A review of bulk powder caking

Stearic Acid as Polymerization Medium, Dopant and Hydrophobizer: Chemical Oxidative Polymerization of Pyrrole

In recent years, fatty acids have garnered significant attention as a natural phase-change material and a hydrophobizer due to their biocompatibility and biodegradability. In this study, the utilization of fatty acid is proposed as a polymerization medium for the first time. As a specific reaction, chemical oxidative polymerizations of pyrrole is conducted using ferric chloride as an oxidant in a stearic acid medium. The polymerizations resulted in the production of micrometer-sized polypyrrole (PPy) grains, which are aggregates of atypical primary particles with submicrometer size. The PPy grains are doped with stearic acid, suggesting that the stearic acid functioned as a dopant and a hydrophobizing agent as well as a polymerization medium. The dried PPy grains can adsorb at the air-water interface and function as a liquid marble stabilizer with light-to-heat photothermal properties. The liquid marble can move on a planar air-water interface by Marangoni flow induced by NIR laser light irradiation.

Use of dairy industry side-stream lactose for tablet manufacturing - proof of concept study

During recent years there have been shortages of certain drugs due to problems in raw material supply. These are often related to active ingredients but could also affect excipients. Lactose is one of the most used excipients in tableting and comes in two anomeric and several solid-state forms. The aim of this study was to utilize lactose from a dairy side-stream and compare it against a commercial reference in direct compression. This would be a sustainable option and would secure domestic availability during crises. Two types of lactose, spray-dried and freeze-dried, were evaluated. Lactose was mixed with microcrystalline cellulose in different ratios together with lubricant and glidant, and flowability and tabletability of the formulations was characterized. The fully amorphous and small particle-sized spray-dried lactose flowed inadequately but exhibited good tabletability. The larger particle-sized, freeze-dried lactose exhibited sufficient flow and better tabletability than the commercial reference. However, disintegration and drug release were slower when using the investigational lactose formulations. This was most likely due to remaining milk proteins, especially caseins, in the lactose. Overall, the investigational lactose provides promise for the use of such a side-stream product during crisis situations but enhancing their properties and/or purity would be needed.

Improving flow dynamics and storage longevity of a low-cost phosphorescent fingerprint powder

An inexpensive, commercially available doped strontium aluminate phosphor with long-lived afterglow was prepared as a luminescent fingerprint dusting powder suited for challenging, highly patterned substrates; however, prolonged exposure to humidity was found to reduce that powder's affinity for fingermarks. Here, an enhanced preparation for synthesizing that fingerprint dusting powder is presented that prevents powder aggregation and loss of function upon exposure to humid environments. This was achieved by introducing a flow regulator during synthesis: hydrophobic silica SIPERNAT® D10 or SIPERNAT® D17. Increasing the hydrophobicity of the powder prevents aggregation by inhibiting the uptake of water, thereby improving the material's flow dynamics and transfer behavior from brush to fingermark. The angle of repose and flow characteristics made by the modified powders were quantified, with excellent affinity for fingermarks observed, even after being stored under 85% (±5%) humidity for 4 weeks. A preliminary comparison of the performance of the modified hydrophobic powders relative to the unmodified precursor revealed that more of the SIPERNAT® treated powder typically adhered to fingermarks while simultaneously imparting less background development. In addition, fewer clumps of particulate were observed in the developed fingermarks after addition of a hydrophobic flow regulator. This technical report outlines the updated method for synthesizing the fingerprint powder, with summarized flow performance results, and a demonstration of the modified powder's affinity for simulated fingermark evidence.

Self-replicating segregation patterns in horizontally vibrated binary mixture of granules

Fluidized granular mixtures of various particle sizes exhibit intriguing patterns as different species segregate and condense. However, understanding the segregation dynamics is hindered by the inability to directly observe the time evolution of the internal structure. We discover self-replicating bands within a quasi-2D container subjected to horizontal agitation, resulting in steady surface waves. Through direct observation of surface flow and evolving internal structures, we reveal the crucial role of coupling among segregation, surface flow, and hysteresis in granular fluidity. We develop Bonhoeffer-van der Pol type equations grounded in experimental observations, reproducing complex band dynamics, such as replication, oscillation, and breathing. It suggests the similarity between pattern formation in granular segregation and that in reaction-diffusion systems.

