Granulated vs. Direct Blend Powders: Which Is Better for Sachets?

Understanding the Basics

Direct blend powders are made by simply mixing the active pharmaceutical ingredient (API) and excipients in a single step, with no additional processing required. This works best when the materials already flow and compress well on their own.

On the other hand, granulation alters the powder’s behavior by converting it into larger, more uniform granules. Wet granulation uses a binder solution to stick the particles together, while dry granulation does it with pressure alone—no liquid needed.

Sachet filling comes with its own challenges. The powder must flow smoothly, create minimal dust, dose accurately, and maintain evenly distributed ingredients. These properties often determine the choice between granulation and direct blending.

Granulated Powders: Key Features

Granules are denser, free-flowing agglomerates that are more mechanically robust than unprocessed powders. They can be produced using wet or dry granulation, and when comparing the flowability of granulated vs direct blend powders, granules generally perform better, especially during high-speed sachet filling.

Advantages

• Flows better and compresses more easily
• Keeps the powder blend uniformity in sachet production more consistent
• Creates less dust and lowers cross-contamination risk
• Stays more stable for hygroscopic or moisture-sensitive APIs
• Packs more tightly, which helps with smaller sachets and accurate fills

Disadvantages

• Takes more time and effort to produce
• Needs extra equipment like a granulator and dryers
• Can lead to uneven granule size and flow properties if not carefully controlled

Direct Blend Powders: Key Features

Direct blending is widely used when all components have suitable physical characteristics without modification.

Advantages

• A simple, fast, and cost-effective process
• Involves minimal processing and less equipment
• A good fit for APIs and excipients with solid flowability and compressibility

Disadvantages

• Weak flow or cohesion can cause dosing errors and segregation
• Tends to create more dust, which affects sachet packaging considerations for powder types
• Less consistent in content, especially in low-dose or multi-component formulas
• May not offer the powder stability in sachets needed for longer shelf life

Key Considerations for Sachet Applications

For single-dose powder packaging, consistent flow is non-negotiable. Powders must move smoothly through the system to avoid clogging or uneven fills. Segregation during filling can lead to dose variability, especially in blends with different particle sizes or densities. High dust levels may also raise safety concerns and affect product quality.

If the formulation is not stable, humidity and temperature shifts during storage can cause problems. Addressing these risks is important for preventing segregation in sachet powder blends and maintaining consistent delivery.

Cost and Operational Factors for Small Pharma

For smaller pharmaceutical operations, manufacturing choices often come down to available resources. Granulation requires greater investment in equipment, process controls, and quality systems, while direct blend powders support a simpler process with faster turnaround.

Larger batch sizes may justify the use of granulation in powder manufacturing, but smaller or pilot-scale runs often benefit from direct blending.

These trade-offs, along with GMP compliance expectations, should be weighed carefully during formulation development and production planning.

When to Choose Granulated Powders

Granulation can be a better choice when powders do not flow or compress well, especially in blends with fine or sticky particles. It often works best for low-dose or multi-component formulations, where keeping things uniform is harder with direct blending.

Granules also offer better physical and chemical stability, which makes them a good fit for products that tend to cake or pick up moisture. In these situations, using powder formulation techniques that improve cohesion and handling can make a big difference in successful sachet powder formulation.

When to Choose Direct Blend Powders

Direct blending works well for formulations that use excipients with good inherent flow and compressibility. It is best suited for simple, stable combinations that do not require additional modification.

This method also supports cost-sensitive or short-run projects, where speed and minimal processing are priorities. For early-stage development, such as pilot-scale batches or clinical trials, direct blending can accelerate production timelines. 

It is also commonly used in direct blend formulation for supplements, where low-potency ingredients reduce the risk of segregation and simplify manufacturing. However, success still depends on carefully mixing and blending the powder to maintain consistency throughout the production process.

Choosing the Right Powder Strategy With Support From Vici Health Sciences

There is no universal answer in the granulation vs direct blending debate. The right approach depends on formulation complexity, process capabilities, and production goals. Use this checklist to guide formulation decisions:

• Are APIs stable and free-flowing? Direct blend may work
• Is the blend multi-component or low-dose? Consider granulation
• Is cost or speed critical? Favor direct blending
• Are there issues with flow or segregation? Reevaluate for granulation

Vici Health Sciences supports small pharma manufacturers through every phase of sachet powder formulation, from early formulation development and feasibility assessments to selecting the right powder formulation techniques and scaling production with precision.

Contact us today to determine the best powder approach for your sachet product and get expert support at every step of development and manufacturing.