Enhance the bioavailability of highly insoluble APIs for optimized patient treatments. We utilize advanced technology and a dedicated team to address your specific needs and achieve exceptional results throughout the formulation and commercialization process.


Fundamentals of Hot Melt Extrusion (HME):

  • Hot Melt Extrusion (HME) is a transformative manufacturing process that merges active pharmaceutical ingredients (APIs) with polymer matrices through the application of heat and shear forces.
  • Hot Melt Extrusion (HME) process results in the formation of a homogenous extrudate where the API is uniformly dispersed within the polymer matrix, often at the molecular level.

Mechanics of HME:

  • The operation typically takes place above the glass transition temperature of the polymer to ensure the material is malleable and can be shaped as desired.
  • A twin-screw extruder is the equipment of choice due to its superior mixing capabilities, allowing for the incorporation of various functional additives into the formulation.

Strategic Applications in Pharmaceutical Manufacturing:

  • HME is adept at enhancing the solubility of BCS class II and IV drugs, which are known for their poor water solubility but high permeability.
  • It’s also employed for the development of controlled-release drug products, where the release of the API is modulated over time.


  • The solvent-free nature of HME aligns with the industry’s push towards more sustainable and environmentally friendly manufacturing practices.
  • The continuous processing capability of HME allows for efficient scale-up from lab to production scales, which is essential for a CDMO’s operational flexibility.

Material Science in HME:

  • The selection of polymers and APIs is a critical aspect of HME, as the materials must be compatible both chemically and physically to ensure a stable and effective final product.
  • The use of plasticizers, lubricants, and other functional excipients can be optimized to achieve the desired product characteristics.

Quality Assurance and Regulatory Compliance:

  • HME processes are closely monitored to ensure consistent quality, with in-line sensors often used to track critical process parameters in real-time.
  • Compliance with regulatory guidelines is paramount, and CDMOs like Renejix must ensure that their HME processes are validated and can withstand regulatory scrutiny.

Renejix’s Capabilities:

  • Renejix offers comprehensive HME services, from formulation development and process optimization to clinical trial material production and commercial-scale manufacturing.
  • The organization’s expertise in HME is backed by a team of scientists and engineers who specialize in the development of complex drug products.

How It Works?


  • Renejix scientists are at the forefront of exploring new applications of HME technology.
  • They focus on enhancing the bioavailability of poorly soluble active pharmaceutical ingredients (APIs).

Customized HME Processes

  • The team customizes the HME process to meet the unique requirements of each API.
  • This involves adjusting the modular twin co-rotating screws for optimal mixing and melting.

Advanced Material Science

  • Researchers at Renejix are delving into the material science aspects of HME.
  • They study the behavior of different excipients under various processing conditions.

Quality by Design (QbD)

  • The QbD approach is central to Renejix’s HME process development.
  • It ensures that quality is built into the product from the earliest stages.

State-of-the-Art Facilities

  • Renejix’s laboratories are equipped with cutting-edge HME equipment.
  • Scientists have access to the latest tools for research and development.

Regulatory Expertise

  • The team possesses in-depth knowledge of regulatory requirements for pharmaceutical manufacturing.
  • They ensure that all HME processes comply with international standards.

Patient-Centric Formulations

  • Renejix scientists prioritize patient needs, developing formulations that enhance patient compliance and convenience.
  • This includes focusing on taste masking and controlled release profiles.

Advantages of Hot Melt Extrusion

Cost-Effectiveness of HME

Material Savings

  • HME technology allows for the use of less expensive, non-solvent based excipients, leading to lower raw material costs.
  • Renejix’s formulation expertise enables the selection of cost-effective materials without compromising product quality.

Operational Cost Reduction

  • The solvent-free nature of HME eliminates the need for costly solvent recovery systems and reduces the risk of solvent contamination.
  • Renejix’s operational protocols are designed to maximize the cost-efficiency of the HME process.

