The effect of the binder size and viscosity on agglomerate growth in fluidised hot melt granulation

Fluidised hot melt granulation (FHMG) is a novel granulation technique for processing pharmaceutical powders. Several process and formulation parameters have been shown to significantly influence granulation characteristics within FHMG. In this study we have investigated the effect of the binder properties (binder particle size and binder viscosity) on agglomerate growth mechanisms within FHMG. Low-melting point co-polymers of polyoxyethylene–polyoxypropylene (Lutrol® F68 Poloxamer 188 and Lutrol® F127 Poloxamer 407) were used as meltable binders for FHMG, while standard ballotini beads were used as model fillers for this process. Standard sieve analysis was used to determine the size distribution of granules whereas we utilised fluorescence microscopy to investigate the distribution of binder within granules. This provided further insight into the growth mechanisms during FHMG. Binder particle size and viscosity were found to affect the onset time of granulation. Agglomerate growth achieved equilibrium within short time-scales and was shown to proceed by two competing processes, breakage of formed granules and re-agglomeration of fractured granules. Breakage was affected by the initial material properties (binder size and viscosity). When using binder with a small particle size (<250 µm), agglomerate growth via a distribution mechanism dominated. Increasing the binder particle size shifted the granulation mechanism such that agglomerates were formed predominantly via immersion. A critical ratio between binder diameter and filler has been calculated and this value may be useful for predicting or controlling granulation growth processes.

Optimisation of high shear granulation of multicomponent fertiliser using response surface methodology

This work describes a novel method of producing multicomponent fertiliser granules using high shear granulation. The granulation process was optimised using the response surface methodology technique. The variables used in the optimisation process include granulation time, batch size, impeller speed and binder concentration. Granulation time, binder concentration and interaction between the batch size and granulation time were found to be the main factors affecting the granule median size. The product yield is mainly influenced by granulation time and binder concentration. The interaction between the impeller speed and batch size also have a significant influence on the product yield. Product yield (2-4 mm) of approximately 60% could be obtained with high sphericity and granule strength (> 0.5 MPa). A low product recycle ratio of about 2:3 can be obtained at the optimised process conditions, compared to typical recycle rations of 6:1 which are obtained in typical fertiliser plants. © 2012 Elsevier B.V. All rights reserved.

Alternative method for producing organic fertiliser from anaerobic digestion liquor and limestone powder:High Shear wet granulation

Generally, the solid and liquid fractions (digestate) from Anaerobic Digestion (AD) energy production are considered as waste. This has a negative impact on the sustainability of AD processes because of the financial outlay required to treat digestate before being discharged into municipal water treatment plants or natural water bodies. The main aim of this research was to investigate feasibility of producing an organic fertiliser using anaerobic digestate and limestone powders as the raw materials employing a high shear granulation process. Two-level factorial experimental design was used to determine the influence of granulation process variables on, the strength, resistance to attrition and yield of the granules. It was concluded from the study that it is technically feasible to produce organic fertiliser granules of acceptable strength and product yield. Increasing the liquid-to-solid ratio during granulation leads to increased granule strength and better product yield. Although the strength of the granules produced was lower than typical strength of commercial synthetic fertiliser granules (about 5 to 7. MPa), this could be improved by mixing the digestate with a polymeric binder or coating the particles post granulation. © 2012 Elsevier B.V.

The variability in nutrient composition of Anaerobic Digestate granules produced from high shear granulation

This study investigates the production of organic fertilizer using Anaerobic Digestate (as a nutrient source) and limestone powder as the raw materials. A two-level factorial experimental design was used to determine the influence of process variables on the nutrient homogeneity within the granules. Increasing the liquid-to-solid ratio during granulation resulted in increased granule nutrient homogeneity. Increasing the processing time and the impeller speed were also found to increase the nutrient homogeneity. In terms of nutrients release into deionized water, the granules effectively released both potassium and phosphate into solution. © 2012 Elsevier Ltd.

