Extrusion Research Articles

An Overview of the Components, Techniques, and Innovation Used for Fast-Dissolving Films.

Fast-dissolving films (FDFs) stand as a cornerstone in modern pharmaceutical innovation, heralded for their unrivaled convenience, patient adherence, and the swift onset of action. Within the realm of this paper lies a meticulous exploration of FDFs, delving deep into their intricate formulation intricacies, manufacturing methodologies, and diverse therapeutic applications. The formulation journey traverses the meticulous selection of film-forming polymers, plasticizers, taste-masking agents, and active pharmaceutical ingredients (APIs), each element meticulously calibrated to achieve optimal efficacy. Diverse production techniques, spanning solvent casting, hot melt extrusion, and spray drying, are scrutinized with precision, shedding light on their inherent advantages and nuanced limitations. Beyond the realm of formulation and manufacturing, this review embarks on an expansive voyage into the vast therapeutic landscape that FDFs traverse. From the treatment areas of central nervous system disorders to the realms of cardiovascular diseases, allergies, and pain management, the versatility and adaptability of FDFs emerge as a beacon of hope for patients and practitioners alike. Yet, amidst the brilliance of FDFs, inherent challenges linger, from stability concerns to the intricate dance of bioavailability and the ever-watchful eye of regulatory scrutiny. However, within these challenges lies the fertile ground for future research and development endeavors, beckoning forth a new era of innovation and advancement in the realm of rapidly dissolving films. This study stands as an indispensable compass, guiding researchers, pharmaceutical scientists, and practitioners toward the forefront of FDF development and implementation.

An Overview of Three-Dimensional Printing in Pharmaceutical Technology

Three-dimensional printing (3DP) in pharmaceutical technology is a new technique that can build the desired objects directly from CAD models using a layer-by-layer material build-up approach. This article presents an overview of the 3DP technique with a brief look into the history of the 3DP process and various methods like stereolithography, fused deposition method, hot melt extrusion, polyjet, etc., their merits and demerits, and applications of 3DP in pharmaceutical technology. The challenges 3DP has surmounted in the areas of pharmaceutical and biomedical research related to additive manufacturing are outlined in this review.. The use of 3DP has increased recently. Personalized medicine may now have access to a whole new range of options due to 3DP. The concept of specialists and researchers is to create customized oral pills using 3DP. Since technology is still developing, any regulations on security, safety, and privacy have yet to exist. Thus, these issues will be of more significant concern shortly. The applications of 3DP technologies in modern drug delivery are highlighted in this article, which expounds on using these technologies for forward-thinking advancements in pharmacy practice.

Influence of Twin Screw Extrusion Conditions on MWCNT Length and Dispersion and Resulting Electrical and Mechanical Properties of Polycarbonate Composites

The processing conditions were varied during the production of polycarbonate-based composites with the multiwalled carbon nanotubes (MWCNTs) Baytubes® C150 P (Bayer MaterialScience AG, Leverkusen, Germany), by melt mixing with an extruder on a laboratory scale. These included the screw design, rotation speed, throughput, feeding position and MWCNT content. Particular attention was paid to the shortening of the MWCNT length as a function of the conditions mentioned. It was found that there is a correlation between the applied specific mechanical energy (SME) during the melt mixing process and MWCNT dispersion, which was quantified by the agglomerate area ratio of the non-dispersed nanotubes based on optical microscopic analysis. The higher the SME value, the lower this ratio, which indicates better dispersion. Above an SME value of about 0.4 kWh/kg, no further improvement in dispersion was achieved. The MWCNT length, as measured by the quantitative analysis of TEM images of the MWCNTs dissolved from the composites, decreased with the SME value down to values of 44% of the original MWCNT length. At a constant loading of 3 wt.%, the tensile strength and tensile modulus were almost independent of the SME, while the elongation at break and notched impact strength showed an increasing trend. The variation in the feeding position showed that feeding the MWCNTs into a side feeder led to slightly better electrical and mechanical properties for both types of MWCNTs studied (Baytubes® C150 P and Nanocyl™ NC7000 (Nanocyl S.A., Sambreville, Belgium)). However, feeding into the hopper led to better CNT dispersion with Baytubes® C150 P, while this was the case with Nanocyl™ NC7000 when feeding into the side feeder. The screw profile had an influence on the dispersion, the MWCNT length and the electrical resistance, but only to a small extent. Distributive screws led to a greater shortening of the MWCNT length than dispersive screws. By varying the MWCNT content, it was shown that a greater MWCNT shortening occurred at higher loadings. Two-stage masterbatch dilution leads to stronger shortening than composite production with direct MWCNT incorporation.

