Pharmaceutical Processing

Pharmaceutical manufacturers trust PK for a wide range of critical production processes. These include the injection, dispersion and blending of APIs, flavors and lubricants prior to tableting, as well as blending and granulating ingredients for tablet production. PK systems for pharmaceutical manufacturers feature stainless steel in product content areas and are used to continuously measure and blend flavors and lubricants, and to continuously monitor, blend, and granulate ingredients for the most consistent quality. PK enables blending, agglomeration, and vacuum drying of ingredients while also recovering solvents to ensure efficiency and sustainability. Other processes include drying pharmaceutical powders and agglomerates, as well as water-wet and solvent-wet pharmaceutical powders and granules.

Product Solutions

Multi-Vessel Processors (MVP)

Versatile design for multiple processes including tumble blending, intensified blending and liquid/solid blending – ideal for pill color coatings.

Twin Shell Blender

Overcome discharge problems and create additional mixing action with two opposed simple cylinders formed in a “V” making for faster, more efficient blending.

Slant Cone Shell Blender

Slanted cone design provides high mixing efficiency and blending uniformity of pharamceutical formulations.

Zig-Zag Continuous Blender

Available in large and small-scale units. Small-scale units are ideal for PAT-compliant applications and have near real time analysis of process attributes.

Continuous Tubular Dryer

Continuous, quick, and uniform drying of water-wet pharmaceutical powders and granules and temperature-sensitive products.

Solids Processor

Highly efficient pill and tablet manufacturing with wet granulation and agglomeration in a single, contained processing unit.

Engineered for the Precision Demands of Pharmaceutical Manufacturing

Pharmaceutical production demands unwavering accuracy, batch-to-batch repeatability, and strict compliance with regulatory standards. Patterson Kelley delivers validated blending, drying, and powder processing solutions engineered for cGMP environments—ensuring uniformity, cleanliness, and confidence at every stage of production.

PK Blenders are purpose-built for API powders, excipients, granules, and sensitive formulations where consistency, safety, and traceability are essential. From R&D to full-scale manufacturing, our equipment supports pharmaceutical processors with proven performance and regulatory-aligned design.

Pharmaceutical Pain Points We Solve

Blend inconsistency and segregation

Long cleaning cycles and sanitation challenges

Moisture variability in sensitive materials

Scale-up inefficiencies between lab and production

Regulatory compliance risks

Cross-contamination concerns

Equipment not suited for cGMP environments

Optimize Your Pharmaceutical Processing Line.

We aim to enable consistent, validated powder processing while reducing risk and improving efficiency.

PK engineers work directly with R&D and production teams to design systems tailored to:

Material characteristics and sensitivity

Required cleanliness and validation standards

Throughput targets

Scale-up between R&D, pilot, and production

Facility layout and containment requirements

Moisture and temperature constraints

Engineered for Pharmaceutical Powder Processing

Integrated Drying & Conditioning

Test 2PK drying technologies, including the Solids Processor (SP) and Tubular Vacuum Dryers, provide gentle, controlled drying ideal for moisture reduction, final conditioning, heat-sensitive APIs and more.

Scalable Systems

Pharma manufacturers benefit from PK’s ability to support every stage of product development. From lab-scale testing with Blend Master and bench-top units to full-scale production systems with integrated sanitary features and everything in between.

High Uniformity Powder Blending

PK’s blending technologies—including Twin Shell, Double Cone, Cross-Flow®, and Slant Cone®—are engineered to deliver exceptional homogeneity with proven blend repeatability.

Why Choose Patterson Kelley

Pharmaceutical Manufacturers Need:

cGMP- and FDA-aligned design for regulated manufacturing

Repeatable, validated blend performance with measurable uniformity

Sanitary, easy-to-clean equipment that supports rapid changeovers

Precise process control for APIs, excipients, and sensitive materials

Broad range of batch sizes—from R&D trials to production-scale systems

Integrated vacuum drying, mixing, and granulation capabilities

Lab testing available to validate formulations before scale-up

PK Benefits

Validated, repeatable blend performance

Faster batch times with predictable outcomes

Sanitary design that supports cGMP compliance

Energy-efficient drying and blending options

Reduced cleaning and changeover time

Longevity and reliability backed by decades of pharma use

Proven performance with difficult or sensitive powders

Technical Advantages

Sanitary welds and pharmaceutical-grade finishes

Precision speed and fill-level control

Sanitary design that supports cGMP compliance

Vacuum drying for heat-sensitive APIs

CIP/SIP-ready configurations

FDA-compliant materials of construction

Batch data capture and process analytics

Custom-engineered designs for OEB-specific containment

Scalable Systems From R&D to Production

Pharma manufacturers benefit from PK’s ability to support every stage of product development. From lab-scale testing with Blend Master and bench-top units and pilot-scale trials to validate blend efficiency and moisture control to full-scale production systems with integrated sanitary features. Our lab testing service allows you to bring your material to PK and validate performance before investing in equipment.

Applications Across Pharmaceutical Manufacturing

PK supports a broad range of pharma powder processing applications:

API blending and finishing
Excipient and filler blending
Granulation and pre-granulation conditioning
Moisture removal and drying
Powder homogenization
Batch blending for tablets, capsules, and powders
Powder conditioning for improved flowability

System Integration Capabilities

PK equipment integrates seamlessly into pharmaceutical production environments, including:

Material transfer systems
Bin and IBC handling
Milling, sifting, and particle sizing
Vacuum transfer and containment systems
Environmental control & dust collection
PLC-based batch tracking and recipe controls

FAQs for Pharmaceutical Blending & Powder Processing

How do PK Blenders achieve uniform pharmaceutical blends?

PK uses controlled geometry, rotational speed, fill levels, and optional intensifier bars to achieve validated blend uniformity with repeatable results.

What sanitary features support cGMP compliance?

Pharma-grade welds, FDA-compliant materials, CIP/SIP options, dust-tight sealing, and smooth internal surfaces reduce contamination risk and simplify cleaning.

Can PK equipment handle highly potent compounds (HPAPI)?

Yes. PK offers containment-ready systems, sealed designs, and integration with isolators or split-valve transfer systems.

How does PK support scale-up from lab to production?

Lab testing, pilot trials, and scalable geometry ensure similar mixing dynamics between testing and production-scale systems.

What drying technologies are suitable for heat-sensitive materials?

Vacuum drying systems such as Tubular Vacuum Dryers and SP Dryers maintain low temperatures while achieving consistent moisture removal.

We Have The Solution For Your Process.

Regardless of the processing industry, PK has been providing solutions to processors for more than a century.