Micro computed tomography images of capillary actions in rough and irregular granular materials

The present work investigates the effect of both surface roughness and particle morphology on the retention behaviour of granular materials via X-ray micro-computed tomography (µCT) observations. X-ray µCT images were taken on two types of spherical glass beads (i.e. smooth and rough) and two different sands (i.e. natural and roughened). Each sample was subjected to drainage and soaking paths consisting in a multiphase 'static' flow of potassium iodine (KI) brine (wetting phase) and dry air (non-wetting phase). Tomograms were obtained at different saturation states ranging from fully brine saturated to air dry conditions with 6.2 μm voxel size resolution. The data acquisition and pre-processing are here described while all data, a total of 48 tomograms, are made publicly available. The combined dataset offers new opportunities to study the influence of surface roughness and particle morphology on capillary actions as well as supporting validation of pore-scale models of multiphase flow in granular materials.

Effect of the Molecular Weight of Polyelectrolyte and Surfactant Chain Length on the Solid-Phase Molecular Self-Assembly

Solid-phase molecular self-assembly (SPMSA) is emerging as an efficient approach, leading to scale-span self-assembled supramolecular films. With SPMSA, freestanding macroscopic supramolecular films can be formed upon mechanically pressing the precipitates formed with polyelectrolytes and oppositely charged surfactants. Herein, we report that the film formation ability and the mechanical strength of the resultant film depend highly on the surfactant chain lengths and the molecular weight of polyelectrolytes. A coarse-grained molecular dynamics study revealed that the longer surfactant chains are beneficial for the ordered assembly of surfactant bilayers in the film, whereas the larger molecular weight of PE favors the enhanced mechanical strength of the film by promoting the long-range order of the surfactant bilayers. The current results disclosed the physical insight of the surfactant chain length and the molecular weight of polyelectrolytes into the film structure and mechanical strength, which is of practical importance in guiding the creation of SPMSA materials.

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.

A step closer to continuous buffer preparation from solids: Predicting powder compaction and how to prevent it

The preparation of buffer solutions used in the biopharmaceutical industry is typically performed manually by the addition of one or multiple buffering reagents to water. Recently, the adaptation of powder feeders for continuous solid feeding was demonstrated for continuous buffer preparation. However, the intrinsic characteristics of powders can change the stability of the process, due to the hygroscopic nature of some substances and humidity induced caking and compaction behavior, but there is no simple and easy methodology available predicting this behavior for buffer species. To predict which buffering reagents are suitable without special precautions and investigate their behavior, force displacement measurements were conducted with a customized rheometer over 18hours. While most of the eight investigated buffering reagents indicated uniform compaction, especially sodium acetate and dipotassium hydrogen phosphate (K₂HPO₄) showed a significant increase in yield stress after 2hours. Experiments conducted with a 3D printed miniaturized screw conveyor confirmed the increased yield stress measurement by visible compaction and failure of the feeding. By taking additional precautions and adjusting the design of the hopper, we demonstrated a highly linear profile of all buffering reagents over a duration of 12 and 24hours. We showed that force displacement measurements accurately predict the behavior of buffer components in continuous feeding devices for continuous buffer preparation and are a valuable tool to identify buffer components that need special precautions. Stable, precise feeding of all tested buffer components was demonstrated, showing the importance of identifying buffers that need a specialized setup with a fast methodology.

