A dimensional analysis approach for modelling the size of droplets formed by bi-fluid atomisation

Development of a Semi-Empirical Model for Droplet Size Determination of a Three-Channel Spray Nozzle for Pellet Coating Based on the Optical Method Concept

The purpose of this study was to investigate the droplet size obtained with a three-channel spray nozzle typically used in fluid bed devices and to construct a semi-empirical model for prediction of droplet size. With the aid of a custom-made optical method concept, the impact of the type of polymer and solvents used through dispersion properties (viscosity, density, and surface tension), dispersion flow rate, atomization pressure, and microclimate pressure on droplet size was investigated. A semi-empirical model with adequate predictability for calculating the average droplet size (R2 = 0.90, Q2 = 0.73) and its distribution (R2 = 0.84, Q2 = 0.61) was constructed by employing dimensional analysis and design of experiments. Newtonian and non-Newtonian dispersion and process parameters on laboratory and on production scale were included, thereby enabling constant droplet size irrespective of the scale. Based on the model results, it would be possible to scale-up the atomization process (e.g., coating process) from laboratory to production scale in a systematic fashion, regardless of the type of solvent or polymer used. For the system investigated, this can be performed by understanding the dispersion properties, such as viscosity, density, and surface tension, as well as the following process parameters: dispersion flow rate, atomization, and microclimate pressure.

Challenges associated with spray drying of lactic acid bacteria: Understanding cell viability loss

Lactic acid bacteria (LAB) cultures used in food fermentation are often dried to reduce transportation costs and facilitate handling during use. Dried LAB ferments are generally lyophilized to ensure high cell viability. Spray drying has come to the forefront as a promising technique due to its versatility and lower associated energy costs. Adverse conditions during spray drying, such as mechanical stress, dehydration, heating, and oxygen exposure, can lead to low LAB cell viability. This reduced viability has limited spray drying's industrial applications thus far. This review aims to demonstrate the operations and thermodynamic principles that govern spray drying, then correlate them to the damage suffered by LAB cells during the spray-drying process. The particularities of spray drying that might cause LAB cell death are detailed in this review, and the conclusion may enhance future studies on ways to improve cell viability.

Comparison of a Novel Miniaturized Screening Device with Büchi B290 Mini Spray-Dryer for the Development of Spray-Dried Solid Dispersions (SDSDs)

Spray-drying is an increasingly popular technology for the production of amorphous solid dispersions (ASDs) in the pharmaceutical industry that is used in the early evaluation and industrial production of formulations. Efficient screening of ASD in the earliest phase of drug development is therefore critical. A novel miniaturized atomization equipment for screening spray-dried solid dispersions (SDSDs) in early formulation and process development was developed. An in-depth comparison between the equipment/process parameters and performance of our novel screening device and a laboratory Büchi B290 mini spray-dryer was performed. Equipment qualification was conducted by comparing the particle/powder attributes, i.e., miscibility/solid state, residual solvent, and morphological properties of binary SDSDs of itraconazole prepared at both screening and laboratory scales. The operating mode of the miniaturized device was able to reproduce similar process conditions/parameters (e.g., outlet temperature (Tout)) and to provide particles with similar drug–polymer miscibility and morphology as laboratory-scale SDSDs. These findings confirm that the design and operation of this novel screening equipment mimic the microscale evaporation mechanism of a larger spray-dryer. The miniaturized spray-dryer was therefore able to provide a rational prediction of adequate polymer and drug loading (DL) for SDSD development while reducing active pharmaceutical ingredient (API) consumption by a factor of 120 and cycle time by a factor of 4.