Thinking ahead together: the HTG Next Gen

Jun 29, 2026 | 3 min read

Product loss, time-consuming cleaning, risky transfers – the granulation process involves many hidden cost drivers. Our HTG Next Gen is the answer, developed from detailed customer feedback and built on proven technology.

Key takeaways
              Advanced Gentlewing impeller reduces wall adhesion and product loss
Greater flexibility thanks to batch sizes with a fill level of 20-80% - from development to blockbuster production
Smart Transfer automates critical interfaces and stabilizes the material flow throughout the entire process chain
Consistent scale-up from the lab to commercial production without process restart

            

Granulation processes present pharmaceutical manufacturers with recurring challenges in everyday production: product losses due to wall adhesion, time-consuming tech transfers, operator-dependent material transfers, and limited batch size flexibility. At the same time, numerous product-specific factors determine the optimal production method – from compressibility and flowability to the mixture's behavior. Added to this are existing registrations and high quality requirements that must be taken into account in every process decision. This is exactly where we come in: The challenges of day-to-day production, which we identify by talking with our customers, are incorporated into the further development of our technologies – as is the case with the HTG.

Innovation through customer collaboration

The HTG Next Gen is the logical evolution of our proven Hüttlin Top Drive Granulator (HTG) platform. Our goal was to make existing processes more robust, flexible, and efficient without affecting existing approvals. Joint formulation and scale-up tests in our pharmaceutical laboratory contribute to this. Building on this foundation, the new HTG combines the reliability of established technology with concrete improvements derived from real-world experience – from development through commercial manufacturing.

“The improvements to the HTG Next Gen all have a specific source: our customers. Every change can be traced back to a real problem that we solved together.”

Fritz-Martin Scholz, Global Product Manager at Syntegon

Higher yield, flexible batches, and a stable path to market readiness

With the new HTG generation, we have adopted Top-Drive as standard, thereby relocating the shaft seals outside the product area. This reduces wear, simplifies cleaning validation, and shortens product changeovers. For pharmaceutical manufacturers, this means shorter downtime, reduced cleaning effort, and overall smoother production under GMP conditions.

The Gentlewing impeller remains at the heart of the system. Its Z-shaped design ensures complete coverage of the container wall, reduces wall adhesion, and increases yield – which is particularly important for expensive or patented APIs. At the same time, the Gentlewing’s geometry remains identical across all sizes. This allows processes to be transferred across all scales without changing systems – from development batches to large-scale production of, for example, acetaminophen, metformin, or ibuprofen. Volumes ranging from 0.5 to 1,800 liters are covered, enabling batch sizes with fill levels between 20 and 80 percent. This lays the foundation for a consistent and low-risk scale-up.

This is complemented by the HTG Next Gen’s Smart Transfer system. Preheated transfer pipes prevent condensation and blockages before they occur. The downstream mill and Gentlewing automatically regulate the discharge rate, while the anti-blocking system continuously monitors the transfer – without operator intervention. The result is a stable, reproducible transfer process. Automated processes reduce unplanned downtime, cut setup times, and ensure that process quality does not depend on the experience of the operating staff.

Overall, these technological advancements address key requirements of our pharmaceutical customers: Yield increases due to reduced product losses, flexibility grows thanks to variable batch sizes ranging from 20 to 80 percent fill level up to 720 kg, and throughput becomes more robust thanks to stable and automated processes. In addition, the HTG Next Gen shortens time to market, as geometric consistency across all sizes makes technology transfer more predictable.

Your benefits at a glance
              Higher yield through minimized product loss
Maximum flexibility in batch sizes
Stable throughput thanks to automated processes
Faster time to market through consistent scale-up

            

The ongoing development of the HTG demonstrates our approach: close collaboration with our customers based on real-world requirements. In an environment characterized by strict regulatory approvals, high-quality standards, and maximum process reliability, sophisticated technologies and practical innovations are essential. This leads to solutions that address real challenges and help make production processes stable, efficient, and future-proof.