1
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Flügel K, Wiedey R, Riehl C, Kaminski I, Riehl M. Genesis, mechanism, and avoidance of cosmetic coating defects - An industrial case study. Int J Pharm 2024; 655:124008. [PMID: 38493837 DOI: 10.1016/j.ijpharm.2024.124008] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/06/2023] [Revised: 03/12/2024] [Accepted: 03/14/2024] [Indexed: 03/19/2024]
Abstract
Film-coated tablets as solid oral dosage forms are a well-accepted way of administering drugs but are not without specific challenges during manufacturing. One relevant criterion of the final product is the visual integrity and therewith, the absence of cosmetic optical defects such as edge chipping. The aim of the present study was to examine the origin of those edge chipping defects, which were observed during commercial manufacturing of film-coated tablets, and to provide recommendations for process optimization to reduce the defect occurrence. The unraveling of the herein described phenomenon necessitated an interplay of in-depth material characterization, discrete element modeling (DEM) as well as an in-house developed optical measurement system for the automated quantification of tablet defects. As a result of this investigation, the automatic unloading step after the tablet coating process was identified as the most critical step for the occurrence of chipping defects and a replacement by manual unloading was proposed to reduce the defect propensity. The recommended optimization was subsequently confirmed in several manufacturing runs and a reduction of defect propensity by a factor of 5 was observed, highlighting the relevance and the impact of the performed thorough investigation.
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Affiliation(s)
- Karsten Flügel
- Global CMC Development, Merck Healthcare KGaA, Darmstadt, Germany
| | - Raphael Wiedey
- Global CMC Development, Merck Healthcare KGaA, Darmstadt, Germany
| | - Carolin Riehl
- Global CMC Development, Merck Healthcare KGaA, Darmstadt, Germany
| | - Ingo Kaminski
- Global CMC Development, Merck Healthcare KGaA, Darmstadt, Germany
| | - Markus Riehl
- Global CMC Development, Merck Healthcare KGaA, Darmstadt, Germany.
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2
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Dan A, Vaswani H, Šimonová A, Ramachandran R. Multi-dimensional population balance model development using a breakage mode probability kernel for prediction of multiple granule attributes. Pharm Dev Technol 2023; 28:638-649. [PMID: 37410512 DOI: 10.1080/10837450.2023.2231074] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/04/2023] [Revised: 06/20/2023] [Accepted: 06/26/2023] [Indexed: 07/07/2023]
Abstract
Milling affects not only particle size distributions but also other important granule quality attributes, such as API content and porosity, which can have a significant impact on the quality of the final drug form. The ability to understand and predict the effects of milling conditions on these attributes is crucial. A hybrid population balance model (PBM) was developed to model the Comil, which was validated using experimental results with an R2 of above 0.9. This presented model is dependent on the process conditions, material properties and equipment geometry, such as the classification screen size. In order to incorporate the effects of different quality attributes in the model physics, the dimensionality of the PBM was increased to account for changes in API content and porosity, which also produced predictions for these attributes in the results. Additionally, a breakage mode probability kernel was used to introduce dynamic breakage modes by predicting the probability of attrition and impact mode, which are dependent on the process conditions and feed properties at each timestep.
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Affiliation(s)
- Ashley Dan
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ, USA
| | - Haresh Vaswani
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ, USA
| | - Alice Šimonová
- Department of Analytical Chemistry, Charles University, Prague, Czech Republic
| | - Rohit Ramachandran
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ, USA
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3
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Yin Z, Wang N, Li T, Peng Y. Experimental investigation of the impact breakage characteristics between grinding media and iron ore particle in ball mills. ADV POWDER TECHNOL 2023. [DOI: 10.1016/j.apt.2023.103982] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/27/2023]
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4
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Muanpaopong N, Davé R, Bilgili E. A comparative analysis of steel and alumina balls in fine milling of cement clinker via PBM and DEM. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118454] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/17/2023]
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5
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Iyer J, Brunsteiner M, Modhave D, Paudel A. Role of Crystal Disorder and Mechanoactivation in Solid-State Stability of Pharmaceuticals. J Pharm Sci 2023; 112:1539-1565. [PMID: 36842482 DOI: 10.1016/j.xphs.2023.02.019] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/23/2023] [Revised: 02/20/2023] [Accepted: 02/20/2023] [Indexed: 02/28/2023]
Abstract
Common energy-intensive processes applied in oral solid dosage development, such as milling, sieving, blending, compaction, etc. generate particles with surface and bulk crystal disorder. An intriguing aspect of the generated crystal disorder is its evolution and repercussion on the physical- and chemical stabilities of drugs. In this review, we firstly examine the existing literature on crystal disorder and its implications on solid-state stability of pharmaceuticals. Secondly, we discuss the key aspects related to the generation and evolution of crystal disorder, dynamics of the disordered/amorphous phase, analytical techniques to measure/quantify them, and approaches to model the disordering propensity from first principles. The main objective of this compilation is to provide special impetus to predict or model the chemical degradation(s) resulting from processing-induced manifestation in bulk solid manufacturing. Finally, a generic workflow is proposed that can be useful to investigate the relevance of crystal disorder on the degradation of pharmaceuticals during stability studies. The present review will cater to the requirements for developing physically- and chemically stable drugs, thereby enabling early and rational decision-making during candidate screening and in assessing degradation risks associated with formulations and processing.