EFFECT OF IMPELLER DESIGN ON PRODUCT HOMOGENIETY IN HIGH SHEAR WET GRANULATION

Design of small mixer impellers is not tailored for granulation as they are designed for a wide range of processes. The Kenwood KM070 was employed as a standard apparatus to undertake this investigation. Five different impeller designs were used, possessing different shapes and surface areas. The aim of this research was to evaluate the performances of these impellers to provide
guidance on the selection and design for the purposes of granulation. Lactose granules were produced using wet granulation with water as the binder.
The efficacy of respective granulates was measured by adding an optically
sensitive tracer.This was used to determine powder concentrations
within various regions of the granulator. It was found that impeller design influenced the homogeneity of the granules; and therefore can affect final product performance.

EFFECT OF POWDER COMPOSITION ON THE GRANULATION OF BINARY MIXTURES

In most granulation processes involving processing of a mixture of powders, the powders have comparable densities and similar particle size distributions. Granulation of powders with large variation differences in powder densities is usually avoided due problems such as particle segregation. The granular product being designed in this work required the use of two different powders namely limestone and teawaste; these materials have different bulk and particle densities.The overall aim of the project was to obtain a granular product in
the size range 2 to 4mm. The two powders were granulated in different proportions using carboxymethyl cellose (CMC) as the binder. The effect of amount of binder added, relative composition of the powder, and type of tea wasted on the product yield was studied. The results show that the optimum product yield was a function of both relative powder composition and the amount of binder used; increasing the composition of teawaste in the powder increased the amount of binder required for successful granulation.Increasing the mass fraction of teawaste in the powder mix must be accompanied by an increase in the amount of binder to achieve the desired product yield. It was found that attrition losses decreased with increasing binder content.

Development of a value-added soil conditioner from high shear co-granulation of organic waste and limestone powder

This paper reports on a technical feasibility study of the production of organo-mineral fertiliser from the co-granulation of limestone powders with tea waste. The results from this preliminary study show that the co-granulation of tea waste provided an alternative method of waste recovery, as it converts the waste into a value-added product. Fertiliser granules were successfully produced from various compositions of limestone and tea waste. The effect of tea waste concentration on granule strength was analysed; the granule strength
was in the range 0.2 to 1.8 MPa depending on powder composition; increasing the tea waste mass fraction resulted in a reduction in granule strength.Varying the teawaste to limestone ratio also influenced the compressibility of the granules; the granules compressibility increased with increasing tea waste mass fraction. It was further found that increasing the mass fraction of tea waste in the binary mixture of powder reduced the granule median size of the batch.

Influence of fill factor variation in high shear granulation on the post granulation processes: Compression and tablet properties

This paper describes an investigation of the effect of fill factor; on the compaction behaviour of the granules during tableting and hence mechanical properties of tablets formed. The fill factor; which is the ratio of volume of wet powder material to vessel volume of the granulator, was used as an indicator of batch size. It has been established previously that in high shear granulation the batch size influences the size distribution and granule mechanical properties [1]. The work reported in this paper is an extension to the work presented in [1], hence granules from the same batches were used in production of tablets. The same tabletting conditions were employed during tabletting to allow a comparison of their properties. The compaction properties of the granules are inferred from the data generated during the tabletting process. The tablet strength and dissolution properties of the tablets were also measured. The results obtained show that the granule batch size affects the strength and dissolution of the tablets formed. The tablets produced from large batches were found to be weaker and had a faster dissolution rate. The fill factor was also found to affect the tablet to tablet variation of a non-functional active pharmaceutical ingredient included in the feed powder. Tablets produced from larger batches show greater variation compared to those from smaller batches.

High shear granulation of binary mixtures: Effect of powder composition on granule properties: Effect of powder composition on granule properties

The granular product being designed in this work required the use of two different powders namely limestone and teawaste; these materials have different bulk and particle densities. The overall aim of the project was to obtain a granular product in the size range of 2 to 4. mm. The two powders were granulated in different proportions using carboxymethylcellulose (CMC) as the binder. The effect of amount of binder added, relative composition of the powder, and type of teawaste on the product yield was studied. The results show that the optimum product yield was a function of both relative powder composition and the amount of binder used; increasing the composition of teawaste in the powder increased the amount of binder required for successful granulation. An increase in the mass fraction of teawaste in the powder mix must be accompanied by an increase in the amount of binder to maintain the desired product yield.