Minimized Waste

  • HME processes generate minimal waste compared to traditional methods, which often require extensive cleanup and waste management.
  • Renejix implements waste reduction strategies in its HME operations to further enhance cost savings.

Throughput Advantages with HME

High Production Capacity

  • HME can produce large quantities of pharmaceutical products in a shorter time frame due to its continuous processing nature.
  • Renejix’s production facilities are optimized for high-capacity output, ensuring timely delivery of large orders.

Reduced Labor Requirements

  • The automation and continuous operation of HME reduce the need for manual intervention and labor, which can be a significant cost in manufacturing.
  • Renejix invests in advanced automation technologies to maintain high throughput with optimal staffing levels.

Streamlined Manufacturing Flow

  • The integration of HME with other manufacturing processes creates a streamlined flow that minimizes transition times between stages.
  • Renejix’s process engineers design manufacturing workflows that minimize bottlenecks and enhance overall efficiency.

Solubility Enhancement Capabilities of HME

Broad Applicability

  • HME can be applied to a wide range of drug molecules, including those that are difficult to process using conventional methods.
  • Renejix’s scientists have developed proprietary techniques to extend the applicability of HME to challenging drug formulations.

Stable Amorphous Forms

  • The ability of HME to produce stable amorphous forms of drugs is a key factor in its solubility enhancement capabilities.
  • Renejix’s research team focuses on understanding the stability mechanisms of amorphous forms to prevent recrystallization during storage.

Customizable Release Mechanisms

  • HME allows for the design of sophisticated release mechanisms that can be fine-tuned to achieve specific release profiles.
  • Renejix’s formulation scientists work closely with clients to develop customized release mechanisms that meet therapeutic goals.

Enhancement Benefits

High Success Rate: Optimize the solubility and bioavailability of poorly soluble drugs, enabling therapeutic breakthroughs.

Customized Dosage Forms: We design customized dosage forms that cater to patient convenience and compliance, such as orally disintegrating tablets and multi-layered films.

Optimal Efficacy and Uncompromising Patient Safety: Our expert teams optimize therapeutics efficacy, enhance safety profiles, and fine-tune release properties to deliver unparalleled patient outcomes.

Accelerated Time to Market: Minimize your time to market through our streamlined processes, ensuring you stay ahead of the competition.


Solubility Enhancement through HME

Mechanism of Solubility Improvement

  • HME enhances solubility by transforming crystalline APIs into amorphous forms within a polymer matrix, disrupting the orderly crystal lattice and increasing the drug’s energy state.
  • The amorphous form has higher free energy than the crystalline form, leading to improved dissolution rates and bioavailability.

Selection of Polymers

  • Renejix scientists select polymers that are compatible with the API and can maintain the amorphous state, preventing recrystallization.
  • Polymers also act as carriers that improve the wettability and dispersibility of the drug.

Optimization of Process Parameters

  • The process parameters, such as temperature, screw speed, and feed rate, are meticulously optimized to ensure the stability and uniformity of the amorphous solid dispersions.

Controlled Release Formulations

Designing Matrix Systems

  • Renejix designs matrix systems where the drug is embedded in a polymer matrix, allowing for a controlled diffusion of the drug.
  • The matrix composition and the drug’s physicochemical properties dictate the release kinetics.

Tailoring Drug Release

  • By varying the type and ratio of polymers, Renejix tailors the drug release profile to achieve the desired therapeutic outcome.
  • The goal is to maintain a consistent drug concentration within the therapeutic window over an extended period.

Microencapsulation Techniques

Encapsulation Efficiency

  • Renejix focuses on achieving high encapsulation efficiency to ensure maximum protection and precise dosing of the API.
  • The size and uniformity of the microcapsules are controlled to achieve specific release rates.

Barrier Properties

  • The encapsulating materials are chosen for their barrier properties to protect the API from environmental factors and to control the release profile.
  • Renejix’s expertise in material science plays a crucial role in selecting the appropriate encapsulating agents.

