Processor and a process for granulation of powders

A fractional lobe processor comprising:

• a barrel with heating and cooling means having two parallel intersecting bores of equal diameter, wherein a centre distance between the two bores is lesser than the diameter of each of the bores;
• a shaft coupled with a plurality of screw elements to form a screw within each bore, wherein the respective screws are intermeshing, and wherein the respective screws form at least four zones within the barrel for conveying, mixing, granulating, drying, and discharging, the zones comprising:
• an intake zone comprising at least one deep flighted shovel element on each intermeshing screw for receiving an input blend comprising an active substance and an excipient;
• a granulation zone consisting of only fractional lobe elements, and having a provision for introducing moisture or a binder solution, for granulating the active substance and the excipient;
• a drying zone for drying the wet granules;
• and
• a discharge zone for discharging the granules;
• wherein the granulation zone is located upstream of the drying and discharge zones and downstream of the intake zone;
• wherein the drying zone and the granulation zone have one or more fractional lobe elements on each shaft;
• and
• wherein each of the intake zone, the granulation zone, the drying zone, and the discharge zone are formed separately, in order, by the intermeshing screws within the barrel.