Enhanced Minor Ginsenoside Contents of Nano-Sized Black Korean Ginseng through Hot Melt Extrusion.

Black ginseng (BG), a traditional medicinal herb produced through a nine-stage steaming and drying process, exhibits stronger pharmacological efficacy, including antioxidant, anti-inflammatory, and anti-cancer properties, when compared to white and red ginseng. The ginsenosides in BG are classified as major and minor types, with minor ginsenosides demonstrating superior pharmacological properties. However, their low concentrations limit their availability for research and clinical applications. In this study, hot melt extrusion (HME) was utilized as an additional processing technique to enhance the content of minor ginsenoside in BG, and the physicochemical properties of the formulation were analyzed. Ginsenoside content in BG and HME-treated BG (HME-BG) was analyzed using high-performance liquid chromatography (HPLC), while their physicochemical properties were evaluated through dynamic light scattering (DLS), electrophoretic light scattering (ELS), X-ray diffraction (XRD), thermogravimetric analysis (TGA), and Fourier-transform infrared spectroscopy (FT-IR). HME treatment resulted in a significant increase in minor ginsenosides Rg3 and compound K (CK) by 330% and 450%, respectively, while major ginsenosides Rg1 and Rb1 decreased or were not detected. Additionally, HME-BG demonstrated reduced particle size, improved PDI, and decreased crystallinity. HME treatment effectively converts major ginsenosides in BG into minor ginsenosides, enhancing its pharmacological efficacy and showing great potential for research and development applications.

Quantification of flows in a rectangular channel of a single-screw extruder with a small helix angle based on the energy dissipation rate

Quantification of flows in a rectangular channel of a single-screw extruder with a small helix angle based on the energy dissipation rate

Exploring the Advancements and Applications of Oral Thin Film Technology

This comprehensive review delves into the recent advancements and diverse applications of oral thin film (OTF) technology in the field of pharmaceuticals. The aim is to provide a thorough exploration of the evolution of OTFs, their unique characteristics, and their expanding role in drug delivery systems. A systematic analysis of the literature was conducted to gather information on the formulation techniques, properties, and challenges associated with OTFs. Additionally, recent developments, innovations, and future trends in OTF technology were examined to understand the dynamic landscape of this drug delivery system. The review highlights the key properties of OTFs, including rapid disintegration, enhanced bioavailability, and patient-centric advantages. Various manufacturing techniques, such as solvent casting, hot melt extrusion, and 3D printing, were explored for their impact on OTF formulation. Challenges, including stability issues and taste masking complexities, were identified. Recent innovations, such as nanotechnology integration, personalized medicine applications, and the use of digital health platforms, showcase the ongoing efforts to overcome these challenges. Oral thin film technology stands at the forefront of pharmaceutical innovation, offering a patient-friendly and adaptable drug delivery system. As evidenced by recent developments, the integration of advanced technologies, personalized medicine approaches, and sustainable practices positions OTFs as a transformative force in the future of drug delivery. The exploration of these advancements and applications contributes to a deeper understanding of the potential impact of OTF technology on healthcare.

Amorphous Solid Dispersion Formation for Enhanced Release Performance of Racemic and Enantiopure Praziquantel.

