together to impart the desired properties to the final part.
The evolution of processing through twin-screw extrusion has been described as plastics since the early/mid-1900s and pharmaceuticals from the late 1980s to today. The similarities are obvious. The basic theory and development of continuous mixing also describe co- and counter-rotating twin-screw extrusion for plastics and pharmaceuticals.
The parallels between plastic and pharmaceutical applications are striking. The superior mixing properties inherent in twin-screw extrusion have allowed this device to dominate other continuous mixers and have spurred intensive development work and experimentation to produce highly engineered formulations for the commodity and high-tech plastic products we use every day.
Today, twin-screw extrusion is a tried and tested manufacturing process that has been proven in a 24h/day industrial environment. The same thing is happening today, with new extrusion technologies being applied to advanced drug delivery systems to facilitate commodity, targeted and alternative delivery systems.