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Affiliation(s)
- Jayant Iyer
- Research Center Pharmaceutical Engineering GmbH (RCPE), Graz, Austria
| | | | - Dattatray Modhave
- Research Center Pharmaceutical Engineering GmbH (RCPE), Graz, Austria
| | - Amrit Paudel
- Research Center Pharmaceutical Engineering GmbH (RCPE), Graz, Austria; Graz University of Technology, Institute of Process and Particle Engineering, Graz Austria.
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6
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Wang Z, Li H, Wang H, Chen H, Xiao J. Quantitative evaluation of energy efficiency for steel slag comminution in a fluidized bed opposed jet mill. PARTICULATE SCIENCE AND TECHNOLOGY 2023. [DOI: 10.1080/02726351.2022.2163946] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/05/2023]
Affiliation(s)
- Zhe Wang
- School of Environment and Resource, Southwest University of Science and Technology, Mianyang, China
| | - Hong Li
- School of Environment and Resource, Southwest University of Science and Technology, Mianyang, China
- Key Laboratory of Solid Waste Treatment and Resource Recycle, Ministry of Education, Southwest University of Science and Technology, Mianyang, China
- Sichuan Provincial Engineering Lab of Non-Metallic Mineral Powder Modification and High-Value Utilization, Southwest University of Science and Technology, Mianyang, China
| | - Huan Wang
- School of Environment and Resource, Southwest University of Science and Technology, Mianyang, China
| | - Haiyan Chen
- School of Environment and Resource, Southwest University of Science and Technology, Mianyang, China
- Key Laboratory of Solid Waste Treatment and Resource Recycle, Ministry of Education, Southwest University of Science and Technology, Mianyang, China
- Sichuan Provincial Engineering Lab of Non-Metallic Mineral Powder Modification and High-Value Utilization, Southwest University of Science and Technology, Mianyang, China
| | - Junhui Xiao
- School of Environment and Resource, Southwest University of Science and Technology, Mianyang, China
- Key Laboratory of Solid Waste Treatment and Resource Recycle, Ministry of Education, Southwest University of Science and Technology, Mianyang, China
- Sichuan Provincial Engineering Lab of Non-Metallic Mineral Powder Modification and High-Value Utilization, Southwest University of Science and Technology, Mianyang, China
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7
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Ge Wang L, Smith R, Litster JD. A Novel Oblique Impact Model for Unified Particle Breakage Master Curve. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.118397] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
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8
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Simplifying Population Balance Models to Promote Broader Use in Industry. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.12.002] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
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9
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Dan A, Kotamarthy L, Ramachandran R. Understanding the effects of process parameters and material properties on the breakage mechanisms and regimes of a milling process. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.10.015] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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10
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Yang Q, Liu N, Yin J, Tian H, Yang Y, Ren TL. Understanding the Origin of Tensile Response in a Graphene Textile Strain Sensor with Negative Differential Resistance. ACS NANO 2022; 16:14230-14238. [PMID: 36094408 DOI: 10.1021/acsnano.2c04348] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/15/2023]
Abstract
The flexible strain sensors based on the textile substrate have natural flexibility, high sensitivity, and wide-range tensile response. However, the textile's complex and anisotropic substructure leads to a negative differential resistance (NDR) response, lacking a deeper understanding of the mechanism. Therefore, we examined a graphene textile strain sensor with a conspicuous NDR tensile response, providing a requisite research platform for mechanism investigation. The pioneering measurement of single fiber bundles confirmed the existence of the NDR effect on the subgeometry scale. Based on the in situ characterization of tensile morphology and measurement, we conducted quantitative behavior analyses to reveal the origin of tensile electrical responses in the full range comprehensively. The results showed that the dominant factor in generating the NDR effect is the relative displacement of fibers within the textile bundles. Based on the neural spiking-like tensile response, we further demonstrated the application potential of the textile strain sensor in threshold detection and near-sensor signal processing. The proposed NDR behavior model would provide a reference for the design and application of wearable intelligent textiles.
