A review of current techniques for the evaluation of powder mixing

Evaluation and Analysis of Cement Raw Meal Homogenization Characteristics Based on Simulated Equipment Models

In recent years, the variability in the composition of cement raw materials has increasingly impacted the quality of cement products. However, there has been relatively little research on the homogenization effects of equipment in the cement production process. Existing studies mainly focus on the primary functions of equipment, such as the grinding efficiency of ball mills, the thermal decomposition in cyclone preheaters, and the thermal decomposition in rotary kilns. This study selected four typical pieces of equipment with significant homogenization functions for an in-depth investigation: ball mills, pneumatic homogenizing silos, cyclone preheaters, and rotary kilns. To assess the homogenization efficacy of each apparatus, scaled-down models of these devices were constructed and subjected to simulated experiments. To improve experimental efficiency and realistically simulate actual production conditions in a laboratory setting, this study used the uniformity of the electrical capacitance of mixed powders instead of compositional uniformity to analyze homogenization effects. The test material in the experiment consisted of a mixture of raw meal from a cement factory with a high dielectric constant and Fe3O4 powder. The parallel plate capacitance method was employed to ascertain the capacitance value of the mixed powder prior to and subsequent to treatment by each equipment model. The fluctuation of the input and output curves was analyzed, and the standard deviation (S), coefficient of variation (R), and homogenization multiplier (H) were calculated in order to evaluate the homogenization effect of each equipment model on the raw meal. The findings of the study indicated that the pneumatic homogenizer exhibited an exemplary homogenization effect, followed by the ball mill. For the ball mill, a higher proportion of small balls in the gradation can significantly enhance the homogenization effect without considering the grinding efficiency. The five-stage cyclone preheater also has a better homogenization effect, while the rotary kiln has a less significant homogenization effect on raw meal. Finally, the raw meal processed by each equipment model was used for clinker calcination and the preparation of cement mortar samples. After curing for three days, the compressive and flexural strengths of the samples were tested, thereby indirectly verifying the homogenization effect of each equipment model on the raw meal. This study helps to understand the homogenization process of raw materials by equipment in cement production and provides certain reference and data support for equipment selection, operation optimization, and quality control in the cement production process.

Reviewing the Impact of Powder Cohesion on Continuous Direct Compression (CDC) Performance

The pharmaceutical industry is undergoing a paradigm shift towards continuous processing from batch, where continuous direct compression (CDC) is considered to offer the most straightforward implementation amongst powder processes due to the relatively low number of unit operations or handling steps. Due to the nature of continuous processing, the bulk properties of the formulation will require sufficient flowability and tabletability in order to be processed and transported effectively to and from each unit operation. Powder cohesion presents one of the greatest obstacles to the CDC process as it inhibits powder flow. As a result, there have been many studies investigating potential manners in which to overcome the effects of cohesion with, to date, little consideration of how these controls may affect downstream unit operations. The aim of this literature review is to explore and consolidate this literature, considering the impact of powder cohesion and cohesion control measures on the three-unit operations of the CDC process (feeding, mixing, and tabletting). This review will also cover the consequences of implementing such control measures whilst highlighting subject matter which could be of value for future research to better understand how to manage cohesive powders for CDC manufacture.

Characterization of Pharmaceutical Tablets by X-ray Tomography

Solid dosage forms such as tablets are extensively used in drug administration for their simplicity and large-scale manufacturing capabilities. High-resolution X-ray tomography is one of the most valuable non-destructive techniques to investigate the internal structure of the tablets for drug product development as well as for a cost effective production process. In this work, we review the recent developments in high-resolution X-ray microtomography and its application towards different tablet characterizations. The increased availability of powerful laboratory instrumentation, as well as the advent of high brilliance and coherent 3rd generation synchrotron light sources, combined with advanced data processing techniques, are driving the application of X-ray microtomography forward as an indispensable tool in the pharmaceutical industry.

