Twin-screw dry granulation for producing solid formulations

A granule produced by the method comprising:

• mixing a first powder comprising at least one active ingredient having a crystal structure and a second powder comprising at least one carrier to form a powder mixture;
• feeding the powder mixture to a twin-screw extruder without a solvent, liquid binder, or meltable binder;
• kneading the powder mixture in a heated screw barrel of the twin-screw extruder, wherein all temperatures along the length of the screw barrel are below a melting point of the at least one active ingredient and below a melting point or a glass transition temperature of the at least one carrier to form a kneaded powder mixture;
• and
• extruding the kneaded powder mixture to form the granule, wherein the granule is free of solvents, liquid binders, and meltable binders, has a surface area of about 0.05-0.45, has an angle of repose of less than or equal to about 30, and the crystal structure of the at least one active ingredient is preserved in the granule.