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Affiliation(s)
- Qisheng Yang
- School of Integrated Circuits & Beijing National Research on Information Science and Technology (BNRist), Tsinghua University, Beijing 100084, China
| | - Ning Liu
- School of Integrated Circuits & Beijing National Research on Information Science and Technology (BNRist), Tsinghua University, Beijing 100084, China
| | - Jiaju Yin
- School of Integrated Circuits & Beijing National Research on Information Science and Technology (BNRist), Tsinghua University, Beijing 100084, China
- School of Aerospace Engineering, Tsinghua University, Beijing 100084, China
| | - He Tian
- School of Integrated Circuits & Beijing National Research on Information Science and Technology (BNRist), Tsinghua University, Beijing 100084, China
| | - Yi Yang
- School of Integrated Circuits & Beijing National Research on Information Science and Technology (BNRist), Tsinghua University, Beijing 100084, China
| | - Tian-Ling Ren
- School of Integrated Circuits & Beijing National Research on Information Science and Technology (BNRist), Tsinghua University, Beijing 100084, China
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11
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Tian Y, Wang S, Yu Y, Sun W, Fan R, Shi J, Gu W, Wang Z, Zhang H, Zheng A. Review of nanosuspension formulation and process analysis in wet media milling using microhydrodynamic model and emerging characterization methods. Int J Pharm 2022; 623:121862. [PMID: 35671851 DOI: 10.1016/j.ijpharm.2022.121862] [Citation(s) in RCA: 9] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/19/2022] [Revised: 05/04/2022] [Accepted: 05/23/2022] [Indexed: 11/18/2022]
Abstract
Wet media milling is a popular technology used to prepare nanosuspensions. However, the theories and methods to guide the research on the formulation and process affecting wet media milling remain limited. The research on wet media milling follows a "black box" approach to a certain extent. This review focuses on exploring the formulation and process parameters factors in wet media milling. The formulation factors include the concentration, hydrophilicity/hydrophobicity, and structure of the drug and stabilizer, whereas the milling process parameters include the milling speed, milling time, and material, size, and filling volume of milling beads. Contrary to other reviews, this review attempts to quantify and visualize these factors by combining a microhydrodynamic model with emerging characterization methods to provide a scientific basis for the selection of nanosuspension formulations and process parameters, as opposed to the conventional trial-and-error approach.
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Affiliation(s)
- Yang Tian
- Institute of Pharmacology and Toxicology, Academy of Military Medical Sciences, Academy of Military Sciences, Beijing 100850, China
| | - Shanshan Wang
- Tianjin University of Science and Technology, Tianjin 300457, China
| | - Yao Yu
- Pharmaceutical Experiment Center, College of Pharmacy, Yanbian University, Yanji 133002, China
| | - Wenjun Sun
- Institute of Pharmacology and Toxicology, Academy of Military Medical Sciences, Academy of Military Sciences, Beijing 100850, China
| | - Ranran Fan
- Bengbu Medical College, Anhui 233003, China
| | - Junfeng Shi
- School of Pharmaceutical Sciences, South-Central University for Nationalities, Wuhan 430074, China
| | - Weinan Gu
- School of pharmacy, XuZhou Medical University, XuZhou 221004, China
| | - Zengming Wang
- Institute of Pharmacology and Toxicology, Academy of Military Medical Sciences, Academy of Military Sciences, Beijing 100850, China
| | - Hui Zhang
- Institute of Pharmacology and Toxicology, Academy of Military Medical Sciences, Academy of Military Sciences, Beijing 100850, China.
| | - Aiping Zheng
- Institute of Pharmacology and Toxicology, Academy of Military Medical Sciences, Academy of Military Sciences, Beijing 100850, China.