Comprehensive Quality Control

Analytical Testing

  • Renejix conducts rigorous analytical testing to characterize the physical and chemical properties of the HME products.
  • Techniques such as differential scanning calorimetry (DSC) and X-ray powder diffraction (XRPD) are used to confirm the amorphous nature of the dispersions.

Stability Studies

  • Long-term and accelerated stability studies are performed to ensure that the HME products remain stable throughout their shelf life.
  • Renejix’s commitment to quality ensures that the final products meet all regulatory and performance standards.

By providing a more detailed understanding of the applications of HME, Renejix CDMO demonstrates its capability to develop advanced pharmaceutical products that meet the complex needs of modern healthcare. The depth of technical expertise and the comprehensive approach to quality control position Renejix as a leader in the field of pharmaceutical manufacturing.

Comprehensive Support

Comprehensive API Characterization: We offer detailed data analysis and interpretation, providing a robust package for regulatory filings and thorough understanding of your API and formulations.

Feasibility and Development Support: Customized programs leverage in-depth evaluation and preformulation data. We prepare various prototype formulations under different processing conditions, backed by accelerated stability studies for comprehensive analysis.

In-House Analytical and Regulatory Expertise: Our services include thorough characterization of APIs and formulations, ensuring adherence to stringent regulatory standards.

End-to-End Product Lifecycle Management: From initial development to market success, we offer comprehensive support. Our approach integrates Lean efficiency standards to optimize all phases of your product’s lifecycle.


HME Technology Overview

Fundamental Process

  • HME involves the application of heat and pressure to melt a mixture of pharmaceutical ingredients and then forcing it through an orifice to shape the material into a product with uniform density and consistency.

Equipment Design

  • The process is carried out using an extruder, which is essentially a high-precision, temperature-controlled, screw-driven pump.
  • Renejix utilizes state-of-the-art extruders with customizable screw designs and processing zones to handle a variety of formulations.

Addressing BCS Class 2 Drugs

Solubility Challenges

  • BCS class 2 drugs are characterized by low solubility and high permeability.
  • HME technology enhances the solubility of these drugs by dispersing them into a polymer matrix, forming amorphous solid dispersions (ASDs).

Renejix’s Approach

  • Renejix scientists employ advanced polymer science to select suitable carriers that maintain the drug in an amorphous state, preventing recrystallization and enhancing bioavailability.

Addressing BCS Class 4 Drugs

Dual Challenges

  • BCS class 4 drugs present both low solubility and low permeability, making them the most challenging in terms of formulation.
  • HME can address these challenges by not only enhancing solubility through ASDs but also by incorporating permeability enhancers into the formulation.

Improving Bioavailability 

  • The team at Renejix is pioneering the use of novel excipients and permeability enhancers that are compatible with HME processing to improve the overall bioavailability of BCS class 4 drugs.

Technological Advancements

Controlled Release

  • HME allows for the precise control of drug release profiles, which is crucial for drugs requiring sustained or delayed release.
  • Renejix leverages this capability to design formulations that meet specific therapeutic needs, ensuring effective and consistent drug delivery.

Particle Size Reduction

  • The mechanical action of the screws in the extruder can reduce the particle size of the drug, which can further enhance solubility and absorption.
  • Renejix’s expertise in screw design and process optimization ensures optimal particle size reduction for each formulation.

By integrating these technological and scientific strategies, Renejix effectively overcomes the formulation challenges associated with BCS class 2 and 4 drugs, offering advanced solutions that enhance drug solubility, permeability, and patient outcomes

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Here are some frequently asked questions about Hot Melt Extrusion

What is Hot Melt Extrusion (HME)?

Hot Melt Extrusion (HME) is a manufacturing process used in the pharmaceutical industry to improve the solubility and bioavailability of drugs. It involves the application of heat and pressure to mix drug substances with polymers and/or excipients until the mixture becomes molten. The molten mixture is then forced through an orifice to form a product in a specific shape, which is cooled and solidified. This continuous process is highly versatile and can be used to produce a variety of dosage forms, including tablets, capsules, films, and implants.