Rapidly evaluating the caking tendency of sugar alcohols by developing a crystal bridge growth model: A case study of xylitol

Caking of crystalline sugar alcohols is a deleterious and undesired agglomeration process during storage in the food industry. Compared with the time-consuming and labor-intensive conventional caking assessment methods, this work develops a rapid methodology for evaluation of the critical caking cycle of xylitol with over 85% time-saving and 90% labor-saving while guaranteeing the precision accuracy. By developing a Caking-Hygroscopicity-Particle size crystal bridge growth model, the correlation and quantitative relationships among hygroscopic properties, particle size and the critical caking cycle are firstly established and confirmed, which can greatly simplify the most time-consuming and laborious experiments of water sorption measurements and caking tests. Besides, the knowledge obtained can help guide the rapid selection of storage humidity conditions and appropriate particle size distributions for maintaining the desired properties and competitive marketability of crystalline sugar alcohols.

Finite Element Analysis of Extrinsic Parameters on the Onset of Tensile Strength in Powders

Most food, pharmaceutical, and chemical industries rely heavily on the supply of free-flowing powders that finds their application in raw materials, additives, and manufactured products. Improper storage conditions combined with environmental factors affect the free-flowing ability of powders. An undesirable transformation of these free-flowing powders into a coherent mass that resists flow is called caking. An important metric that can be used to measure the caking propensity of a material is the tensile strength, which is essentially the resistant stress needed to separate two layers of materials using an isostatic tensile strain. Even though several models have quantified the propensity of caking, the complex nature of interactions between the powder and its micro-environment makes the prediction of caking a challenging task. In the present work, the onset of tensile strength in isomalt with changes in temperature, relative humidity, and consolidation pressures using a shear cell was modeled using a finite element approach. The study found that at a consolidation pressure of 3 kPa and relative humidity of 85±0.1%, an increase in temperature by 5˚C increased the tensile strength of isomalt by a factor of 2. On the other hand, at a constant temperature of 25˚C, an increase in relative humidity from 85±0.1% to 86±0.1% registered an increase in tensile strength by 42.7%. This study also found that an increase in consolidation pressure from 3 kPa to 6 and 9 kPa increased the tensile strength by a factor of 1.79 and 2.54, respectively. The model had good agreement with the measurements and had an overall MAPE of 12.13%. This model can be applied to study the influence of extrinsic parameters on the propensity of caking during storage of bulk solids.

Impurities of natural salts of the earth

In this study, 18 different samples of unrefined coarse food salt were examined using inductively coupled plasma mass spectrometry and Fourier transform infrared spectroscopy. Additionally, microphotographs were taken to determine the visual distribution of the impurities in the salt samples. None of the salt samples analysed contained arsenic, mercury, tin, and antimony. Cadmium, chromium, nickel, lead, barium, lithium, aluminium, titanium, vanadium, cobalt, cupper, iron, zinc, manganese, magnesium, and calcium were determined in some salt samples. According to the results of FTIR analysis mainly polyamide polymer derivatives were found in Himalaya White, Himalaya, Klodawa, Nakhchivan, Delice, Guérande Flake, Guérande Celtic, Maldon, Havaii Black, Havaii Green, Havaii Red, Maras, and İzmir salts.

Evaluation of Time Consolidation Effect of Pharmaceutical Powders

PURPOSE

We aim to perform a systematic study of the time consolidation effect, i.e. the reduction of powder flowability resulting from at-rest storage, on a diverse array of pharmaceutical powders under different stress, humidity, and length of time.

METHODS

A ring shear cell-based methodology was employed. An instantaneous flow function was obtained, followed immediately by at-rest consolidation at precisely controlled humidity, stress, and duration. The consolidated powder was then subjected to shear-cell measurement. The difference in flowability between the immediate and consolidated specimens were attributed to the time consolidation effect.

RESULTS

Among the six excipients tested, three exhibited time consolidation at varying extents. Citric acid and starch underwent time consolidation only at high relative humidity (RH = 75%), promoted by vapor condensation and liquid bridge formation. For both materials, the flowability decreased with time, and the extent of time consolidation was not sensitive to the stress applied (0.4-2 kPa). Importantly, mannitol was found to time consolidate under both 50% and 75% RH. Given time, mannitol formed cake, giving rise to flow function below unity. Inverse gas chromatography analysis indicated that mannitol possesses high total surface energy among known pharmaceutical powders.

