Spray drying
Optimize production with fast, reliable insights into particle size, shape, and morphology
Challenges
in the Spray Drying Processes
Optimizing spray dryer parameters is a complex task. A liquid droplet in a Spray Drayer can follow multiple morphological pathways, leading to a variety of particle structures - each linked to a set of challenges
Inconsistent Particle Size and Shape
Leading to powder flowability, solubility, and product performance variations
Hollow or Collapsed Particles
Impacting bulk density and product stability
Variability in Powder Morphology
Affecting dissolution rates and end-use applications
Agglomerates or Deposits Formation
Affecting yield and process efficiency
Moisture Content and Drying Efficiency
Difficulty in achieving the desired drying results and efficiency
Excessive Fines/Dust Formation
Resulting in compliance issues when producing allergens
How ParticleTech
Helps
12
Distribution with Precision
Measures particle size distribution with high precision, ensuring consistent powder characteristics.
Quantifies the Fraction
Identifies and quantifies the fraction of agglomerates, optimizing drying conditions to reduce defects.
Differentiates
Differentiates between hollow, collapsed, and intact particles to assess drying efficiency and product quality.
Morphology Analysis
Provides morphology analysis to detect process deviations early and prevent unwanted product variations.
Rapid Feedback
Enables rapid feedback for process adjustments and improving batch-to-batch consistency.
Quantify Fines/Dust
Accurately quantify fines/dust (particles smaller than 5-10 µm) to minimize allergen exposure.
Application
Areas
- Optimization of Spray Drying Parameters: To achieve desired particle properties and ensure the quantity of fines/dust is within the limits
- Formation of Agglomerates and Deposits: Help monitor and controll the formation of both of agglomerates and deposits
- Powder Bulk Density and Flowability: Evaluating powder bulk density and flowability for improved packaging and handling
- Uniform Particle Morphology: Ensuring uniform particle morphology for enhanced dissolution and performance
- Quality Control of Spray-dried Powders: Performing quality control of spray-dried powders before final product formulation.
WorkFlow
of a Practical Analysis
1.
Minimal Sample Preparation
Analyze dry powders directly using the ParticleTech CombiCell
2.
Setup & Run
No calibration or cleaning required, ensuring seamless operation
3.
Results after just 2 Minutes
Allowing for real-time process monitoring and optimization
Business Benefits
of using ParticleTech for Spray Drying
- Provides fast, comprehensive particle characterization with minimal effort
- Enables real-time process optimization with rapid feedback loops
- Eliminates human subjectivity compared to traditional microscopy-based methods
- Detects and quantifies defects that impact product performance
- Variability in powder morphology
- Applicable to various spray-dried powders, including food, pharmaceuticals, and chemicals