Parametric Effects on the Mixing Efficiency of Resonant Acoustic Mixing Technology for High-Viscosity Mixture: A Numerical Study

Numerical investigations were conducted on the mixing efficiency of resonant acoustic mixing (RAM) technology using a high-viscosity mixture under vertically forced vibrations. The density distribution was analyzed for a mixture of high-melting explosive (HMX) and trinitrotoluene (TNT). The effects of mixing time, amplitude, frequency, fill level, and mixing vessel geometry were evaluated to determine their influence on the blend homogeneity and the efficiency of the mixing process. The results showed that amplitude and frequency both have significant influences on the mixing efficiency of the RAM process. With higher values of amplitude and frequency, the mixing efficiency was very good, and uniform mixing was achieved in a much shorter time. At the same time, it was seen that geometric changes did not affect the mixing process; in contrast, varying the fill level did have a significant effect. This approach could potentially be used for pharmaceutical blending, cosmetics, and explosive applications, where only small quantities of active particle ingredients (APIs) can change the behavior of the mixture.

Reduced Fine API Agglomeration After Dry Coating for Enhanced Blend Uniformity and Processability of Low Drug Loaded Blends

PURPOSE

The impact of dry coating on reduced API agglomeration remains underexplored. Therefore, this work quantified fine cohesive API agglomeration reduction through dry coating and its impact on enhanced blend uniformity and processability, i.e., flowability and bulk density of multi-component blends API loading as low as 1 wt%.

METHODS

The impact of dry coating with two different types and amounts of silica was assessed on cohesion, agglomeration, flowability, bulk density, wettability, and surface energy of fine milled ibuprofen (~ 10 µm). API agglomeration, measured using Gradis/QicPic employing gentler gravity-based dispersion, resulted in excellent size resolution. Multi-component blends with fine-sized excipients, selected for reduced segregation potential, were tested for bulk density, cohesion, flowability, and blend content uniformity. Tablets formed using these blends were tested for tensile strength and dissolution.

RESULT

All dry coated ibuprofen powders exhibited dramatic agglomeration reduction, corroborated by corresponding decreased cohesion, unconfined yield strength, and improved flowability, regardless of the type and amount of silica coating. Their blends exhibited profound enhancement in flowability and bulk density even at low API loadings, as well as the content uniformity for the lowest drug loading. Moreover, hydrophobic silica coating improved drug dissolution rate without appreciably reducing tablet tensile strength.

CONCLUSION

The dry coating based reduced agglomeration of fine APIs for all three low drug loadings improved overall blend properties (uniformity, flowability, API release rate) due to the synergistic impact of a minute amount of silica (0.007 wt %), potentially enabling direct compression tableting and aiding manufacturing of other forms of solid dosing.

4D study of liquid binder penetration dynamics in pharmaceutical powders using synchrotron X-ray micro computed tomography

The properties of pharmaceutical powders, and the liquid binder, directly influence the penetration behavior in the wet granulation process of the pharmaceutical industry. Conventional methods encounter challenges in understanding this fast process. In this work, an emerging synchrotron-based X-ray imaging technique (having fast imaging capability) was employed to investigate the internal process from 2D and 3D to real-time (in-situ with ms time intervals) 3D (also considered 4D) perspectives. Two commonly used excipients (lactose monohydrate (LMH) and microcrystalline cellulose (MCC)) were used to make binary mixtures with acetaminophen (APAP) as the active pharmaceutical ingredient (API). Isopropanol and water were employed as liquid binders in the single droplet impact method. Results showed that for most of the mixtures, the porosity increased at higher fractions of APAP. MCC mixtures experienced less agglomeration and more uniform pore distribution than LMH ones, resulting in a faster droplet penetration with isopropanol. Moreover, the imbibition-spreading studies showed that isopropanol penetration in MCC powders followed more unidirectional vertical movement than horizontal spreading. Our results also demonstrated that simultaneous granulation of LMH with water resulted in much slower penetration. This study revealed that synchrotron X-ray imaging can investigate 3D internal pore structures and how they affect the quantitively real-time internal penetration dynamics.