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12
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Baraldi L, De Angelis D, Bosi R, Pennini R, Bassanetti I, Benassi A, Bellazzi GE. Mechanical Characterization of Pharmaceutical Powders by Nanoindentation and Correlation with Their Behavior during Grinding. Pharmaceutics 2022; 14:pharmaceutics14061146. [PMID: 35745719 PMCID: PMC9228926 DOI: 10.3390/pharmaceutics14061146] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/05/2022] [Revised: 05/17/2022] [Accepted: 05/25/2022] [Indexed: 01/27/2023] Open
Abstract
Controlling the size of powder particles is pivotal in the design of many pharmaceutical forms and the related manufacturing processes and plants. One of the most common techniques for particle size reduction in the process industry is powder milling, whose efficiency relates to the mechanical properties of the powder particles themselves. In this work, we first characterize the elastic and plastic responses of different pharmaceutical powders by measuring their Young modulus, the hardness, and the brittleness index via nano-indentation. Subsequently, we analyze the behavior of those powder samples during comminution via jet mill in different process conditions. Finally, the correlation between the single particle mechanical properties and the milling process results is illustrated; the possibility to build a predictive model for powder grindability, based on nano-indentation data, is critically discussed.
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Affiliation(s)
- Laura Baraldi
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
| | - Davide De Angelis
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
| | - Roberto Bosi
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
| | - Roberto Pennini
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
| | - Irene Bassanetti
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
| | - Andrea Benassi
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
- Condensed Matter Theory Sector, International School for Advanced Studies (SISSA), Via Bonomea, 265, 34136 Trieste, Italy
| | - Guido Enrico Bellazzi
- Chiesi Farmaceutici S.p.A., Largo Belloli 11A, 43122 Parma, Italy; (L.B.); (D.D.A.); (R.B.); (R.P.); (I.B.); (A.B.)
- Correspondence: ; Tel.: +39-0521-1689463
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13
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Effects of bead packing limit concentration on microhydrodynamics-based prediction of breakage kinetics in wet stirred media milling. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117433] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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14
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Xue F, Gao F. Experimental investigation of energy efficiency of an air classifier mill pulverizing a raw material of aquafeed. PARTICULATE SCIENCE AND TECHNOLOGY 2022. [DOI: 10.1080/02726351.2021.1929605] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
Affiliation(s)
- Fei Xue
- R&D Department, Famsun Group Co., Ltd, Yangzhou, China
| | - Fei Gao
- R&D Department, Famsun Group Co., Ltd, Yangzhou, China
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15
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Bellinghausen S, Gavi E, Jerke L, Barrasso D, Salman AD, Litster JD. Model-driven design using population balance modelling for high-shear wet granulation. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.10.028] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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16
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Han Y, Zhao D, Chu Y, Zhen J, Li G, Zhao H, Jia F. Breakage behaviour of single rice particles under compression and impact. ADV POWDER TECHNOL 2021. [DOI: 10.1016/j.apt.2021.10.017] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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17
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Han Y, Li G, Jia F, Meng X, Chu Y, Chen P, Bai S, Zhao H. Analysis of breakage behavior of rice under impact. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.08.084] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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18
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19
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Konan NA, Huckaby ED. Multi-fidelity kinetic theory-based approach for the prediction of particle attrition: Application to jet cup attrition system. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.06.014] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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20
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Rácz Á, Csőke B. Comminution of single real waste particles in a swing-hammer shredder and axial gap rotary shear. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.05.064] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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21
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Cabiscol R, Finke JH, Kwade A. A bi-directional DEM-PBM coupling to evaluate chipping and abrasion of pharmaceutical tablets. ADV POWDER TECHNOL 2021. [DOI: 10.1016/j.apt.2021.06.002] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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22
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Wang LG, Ge R, Chen X, Zhou R, Chen HM. Multiscale digital twin for particle breakage in milling: From nanoindentation to population balance model. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.03.005] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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23
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Ketterhagen WR, Larson J, Spence K, Baird JA. Predictive Approach to Understand and Eliminate Tablet Breakage During Film Coating. AAPS PharmSciTech 2021; 22:178. [PMID: 34128124 DOI: 10.1208/s12249-021-02061-3] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/04/2021] [Accepted: 05/19/2021] [Indexed: 11/30/2022] Open
Abstract
Pharmaceutical tablets can be susceptible to damage such as edge chipping or erosion of the core during the tablet coating process. The intersection of certain process parameters, equipment design, and tablet properties may induce more significant tablet damage such as complete tablet fracture. In this work, a hybrid predictive approach was developed using discrete element method (DEM) modeling and lab-based tablet impact experiments to identify conditions that may lead to tablet breakage events. The approach was extended to examine potential modifications to the coating equipment and process conditions in silico to mitigate the likelihood of tablet breakage during future batches. The approach is shown to enhance process understanding, identify optimal process conditions within development constraints, and de-risk the manufacture of future tablet coating batches.
