Process Characterization of Polyvinyl Acetate Emulsions Applying Inline Photon Density Wave Spectroscopy at High Solid Contents

Real-Time Monitoring of Particle Size in Emulsion Polymerization: Simultaneous Turbidity and Photon Density Wave Spectroscopy

Particle size evolution in seeded semibatch emulsion polymerization is monitored by two real-time monitoring techniques: online turbidity spectroscopy (TUS) and inline photon density wave spectroscopy (PDWS). An automatic dilution system that withdraws a sample from the reactor and upon dilution transfers to the measurement cell is used for the online TUS analysis. A PDWS probe is immersed in the reactor and collects inline the scattered light directly from the reacting latex. The particle sizes retrieved from TUS and PDWS are compared to offline dynamic light scattering (DLS) values. The particle size obtained by TUS is close to the intensity-average particle size obtained offline by DLS, while the particle size obtained by PDWS lies closer to the number-average particle size from DLS.

Advanced Particle Size Analysis in High-Solid-Content Polymer Dispersions Using Photon Density Wave Spectroscopy

High-solid-content polystyrene and polyvinyl acetate dispersions of polymer particles with a 50 nm to 500 nm mean particle diameter and 12-55% (w/w) solid content have been produced via emulsion polymerization and characterized regarding their optical and physical properties. Both systems have been analyzed with common particle-size-measuring techniques like dynamic light scattering (DLS) and static light scattering (SLS) and compared to inline particle size distribution (PSD) measurements via photon density wave (PDW) spectroscopy in undiluted samples. It is shown that particle size measurements of undiluted polystyrene dispersions are in good agreement between analysis methods. However, for polyvinyl acetate particles, size determination is challenging due to bound water in the produced polymer. For the first time, water-swelling factors were determined via an iterative approach of PDW spectroscopy error (Χ2) minimization. It is shown that water-swollen particles can be analyzed in high-solid-content solutions and their physical properties can be assumed to determine the refractive index, density, and volume fraction in dispersion. It was found that assumed water swelling improved the reduced scattering coefficient fit by PDW spectroscopy by up to ten times and particle size determination was refined and enabled. Particle size analysis of the water-swollen particles agreed well with offline-based state-of-the-art techniques.

Polymer Colloids: Current Challenges, Emerging Applications, and New Developments

Polymer colloids are complex materials that have the potential to be used in a vast array of applications. One of the main reasons for their continued growth in commercial use is the water-based emulsion polymerization process through which they are generally synthesized. This technique is not only highly efficient from an industrial point of view but also extremely versatile and permits the large-scale production of colloidal particles with controllable properties. In this perspective, we seek to highlight the central challenges in the synthesis and use of polymer colloids, with respect to both existing and emerging applications. We first address the challenges in the current production and application of polymer colloids, with a particular focus on the transition toward sustainable feedstocks and reduced environmental impact in their primary commercial applications. Later, we highlight the features that allow novel polymer colloids to be designed and applied in emerging application areas. Finally, we present recent approaches that have used the unique colloidal nature in unconventional processing techniques.

Deciphering the Emulsification Process to Create an Albumin-Perfluorocarbon-(o/w) Nanoemulsion with High Shelf Life and Bioresistivity

This work aimed at the development of a stable albumin-perfluorocarbon (o/w) emulsion as an artificial oxygen carrier suitable for clinical application. So far, albumin-perfluorocarbon-(o/w) emulsions have been successfully applied in preclinical trials. Cross-linking a variety of different physical and chemical methods for the characterization of an albumin-perfluorocarbon (PFC)-(o/w) emulsion was necessary to gain a deep understanding of its specific emulsification processes during high-pressure homogenization. High-pressure homogenization is simple but incorporates complex physical reactions, with many factors influencing the formation of PFC droplets and their coating. This work describes and interprets the impact of albumin concentration, homogenization pressure, and repeated microfluidizer passages on PFC-droplet formation; its influence on storage stability; and the overcoming of obstacles in preparing stable nanoemulsions. The applied methods comprise dynamic light scattering, static light scattering, cryo- and non-cryo-scanning and transmission electron microscopies, nuclear magnetic resonance spectroscopy, light microscopy, amperometric oxygen measurements, and biochemical methods. The use of this wide range of methods provided a sufficiently comprehensive picture of this polydisperse emulsion. Optimization of PFC-droplet formation by means of temperature and pressure gradients results in an emulsion with improved storage stability (tested up to 5 months) that possibly qualifies for clinical applications. Adaptations in the manufacturing process strikingly changed the physical properties of the emulsion but did not affect its oxygen capacity.

Scale-up of Emulsion Polymerisation up to 100 L and with a Polymer Content of up to 67 wt%, Monitored by Photon Density Wave Spectroscopy

The scale-up process of the high solid content (up to 67 wt%) emulsion polymerisation of vinyl acetate and Versa^®10 from 1 L over 10 L to 100 L was investigated. An emulsion copolymerisation of vinyl acetate and neodecanoic acid vinyl ester in a molar ratio of 9:1 was carried out in a starved-fed semi-batch operation. As a radical source, a redox initiator system consisting of L-ascorbic acid, tert-butyl hydroperoxide and ammonium iron (III) sulphate was used. The process parameters, such as the required stirring speed and heat dissipation, were determined and adjusted beforehand via reaction calorimetry to ensure a successful scale-up without safety issues. In addition, the emulsion polymerisation was monitored inline by Raman (qualitative monomer accumulation), as well as Photon Density Wave spectroscopy (particle size and scattering coefficient) and temperature measurements. The data provided by Raman spectroscopy and temperature measurements revealed mixing difficulties due to an insufficient stirring rate, while the inline measurement with Photon Density Wave spectroscopy offered an insight into the development of the product properties. It proved to be reliable and precise throughout the entire scale-up process, especially compared to conventional offline methods, such as dynamic light scattering or sedimentation analysis by means of a disc centrifuge, both of which encountered issues when using higher polymer contents.

Promoting Sustainability through Next-Generation Biologics Drug Development

The fourth industrial revolution in 2011 aimed to transform the traditional manufacturing processes. As part of this revolution, disruptive innovations in drug development and data science approaches have the potential to optimize CMC (chemistry, manufacture, and control). The real-time simulation of processes using “digital twins” can maximize efficiency while improving sustainability. As part of this review, we investigate how the World Health Organization’s 17 sustainability goals can apply toward next-generation drug development. We analyze the state-of-the-art laboratory leadership, inclusive personnel recruiting, the latest therapy approaches, and intelligent process automation. We also outline how modern data science techniques and machine tools for CMC help to shorten drug development time, reduce failure rates, and minimize resource usage. Finally, we systematically analyze and compare existing approaches to our experiences with the high-throughput laboratory KIWI-biolab at the TU Berlin. We describe a sustainable business model that accelerates scientific innovations and supports global action toward a sustainable future.

Compact setup to determine size and concentration of spherical particles in a turbid medium

We propose a compact setup to determine the size and concentration of spherical particles in a turbid medium. A pair of plane mirrors is used to multifold the undeviated laser beam, and measure it at a detector placed close to the sample, to determine the interaction coefficient. The size of particles is uniquely determined by comparison of the scattered light from the medium, measured at two separate detectors placed at two different angular positions, with that from Monte Carlo simulations. The methodology is verified using measurements with turbid samples comprising polystyrene spheres.