Triboelectrification: A review of experimental and mechanistic modeling approaches with a special focus on pharmaceutical powders

Assessment of Tribo-charging and Continuous Feeding Performance of Direct Compression Grades of Isomalt and Mannitol Powders

Tribo-charging is often a root cause of mass flow deviations and powder adhesion during continuous feeding. Thus, it may critically impact product quality. In this study, we characterized the volumetric (split- and pre-blend) feeding behavior and process-induced charge of two direct compression grades of polyols, galenIQ™ 721 (G721) for isomalt and PEARLITOL^® 200SD (P200SD) for mannitol, under different processing conditions. The feeding mass flow range and variability, hopper end fill level, and powder adhesion were profiled. The feeding-induced tribo-charging was measured using a Faraday cup. Both materials were comprehensively characterized for relevant powder properties, and their tribo-charging was investigated for its dependence on particle size and relative humidity. During split-feeding experiments, G721 showed a comparable feeding performance to P200SD with lower tribo-charging and adhesion to the screw outlet of the feeder. Depending on the processing condition, the charge density of G721 ranged from -0.01 up to -0.39 nC/g, and for P200SD from -3.19 up to -5.99 nC/g. Rather than differences in the particle size distribution of the two materials, their distinct surface and structural characteristics were found as the main factors affecting their tribo-charging. The good feeding performance of both polyol grades was also maintained during pre-blend feeding, where reduced tribo-charging and adhesion propensity was observed for P200SD (decreasing from -5.27 to -0.17 nC/g under the same feeding settings). Here, it is proposed that the mitigation of tribo-charging occurs due to a particle size-driven mechanism.

Computational Modeling of Fluidized Beds with a Focus on Pharmaceutical Applications: A Review

The fluidized bed is an essential and standard equipment in the field of process development. It has a wide application in various areas and has been extensively studied. This review paper aims to discuss computational modeling of a fluidized bed with a focus on pharmaceutical applications. Eulerian, Lagrangian, and combined Eulerian-Lagrangian models have been studied for fluid bed applications with the rise of modeling capabilities. Such models assist in optimizing the process parameters and expedite the process development cycle. This paper discusses the background of modeling and then summarizes research papers relevant to pharmaceutical unit operations.

Loss-in-weight feeding, powder flow and electrostatic evaluation for direct compression hydroxypropyl methylcellulose (HPMC) to support continuous manufacturing

Minimizing variability in the feeding process is important for continuous manufacturing since materials are fed individually and can impact the final product. This study demonstrates the importance of measuring powder properties and highlights the need to characterize the feeding performance both offline with multiple refills and in the intended configuration for the continuous manufacturing equipment. The standard grade hydroxypropyl methylcellulose (HPMC) had material buildup on the loss-in-weight feeder barrel from triboelectric charging and resulted in more mass flow excursions and failed refills which were not observed with the direct compression grades. The location of the electrostatic buildup changed when the feeder was connected to a hopper instead of feeding offline into a collection bucket. Overall, the direct compression HPMC exhibited better flow which resulted in more accurate loss-in-weight feeding with less excursions from the target mass flow and all refills were completed in the first attempt. The improvements with the direct compression HPMC would be beneficial when running any continuous process (wet granulation, roller compaction, or direct compression) or other processes where loss-in-weight feeding is utilized, such as melt extrusion or twin screw granulation.

Discrete Element Modeling (DEM) based investigation of tribocharging in the pharmaceutical powders during hopper discharge

Triboelectric charging is defined as the phenomenon of charge transfer between two different material surfaces when they are brought into contact and separated. The focus of this research is the development of a Discrete Element Method (DEM) based simulation model to predict tribocharging during hopper discharge. Due to decreased particle-wall interactions and reduced particle wall contact times, net charges generated during hopper discharge are low. The simulation model confirmed this effect and was implemented to predict the triboelectric behavior of glass beads and MCC particles during hopper flow, along with the prediction of percent charged and uncharged particles. Approximately one-third of the particles were predicted to remain uncharged during the hopper discharge simulations for mono-dispersed particles, thus rendering a comparatively high amount of charge distribution into a small concentration of materials. The DEM model acted as a tool to predict charges that can be generated during hopper discharge at a specified geometry, with a potential to mitigate particle charging, when used for appropriate selection of hopper angles, and hopper wall materials.

