Controlled release, discrete,
solid particles which contain an encapsulated and / or embedded component such as a
heat sensitive or readily oxidizable pharmaceutically, biologically, or nutritionally
active component are continuously produced without substantial destruction of the matrix material or encapsulant. A release-rate controlling component is incorporated into the matrix to control the rate of release of the encapsulant from the particles. The additional component may be a hydrophobic component or a high
water binding capacity component for extending the
release time. The plasticizable matrix material, such as
starch, is admixed with at least one
plasticizer, such as water, and at least one release-rate controlling component under low shear mixing conditions to plasticize the plasticizable material without substantially destroying the at least one plasticizable material and to obtain a substantially homogeneous plasticized
mass. The
plasticizer content is substantially reduced and the temperature of the plasticized
mass are substantially reduced prior to admixing the plasticized
mass with the encapsulant to avoid substantial destruction of the encapsulant and to obtain a formable, extrudable mixture. The mixture is extruded through a die without substantial or essentially no expansion and
cut into discrete, relatively dense particles. Release properties may also be controlled by precoating the encapsulant and / or
coating the extrudate particles with a film-forming component.