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24
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Soda R, Ishihara S, Kushimoto K, Kano J, Ozaki K. Single-particle crush test for ultrafine particles and direct numerical simulation of fracture process. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.02.023] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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25
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Böttcher AC, Thon C, Fragnière G, Chagas A, Schilde C, Kwade A. Rigidly-mounted roll mill as breakage tester for characterizing fine particle breakage. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.01.055] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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26
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Abstract
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.
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Affiliation(s)
- Lennart Fries
- Nestlé Research Lausanne, Vers-Chez-les-Blanc, 1000 Lausanne 26, Switzerland;
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27
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Bonakdar T, Ali M, Ghadiri M. Particle breakability assessment using an Aero S disperser. Int J Pharm 2021; 597:120365. [PMID: 33571623 DOI: 10.1016/j.ijpharm.2021.120365] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/26/2020] [Revised: 02/02/2021] [Accepted: 02/04/2021] [Indexed: 11/15/2022]
Abstract
Milling is widely used in various industries to tailor the particle size distribution for desired attributes. The ability to predict milling behaviour by testing the breakability of a small quantity of material is of great interest. In this paper, a widely available aerodynamic dispersion method, i.e. the Aero S disperser of Malvern Mastersizer 3000 has been evaluated for this purpose. This device is commonly used for dispersion of fine and cohesive powders, as the particles are accelerated and impacted at a bend, but here its use for assessing particle breakability is explored. The fluid flow field is modelled using one-way coupled Computational Fluid Dynamics approach, as the particle concentration is low, following which the particle impact velocity is calculated by Lagrangian tracking and used in the analysis of particle breakage. Experimental work on the breakability is carried out using aspirin, paracetamol, sucrose and α-lactose monohydrate particles. The relative shift in the specific surface area is determined and together with the calculated particle impact velocity and physical properties, they are used to calculate the breakability index. A good agreement is obtained with the single particle impact testing and aerodynamic dispersion by Scirocco disperser, indicating the breakability could also be inferred from this method.
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Affiliation(s)
- Tina Bonakdar
- School of Chemical and Process Science and Engineering, University of Leeds, Leeds LS2 9JT, UK
| | - Muzammil Ali
- School of Chemical and Process Science and Engineering, University of Leeds, Leeds LS2 9JT, UK
| | - Mojtaba Ghadiri
- School of Chemical and Process Science and Engineering, University of Leeds, Leeds LS2 9JT, UK.
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28
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Amini H, Akseli I. A Multi-variate Mathematical Model for Simulating the Granule Size Distribution in Roller Compaction-Milling Process. AAPS PharmSciTech 2021; 22:97. [PMID: 33694033 DOI: 10.1208/s12249-021-01955-6] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/30/2020] [Accepted: 02/09/2021] [Indexed: 11/30/2022] Open
Abstract
Granule size distribution (GSD) is one of the critical quality attributes in the roller compaction (RC) process. Determination of GSD for newly developed pharmaceutical compounds with unknown ribbon breakage behaviors at the RC milling step requires a quantitative insight into process parameters and ribbon attributes. Despite its pivotal role in mapping the process operating conditions to achieve desired granule size, limited work has been presented in literature with a focus on RC-milling modeling. In this study, a multi-variate mathematical model is presented to simulate the full size-distribution of granulated ribbons as a function of ribbon mechanical properties. Experimental data with a lab-scale oscillating milling apparatus were generated using ribbons made of various powder compositions. Model parameters were determined by fitting it to experimental data sets. Parameters obtained from the first step were correlated to ribbon Young's modulus. The model was validated by predicting GSD of data that were excluded in model development step. Predictive capabilities of the developed model were further explored by simulating GSD profiles of a granulated pharmaceutical excipient obtained at three different conditions of a real-scale Gerteis RC system. While maintaining the milling operating conditions similar to the lab-scale apparatus (i.e., screen size and spacing, and low rotor speed), the proposed modeling approach successfully predicted the GSD of roller compacted MCC powder as the model compound. This model can be alternatively utilized in conjunction with an RC model in order to facilitate the process understanding to obtain granule attributes as part of Quality-by-Design paradigm.