Investigation into powder tribo-charging of pharmaceuticals. Part I: Process-induced charge via twin-screw feeding

Powder feeding is a crucial unit operation in continuous manufacturing (CM) of pharmaceutical products. Twin-screw feeders are typically employed to ensure the accurate mass flow of pharmaceutical materials throughout the production process. Here, contact and separation of particles can give rise to electrostatic charges, affecting feeder performance and final product quality. The knowledge of the material charging tendency would therefore be beneficial for both formulation and process design. At the early stage of product development, only a limited amount of material is available and the propensity of the powders to charge needs to be assessed on lab test equipment, which not necessarily represent the material state during processing. In this study, the tribo-charging behaviour of a set of common pharmaceutical materials (i.e., microcrystalline cellulose, D-mannitol, paracetamol and magnesium stearate) was experimentally evaluated. To this end, powder materials were let to flow over the stainless-steel pipes of the GranuCharge™ instrument. The resulting charge was compared to the one acquired during twin-screw feeding. In both cases, paracetamol exhibited the highest charging tendency followed by D-mannitol and microcrystalline cellulose and last by magnesium stearate. A good correlation was found for charge values obtained for both methods, despite the different tribo-charging mechanisms involved in the two set-ups. However, these differences in experimental set-ups led to diverse magnitudes and, in one case, polarity of charge. Additionally, an extensive material characterization was performed on the selected powders and results were statistically analyzed to identify critical material attributes (CMAs) affecting powder tribo-charging. A strong correlation was obtained between the measured charge and inter-particle friction. This indicated the latter as one of the most influencing material characteristic impacting the powder tribo-charging phenomenon of the selected materials.

Impact of Hot-Melt-Extrusion on Solid-State Properties of Pharmaceutical Polymers and Classification Using Hierarchical Cluster Analysis

The impact of hot-melt extrusion (HME) on the solid-state properties of four methacrylic (Eudragit® L100-55, Eudragit® EPO, Eudragit® RSPO, Eudragit® RLPO) and four polyvinyl (Kollidon® VA64, Kollicoat® IR, Kollidon® SR, and Soluplus®) polymers was studied. Overall, HME decreased Tg but increased electrostatic charge and surface free energy. Packing density decreased with electrostatic charge, whereas Carr’s and Hausner indices showed a peak curve dependency. Overall, HME reduced work of compaction (Wc), deformability (expressed as Heckel PY and Kawakita 1/b model parameters and as slope S′ of derivative force/displacement curve), and tablet strength (TS) but increased elastic recovery (ER). TS showed a better correlation with S′ than PY and 1/b. Principal component analysis (PCA) organized the data of neat and extruded polymers into three principal components explaining 72.45% of the variance. The first included Wc, S′ and TS with positive loadings expressing compaction, and ER with negative loading opposing compaction; the second included PY, 1/b, and surface free energy expressing interactivity with positive loadings opposing tap density or close packing. Hierarchical cluster analysis (HCA) assembled polymers of similar solid-state properties regardless of HME treatment into a major cluster with rescaled distance Cluster Combine Index (CCI) < 5 and several other weaker clusters. Polymers in the major cluster were: neat and extruded Eudragit® RSPO, Kollicoat® IR, Kollidon® SR, Soluplus®, and extruded Eudragit® L100-55. It is suggested that PCA may be used to distinguish variables having similar or dissimilar activity, whereas HCA can be used to cluster polymers based on solid-state properties and pick exchangeable ones (e.g., for sustain release or dissolution improvement) when the need arises.

A Simplex Centroid Design to Quantify Triboelectric Charging in Pharmaceutical Mixtures

The present study focuses on the implementation of a modified simplex centroid statistical design to predict the triboelectrification phenomenon in pharmaceutical mixtures. Two drugs (Ibuprofen and Theophylline), 2 excipients (lactose monohydrate and microcrystalline cellulose/MCC), and 2 blender wall materials (aluminum and poly-methyl methacrylate) were studied to identify the trends in charge transfer in pharmaceutical blends. The statistical model confirmed the excipient-drug interactions, irrespective of the blender wall materials, as the most significant factor leading to reduced charging. Also, lactose monohydrate was able to explain the charge variability more consistently compared with MCC powders when used as secondary material. The ratio of the individual components in the blends explained almost 80% of the bulk charging for Ibuprofen mixtures and 70% for Theophylline mixtures. The study also explored the potential lack of efficacy of lactose-MCC as a combination in ternary systems when compared with binary mixtures, for impacts on charge variability in pharmaceutical blends.

