Beruflich Dokumente
Kultur Dokumente
Technology
Mahbubul Karim
Topics
Introduction to granulation
Characterization of granulation
Principle governing particle size
enlargement
Granule size enlargement and
interpretation of size data
Characterization of granule shape
friability
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Topics
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Introduction to granulation and
granules
What is Granulation.
a size-enlargement process
during which small particles are formed
into larger,
physically strong agglomerates in which
the original particles can still be
indentified.
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granulation and granules
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granulation and granules
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Reasons for granulation
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Reasons for granulation
Densify the powder mixture and reduce
dust
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Reasons for granulation
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Characterization
of Granulation
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PHYSICAL AND CHEMICAL
CHARACTERIZATION OF GRANULES
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PHYSICAL AND CHEMICAL
CHARACTERIZATION OF GRANULES
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PHYSICAL AND CHEMICAL
CHARACTERIZATION OF GRANULES
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PHYSICAL AND CHEMICAL
CHARACTERIZATION OF GRANULES
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Desirable Granule Properties
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Monitor & Control
(What, When, How & Why)
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Principle governing
particle size
enlargement
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Method of Granulation
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Wet Granulation
(involving wet massing)
Wet granulation involves mix of dry
primary powder particles using a
granulating fluid. The fluid contains a
solvent which must be volatile so that it
can be removed by drying, and be non-
toxic. Typical liquids include water, ethanol
and isopropanol, either alone or in combination.
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Wet Granulation
(involving wet massing) contd
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Wet Granulation
(involving wet massing) contd
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Wet Granulation
(involving wet massing) contd
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Wet Granulation
(involving wet massing) contd
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Wet Granulation
(involving wet massing) contd
Methods
> Low Shear Wet Granulation
> High Shear Wet Granulation
> Spray Granulation
> Melt Granulation and Pelletization:
Melt granulation and melt pelletization are agglomeration processes
that have gathered increasing interest in the pharmaceutical industry
for the concept of utilizing a molten liquid as a binder.
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Dry Granulation
In dry methods of granulation the primary
powder particles are aggregated under high
pressure.
There are two main processes:
> Slugging, is produced in a heavy-duty
tabletting press (a process known as 'slugging') or
> Compaction, powder is squeezed between
two rollers to produce a sheet of material ('roller
compaction').
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Dry Granulation contd
In both cases
these intermediate products are broken
using a suitable milling technique to
produce granular material, which is usually
sieved to separate the desired size
fraction.
The unused fine material may be reworked to
avoid waste.
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Dry Granulation contd
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GRANULATION MECHANISMS
Particle-bonding mechanisms
To form granules, bonds must be formed
between powder particles so that they
adhere to each other and these bonds
must be sufficiently strong to prevent
breakdown of the granule to powder in
subsequent handling operation..
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GRANULATION MECHANISMS contd
5. Mechanical interlocking.
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
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GRANULATION MECHANISMS contd
Interfacial forces in mobile liquid films
At low moisture levels, termed the pendular state, the
particles are held together by lens-shaped rings of
liquid.
When all the air has been displaced from between the
particles the capillary state is reached, and the
particles are held by capillary suction at the liquid/air
interface, which is now only at the granule surface.
The funicular state represents an intermediate stage
between the pendular and capillary states. Moist granule
tensile strength increases about three times between the
pendular and the capillary state.
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GRANULATION MECHANISMS contd
Solid bridges
These can be formed by:
1. partial melting
2. hardening binders
3. crystallization of dissolved substances.
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GRANULATION MECHANISMS contd
Solid bridges
1. Partial melting
Although not considered to be a predominant
mechanism in pharmaceutical materials, it is
possible that the pressures used in dry
granulation methods may cause melting of low
melting-point materials where the particles touch
and high pressures are developed. When the
pressure is relieved, crystallization will take
place and bind the particles together.
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GRANULATION MECHANISMS contd
Solid bridges
2. Hardening binders
This is the common mechanism. An adhesive is
included in the granulating solvent.
The liquid will form liquid bridges, and the
adhesive will harden or crystallize on drying to
form solid bridges to bind the particles.
Adhesives such as PVP, the cellulose derivatives (such
as CMC) and pregelatinized starch function in this way.
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GRANULATION MECHANISMS contd
Solid bridges
3. Crystallization of dissolved substances
The solvent used to mass the powder during wet
granulation may partially dissolve one of the powdered
ingredients.
When the granules are dried, crystallization of this
material will take place and the dissolved substance then
acts as a hardening binder.
