Scale-up of high shear granulation based on agitation power

Scale-up of wet granulation in a vertical high shear mixer was conducted. Pharmaceutical excipient mixtures composed of lactose, cornstarch and micro-crystalline cellulose, and hydroxypropylecellulose as a binder were mixed together and then granulated with purified water under various operating conditions and vessel scales. Torque of agitator shaft was continuously measured and then agitation power per unit vessel volume was calculated. The agitation power per unit vessel volume showed a good correlation with physical properties of obtained granules, such as mass median diameter, strength and compressibility. This implied that the scale-up characteristics could be well analyzed by means of the agitation power per unit vessel volume. In addition, the effects of agitator tip speed and Froude number on the agitation power per unit vessel volume were investigated. The results showed that the agitation power per unit vessel volume was well characterized by the tip speed rather than the Froude number. This meant that the granule growth mainly progressed by the shear stress from the agitator blade. Dynamic characteristics of high shear granulation were also discussed here.     

Scale-up of high shear granulation based on the internal stress measurement

Scale-up of wet granulation in a vertical high shear mixer was conducted. Pharmaceutical excipient powders composed of lactose, cornstarch and micro-crystallinecellulose, and hydroxypropylcellulose as a binder were mixed together and then granulated with purified water under various operating conditions and vessel scales. A novel internal stress measurement system was developed and stress of normal and tangential directions that granules received from the agitator blade during the granulation was continuously measured. The results indicated that granules received stress mainly from the tangential direction, which also showed the largest value near at the vessel wall. The effects of the agitator tip speed and the centrifugal acceleration on the measured stress was investigated. It was found that the tip speed of the agitator blade could be the main factor for the granule growth. The physical properties such as strength, size distribution and compressibility of granules prepared by changing the operating conditions and the vessel scales were evaluated and the scale-up characteristics of high shear granulation were investigated experimentally. The results showed that these physical properties had linear correlations with the tip speed. It was finally concluded that the scale-up of high shear granulation could be well conducted by means of the tip speed of the agitator blade.     

Scale-up of wet kneading in a novel vertical high shear kneader

A novel multi-functional vertical high shear kneader has been developed and its performance in wet kneading has previously been reported [Watano et al., Chem. Pharm. Bull., 50(3), 341-345 (2002)]. In this study, scale-up of wet kneading in the novel vertical high shear kneader was conducted. Pharmaceutical excipients composed of lactose, cornstarch and micro-crystalline cellulose were used as powder samples. Kneading operations were conducted under various operating conditions and three different vessel scales. The dried pellets were then prepared by extruding the wet kneaded masses through a dome-type extruder and their drying by a fluidized bed. The physical properties such as strength and disintegration time of the dried pellets were evaluated. It was found that the properties of the dried pellets and their scale-up characteristics were well expressed by an agitation power per unit vessel volume and dimensionless Froude number.     

Investigation of high shear wet granulation processes using different parameters and formulations

This study compared the granulation processes for different formulations using a laboratory-scale high shear mixer. The effects of critical process parameters (impeller speed, chopper speed and kneading time) on granule characteristics were evaluated. The characteristics of the granules studied included the size distribution, friability and morphological properties. The flow profiles of the wet mass and material deposition during the process were also studied. The results obtained showed that the effect of the impeller speed was determined by the starting material system. On the other hand, chopper speeds from 1200 to 3600 rpm and kneading times from 120 to 240 s had a consistent influence on all formulations. Moreover, it was found that the toroidal flow pattern of the wet mass could be maintained for a longer period and granules with a good spherical shape were obtained by removing the chopper during the last 120 s of the granulation process. In addition, the use of the pregelatinized starch in the formulation also led to a reduction in the wall adhesion of the material. It was concluded that the effectiveness of high shear wet granulation could be improved by choosing a proper combination of starting material and process parameters and by monitoring the mass motion during the process.     