Influence of Particle Contact Number on Triboelectric Separation Selectivity

Triboelectric separation is a promising technology to separate fine powders. To enable triboelectric separation for its application in industry, the impact of the process and product parameters must be examined. In this study, with regards to different wall materials in the charging step (PTFE, POM, PE, PVC, and PMMA), the influence of the powder composition of a binary starch-protein mixture with a protein content of 15 wt.%, 30 wt.% and 45 wt.% was studied. By increasing the protein content in the feed, the separation selectivity increased. No dependency of the empirical triboelectric series was determined for all powder compositions. The variation in the protein content of the initial powder and turbulent flow profiles results in a variation in the contact number of particles calculated. An increase in the contact number of particles leads to an increase in the protein content separated on the cathode, whereas the protein content on the anode is only slightly affected. These findings underpin the assumption that particle-particle interaction plays a decisive role in triboelectric charging of fine powders.

Delivery of Dry Powders to the Lungs: Influence of Particle Attributes from a Biological and Technological Point of View

Dry powder inhalers are medical devices used to deliver powder formulations of active pharmaceutical ingredients via oral inhalation to the lungs. Drug particles, from a biological perspective, should reach the targeted site, dissolve and permeate through the epithelial cell layer in order to deliver a therapeutic effect. However, drug particle attributes that lead to a biological activity are not always consistent with the technical requirements necessary for formulation design. For example, small cohesive drug particles may interact with neighbouring particles, resulting in large aggregates or even agglomerates that show poor flowability, solubility and permeability. To circumvent these hurdles, most dry powder inhalers currently on the market are carrier-based formulations. These formulations comprise drug particles, which are blended with larger carrier particles that need to detach again from the carrier during inhalation. Apart from blending process parameters, inhaler type used and patient's inspiratory force, drug detachment strongly depends on the drug and carrier particle characteristics such as size, shape, solid-state and morphology as well as their interdependency. This review discusses critical particle characteristics. We consider size of the drug (1-5 µm in order to reach the lung), solid-state (crystalline to guarantee stability versus amorphous to improve dissolution), shape (spherical drug particles to avoid macrophage clearance) and surface morphology of the carrier (regular shaped smooth or nano-rough carrier surfaces for improved drug detachment.) that need to be considered in dry powder inhaler development taking into account the lung as biological barrier.

Contact-Electrification between Two Identical Materials: Curvature Effect

It is known that contact-electrification (or triboelectrification) usually occurs between two different materials, which could be explained by several models for different materials systems ( Adv. Mater. 2018, 30, 1706790; Adv. Mater. 2018, 30, 1803968). But contact between two pieces of the chemically same material could also result in electrostatic charges, although the charge density is rather low, which is hard to understand from a physics point of view. In this paper, by preparing a contact-separation mode triboelectric nanogenerator using two pieces of an identical material, the direction of charge transfer during contact-electrification is studied regarding its dependence on curvatures of the sample surfaces. For materials such as polytetrafluoroethylene, fluorinated ethylene propylene, Kapton, polyester, and nylon, the positive curvature surfaces are net negatively charged, while the negative curvature surfaces tend to be net positively charged. Further verification of the above-mentioned trends was obtained under vacuum (∼1 Pa) and higher temperature (≤358 K) conditions. Based on the received data acquired for gentle contacting cases, we propose a curvature-dependent charge transfer model by introducing curvature-induced energy shifts of the surface states. However, this model is subject to be revised if the mutual contact mode turns into a sliding mode or more complicated hard-pressed contact mode, in which a rigorous contact between the two pieces of the same material could result in nanoscale damage/fracture and possible species transfer. Our study provides a primitive step toward understanding the basics of contact-electrification.

