Hot Melt Extrusion Technology in Taste Masking

Abstract Hot melt extrusion (HME) is a widely used method of taste masking in medication formulations, notably for bitter Active Pharmaceutical Ingredients (APIs). This continuous, solvent-free technique successfully wraps APIs within a polymer matrix, forming a barrier that considerably decreases bitterness perception. These advantageous properties of HME in taste masking are especially important for pediatric, geriatric, and veterinary formulations, where palatability is critical. The technique entails melting a polymer matrix and combining it with the medicine, followed by extrusion to make granules or dosage forms. The efficacy of taste masking is dependent on selecting acceptable excipients and ensuring their compatibility with the medicine. Temperature, screw speed, and drug-to-polymer ratio are critical process parameters that must be tuned. Various screw configurations can influence the physical condition of the API during extrusion, increasing taste-masking efficacy. Future advances in HME technology are expected, with a focus on enhancing taste masking for a broader range of APIs. Innovations in the study of polymers and the combination of process analytical technology (PAT) will significantly enhance the effectiveness and reliability of flavor-masked formulations, resolving the important need for patient-friendly drugs that are taken orally.