What are the Main Advantages of HME in Drug Formulation?

The main advantages of HME in drug formulation include enhanced solubility and bioavailability of poorly soluble drugs, controlled drug release profiles, and the elimination of solvents, making it an environmentally friendly option. HME also allows for the precise dosing and uniform distribution of the drug within the dosage form, improving product consistency and efficacy. Furthermore, HME can streamline manufacturing processes by reducing the number of production steps and increasing scalability.

What Types of Products Can Be Manufactured Using HME?

HME can manufacture a wide range of pharmaceutical products, including solid dispersions, sustained-release tablets, transdermal patches, ocular implants, and buccal films. The versatility of the HME process allows for the development of innovative dosage forms that can meet specific therapeutic needs, enhance patient compliance, and improve drug delivery mechanisms.

How Does HME Enhance the Solubility of Poorly Soluble Drugs? Answer: HME enhances the solubility of poorly soluble drugs by dispersing them into a polymer matrix at the molecular level, forming a solid solution or dispersion. This process can convert crystalline forms of drugs into amorphous forms, which have higher solubility and dissolution rates. The use of appropriate polymers and plasticizers in the extrusion process can further improve the drug's solubility and bioavailability.

HME enhances the solubility of poorly soluble drugs by dispersing them into a polymer matrix at the molecular level, forming a solid solution or dispersion. This process can convert crystalline forms of drugs into amorphous forms, which have higher solubility and dissolution rates. The use of appropriate polymers and plasticizers in the extrusion process can further improve the drug's solubility and bioavailability.

Can HME Be Used for Controlled Release Formulations?

Yes, HME is particularly well-suited for the development of controlled release formulations. By selecting specific polymers and adjusting the process parameters, it is possible to engineer the matrix structure and drug distribution within the extrudate to achieve desired release profiles. This includes sustained release, delayed release, or targeted release formulations, providing flexibility in drug delivery strategies.

What Expertise Does a CDMO Offer in HME Services?

A CDMO offers comprehensive expertise in HME services, including formulation development, process optimization, scale-up, and manufacturing. The CDMO's team of scientists and engineers has extensive experience in selecting suitable excipients, designing formulation strategies, and optimizing extrusion parameters to achieve the desired product specifications. Additionally, a CDMO can provide analytical testing, regulatory support, and packaging services to ensure the successful development and commercialization of HME products.

How Does a CDMO Ensure Quality in HME Production?

A CDMO ensures quality in HME production by implementing strict quality control measures throughout the development and manufacturing processes. This includes the use of validated methods for formulation and process development, rigorous in-process controls, and comprehensive testing of the final product for uniformity, potency, and stability. Compliance with Good Manufacturing Practices (GMP) and adherence to regulatory guidelines further ensure the production of high-quality HME products.

What Regulatory Considerations Are Important for HME Products?

Regulatory considerations for HME products include ensuring the safety and efficacy of the drug product, compliance with GMP regulations, and the submission of appropriate documentation to regulatory agencies. This involves detailed characterization of the drug product, including its physical and chemical properties, bioavailability studies, stability testing, and quality control measures. A CDMO can provide expertise in navigating the regulatory landscape and supporting the submission process.

What is the Process for Developing an HME Product with a CDMO?

Developing an HME product with a CDMO typically involves several stages, starting with a feasibility study to assess the suitability of HME for the drug formulation. This is followed by formulation development and optimization, process development, pilot-scale trials, and finally, scale-up to commercial production. Throughout the process, the CDMO collaborates closely with the client to ensure that the product meets the desired specifications and regulatory requirements.

Can HME be Used for Veterinary Pharmaceuticals?

Yes, HME can be used for the development and manufacturing of veterinary pharmaceuticals. The technology is suitable for creating dosage forms that are easy to administer to animals, such as chewable treats or long-acting implants. The ability to enhance the solubility and bioavailability of active ingredients, as well as to tailor release profiles, makes HME an attractive option for veterinary drug formulation, offering improved therapeutic outcomes and enhanced compliance.