Praziquantel (PZQ) is the treatment of choice for schistosomiasis, which affects more than 250 million people globally. Commercial tablets contain the crystalline racemic compound (RS-PZQ) which limits drug dissolution and oral bioavailability and can lead to unwanted side effects and poor patient compliance due to the presence of the S-enantiomer. While many approaches have been explored for improving PZQ's dissolution and oral bioavailability, studies focusing on investigating its release from amorphous solid dispersions (ASDs) have been limited. In this work, nucleation induction time experiments were performed to identify suitable polymers for preparing ASDs using RS-PZQ and R-PZQ, the therapeutically active enantiomer. Cellulose-based polymers, hydroxypropyl methylcellulose acetate succinate (HPMCAS, MF grade) and hydroxypropyl methylcellulose (HPMC, E5 LV grade), were the best crystallization inhibitors for RS-PZQ in aqueous media and were selected for ASD preparation using solvent evaporation (SE) and hot-melt extrusion (HME). ASDs prepared experimentally were subjected to X-ray powder diffraction to verify their amorphous nature and a selected number of ASDs were monitored and found to remain physically stable following several months of storage under accelerated-stability testing conditions. SE HPMCAS-MF ASDs of RS-PZQ and R-PZQ showed faster release than HPMC E5 LV ASDs and maintained good performance with an increase in drug loading (DL). HME ASDs of RS-PZQ formulated using HPMCAS-MF exhibited slightly enhanced release compared to that of SE ASDs. SE HPMCAS-MF ASDs showed a maximum release increase of the order of 6 times compared to generic and branded (Biltricide) PZQ tablets. More importantly, SE R-PZQ ASDs with HPMCAS-MF released the drug as effectively as RS-PZQ or better, depending on the DL used. These findings have significant implications for the development of commercial PZQ formulations comprised solely of the R-enantiomer, which can result in mitigation of the biopharmaceutical and compliance issues associated with current commercial tablets.

PSIX-3 Dental stick extrusion utilizing spray dried plasma

Abstract Dental stick extrusion utilizes various ingredients to form the ideal texture and quality product. Alternative ingredients to enhance or impact texture, palatability and/or plaque removal can be useful to improve dental stick manufacturing. Spray dried plasma (SDP) is a consistent high protein ingredient commonly utilized in pet food for functional texture properties, enhancing palatability, and supporting overall health. Thus, the study objective was to evaluate how SDP inclusion with other ingredients impacts texture of extruded dental formulas. Three formulas were developed utilizing SDP to replace wheat starch (WS) or Arabic gum in the control formula. The formulas were: Control: WS and gum; SDP1: SDP and WS replacing gum; and SDP2: SDP replacing WS and gum. Dental sticks were made at the Extru-Tech technology testing center using a 525 single screw extruder with the product densification unit (PDU) removed and replaced with a mid-barrel valve and 3 cooling heads to cause densification. The sticks were manufactured as solid square sticks. Generally, a single screw with a PDU, or a traditional parallel-shaft twin screw is used to manufacture dental sticks. However, the equipment alterations used worked like a single screw with a PDU; thus, it would be expected that the results would translate to a traditional single screw configuration. Glycerin at 12% (% to dry feed rate) and chicken fat were added to the pre-conditioner at set rates to optimize expansion and product quality. Processing conditions were monitored and adjusted on the various formulations during production to optimize extrusion. Texture was measured on a TA.XT Plus utilizing an adjustable bridge with a rounded-end knife probe for a 3-point bend. Dental sticks of 8 cm in length were placed over the two bridge spans spaced 5 cm apart to measure maximum force (hardness) and work to peak force (work to break) to determine texture parameters. Ten dental sticks per treatment were analyzed. All formulas utilizing SDP were successful in producing dental sticks. No differences (P > 0.05) were noted in force with SDP formulas compared with control. Work to peak was greater (P < 0.05) in SDP formulas compared with control formula. Formulation matrix impacts results. In the current formulas, both Arabic gum and WS were altered in the formulas and depending on amount of SDP used similar texture was noted. In conclusion, SDP can be incorporated into dental stick formulas and utilized as a processing aide. Overall, depending on target hardness and ingredient matrix, SDP can be an alternative to various ingredients to maintain or improve product quality.

In Situ Enzymatic Polymerization of Ethylene Brassylate Mediated by Artificial Plant Cell Walls in Reactive Extrusion.

Herein, we describe a solvent-free bioinspired approach for the polymerization of ethylene brassylate. Artificial plant cell walls (APCWs) with an integrated enzyme were fabricated by self-assembly, using microcrystalline cellulose as the main structural component. The resulting APCW catalysts were tested in bulk reactions and reactive extrusion, leading to high monomer conversion and a molar mass of around 4 kDa. In addition, we discovered that APCW catalyzes the formation of large ethylene brassylate macrocycles. The enzymatic stability and efficiency of the APCW were investigated by recycling the catalyst both in bulk and reactive extrusion. The obtained poly(ethylene brassylate) was applied as a biobased and biodegradable hydrophobic paper coating.