CONCLUSION

While time consolidation is prevalent among pharmaceutical powders, most can be mitigated by controlling the RH to below 75%. Notably, for materials possessing high surface energy, such as mannitol, time consolidation could occur at ambient humidity. Therefore, it is desirable to consider in-depth time consolidation evaluation for high surface energy powders, e.g. those subjected to milling or of amorphous nature.

Oxidative stability and sensory evaluation of sodium caseinate-based yak butter powder

Yak butter's high unsaturated fatty acid level predisposes it to oxidation, hence must be converted into more stable forms like powder. This study aimed to spray dry yak butter using 10% yak butter and four sodium caseinate (NaCas) formulations: sample A: 100% NaCas; sample B: 50% NaCas, 50% lactose; sample C: 75% NaCas, 25% lactose; and sample D: 25% NaCas, 75% maltodextrin. The powders were vacuum and hermetically sealed, and evaluated for oxidative stability, physical and sensory properties during storage at 65 ℃ for 30 days. The results showed that samples B and D had similar and most favorable physical properties (such as, moisture, water activity, particle size, bulk density re-dispersion time, and encapsulation efficiency); though sample B, together with sample C, browned the most during storage. The majority of the sensory panelists preferred samples B and D; observed high caking in samples C and B; and the least whiteness loss and caking in samples D and A but high off-flavors in samples A and C. After storage, peroxide and thiobarbituric acid values of powder samples ranged from 34.98 to 69.54 meqO2/kg and 1.85-9.43 mg MD/kg, respectively, in the decreasing order of A, C, B, and D. Sample D, followed by B, showed the highest radical scavenging activity. Therefore, for optimum yak butter powder physical properties and oxidative stability, 50%:50%, NaCas: lactose, and 25%:75%, NaCas: maltodextrin formulations should be used. This study provides essential knowledge for butter powder processors.

The effect of high relative humidity on a network of water-sensitive particles (couscous) as revealed by in situ X-ray tomography

Water significantly influences the mechanical behaviour of all granular materials but none as much as hygroscopic amorphous particles. With sufficiently high water content, particles can swell, agglomerate and their mechanical properties can be reduced, having direct effects on the macroscopic response of the material. In the food and pharmaceutical industry this can cause loss of product functionality. Despite their relevance, very little is known about the microscopic processes that induce these phenomena. Previous studies focused on single particle behaviour, the strength of agglomerated particles and the material flowability, leaving unexplored the link connecting the particle behaviour and the bulk response. This experimental study aims to investigate this aspect with quantitative measurements at both particle and macroscopic scales. A sample of fine couscous is exposed to a high relative humidity (RH) air flow, while being subjected to oedometric conditions, in order to reproduce the storage-silo conditions. In the meantime, X-ray tomographies are acquired continuously and the resulting images are analysed. The designed spatial resolution allows each particle of the sample to be identified and tracked, allowing volumetric evolution to be compared to the properties of the whole sample. The analysis reveals a dilation-compaction macroscopic behaviour, a result of the competition between the particle swelling and the higher deformability as the water content increases. The number, orientations and inter-particle contacts are computed. Their area is related to the applied boundary conditions, and is found to be consistent with the particle swelling and dependent on the applied stress direction.

Data-driven approach to mitigate quality impact of hygroscopic pharmaceutical raw materials throughout the supply chain

The challenges of working with hygroscopic pharmaceutical raw materials can have a significant impact on the industry's ability to make high-quality medicines. In order to mitigate the impact to the manufacturing process or product quality it is critical to understand the hygroscopicity of the raw materials across the entire supply chain so that the proper management strategies can be implemented, from the raw material manufacturing to the use of the raw material in the drug manufacturing process. Employing suitable controls protects these materials from physical and chemical changes due to moisture uptake such as caking or hydrolysis. We have developed a fit for purpose and data-driven approach to hygroscopicity classifications of over 200 commonly used chemicals, excipients, media and resins in drug manufacturing processes. Dynamic vapor sorption data is presented with supporting thermal gravimetric analysis and X-ray powder diffraction data where pertinent. Approximately 60% of all raw materials tested were determined to be hygroscopic. Strategies for applying this data to reduce the potential impact of hygroscopic materials on the manufacturing of pharmaceuticals are discussed with examples.

