Problem of the Month: August 2026

Think You’re An Expert? High Shear Granulation: Occupancy Plays An Important Role

Is this good or bad?

Inadequate occupancy

Just right

If you cannot blend just any quantity of powder in a specific size of a double cone, a twin shell or a tote bin; then why do you think you can granulate just any quantity of powder in a high shear granulator?

Occupancy, based on bulk density, is one of several factors we use to standardize processing assumptions in this critical operation. Changes in occupancy mean changes in the outcome. And changes often take the form in content uniformity, tablet hardness and in capping or lamination. Notice in these pictures that one chopper is visible while in the other picture it is not. How can you expect the same outcome?

And what exactly is the perfect batch size? There isn’t. But there is perfect occupancy. Covering both the chopper and impeller and then adding 5-10 cm on top of that.

Check your process. You may have already introduced process variation by expecting your high shear granulator to some how granulate all batch sizes the same.

See you in India and Algeria!