Dosage by design – 3D printing individualized cabozantinib tablets with immediate release

Production of patient-specific dosage forms is important to improve patient adherence and effectiveness while reducing the prevalence and severity of adverse effects. Due to its possibility of rapid prototyping 3D printing can be used to produce individual dosages while utilizing techniques such as hot melt extrusion to increase the bioavailability of poorly soluble drugs. In this work, Parteck MXP and Kollicoat IR were used as water-soluble polymer bases for formulation development for 3D printing of various dosages incorporating cabozantinib while enabling immediate release. The effect of tablet design and the excipients sorbitol, croscarmellose sodium, and sodium starch glycolate was investigated for this goal. A way to calculate the size of tablets for predetermined dosages is proposed to enable the printing of individual strengths from one formulation. Rheological data were collected to deepen the understanding of the role of melt viscosity in 3D printing and hot melt extrusion processes. The production of immediate-release cabozantinib tablets containing every therapeutically relevant dosage in a single unit produced by two-step 3D printing was realized.

Fabrication and performance of short glass fiber reinforced polyamide composites

This article deals with the impact of short glass fiber (GF) on the performance of 60/40 wt% of polyamide 6/polyamide 12 (PA6/PA12) blend. The short fiber-reinforced composites were fabricated by using melt compounding via twin screw extruder and injection molding. The morphological, water uptake, rheological, thermo-mechanical, and mechanical properties of the composites were discussed. The morphological observations show that the PA6/PA12 blend exhibited compatible morphology and also adhesion between the fiber and matrix was quite strong. The tensile strength/modulus and storage modulus of the blend were substantially improved with GF reinforcement as a result of these morphological findings. While the water uptake of neat PA6 decreased significantly after blending with PA12, the incorporation of GF further reduced the water uptake of the PA6/PA12 blend. The thermomechanical analysis showed the enhancement of the stiffness of the composites and also glass transition temperature increment.

Investigation of the Influence of Copovidone Properties and Hot-Melt Extrusion Process on Level of Impurities, In Vitro Release, and Stability of an Amorphous Solid Dispersion Product.

Hot-melt extrusion (HME) is a widely used method for creating amorphous solid dispersions (ASDs) of poorly soluble drug substances, where the drug is molecularly dispersed in a solid polymer matrix. This study examines the impact of three different copovidone excipients, their reactive impurity levels, HME barrel temperature, and the distribution of colloidal silicon dioxide (SiO2) on impurity levels, stability, and drug release of ASDs and their tablets. Initial peroxide levels were higher in Kollidon VA 64 (KVA64) and Plasdone S630 (PS630) compared to Plasdone S630 Ultra (PS630U), leading to greater oxidative degradation of the drug in fresh ASD tablets. However, stability testing (50 °C, closed container, 50 °C/30% RH, open conditions) showed lower oxidative degradation impurities in ASD tablets prepared at higher barrel temperatures, likely due to greater peroxide degradation. Plasdone S630 is suitable for ASDs with drugs prone to oxidative degradation, while standard purity grades may benefit drugs susceptible to free radical degradation, as they generate fewer free radicals post-HME. ASD tablets exhibited greater physical stability than milled extrudate samples, likely due to reduced exposure to stability conditions within the tablet matrix. Including SiO2 in the extrudate composition resulted in greater physical stability of the ASD system in the tablet; however, it negatively affected chemical stability, promoting greater oxidative degradation and hydroxylation of the drug substance. No impact of the distribution of SiO2 on drug release was observed. The study also confirmed the congruent release of copovidone, the drug substance, and Tween 80 using flow NMR coupled with in-line UV/vis. This research highlights the critical roles of peroxide levels and SiO2 in influencing the dissolution and physical and chemical stability of ASDs. The findings provide valuable insights for developing stable and effective pharmaceutical formulations, emphasizing the importance of controlling reactive impurities and excipient characteristics in ASD products prepared by using HME.