Investigation of the flowability, thermal stability and emulsification properties of two milk protein concentrates having different levels of native whey proteins

Milk protein concentrate-85 (MPC85) is a dairy ingredient which has a diverse range of applications in food products. The technofunctional properties of two MPC85 samples having similar gross composition but different levels of native whey protein (WP), i.e., MPC85S1 and MPC85S2 with 16.6 and 6.0 g native WP/100 g protein, respectively, were compared. Rheometeric analysis showed that under an applied normal stress of 1.0-15.0 kPa, the compressibility, the air permeability and the cohesiveness of MPC85S2 was higher compared to MPC85S1. Differential scanning calorimetry showed that protein denaturation in MPC85S1 began at 63 °C while for MPC85S2 it began at 70 °C. The heat coagulation time (HCT at 140 °C) for 4.2% (w/v, on a protein basis) reconstituted MPC85S1 and MPC85S2 was 2.2 and 2.7 min, respectively. While a higher lightness for MPC85S1 was evidenced using colourimeter analysis, the colour stability on oven drying at 95 °C for MPC85S2 was higher than MPC85S1. The emulsion produced with MPC85S1 flocculated after 1 d and phase separation occurred after 14 d. In the case of MPC85S2, flocculation began after 4 d while phase separation was observed at 33 d. The viscosity of MPC85S2 (4.2% (w/v) protein) was higher than MPC85S1. This study showed differences between the flowability, viscosity, colour properties, thermal stability (in powder and in reconstituted format), emulsification and buffering capacity for MPC samples having two different levels of WP denaturation. The results demonstrated that the MPCs studied having two different levels of WP denaturation could be targeted for different functional applications. The minimal/maximum level of denaturation required to induce technofunctional property differences requires further study.

Revisiting the Nature of Adsorption and Desorption Branches: Temperature Dependence of Adsorption Hysteresis in Ordered Mesoporous Silica

To gain a deeper understanding as to the nature of the adsorption hysteresis due to capillary condensation of nitrogen in ordered mesoporous silicas, we calculated the temperature dependences of the activated condensation, equilibrium transition, and activated desorption pressures for nitrogen in spherical and cylindrical silica pores with several different pore sizes on the basis of semimacroscopic continuum models. The results clearly indicate that the models capture the exact nature of capillary condensation and evaporation phenomena of a fluid in cagelike and cylindrical mesopores. The temperature dependences of the adsorption hysteresis of nitrogen measured confirm previous theoretical predictions for cylindrical pores: for the ordered mesoporous silicas with cylindrical mesopores at least greater than ∼7 nm in diameter, the capillary condensation takes place via a nucleation process followed by a growth process of a bridging meniscus at pressures higher than the equilibrium transition, while the capillary evaporation takes place via a receding meniscus from pore ends at the equilibrium. For SBA-15 and MCM-41 with smaller mesopore sizes, on the other hand, the capillary condensation takes place close to the equilibrium transition pressures, while the capillary evaporation takes place at pressures lower than the equilibrium, owing to single pore blocking due to corrugation of the cylindrical pores. We discuss the effect of curvature on surface tension in capillary condensation, as well as the relation between a change in the mechanisms of adsorption and desorption and the pore corrugation in the cylindrical pores.