Applications of Probiotic-Based Multi-Components to Human, Animal and Ecosystem Health: Concepts, Methodologies, and Action Mechanisms

Probiotics and related preparations, including synbiotics and postbiotics, are living and non-living microbial-based multi-components, which are now among the most popular bioactive agents. Such interests mainly arise from the wide range and numerous beneficial effects of their use for various hosts. The current minireview article attempts to provide an overview and discuss in a holistic way the concepts, methodologies, action mechanisms, and applications of probiotic-based multi-components in human, animal, plant, soil, and environment health. Probiotic-based multi-component preparations refer to a mixture of bioactive agents, containing probiotics or postbiotics as main functional ingredients, and prebiotics, protectants, stabilizers, encapsulating agents, and other compounds as additional constituents. Analyzing, characterizing, and monitoring over time the traceability, performance, and stability of such multi-component ingredients require relevant and sensitive analytical tools and methodologies. Two innovative profiling and monitoring methods, the thermophysical fingerprinting thermogravimetry-differential scanning calorimetry technique (TGA-DSC) of the whole multi-component powder preparations, and the Advanced Testing for Genetic Composition (ATGC) strain analysis up to the subspecies level, are presented, illustrated, and discussed in this review to respond to those requirements. Finally, the paper deals with some selected applications of probiotic-based multi-components to human, animal, plant, soil and environment health, while mentioning their possible action mechanisms.

Variability in the unregulated opioid market in the context of extreme rates of overdose

BACKGROUND

Drug checking uses analytical chemistry technologies to report on the composition of drugs from the unregulated market to reduce substance use-related risks, while additionally allowing for monitoring and reporting of the supply. In the context of an overdose crisis linked to fentanyl, we used drug checking data to examine variability within the illicit opioid supply.

METHODS

In this time-series analysis, data was collected from a drug checking service in Victoria, Canada from November 2020 to July 2021. Drugs reported as opioids by participants of the service (N = 454) were analyzed to determine sample composition and paper spray mass spectroscopy was used to quantify low-concentration actives. Interquartile and statistical process control (SPC) analysis, namely standard deviation control charts, were used to examine the degree of variability among samples.

RESULTS

Fentanyl was found in 96% of samples reported to be opioids, with a median concentration of 9%. Concentrations varied significantly, with a standard deviation of 7% for fentanyl and where nearly 20% of data points fell outside the control limits. Over half of the samples contained an additional and unexpected active, most commonly etizolam (43% of samples). Etizolam also showed a large level of variability, uncorrelated to that of fentanyl.

CONCLUSIONS

Based on our chemical quantification and SPC analysis, a high degree of variability was found in opioid samples from the unregulated market in both the drugs detected and the concentrations of those drugs. This demonstrated the opioid crisis to be less attributable to a bad batch of drugs but rather the general variability found in the unregulated market.

Optimization of the Preformulation and Formulation Parameters in the Development of New Extended-Release Tablets Containing Felodipine

Herein, new extended-release tablets containing felodipine were developed. For the orally administered formulations, optimization of the preformulation and formulation parameters was performed to assess the performance of the dosage form. Initially, the morphological and physical characterization of two forms of felodipine (microcrystalline and macrocrystalline) using Fourier transform infrared spectroscopy, differential scanning calorimetry and optical microscopy was performed. The pharmaco-technical properties of the two felodipine forms were also determined. Subsequently, formulation studies for felodipine extended-release tablets were performed. Mathematical modelling of release kinetics of felodipine from developed formulations using a power law model was also performed. Based on the influence of formulation factors on the in vitro availability of felodipine in experimental tablets, a new extended-release tablet formulation was established.

A comprehensive review of the application of DEM in the investigation of batch solid mixers

Powder mixing is a vital operation in a wide range of industries, such as food, pharmaceutical, and cosmetics. Despite the common use of mixing systems in various industries, often due to the complex nature of mixing systems, the effects of operating and design parameters on the mixers’ performance and final blend are not fully known, and therefore optimal parameters are selected through experience or trial and error. Experimental and numerical techniques have been widely used to analyze mixing systems and to gain a detailed understanding of mixing processes. The limitations associated with experimental techniques, however, have made discrete element method (DEM) a valuable complementary tool to obtain comprehensive particle level information about mixing systems. In the present study, the fundamentals of solid-solid mixing, segregation, and characteristics of different types of batch solid mixers are briefly reviewed. Previously published papers related to the application of DEM in studying mixing quality and assessing the influence of operating and design parameters on the mixing performance of various batch mixing systems are summarized in detail. The challenges with regards to the DEM simulation of mixing systems, the available solutions to address those challenges and our recommendations for future simulations of solid mixing are also presented and discussed.