3D printing food flow in different extruders based on crazy and adaptive salp swarm algorithm-deep extreme learning machine improved-lattice Boltzmann method

Extrusion is significant in achieving 3D printing emulsion. The piston and screw extruders are the common structures to achieve the extrusion. The chocolate emulsion is taken for example, two extruders are numerically investigated and compared based on the fluid dynamic analysis. To conduct the simulations, the crazy and adaptive salp swarm algorithm-deep extreme learning machine (CASSA-DELM) is proposed to predict the viscosity of the chocolate emulsion, which is used to replace the traditional fitted model. The built model can avoid non-consistency in the whole shearing rate range. Then, an improved lattice Boltzmann method (I-LBM) is introduced to process the non-Newtonian behavior of the emulsion. In the simulation, the CASSA-DELM model provides the viscosities for each iteration in I-LBM based on the obtained shearing rates. Because the attachment(s) may be generated on the walls, the no-attachment and with-attachment(s) cases are explored, and the necessary results are obtained, which indicate that the piston extruder is more suitable for extruding the single component of food fluid. The screw extruder is recommended for the multiple components of food fluid because the vortex in the X-Y cross-section contributes to further mixing action for the emulsion containing different materials, such as the investigated chocolate emulsion. The indirect experiments are conducted to validate the above conclusions. The current work can contribute to improving the extruding theory of material extrusion technologies.

Closed-loop circular economy in ‘upcycled’ acrylonitrile–butadiene–styrene vitrimer

Today, the issue of plastic waste pollution has reached unprecedented levels. The increasing production of plastics, combined with a decreasing rate of recycling, has significantly worsened this problem in recent years. While a wide range of plastics are manufactured, thermoplastics are a type that can be recycled relatively easily. However, recycled thermoplastics often have lower mechanical properties compared to new ones. Considering this challenge, making thermoplastics recyclable could revolutionize the recycling process and represent a major advancement towards establishing a circular economy for plastics. In this study, virgin acrylonitrile–butadiene–styrene (ABS) was transformed into a vitrimer through reactive melt extrusion using a bio-derived crosslinker containing dynamic imine linkages. This crosslinker results in a dynamic network, in the melt, as observed from the higher gel fraction and imparts recyclability to the resulting ABS vitrimer, which exhibits higher yield strength (by 15 %) and Young’s modulus (by 19 %). Remarkably, the mechanical and thermal properties of the vitrimer remain largely unchanged even after undergoing five cycles of reprocessing. In addition, the resulting vitrimer is dimensionally stable as inferred from creep studies and shows rapid stress relaxation at higher temperature following Arrhenius behaviour. The electron paramagnetic resonance (EPR) spectra were captured at room temperature for both ABS and its vitrimer. The difference in singlet band intensities in the spectra begins to suggest that the vitrimer is more stable post multiple recycling. While this research focused on virgin ABS, the approach outlined in the study has the potential to be applied to post-consumer recycled (PCR) ABS. This could introduce recyclability to PCR ABS and pave the way for a closed-loop circular economy for ABS plastics.

Solvent Minimized Synthesis of Amides by Reactive Extrusion

AbstractHerein, we report on the translation of a small scale ball‐milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin‐screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid‐liquid, solid–liquid and solid‐solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7‐hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

Solvent Minimized Synthesis of Amides by Reactive Extrusion.

Herein, we report on the translation of a small scale ball-milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin-screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid-liquid, solid-liquid and solid-solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7-hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

Hot Melt Extruded High-Dose Amorphous Solid Dispersions Containing Lumefantrine and Soluplus

Over the last 15 years, a small number of paediatric artemisinin-based combination therapy products have been marketed. These included Riamet® and Coartem® dispersible tablets, a combination of artemether and lumefantrine, co-developed by the Medicines for Malaria Venture and Novartis. Disappointingly, patient compliance, requirement for high-fat meal, and sporadic drug dissolution behaviours following administration still result in considerable challenges for these products. The first and foremost barrier that needs addressed for successful delivery of the artemether/lumefantrine combination is the poor solubility of lumefantrine within the gastrointestinal fluids. In this work, amorphous solid dispersions of lumefantrine within Soluplus®-based matrices have been manufactured using hot melt extrusion as a potential formulation strategy to achieve enhanced dissolution and apparent solubility. The drug loading capacity of Soluplus® to accommodate amorphous lumefantrine, whilst ensuring improved in-vitro dissolution performance, was investigated. The extrusion process employed a variety of processing parameters, including various temperature profiles and different production scales. The influence of variation in extrusion conditions upon the physical stability of manufactured amorphous solid dispersions was also examined. This allowed for a greater understanding of the role of extrusion processing conditions on the performance of supersaturated amorphous solid dispersions during dissolution and storage. This may allow for the design and manufacture of drug enabled formulations with lower drug dosing and thus a lower risk of adverse effects.