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Diemer RB. Applications of the Linear Mass-Sectional Breakage Population Balance to Various Milling Process Configurations. AAPS PharmSciTech 2021; 22:86. [PMID: 33655398 DOI: 10.1208/s12249-020-01834-6] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/30/2020] [Accepted: 09/25/2020] [Indexed: 11/30/2022] Open
Abstract
After an initial grounding discussion, in which the linear mass-sectional population balance is described, and models for reducing the number of its parameters are discussed, this modeling approach is applied to a wide range of processes including batch mills, single-pass continuous mills, mills in series, mills with recycle, milling circuits including classification, and recycled-batch milling. The linearity of the model allows its straightforward inclusion in calculations for all of these processes. The sensitivity of the model to its inputs (order of rate kernel in size, fragment distribution) is explored for batch operations. Then, the effects of key continuous process design variables are explored including the (a) number of mill passes in pendulum milling (mills in series), (b) classifier properties in circuits with classification, and (c) ratio of feed tank-to-mill residence time in recycled-batch operations.
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Chen Z, Wassgren C, Ambrose RK. Measured damage resistance of corn and wheat kernels to compression, friction, and repeated impacts. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.11.012] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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Reyes-Urrutia A, Soria J, Saffe A, Zambon M, Echegaray M, Suárez SG, Rodriguez R, Mazza G. Fluidization of biomass: a correlation to assess the minimum fluidization velocity considering the influence of the sphericity factor. PARTICULATE SCIENCE AND TECHNOLOGY 2021. [DOI: 10.1080/02726351.2021.1879981] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
Affiliation(s)
- Andrés Reyes-Urrutia
- Instituto de Investigación y Desarrollo en Ingeniería de Procesos, Biotecnología y Energías Alternativas PROBIEN (CONICET-UNCo), Neuquén, Argentina
| | - José Soria
- Instituto de Investigación y Desarrollo en Ingeniería de Procesos, Biotecnología y Energías Alternativas PROBIEN (CONICET-UNCo), Neuquén, Argentina
| | - Alejandra Saffe
- Instituto de Ingeniería Química, Facultad de Ingeniería, UNSJ–Grupo Vinculado al PROBIEN (CONICET-UNCo), San Juan, Argentina
| | - Mariana Zambon
- Instituto de Investigación y Desarrollo en Ingeniería de Procesos, Biotecnología y Energías Alternativas PROBIEN (CONICET-UNCo), Neuquén, Argentina
| | - Marcelo Echegaray
- Instituto de Ingeniería Química, Facultad de Ingeniería, UNSJ–Grupo Vinculado al PROBIEN (CONICET-UNCo), San Juan, Argentina
| | - Sergio G. Suárez
- Laboratorio de Colisiones Atómicas, Centro Atómico Bariloche, Comisión Nacional de Energía Atómica, San Carlos de Bariloche, Argentina
| | - Rosa Rodriguez
- Instituto de Ingeniería Química, Facultad de Ingeniería, UNSJ–Grupo Vinculado al PROBIEN (CONICET-UNCo), San Juan, Argentina
| | - Germán Mazza
- Instituto de Investigación y Desarrollo en Ingeniería de Procesos, Biotecnología y Energías Alternativas PROBIEN (CONICET-UNCo), Neuquén, Argentina
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Abstract
The worldwide shortage of natural sand has created a need for improved methods to create a replacement product. The use of vertical shaft impact (VSI) crushers is one possible solution, since VSI crushers can create particles with a good aspect ratio and smooth surfaces for use in different applications such as in construction. To evaluate the impact a VSI crusher has on the process performance, a more fit-for-purpose model is needed for process simulations. This paper aims to present a modelling framework to improve particle breakage prediction in VSI crushers. The model is based on the theory of energy-based breakage behavior. Particle collision energy data are extracted from discrete element method (DEM) simulations with particle velocities, i.e., rotor speed, as the input. A selection–breakage approach is then used to create the particle size distribution (PSD). For each site, the model is trained with two datasets for the PSDs at different VSI rotor tip speeds. This allows the model to predict the product output for different rotor tip speeds beyond the experimental configurations. A dataset from 24 different sites in Sweden is used for training and validating the model to showcase the robustness of the model. The model presented in this paper has a low barrier for implementation suitable for trying different speeds at existing sites and can be used as a replacement to a manual testing approach.