A New Perspective to Tribocharging: Could Tribocharging Lead to the Development of a Non-Destructive Approach for Process Monitoring and Quality Control of Powders?

This study explores a new perspective on triboelectrification that could potentially lead to the development of a non-destructive approach for the rapid characterization of powders. Sieved yellow pea powders at various particle sizes and protein contents were used as a model system for the experimental charge measurements of the triboelectrified powders. A tribocharging model based on the prominent condenser model was combined with a Eulerian-Lagrangian computational fluid dynamics (CFD) model to simulate particle tribocharging in particle-laden flows. Further, an artificial neural network model was developed to predict particle-wall collision numbers based on a database obtained through CFD simulations. The tribocharging and CFD models were coupled with the experimental tribocharging data to estimate the contact potential difference of powders, which is a function of contact surfaces' work functions and depends on the chemical composition of powders. The experimentally measured charge-to-mass ratios were linearly related to the calculated contact potential differences for samples with different protein contents, indicating a potential approach for the chemical characterization of powders.

Shear-induced mixing of granular materials featuring broad granule size distributions

Granular flows during a shear-induced mixing process are studied using discrete element methods. The aim is to understand the underlying elementary mechanisms of transition from unmixed to mixed phases for a granular material featuring a broad distribution of particles, which we investigate systematically by varying the strain rate and system size. Here the strain rate varies over four orders of magnitude and the system size varies from ten thousand to more than a million granules. A strain rate-dependent transition from quasistatic to purely inertial flow is observed. At the macroscopic scale, the contact stresses drop due to the formation of shear-induced instabilities that serves as an onset of granular flows and initiates mixing between the granules. The stress-drop displays a profound system size dependence. At the granular scale, mixing dynamics are correlated with the formation of shear bands, which result in significantly different timescales of mixing, especially for those regions that are close to the system walls and the bulk. Overall, our results reveal that although the transient dynamics display a generic behavior, these have a significant finite-size effect. In contrast, macroscopic behaviors at steady states have negligible system size dependence.

Experimental and Discrete Element Model Investigation of Limestone Aggregate Blending Process in Vertical Static and/or Conveyor Mixer for Application in the Concrete Mixture

The numerical model of the granular flow within an aggregate mixture, conducted in the vertical static and/or the conveyor blender, was explored using the discrete element method (DEM) approach. The blending quality of limestone fine aggregate fractions binary mixture for application in self-compacting concrete was studied. The potential of augmenting the conveyor mixer working efficiency by joining its operation to a Komax-type vertical static mixer, to increase the blending conduct was investigated. In addition the impact of the feed height on the flow field in the cone-shaped conveyor mixer was examined using the DEM simulation. Applying the numerical approach enabled a deeper insight into the quality of blending actions, while the relative standard deviation criteria ranked the uniformity of the mixture. The primary objective of this investigation was to examine the behavior of mixture for two types of blenders and to estimate the combined blending action of these two mixers, to explore the potential to augment the homogeneity of the aggregate fractions binary mixture, i.e., mixing quality, reduce the blending time and to abbreviate the energy-consuming.