Any material soluble in the granulating liquid will function
in this manner,e.g. lactose incorporated into dry
powders granulated with water.
Solid bridges
3. Crystallization of dissolved substances
The size of the crystals produced in the bridge will be
influenced by the rate of drying of the granules:
the slower the drying time, the larger the particle size.
It is important that the drug does not dissolve in the
granulating liquid and recrystallize, because it may
adversely affect the dissolution rate of the drug if crystals
larger than that of the starting material are produced.
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GRANULATION MECHANISMS contd
Electrostatic forces
Van der Waals forces
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GRANULATION MECHANISMS contd
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Theory of granulation
The theory of granulation can be described in four
stages. These four states are termed:
1. Pendular
2. Funicular
3. Capillary, and
4. Droplet or Suspension State.
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Mechanisms of granule formation
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Mechanisms of granule formation
1. Nucleation
Granulation starts with particle-particle
contact and adhesion due to liquid
bridges. A number of particles will join to
form the pendular state illustrated in
Figure1. Further agitation densities the
pendular bodies to form the capillary state,
and these bodies act as nuclei for further
granule growth.
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Mechanisms of granule formation
2. Transition:
Nuclei can grow in two possible ways: either single particles can
be added to the nuclei by pendular bridges, or two or more nuclei
may combine. The combined nuclei will be reshaped by the
agitation of the bed.
This stage is characterized by the presence of a large number of
small granules with a fairly wide size distribution. If the size
distribution is not excessively large, this point represents a suitable
endpoint for granules used in capsule and tablet manufacture. as
relatively small granules will produce a uniform tablet die or capsule
fill. Larger granules may give rise to problems in small-diameter dies
owing to bridging across the die and uneven fill.
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Mechanisms of granule formation
3. Ball growth
Further granule growth produces large, spherical
granules and the mean particle size of the
granulating system will increase with time.
If agitation is continued, granule coalescence
will continue and produce an unusable,
overmassed system, although this is dependant
upon the amount of liquid added and the
properties of the material being granulated.
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Mechanisms of granule formation
The four possible mechanisms of ball growth
are illustrated in Figure 2.
1.Coalescence
Two or more granules join to form a larger
granule.
2.Breakage
Granules break into fragments which adhere
to other granules, forming a layer of material
over the surviving granule.
3. Abrasion transfer
Agitation of the granule bed leads to the
attrition of material from granules. This
abraded material adheres to other granules,
increasing their size.
4.Layering
When a second batch of powder mix is
added to a bed of granules the powder will
adhere to the granules, forming a layer over
the surface and increasing the granule size.
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Equipment
of Granulation
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Equipments
Wet Granulation
Dry Granulation
Mixer Grinder
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Equipments
Title of Slide
High Speed Mixer
Wet Granulator
Paste Kettle
Fluid Bed Dryer
Dry Granulator
Final Blender
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Equipments
Title of Slide
The equipments used during the
granulation processes are classified into
three major categories, based on the
shearing strength it generates on the
powder bed.
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Equipments
Title of Slide
1. Low-shear granulatorstwin shell with an agitator
bar, dough mixer or planetary mixer, ribbon blenders,
and fluid bed granulator without the rotogranulator.
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Low shear granulator
Fig 6 : Sigma blade mixer.
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Low shear granulator
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Medium shear granulator
Title of Slide
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Medium shear granulator
Title of Slide
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Medium shear granulator
Title of Slide
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HighTitle
shear granulator
of Slide
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HighTitle
shear granulator
of Slide
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Granulation process parameters
Impeller Speed
Chopper Speed
Water Addition Rate and Method
Massing Time
Load of the Mixer
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Granulation process parameters
Impeller Speed
Higher Impeller speeds generally results in
denser and smaller granules. Low impeller
speeds generally result in more porous, large
granules.
Chopper Speed
Generally Chopper speed has no significant
effect on granule size and density but in cases
where the chopper is large, it may function
as a secondary impeller.
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Granulation process parameters
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Granulation process parameters
Massing Time
Massing time is normally in the order of 1 to 10
minutes. Long massing times (> 20 mins) may
lead to decreased dissolution rates due to
decreased disintegrant function or due to the
formation of denser granules.
Load of the Mixer
Generally, the load of the mixer is less than
two-thirds the volume of the mixer.