Controlling Surface Charge Generated by Contact Electrification: Strategies and Applications

Contact electrification is the phenomenon in which charge is generated on the surfaces of materials after they come into contact. The surface charge generated has traditionally been known to cause a vast range of undesirable consequences in our lives and in industry; on the other hand, it can also give rise to many types of useful applications. In addition, there has been a lot of interest in recent years for fabricating devices and materials based on regulating a desired amount of surface charge. It is thus important to understand the general strategies for increasing, decreasing, or controlling the surface charge generated by contact electrification. Herein, the fundamental mechanisms for influencing the amount of charge generated, the methods used for implementing these mechanisms, and some of the recent interesting applications that require regulating the amount of surface charge generated by contact electrification, are briefly summarized.

Quantification of Moisture-Induced Cohesion in Pharmaceutical Mixtures

Moisture-induced flow variabilities in pharmaceutical blends lead to multiple impediments during manufacturing of solid dosage formulations. Processing and storage humidity conditions both govern the moisture contents of the pharmaceutical mixtures and bear significant impact on the final product quality. In this study, experimentally validated discrete element method-based computational models along with statistical formalism have been implemented to develop a predictive tool for moisture-induced cohesion in binary and tertiary mixtures. V-blending was applied to prepare the pharmaceutical blends, and mixing characterization was performed using a Raman PhAT probe. Optimum fill volume was established for the mixing conditions to minimize static charging due to blender wall interactions on the pharmaceutical powders. A simplex-centroid (augmented) design for 3-component system was implemented to predict and quantify the nonlinear behavior of moisture-induced cohesion between the pharmaceutical powders based on their systematic hopper discharge studies (experiments and simulations). A methodical implementation of these quantification tools was hence performed to validate a design space that enables an approach to the appropriate selection of blend concentrations that achieve minimum mixture flow variability across different humidity conditions.

Toward Constitutive Models for Momentum, Species, and Energy Transport in Gas-Particle Flows

As multiscale structures are inherent in multiphase flows, constitutive models employed in conjunction with transport equations for momentum, species, and energy are scale dependent. We suggest that this scale dependency can be better quantified through deep learning techniques and formulation of transport equations for additional quantities such as drift velocity and analogies for species, energy, and momentum transfer. How one should incorporate interparticle forces, which arise through van der Waals interaction, dynamic liquid bridges between wet particles, and tribocharging, in multiscale models warrants further study. Development of multiscale models that account for all the known interactions would improve confidence in the use of simulations to explore design options, decrease the number of pilot-scale experiments, and accelerate commercialization of new technologies.

On the Electron-Transfer Mechanism in the Contact-Electrification Effect

A long debate on the charge identity and the associated mechanisms occurring in contact-electrification (CE) (or triboelectrification) has persisted for many decades, while a conclusive model has not yet been reached for explaining this phenomenon known for more than 2600 years! Here, a new method is reported to quantitatively investigate real-time charge transfer in CE via triboelectric nanogenerator as a function of temperature, which reveals that electron transfer is the dominant process for CE between two inorganic solids. A study on the surface charge density evolution with time at various high temperatures is consistent with the electron thermionic emission theory for triboelectric pairs composed of Ti-SiO₂ and Ti-Al₂ O₃ . Moreover, it is found that a potential barrier exists at the surface that prevents the charges generated by CE from flowing back to the solid where they are escaping from the surface after the contacting. This pinpoints the main reason why the charges generated in CE are readily retained by the material as electrostatic charges for hours at room temperature. Furthermore, an electron-cloud-potential-well model is proposed based on the electron-emission-dominatedcharge-transfer mechanism, which can be generally applied to explain all types of CE in conventional materials.

Reversible and Continuously Tunable Control of Charge of Close Surfaces

Surfaces of almost all types of materials are often charged easily by contact electrification or deposition of ions; hence, surface charge is ubiquitous and has a vast range of influences in our lives and in industry. Since the 19th century, scientists have been measuring the charge of multiple materials collectively. The common expectation is that the total charge of multiple materials is equal to the sum of the charges of the individual materials. This study describes a previously unreported phenomenon in which the total charge of two insulating surfaces decreases when the surfaces are brought close to each other. The charge varies continuously and reversibly depending on the distance of separation between the surfaces. Experimental results derived from analyzing the movement of charge suggest that the changes are due to a rapid exchange of charge between the surfaces and their surrounding air. This change can be used to control the surface charge of the materials flexibly and reversibly.