Scale-up of counter-current chromatography: Demonstration of predictable isocratic and quasi-continuous operating modes from the test tube to pilot/process scale

Predictable scale-up from test tube derived distribution ratios and analytical-scale sample loading optimisation is demonstrated using a model sample system of benzyl alcohol and p-cresol in a heptane:ethyl acetate:methanol:water phase system with the new 18 L Maxi counter-current chromatography centrifuge. The versatility of having a liquid stationary phase with its high loading capacity and flexible operating modes is demonstrated at two different scales by separating and concentrating target compounds using a mixture of caffeine, vanillin, naringenin and carvone using a quasi-continuous technique called intermittent counter-current extraction.     

A review on key aspects of wet granulation process for continuous pharmaceutical manufacturing of solid dosage oral formulations

Wet granulation process is a major unit operation in production of pharmaceuticals as solid dosage oral formulation. Indeed, granulation is used to improve the formulation properties such as flowability, compressibility, and so on for pharmaceutical manufacturing. Different types of granulations can be used in pharmaceutical manufacturing in which the selection of proper process depends on the operational conditions as well as formulation properties. In current decades, twin-screw wet granulation has been of paramount interest owing to its superior properties. Pharmaceutical manufacturing industry are trying to move towards continuous mode by which the efficiency can be improved compared to the batch mode. Therefore, development of continuous granulation process is of great importance. In this review article, various processing units applicable for wet granulation of pharmaceutical formulations for solid dosage forms are reviewed and discussed. The advantages and disadvantages of the processes are discussed and listed along with modeling approaches for simulation of process. The governing models and numerical schemes applicable for design of wet granulation are also critically discussed. The main focus is on wet granulation as this method has attracted much attention in pharmaceutical processing.     

Feasibility of scaling from pilot to process scale

The pharmaceutical industry is looking for new technology that is easy to scale up from analytical to process scale and is cheap and reliable to operate. Large scale counter-current chromatography is an emerging technology that could provide this advance, but little was known about the key variables affecting scale-up. This paper investigates two such variables: the rotor radius and the tubing bore. The effect of rotor radius was studied using identical: length, beta-value, helix angle and tubing bore coils for rotors of different radii (50 mm, 110 mm and 300 mm). The effect of bore was researched using identical: length, helix angle and mean beta-value coils on the Maxi-DE centrifuge (R=300 mm). The rotor radius results show that there is very little difference in retention and resolution as rotor radius increases at constant bore. The tubing bore results show that good retention is maintained as bore increases and resolution only decrease slightly, but at the highest bore (17.5 mm) resolution can be maintained at very high flow rates making it possible for process scale centrifuges to be designed with throughputs exceeding 25 kg/day.     

On-line monitoring of granule growth in high shear granulation by an image processing system

A novel system has been developed to continuously monitor granule growth in a high shear granulation. The system consists of an image processing system and a particle image probe comprising a CCD camera, lighting unit and air purge system. Segregation during powder mixing was investigated experimentally and the optimal positioning of the probe was determined. High shear granulation was conducted using pharmaceutical powders, and granule size and product's yield of various size ranges were continuously measured by the developed system. Sieve analysis of the granulated products sampled out during the granulation was simultaneously conducted, and the obtained data was compared with that by the on-line image processing system. An extremely close relationship could be found between both data, proving that the developed system could monitor the granule growth accurately and continuously throughout the granulation. An on-off control system was developed to control the granulation process, and the performance of the system was confirmed.     

Scale-up of microwave heating process for the production of bio-oil from sewage sludge

A pilot-scale microwave heating apparatus was constructed for the production of bio-oil from sewage sludge, and the effects of important microwave processing parameters and chemical additives on the quality and yield of bio-oils were investigated. It was found that bio-oil was mainly formed at the pyrolysis temperature range of 200–400 °C. A higher heating rate (faster pyrolysis) not only increased the yield of bio-oil, but also improved the quality of bio-oil according to the elemental composition and calorific values. The maximum bio-oil yield was 30.4% of organic fraction, obtained from the pyrolysis of original sewage sludge at microwave radiation power of 8.8 kW and final pyrolysis temperature of 500 °C. All of five simple additives (KOH, H₂SO₄, H₃BO₃, ZnCl₂, and FeSO₄) reduced the bio-oil yield, but the composition and property of bio-oil varied with the additive types greatly. KOH, H₂SO₄, H₃BO₃ and FeSO₄ were found to improve the quality of bio-oils remarkably according to the calorific value, density, viscosity and carbon content of bio-oils, but ZnCl₂ treatment went against that. GC–MS analysis of the bio-oils showed that, alkali treatment promoted the formation of alkanes and monoaromatics, while acid treatment favored the formation of heterocyclics, ketones, alcohols and nitriles. Compared with sulfate slat FeSO₄, chloride salt ZnCl₂ was a better catalyst for selective catalytic pyrolysis of sewage sludge. The addition of ZnCl₂ only promoted the formation reactions of a few kinds of nitriles and ketones remarkably. It is technologically feasible to produce bio-oil form microwave-induced pyrolysis of sewage sludge by optimizing pyrolysis conditions and selecting appropriate additives.     

