Thakore, Samarth D.Samarth D.ThakoreReddy, Katangur VishruthKatangur VishruthReddyDantuluri, Ajay K.Ajay K.DantuluriPatel, DeepikaDeepikaPatelKumawat, AkshantAkshantKumawatSihorkar, VaibhavVaibhavSihorkarGhoroi, ChinmayChinmayGhoroiBansal, Arvind K.Arvind K.Bansal2025-08-312025-08-312022-12-0110.1007/s11095-022-03369-w2-s2.0-85136914289http://repository.iitgn.ac.in/handle/IITG2025/2584736002616Pharmaceutical tablet manufacturing has seen a paradigm shift toward continuous manufacturing and twin-screw granulation-based technologies have catalyzed this shift. Twin-screw granulator can simultaneously perform unit operations like mixing, granulation, and drying of the granules. The present study investigates the impact of polymer concentration and processing parameters of twin-screw melt granulation, on flow properties and compaction characteristics of a model drug having high dose and poor tabletability. Acetaminophen (AAP) and polyvinylpyrrolidone vinyl acetate (PVPVA) were used as a model drug (90–95% w/w) and polymeric binder (5–10%w/w), respectively, for the current study. Feed rate (~650–1150 g/h), extruder screw speed (150–300 rpm), and temperature (60–150°C) were used as processing variables. Results showed the reduction in particle size of drug in the extrudates (D<inf>90</inf> of 15–25 μm from ~80 μm), irrespective of processing condition, while flow properties were a function of polymer concentration. Overall, good flowability of the products and their tablets with optimum tensile strength can be obtained through using high polymer concentration (i.e., 10% w/w), lower feed rate (~650 g/h), lower extruder screw speed (150 rpm), and higher processing temperatures (up to 120°C). The findings from the current study can be useful for continuous manufacturing of tablets of high dose drugs with minimal excipient loading in the final dosage form.falseAcetaminophen | Polyvinylpyrrolidone vinyl acetate | Tabletability | Twin-screw melt granulationArticle1573904X3241-3257December 20225arJournal5WOS:000843990600001