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Volume 107
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icotabarren@plapiqui.edu.ar
A novel regime map for twin-screw melt granulation: Unveiling new insights into key operating variables
Jacquelina C. Lobos de Ponga a b, Marcos Díaz Muñoz a, Ivana M. Cotabarren a c 1 *, Juliana Piña a c 1
a Planta Piloto de Ingeniería Química (PLAPIQUI, UNS-CONICET), Bahía Blanca, Buenos Aires, Argentina
b Departamento de Ingeniería (DI), Universidad Nacional del Sur (UNS), Bahía Blanca, Buenos Aires, Argentina
c Departamento de Ingeniería Química (DIQ), Universidad Nacional del Sur (UNS), Bahía Blanca, Buenos Aires, Argentina
10.1016/j.partic.2025.09.012
Volume 107, December 2025, Pages 11-25
Received 10 April 2025, Revised 27 July 2025, Accepted 18 September 2025, Available online 25 September 2025, Version of Record 3 October 2025.
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Highlights

• A regime map for twin-screw melt granulation (TSMG) was developed including molten binder fraction as a variable.

• The TSMG regime map was validated with data from previous studies.

• Most experimental runs fell within the breakage-dominated growth regime.

• A Box-Behnken design was used to optimize the effects of key operating variables.


Abstract

Regime maps are vital in twin-screw granulation, predicting outcomes via dimensionless numbers. This study develops a novel regime map for twin-screw melt granulation, adapting a wet granulation model. Using Design of Experiments, screw speed, screw configuration, temperature, and binder amount were optimized with lactose and PEG 6000. Results show how these variables impact on particle size and flowability. Optimal conditions (20 wt% PEG, 70 °C, 100 rpm) yielded granules with 0.360 mm median size and 6.67 % Carr Index, indicating excellent flow. Increased binder and kneading elements led to larger granules, while higher screw speed enhanced mixing. Elevated temperatures boosted binder melting. The regime map accurately categorized growth, largely in the breakage-dominated region, and was validated across systems, proving its predictive potential.

Graphical abstract
Keywords
Regime map; Twin-screw melt granulation; Granulation regimes; Box-Behnken design
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