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Bilgili E, Guner G. Mechanistic Modeling of Wet Stirred Media Milling for Production of Drug Nanosuspensions. AAPS PharmSciTech 2020; 22:2. [PMID: 33222036 DOI: 10.1208/s12249-020-01876-w] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/18/2020] [Accepted: 11/05/2020] [Indexed: 12/22/2022] Open
Abstract
Drug nanocrystals have been used for a wide range of drug delivery platforms in the pharmaceutical industry, especially for bioavailability enhancement of poorly water-soluble drugs. Wet stirred media milling (WSMM) is the most widely used process for producing dense, stable suspensions of drug nanoparticles, also referred to as nanosuspensions. Despite a plethora of review papers on the production and applications of drug nanosuspensions, modeling of WSMM has not been thoroughly covered in any review paper before. The aim of this review paper is to briefly expose the pharmaceutical scientists and engineers to various modeling approaches, mostly mechanistic, including computational fluid dynamics (CFD), discrete element method (DEM), population balance modeling (PBM), coupled methods, the stress intensity-number model (SI-SN model), and the microhydrodynamic (MHD) model with a main focus on the MHD model for studying the WSMM process. A total of 71 studies, 30 on drugs and 41 on other materials, were reviewed. Analysis of the pharmaceutics literature reveals that WSMM modeling is largely based on empirical, statistically based modeling approaches, and mechanistic modeling could help pharmaceutical engineers develop a fundamental process understanding. After a review of the salient features and various pros-cons of each modeling approach, recent advances in microhydrodynamic modeling and process insights gained therefrom were highlighted. The SI-SN and MHD models were analyzed and critiqued objectively. Finally, the review points out potential research directions such as more mechanistic and accurate CFD-DEM-PBM simulations and the coupling of the MHD-PBM models with the CFD.
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The influence of the rotation frequency of a planetary ball mill on the limiting value of the specific surface area of the WC and Co nanopowders. ADV POWDER TECHNOL 2020. [DOI: 10.1016/j.apt.2020.07.033] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022]
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Cotabarren I, Fernández MP, Di Battista A, Piña J. Modeling of maize breakage in hammer mills of different scales through a population balance approach. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.08.016] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Clarke J, Gamble JF, Jones JW, Tobyn M, Dawson N, Davies C, Ingram A, Greenwood R. Determining the Impact of Roller Compaction Processing Conditions on Granule and API Properties. AAPS PharmSciTech 2020; 21:218. [PMID: 32743765 DOI: 10.1208/s12249-020-01773-2] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/09/2020] [Accepted: 07/22/2020] [Indexed: 01/08/2023] Open
Abstract
The attrition of drug particles during the process of dry granulation, which may (or may not) be incorporated into granules, could be an important factor in determining the subsequent performance of that granulation, including key factors such as sticking to punches and bio-performance of the dosage form. It has previously been demonstrated that such attrition occurs in one common dry granulation process train; however, the fate of these comminuted particles in granules was not determined. An understanding of the phenomena of attrition and incorporation into granule will improve our ability to understand the performance of granulated systems, ultimately leading to an improvement in our ability to optimize and model the process. Unique feeding mechanisms, geometry, and milling systems of roller compaction equipment mean that attrition could be more or less substantial for any given equipment train. In this work, we examined attrition of API particles and their incorporation into granule in an equipment train from Gerteis, a commonly used equipment train for dry granulation. The results demonstrate that comminuted drug particles can exist free in post-milling blends of roller compaction equipment trains. This information can help better understand the performance of the granulations, and be incorporated into mechanistic models to optimize such processes.
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Li Z, Wang LG, Chen W, Chen X, Liu C, Yang D. Scale-up procedure of parameter estimation in selection and breakage functions for impact pin milling. ADV POWDER TECHNOL 2020. [DOI: 10.1016/j.apt.2020.06.041] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Li P, Cao Z, Zhao R, Li G, Yu M, Zhang S. The kinetics and efficiency of batch ball grinding with cemented tungsten carbide balls. ADV POWDER TECHNOL 2020. [DOI: 10.1016/j.apt.2020.04.007] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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Taylor L, Skuse D, Blackburn S, Greenwood R. Stirred media mills in the mining industry: Material grindability, energy-size relationships, and operating conditions. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.04.057] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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Investigation of particle dynamics and classification mechanism in a spiral jet mill through computational fluid dynamics and discrete element methods. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.02.029] [Citation(s) in RCA: 20] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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Pin Goh W, Ali M, Sinha K, Nere NK, Ho R, Bordawekar S, Sheikh A, Ghadiri M. Assessment of impact breakage of carbamazepine dihydrate due to aerodynamic dispersion. Int J Pharm 2019; 572:118780. [PMID: 31715356 DOI: 10.1016/j.ijpharm.2019.118780] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/14/2019] [Revised: 09/20/2019] [Accepted: 10/09/2019] [Indexed: 11/17/2022]
Abstract
Acicular crystals are very common in pharmaceutical manufacturing. They are very prone to breakage, causing unwanted particle size degradation and problems such as segregation and lump formation. We investigate the breakage pattern of carbamazepine dihydrate, an acicular and platy crystal with cleavage planes. It readily undergoes attrition during isolation and drying stage, causing processing difficulties. We use the aerodynamic dispersion of a very small quantity of powder sample to induce breakage by applying a pulse of pressurised air. The dispersion unit of Morphologi G3 is used for this purpose. The broken particles settle in a chamber and are subsequently analysed using the built-in image analysis software. The shift in the particle size and shape distributions is quantified through which the extent of breakage is determined as a function of the dispersion pressure. The analysis reveals a change of breakage mechanism as the dispersion pressure is increased from primarily snapping along the crystal length to one in which chipping has also a notable contribution. The breakage data are analysed using a modified impact-based breakage model and the breakability index of the carbamazepine dihydrate is determined for the two breakage regimes. The method provides a quick and easy testing of particle breakability, a useful tool for assessing attrition in process plant and grindability in milling operations.