A thermobalance for high pressure process studies

A DuPont 950 TG has been modified to permit operation at up to 30 atm, 1100°C, with corrosive atmospheres, and steam partial pressures up to 20 atm.The major areas of instrument development included: weight and temperature measurement at high pressures in a dynamic flow system; modification of a TG to accept corrosive gas atmospheres containing high partial pressures of steam; design of a pressure balanced flow system for safe introduction of corrosive gas atmospheres; design of a working steam generation system for low flows.Process studies illustrating the utility of the high presure thermobalance include the cyclic CO₂-acceptor reaction for half-calcined dolomite

and the cyclic H₂S absorption and regeneration reaction for half-calcined dolomite

     

Development of a novel vertical high shear kneader and its performance in wet kneading of pharmaceutical powders

A novel multi-functional vertical high shear kneader has been developed. Wet kneading of pharmaceutical powders was conducted under various blade components and operating conditions. Compression properties of wet kneaded mass was analyzed and dispersion of hinder liquid (water) among the mass was investigated by assaying tracer aqueous pigment. Pellets were produced through a dome type extrusion granulator with continuous extrusion pressure measurement device and a fluidized bed drier, and then the physical properties were measured. Quantitative relationship between the pellet's physical properties and the binder dispersion condition as well as the compression properties could be obtained. It was found that the newly developed kneader was very effective to uniformly disperse binder as well as impart high shear stress to the wet mass without generating obvious adhesion onto the vessel wall. It was also pointed out that the extrusion pressure could determine the physical strength of pellet. This method proposes a new methodology for continuous monitoring of kneading condition as well as predicting pellet's physical properties.     

Recovery of rare earth elements from wet process extraction phosphoric acid

It is shown that an increase in the recovery of rare earth elements in fluorophosphate concentrates, which are obtained by treating the wet process phosphoric acid by ammonium fluoride, is achieved by prior partial neutralization of H₃PO₄ by ammonia. Therewith the consumption of ammonium fluoride is reduced that provides almost complete precipitation of rare earth elements.     

Application of wet chemistry techniques to process analysis and control

The availability of reliable and rugged automatic titrators, flow-injection analysers and ion chromatographs provides opportunities for their application in industrial process analysis. The control of industrial processes such as the removal of sulphur during gas treatment presents a challenge as accurate on-line and in-line analysers are required. The application of automatic titrators and ion chromatographs to the compositional analysis of caustic and alkanolamine gas sweetening solutions is described. Comparisons with other techniques such as flow-injection analysis and ultraviolet and near-infrared spectrometry are made and the pertinent features and benefits of each are discussed.     

Industrial scale production of Selectfluor™ fluorination agent: from initial concept to full scale commercial production in a 5 year period

The Selectfluor™ electrophilic fluorination agent 1 is now produced in multi-ton per year quantities and is one of only a few fluorine-containing fine chemicals that are produced by direct fluorination with F₂ on an industrial scale. From the initial concept of the “ideal fluorination agent” to the present day industrial scale production of Selectfluor™, the route to the successful commercialization included a series of critical steps. A chronological account of the road to commercialization of Selectfluor™, noting the important product development factors, is provided herein.     