The Designs and Testing of Biodegradable Energy-Absorbing Inserts for Enhanced Crashworthiness in Sports Helmets.

This article addresses manufacturing structures made via injection molding from biodegradable materials. The mentioned structures can be successfully used as energy-absorbing liners of all kinds of sports helmets, replacing the previously used expanded polystyrene. This paper is focused on injection technological tests and tensile tests (in quasi-static and dynamic conditions) of several composites based on a PLA matrix with the addition of other biodegradable softening agents, such as PBAT and TPS (the blends were prepared via melt blending using a screw extruder with mass compositions of 50:50, 30:70, and 15:85). Tensile tests showed a positive strain rate sensitivity of the mixtures and a dependence of the increase in the ratio of the dynamic to static yield stress on the increase in the share of the plastic component in the mixture. Technological tests showed that increasing the amount of the plasticizing additive by 35% (from 50% to 85%) results in a decrease in the minimal thickness of the thin-walled element that can be successfully injection molded by about 32% in the case of PLA/PBAT blends (from 0.22 mm to 0.15 mm) and by about 26% in the case of PLA/TPS blends (from 0.23 mm to 0.17 mm). Next, the thin-walled elements (dimensions of 55 × 55 × 20 mm) were manufactured and evaluated using a spring-loaded drop hammer. The 60 J impact energy was tested in accordance with the EN 1078 standard. The dynamic crushing test included checking the influence of the materials' temperature (-20, 0, 20, and 40 °C) and the impact velocity. It was proven that the maximum deflection increases with increasing material temperature and an increase in the share of the plastic component in the mixture. The PLA15PBAT85 blend was selected as the most effective material in terms of its use as an energy-absorbing liner for sport helmets. Johnson-Cook and Cowper-Symonds material plasticizing models were constructed. Their use during dynamic FE simulation provided results that were in good agreement with those of the conducted experiment.

Modelling of Bond Formation during Overprinting of PEEK Laminates.

The rapid technological progress of large-scale CNC (computer numerical control) systems for Screw Extrusion Additive Manufacturing (SEAM) has made the overprinting of composite laminates a much-discussed topic. It offers the potential to efficiently produce functionalised high-performance structures. However, bonding the 3D-printed structure to the laminate has proven to be a critical point. In particular, the bonding mechanisms must be precisely understood and controlled to ensure in situ bonding. This work investigates the applicability of healing models from 3D printing to the overprinting of thermoplastic laminates using semi-crystalline, high-performance material like PEEK (polyether ether ketone). For this purpose, a simulation methodology for predicting the bonding behaviour is developed and tested using experimental data from a previous study. The simulation consists of a transient heat analysis and a diffusion healing model. Using this model, a qualitative prediction of the bond strength could be made by considering the influence of wetting. It was shown that the thermal history of the interface and, in particular, the tolerance of the deposition of the first layer are decisive for in situ bonding. The results show basic requirements for future process and component developments and should further advance the maturation of overprinting.

Manufacturing processes, additional nutritional value and versatile food applications of fresh microalgae Spirulina.

Spirulina is capable of using light energy and fixing carbon dioxide to synthesize a spectrum of organic substances, including proteins, polysaccharides, and unsaturated fatty acids, making it one of the most coveted food resources for humanity. Conventionally, Spirulina products are formulated into algal powder tablets or capsules. However, the processing and preparation of these products, involving screw pump feeding, extrusion, high-speed automation, and high-temperature dewatering, often result in the rupture of cell filaments, cell fragmentation, and the unfortunate loss of vital nutrients. In contrast, fresh Spirulina, cultivated within a closed photobioreactor and transformed into an edible delight through harvesting, washing, filtering, and sterilizing, presents a refreshing taste and odor. It is gradually earning acceptance as a novel health food among the general public. This review delves into the manufacturing processes of fresh Spirulina, analyzes its nutritional advantages over conventional algal powder, and ultimately prospects the avenues for fresh Spirulina's application in modern food processing. The aim is to provide valuable references for the research and development of new microalgal products and to propel the food applications of microalgae forward.