Updating insights into the rehydration of dairy-based powder and the achievement of functionality

Dairy-based powder had considerable development in the recent decade. Meanwhile, the increased variety of dairy-based powder led to the complex difficulties of rehydrating dairy-based powder, which could be the poor wetting or dissolution of powder. To solve these various difficulties, previous studies investigated the rehydration of powder by mechanical and chemical methods on facilitating rehydration, while strategies were designed to improve the rate-limiting rehydration steps of different powder. In this review, special emphasis is paid to the surface and structure of the dairy-based powder, which was accountable for understanding rehydration and the rate-limiting step. Besides, the advantage and disadvantage of methods employed in rehydration were described and compared. The achievement of the powder functionality was finally discussed and correlated with the rehydration methods. It was found that the surface and structure of dairy-based powder were decided by the components and production of powder. Post-drying methods like agglomeration and coating can tailor the surface and structure of powder afterwards to obtain better rehydration. The merit of the mechanical method is that it can be applied to rehydrate dairy-based powder without any addition of chemicals. Regarding chemical methods, calcium chelation is proved to be an effective chemical in rehydration casein-based powder.

Modeling Food Particle Systems: A Review of Current Progress and Challenges

For many years, food engineers have attempted to describe physical phenomena such as heat and mass transfer in food via mathematical models. Still, the impact and benefits of computer-aided engineering are less established in food than in most other industries today. Complexity in the structure and composition of food matrices are largely responsible for this gap. During processing of food, its temperature, moisture, and structure can change continuously, along with its physical properties. We summarize the knowledge foundation, recent progress, and remaining limitations in modeling food particle systems in four relevant areas: flowability, size reduction, drying, and granulation and agglomeration. Our goal is to enable researchers in academia and industry dealing with food powders to identify approaches to address their challenges with adequate model systems or through structural and compositional simplifications. With advances in computer simulation capacity, detailed particle-scale models are now available for many applications. Here, we discuss aspects that require further attention, especially related to physics-based contact models for discrete-element models of food particle systems.

Application of void forming index (VFI): Detection of the effect of physical properties of dry powder inhaler formulations on powder cohesion

Dry powder inhaler (DPI) is an attractive alternative for non-invasive drug administration and can make the use of critical biopharmaceutical formulations more convenient for patients. Inhalation of biopharmaceutical formulations can provide targeted delivery to the lungs as well as systemic delivery. Generally, biopharmaceutical DPI formulations consist of highly cohesive powders that tend to agglomerate. For successful delivery to the lungs, the detection of powder cohesiveness and its effect on the performance of the formulations is mandatory. Herein, the effects of the physical properties of mannitol on the cohesiveness of DPI formulations were investigated. The powder cohesion was detected using the void forming index (VFI) measured by inverse gas chromatography (iGC) at 4 h (VFI_4h), which was defined as the pressure drop ratio of 4 h purged sample to that of the initial sample. VFI_4h was found to correlate well with the cohesiveness of DPI formulations. The amount of investigated samples required for VFI measurement was less than that required for conventional measurements. VFI showed a good relationship between the cohesiveness of DPI formulations and the physical properties of mannitol. Thus, VFI can be a reliable standard index to evaluate the cohesiveness of DPI formulations.

Bulk and Surface Wettability Characteristics of Probiotic Powders in Their Compressed Disc and Packed-Bed Column Forms

Most probiotic-based products are available in powder particles under different solid-state forms. Such diversity can affect the probiotic stability, viability, and performance at different stages of processing, storage, and use. Here, we apply complementary physical chemistry techniques to characterize the bulk and surface properties of probiotic powder particles under different forms and report quantitative results of a highly concentrated multistrain reference product. The solid particle morphology, size/shape distribution, and the powder surface wettability in the compressed disc and porous packed bed forms are successively measured by sessile drop and capillary rise techniques. A complete wettability of the disc surface is observed through equilibrium contact angle measurements for various solvents, whereas the associated capillary rise data exhibit two regimes: a power law regime for the first few moments followed by a second regime, which can be described using Darcy's law. The use of this modeling approach shows the possibility of assessing the particle-packed bed permeability and porosity. These results open a new route of the structure-activity relationship study on the impact of probiotic solid particles on their functionalities and performance in promoting health benefits, related particularly to the human and animal gut permeability. This statement also strengthens the idea of using the compressed disc technique for easily performing probiotic wettability measurements.