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Table 1 : Steps in Different Methods of Tablet
Manufacture (Unit Operations)
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Table 2 : Relative merits and demerits of
different granulation process
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Granule size
enlargement and
interpretation of
size data
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Introduction
The particle size of a granulation is known to affect the
average tablet weight, tablet weight variation,
disintegration time, granule friability, granulation
flowability and the drying rate kinetics of wet granulation.
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A. Methods of Data Presentation
for Particle size distribution Table1: Size distribution data for a
hypothetical tablet granulation
Tabular Presentation
The most precise and explicit way of
presenting size distribution data is by tabular
form. The frequency data table 1 are
represented by weight rather than by
number. The size distribution can be defined
in terms of the weight or number of particles
within a given size range.
Graphical Presentation
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Frequency Histograms
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Cumulative Frequency
Curve
Cumulative frequency
curves are arrived at by
plotting the percent of
particles less than (or
greater than) a given
particle size versus
particle size.
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B. Method for determining Particles Size distribution
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Microscopy: Microscopy provides a more exact
measurement of particle size, but it is a labor-sensitive
method.
Computer aided image analysis techniques have been
employed to simplify the method.
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Characterization of
granule shape
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Granule Shape
Particle shape can have a significant effect on the bulk
properties of a powder.
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Spherical particles flow better, pack better, and
have a lower surface to volume ratio.
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Granule Shape summary
Factor Effect on particle
Volume shape factor , v For sphere v equals to /6 . As
the volume shape
factor increased , bulk density increased,
because more spherical or more regular-shape particles
produce the closest packing arrangement
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Granule density and
packing characteristic
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Terminology Definition
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Granule density
The bulk density is determined by measuring the
volume of a known mass of powder, that has been
passed through a screen, into a graduated cylinder.
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Granule density
Dense particles are generally less cohesive than
less dense particles of the same size and shape.
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Granule density
For powders having comparable true densities an
increase in bulk density causes a decrease in
porosity.
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Granule density
Table 1: Scale of flowability
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Packing characteristic
Bulk density and porosity are used to characterize packing geometry of
particles or granules. Packing studies are carried out by filling a volumetrically
calibrated cylinder with powder and tapping it.
Granule size increases bulk density decreases.- higher porosity loose packing
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Packing characteristic
Theoretical porosity of powder consist of uniform sphere in
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Factors affecting packing geometry
3. Surface properties
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Electrostatic properties
of tablets
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Electrostatic Properties
Interparticulate forces acting between the granules/
solid particles can affect the flow properties of a solid.
Interparticular attraction makes the flow property
poor. Electrostatic repulsion may facilitate flow of a
powder bed.
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Electrostatic Properties
Electrostatic charge highly influences bulk density.
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Rheological properties
of granules
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Rheological Properties
Common methods for determining powder/granule flowability
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Angle of Repose
Angle of repose is a characteristic related to
interparticulate friction, or resistance to movement
between particles.
The angle of repose is the constant, three-dimensional
angle (relative to the horizontal base) assumed by a
cone-like pile of material which is formed when the
powder is passed through a funnel-like container.
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Angle of Repose
The angle of repose is determined
by the following equation :
Where
= angle of repose.
H=height
R= Radius of base of the
conical pile
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Angle of Repose
Table: Flow properties and corresponding angle of repose
The powders that can flow well give small angle of repose.
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Factor influencing angle of repose
Several factors and granule characteristics have been
studied for their effect on the angle of repose such as
particle size ,
use of glidants ,
moisture effects, and
particle shape.
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Factor influencing angle of repose
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Title of Slide
I. In a general sense, the repose angle normally increases as
particle size is reduced and this effect is usually dramatic small
particle size range.
II. the angle of repose of goes through a minimum and the
increases as glidant concentration increases.
III. when materials that take up moisture from the atmosphere are
exposed to high humidities , the materials generally become
more cohesive , cake in their container and exhibit very poor
flow characteristics.
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Summary
Factor influencing angle of repose
Factor Effect on angle of repose
Moisture content higher the moisture content greater the cohesion &
adhesion exhibit very poor flow characteristics
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Granule Strength
Measurements of granule strength are aimed at
estimating the relative magnitude of attractive
forces seeking to hold the granule together.
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Friability
Compression strength & friability measurement:
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Moisture Control
Moisture could affect flow of granules, tablet
compression, tablet disintegration, crystal habit,
capsule brittleness, chemical stability, and many
other properties.
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Moisture Control
Too much moisture in granulation will result in one set of
problems (sticking, picking, microbial growth,
stability issues) while too little will result in a different
set of problems (lamination and).
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Title of Slide
Slide Text
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