Effect of Mixer Type on Particle Coating by Magnesium Stearate for Friction and Adhesion Modification

Glidants and lubricants are often used to modify interparticle friction and adhesion in order to improve powder characteristics, such as flowability and compactability. Magnesium stearate (MgSt) powder is widely used as a lubricant. Shear straining causes MgSt particles to break, delaminate, and adhere to the surfaces of the host particles. In this work, a comparison is made of the effect of three mixer types on the lubricating role of MgSt particles. The flow behaviour of α-lactose monohydrate, coated with MgSt at different mass percentages of 0.2, 0.5, 1, and 5 is characterised. The mixing and coating process is carried out by dry blending using Turbula, ProCepT, and Mechanofusion. Measures have been taken to operate under equivalent mixing conditions, as reported in the literature. The flow resistance of the coated samples is measured using the FT4 rheometer. The results indicate that the flow characteristics of the processed powders are remarkably similar in the cases of samples treated by Turbula and Mechanofusion, despite extreme conditions of shear strain rate. The least flow resistance of samples is observed in the case of samples treated by the ProCepT mixer. High-velocity collisions of particles round off the sharp corners and edges, making them less resistant to flow. The optimal percentage of magnesium stearate is found to be approximately 1% by weight for all mixer types, as the addition of higher amounts of lubricant does not further improve the flowability of the material.

Ensuring Homogeneity in Powder Mixtures for Pharmaceuticals and Dietary Supplements: Evaluation of a 3-Axis Mixing Equipment

The mixing process plays a pivotal role in the quality of pharmaceuticals and food/dietary supplements, as it can impact the homogeneity of the substances in their dosage form and affect characteristics such as dissolution and stability. Thus, the choice of the right mixing device is paramount for compounding pharmacies. In this paper, we evaluated the mixing efficacy of a new 3-axis mixer device and determined its optimal working conditions. Three different formulations were compounded with the device and a total of 540 individual assays were performed by HPLC or ICP-MS to validate its use, in addition to a direct comparison among it and two alternative mixing methods. The 3-axis mixer device was able to provide homogeneous mixtures and finished capsules with adequate content uniformity with a broad range of conditions of use (mixing times from 2 to 8 min, and speed of rotation from 10 to 100 rpm). In addition, the device was superior to classical mixing methods (such as the use of manually shaken plastic bags) and at least equivalent to well-established ones (Y-shaped mixer). Finally, we proposed a cleaning procedure that was also adequate to prevent cross-contamination among products compounded with the same device.

Determination of Residence Time Distribution in a Continuous Powder Mixing Process With Supervised and Unsupervised Modeling of In-line Near Infrared (NIR) Spectroscopic Data

Successful implementation of continuous manufacturing processes requires robust methods to assess and control product quality in a real-time mode. In this study, the residence time distribution of a continuous powder mixing process was investigated via pulse tracer experiments using near infrared spectroscopy for tracer detection in an in-line mode. The residence time distribution was modeled by applying the continuous stirred tank reactor in series model for achieving the tracer (paracetamol) concentration profiles. Partial least squares discriminant analysis and principal component analysis of the near infrared spectroscopy data were applied to investigate both supervised and unsupervised chemometric modeling approaches. Additionally, the mean residence time for three powder systems was measured with different process settings. It was found that a significant change in the mean residence time occurred when comparing powder systems with different flowability and mixing process settings. This study also confirmed that the partial least squares discriminant analysis applied as a supervised chemometric model enabled an efficient and fast estimate of the mean residence time based on pulse tracer experiments.

A quantitative structural characterisation of active semiconducting materials (mSi; SiO2; Al2O3; TiO2) for use in printed electronics using a combination of Small Angle Light Scattering (SALS) and Ultra Small Angle X-ray Scattering (USAXS)

Four nanostructured active semiconducting materials currently used in electronic inks have been structurally characterised using a combination of small angle scattering techniques and scanning electron microscopy. The percolation theory and scaling laws have been used to obtain quantitative correlations of the network topologies and the local micro-structures with the electronic and electrical properties of the printed, electronic devices. The small angle light scattering has been used to expand the lower q-range of the Ultra Small Angle x-ray Scattering curves of the 2503 metallurgical grade silicon (mSi), silicon dioxide (SiO₂), aluminium dioxide (Al₂O₃) and titanium dioxide (TiO₂) materials by close to an order of magnitude, thereby providing valuable clustering properties for each material. Each scattering curve presented a series of multiple structural levels, which are then quantified using the Unified power-law approach to provide valuable clustering characteristics such as the degree of aggregation, polydispersity and geometry standard deviation. Subsequently, a fully screen-printed field effect transistor that uses mSi as the active material is demonstrated. The transistor had an ON/OFF current-ratio of 10⁴; an electron mobility of 0.7 cm²/V s; a leakage current in the order of 5 × 10^-9 A, and no current saturation.