Morphological characterization of nylon‐6 nanocomposite following a large‐scale simple shear process

A commercial grade nylon‐6/clay nanocomposite (from Ube industries) is subjected to a large‐scale simple shear orientation process and the resulting morphology is investigated. Both the orientation and aspect ratio of nanoclays, which can be altered by the simple shear process, are studied. The incorporation of well‐dispersed nanoclays into the nylon matrix greatly reduces the nylon chain mobility as well as the percent crystallinity. Two types of lamellar orientation have been found, as revealed by small‐angle X‐ray scattering. One type of lamellae is oriented ～41° away from the clay surface, whereas the simple shear process induces another weakly preferred lamellar orientation nearly perpendicular to the clay surface. The formation of the above lamellar orientations appears to be related to both orientation of the clay in the nanocomposite and the simple shear process. The possible molecular mechanisms leading to the final morphology of the nylon‐6/clay nanocomposite is discussed. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 3555–3566, 2005     

NC-AFM observation of atomic scale structure of rutile-type TiO2(110) surface prepared by wet chemical process

We succeeded in observing the atomic scale structure of a rutile-type TiO2(110) single-crystal surface prepared by the wet chemical method of chemical etching in an acid solution and surface annealing in air. Ultrahigh vacuum noncontact atomic force microscopy (UHV-NC-AFM) was used for observing the atomic scale structures of the surface. The UHV-NC-AFM measurements at 450 K, which is above a desorption temperature of molecularly adsorbed water on the TiO2(110) surface, enabled us to observe the atomic scale structure of the TiO2(110) surface prepared by the wet chemical method. In the UHV-NC-AFM measurements at room temperature (RT), however, the atomic scale structure of the TiO2(110) surface was not observed. The TiO2(110) surface may be covered with molecularly adsorbed water after the surface was prepared by the wet chemical method. The structure of the TiO2(110) surface that was prepared by the wet chemical method was consistent with the (1 x 1) bulk-terminated model of the TiO2(110) surface.     

Particle capture processes and evaporation on a microscopic scale in wet filters

This paper details results of an experimental study of the capture of solid and liquid aerosols on fibrous filters wetted with water. A microscopic cell containing a single fibre (made from a variety of materials) was observed via a microscope, with a high speed CCD camera used to dynamically image the interactions between liquid droplets, zeolite and PSL particles and fibres. Variable quantities of liquid irrigation were used, and the possibility for subsequent fibre regeneration after clogging or drying was also studied. It was found that drainage of the wetting liquid (water) from the fibres occurred, even at very low irrigation rates when the droplet consisted almost completely of captured particles. It was also found that the fibre was rapidly loaded with captured particles when the irrigation was not supplied. However, almost complete regeneration (removal of the collected cake) by the liquid droplets occurred shortly after recommencement of the water supply. The study also examined the capture of oily liquid aerosols on fibres wetted with water. A predominance of the barrel shaped droplet on the fibre was observed, with oil droplets displacing water droplets (if the oil and fibre combination created a barrel shaped droplet), creating various compound droplets of oil and water not previously reported in literature. This preferential droplet shape implies that whatever the initial substance wetting a filter, a substance with a greater preferential adherence to the fibre will displace the former one.     

Photoinduced reaction on quantized GaAs nanocrystals prepared by wet process

Gallium arsenide nanocrystals of 1.5 to 9.0 nm were prepared in triethylene glycol dimethylether (triglyme), and photoinduced reduction of methylviologen (MV²⁺) on the nanocrystals was investigated. The rate of MV+ production determined for an initial stage of photoinduced reduction of MV²⁺ was found to be low compared to that determined for bulk GaAs particles of 0.4 mm, if the rate was evaluated for unit surface area of the semiconductor particles. To account for this finding, the apparent association constant of MV²⁺ to GaAs was determined, which suggested that molecular species which worked as stabilizing agents for the GaAs nanocrystals retarded the adsorption of MV²⁺ onto the particle surfaces.     

Mechanisms of particle removal from silicon wafer surface in wet chemical cleaning process

A quantitative mechanism of particle removal from silicon wafer surfaces by a wet chemical cleaning process is proposed. The particles are removed from the surface due to the combined effects of chemical etching and a net repulsive interaction between the particle and surface. The mechanism suggests that a critical etching depth, which has been determined theoretically, and an optimal etching rate, which can be determined from etching profile calculation, are required for particle removal. The study will help in the optimization of cleaning processes and formulation of superior cleaning solutions.