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Affiliation(s)
- Wei Pin Goh
- School of Chemical and Process Engineering, University of Leeds, Leeds LS2 9JT, UK
| | - Muzammil Ali
- School of Chemical and Process Engineering, University of Leeds, Leeds LS2 9JT, UK
| | - Kushal Sinha
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, IL 60064, United States
| | - Nandkishor K Nere
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, IL 60064, United States
| | - Raimundo Ho
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, IL 60064, United States
| | - Shailendra Bordawekar
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, IL 60064, United States
| | - Ahmad Sheikh
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, IL 60064, United States
| | - Mojtaba Ghadiri
- School of Chemical and Process Engineering, University of Leeds, Leeds LS2 9JT, UK.
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A Review of Chemicals to Produce Activated Carbon from Agricultural Waste Biomass. SUSTAINABILITY 2019. [DOI: 10.3390/su11226204] [Citation(s) in RCA: 105] [Impact Index Per Article: 21.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/17/2023]
Abstract
The choice of activating agent for the thermochemical production of high-grade activated carbon (AC) from agricultural residues and wastes, such as feedstock, requires innovative methods. Overcoming energy losses, and using the best techniques to minimise secondary contamination and improve adsorptivity, are critical. Here, we review the importance and influence of activating agents on agricultural waste: how they react and compare conventional and microwave processes. In particular, adsorbent pore characteristics, surface chemistry interactions and production modes were compared with traditional methods. It was concluded that there are no best activating agents; rather, each agent reacts uniquely with a precursor, and the optimum choice depends on the target adsorbent. Natural chemicals can also be as effective as inorganic activating agents, and offer the advantages that they are usually safe, and readily available. The use of a microwave, as an innovative pyrolysis approach, can enhance the activation process within a duration of 1–4 h and temperature of 500–1200 °C, after which the yield and efficiency decline rapidly due to molecular breakdown. This study also examines the biomass milling process requirements; the influence of the dielectric properties, along with the effect of washing; and experimental setup challenges. The microwave setup system, biomass feed rate, product delivery, inert gas flow rate, reactor design and recovery lines are all important factors in the microwave activation process, and contribute to the overall efficiency of AC preparation. However, a major issue is a lack of large-scale industrial demonstration units for microwave technology.
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Neugebauer C, Diez E, Bück A, Palis S, Heinrich S, Kienle A. On the dynamics and control of continuous fluidized bed layering granulation with screen-mill-cycle. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.05.030] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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Uhlemann J, Costa R, Charpentier JC. Product Design and Engineering in Chemical Engineering: Past, Present State, and Future. Chem Eng Technol 2019. [DOI: 10.1002/ceat.201900236] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Jens Uhlemann
- Bayer AG Head of Environmental Science Formulation Technology Crop Science Division Alfred-Nobel-Strasse 50 40789 Monheim Germany
| | - Raquel Costa
- University of Coimbra CIEPQPF – Chemical Engineering Processes and Forest Products Research Center Department of Chemical Engineering Rua Silvio Lima 3030-790 Coimbra Portugal
| | - Jean-Claude Charpentier
- Université de Lorraine Laboratoire Réactions et Génie des Procédés CNRS – ENSIC 1, rue Grandville 54000 Nancy France
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A Computationally Efficient Surrogate-Based Reduction of a Multiscale Comill Process Model. J Pharm Innov 2019. [DOI: 10.1007/s12247-019-09388-2] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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Bhonsale SS, Telen D, Stokbroekx B, Van Impe J. Comparison of numerical solution strategies for population balance model of continuous cone mill. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.01.043] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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