Thermophysical Fingerprinting of Probiotic-Based Products

Variability in efficacy and safety is a worldwide concern with commercial probiotics for their growing and inevitable use in food and health sectors. Here, we introduce a probiotic thermophysical fingerprinting methodology using a coupling thermogravimetry and differential scanning calorimetry. Qualitative and quantitative information on the material decomposition and transition phases is provided under heating conditions. By monitoring the changes in both mass and internal energy over temperature and time, a couple of thermal data at the maximum decomposition steps allow the creation of a unique and global product identity, depending on both strain and excipient components. We demonstrate that each powder formulation of monostrain and multistrain from different lots and origins have a unique thermophysical profile. Our approach also provides information on the formulation thermostability and additive/excipient composition. An original fingerprint form is proposed by converting the generated thermal data sequence into a star-like pattern for a perspective library construction.

Variability in content and dissolution profiles of MDMA tablets collected in the UK between 2001 and 2018 - A potential risk to users?

3,4-Methylenedioxymethamphetamine (MDMA, Ecstasy) tablets are widely used recreationally, and not only vary in appearance, but also in MDMA content. Recently, the prevalence of high-content tablets is of concern to public health authorities. To compare UK data with other countries, we evaluated MDMA content of 412 tablets collected from the UK, 2001-2018, and investigated within-batch content variability for a sub-set of these samples. In addition, we investigated dissolution profiles of tablets using pharmaceutical industry-standard dissolution experiments on 247 tablets. All analyses were carried out using liquid chromatography-tandem mass spectrometry (LC-MS/MS). Our data supported other studies, in that recent samples (2016-2018) tend to have higher MDMA content compared to earlier years. In 2018, the median MDMA content exceeded 100 mg free-base for the first time. Dramatic within-batch content variability (up to 136 mg difference) was also demonstrated. Statistical evaluation of dissolution profiles at 15-minutes allowed tablets to be categorized as fast-, intermediate-, or slow-releasing, but no tablet characteristics correlated with dissolution classification. Hence, there would be no way of users knowing a priori whether a tablet is more likely to be fast or slow-releasing. Further, within-batch variation in dissolution rate was observed. Rapid assessment of MDMA content alone provides important data for harm reduction, but does not account for variability in (a) the remainder of tablets in a batch, or (b) MDMA dissolution profiles. Clinical manifestations of MDMA toxicity, especially for high-content, slow-releasing tablets, may be delayed or prolonged, and there is a significant risk of users re-dosing if absorption is delayed.

Methods to Assess Mixing of Pharmaceutical Powders

The pharmaceutical manufacturing process consists of several steps, each of which must be monitored and controlled to ensure quality standards are met. The level of blending has an impact on the final product quality; therefore, it is important to be able to monitor blending progress and identify an end-point. Currently, the pharmaceutical industry assesses blend content and uniformity through the extraction of samples using thief probes followed by analytical methods, such as spectroscopy, to determine the sample composition. The development of process analytical technologies (PAT) can improve product monitoring with the aim of increasing efficiency, product quality and consistency, and creating a better understanding of the manufacturing process. Ideally, these are inline methods to remove issues related to extractive sampling and allow direct monitoring of the system using various sensors. Many technologies have been investigated, including spectroscopic techniques such as near-infrared spectroscopy, velocimetric techniques that may use tracers, tomographic techniques, and acoustic emissions monitoring. While some techniques have demonstrated potential, many have significant disadvantages including the need for equipment modification, specific requirements of the material, expensive equipment, extensive analysis, the location of the probes may be critical and/or invasive, and lastly, the technique may only be applicable to the development phase. Both the advantages and disadvantages of the technologies should be considered in application to a specific system.