MASTERING PARTICLE PROCESSING METHODS
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This document summarizes AVEKA's expertise in processing engineered particles through various methods. It discusses AVEKA's facilities and capabilities, an overview of engineered particles, and challenges in particle processing. It then provides examples of AVEKA applying methods like spray drying, coating, and prilling to address needs like separating cellulose fibers, encapsulating omega-3 oils, and producing monodisperse wax beads. While results were promising, further refinement was sometimes needed, highlighting the importance of testing and understanding materials at multiple scales.
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MASTERING PARTICLE PROCESSING METHODS
- 1. AVEKAGroup MASTERING THE PROCESSING METHODS OF ENGINEERED PARTICLES MAY 13, 2020 PA RT I C L E P RO C ES S I N G S E RV I C ES TO L L M A N U FAC T U R I N G R ES EA RC H & D E V E LO P M E N T I N N O VAT I V E S O LU T I O N S AVEKA PRESENTED BY: WILLIE HENDRICKSON, CEO & FOUNDER
- 2. Presentation Outline Overview of AVEKA What are engineered particles? How do you approach making engineered particles? General processing methods to consider Practical challenges Separation example Coating example Atomization example Conclusions
- 3. AVEKAGroup Overview • Particle technology company focused on contract manufacturing • Spin-off of 3M in 1994 • Comprised of 5 separate companies • ISO certifications / food-grade certifications • Currently 290 employees
- 4. AVEKA’s Vision AVEKA AVEKA’sVision Building the legacy of leadership and innovation in manufacturing solutions for particle technology AVEKA’s Mission Our team of employee owners will deliver custom solutions, quality manufacturing, and excellent customer service for the benefit of our customers, employees and communities.
- 5. TheAVEKA Group • 75 people • Corporate Headquarters • R&D, Manufacturing, Specialty Process Suites AVEKA Inc • 96 people – Fredericksburg, Iowa • Large scale manufacturing • Spray Drying, Hammer Milling, Fluid Bed Drying, Tumble Coating, Agglomeration AVEKA Manufacturing • 50 people – Cresco, Iowa • Food Processing • Spray Drying, Prilling, Drum Drying, Extraction, Wet Blending Cresco Food Technologies • 40 people – Waukon Iowa • Value Added Food Processing • Spray Drying, Roll Drying, Microfiltration/Nanofiltration, Specialty Separations AVEKA Nutra Processing • 15 People – Cottage Grove, Minnesota • Industrial Materials, Abrasives, Ceramics, Minerals • Jet Milling and Classification AVEKA CCE Technologies
- 6. AVEKA ParticleCharacterization Particle size analysis ◦ Particles 1 nm to 2+ mm ◦ Particle size distribution (PSD) ◦ Sonic sieving ◦ Rototap Imaging ◦ Optical microscopy ◦ Scanning electron microscopy (SEM) with EDS Surface area analysis True density analysis ◦ Helium pycnometry Formulation analysis ◦ High performance liquid chromatography (HPLC) ◦ Thermogravimetric analysis (TGA) ◦ Spectrophotometer ◦ Differential scanning calorimetry (DSC) Flow characteristics ◦ Freeman FT4 ◦ Zeta potential analysis (ZP) ◦ Rheological analysis ◦ Moisture and solids analysis (MSA) ◦ Karl Fisher
- 7. What are Engineered Particles? • Size controlled • Multicomponent • Tightly adjusted composition • Complex structure or shape • Functional property • Chemically or biologically active • Controlled release
- 8. It’sAllAbout Knowing theTrick CARL FRIEDRICH GAUSS NORA, ORRIN, LAINA YATES AVEKA
- 10. Particle Knowledge Sources ▪Academic literature ▪Patent literature ▪General reading ▪YouTube ▪How it’s made AVEKA
- 11. What DoYou Need to Know? Chemistry Properties M.p., b.p., solubility, pH, density Functional Properties Particle size, viscosity, powder flow Financial Considerations Cost, volumes, profitability What equipment do you have available?
- 12. Processing Dilemmas ▪Available equipment dilemma ▪Spray drying dilemma ▪Mass balance dilemma ▪Scalability dilemma AVEKA
- 13. Particle Processing Tools ▪ GRANULATION ▪ DRYING ▪ ATOMIZATION ▪ GRINDING ▪ COATING ▪ SEPARATION AVEKA Spray Drying ▪ 5-120 micron particle size ▪ 10-60% solids (slurries or solutions) ▪ 1-200 cps Liquid viscosity ▪ Particles can be solid or hollow
- 14. The Examples…. Finally Cellulose Fiber Separation ◦ Water holding enhancement Encapsulation of Omega-3 Oils ◦ Reduced oxidation and odor Monodisperse Particles ◦ Medical device testing ❖Statement of need ❖How we approached the problem ❖What went right ❖What went wrong AVEKA
- 15. Preparation ofCellulose Fiber from Corn Bran The Solution • Starch:1-10% • Protein: 1-8% • Oils: 0-2% • Ash: 1-6% • Water: 1-10% • Fiber: 80-90% • Cellulose: 25-30% • Hemicellulose: 60-70% • Lignin: 1-6% Statement of challenge • Scale-up proven process • Produce high concentration of cellulose fiber with high water holding property AVEKA Corn Bran Starting Material Composition Starch 1-10% Protein 1-8% Oils 0-2% Ash 1-6% Water 1-10% Fiber 80-90% • Cellulose 25-30% • Hemicellulose 60-70% • Lignin 1-6%
- 16. Process andCellulose Images ▪Slurry in Water ▪Remove digested starch and fats ▪Add caustic to solubilize hemicellulose and lignin ▪Centrifuge and dry AVEKA
- 17. WHATWENT WRONG? • Yields were poor • Process incredible inconsistent • Water holding results were inconsistent THE SOLUTION • Analyze • Understand AVEKA
- 18. TGA ofCellulose and Hemicellulose Wood Cellulose Hemicellulose AVEKA
- 19. TGA ofCorn Bran and PurifiedCellulose Corn Bran Processed Cellulose AVEKA
- 20. Preparation of Microencapsul atedOmega-3 FishOil Statement of challenge • No known method for protecting Omega-3 oils from oxidation • Overcome oxygen disfusion through cell wall • Consider biomimicry The Solution
- 21. ProposedStructure Oil core Organelle shell Alginate shell Carbohydrate/protein/fiber shell Fat/fiber shell Oil Core AVEKA
- 22. WHATWENT WRONG? • Multilayer structure was made using atomization and spray drying methods followed by coating process • Results were as good as industry standards – not better THE SOLUTION • Change materials • Improve on oleosin usage AVEKA
- 23. Preparation of Monodisperse Wax Beads Statement of challenge • 4mm monodisperse beads needed for bio assay end use • Need to be sterile • Need to be tight size and weight • Minimal waste of raw material The Solution • Prilling process • Underwater formation and cooling • New atomization method needed
- 24. Particles from Liquids: Prilling •Spherical particles (10-2000 micron) •Up to 50% active loading •Matrix: phytosterols, hydrogenated oils, PLA •Actives: oils, flavors, particles,CMC, biocides •Throughputs: 1 – 2000 lb/hr Rayleigh Breakup AVEKA
- 25. Microencapsulation via Prilling ▪ Process Parameters ▪ Melts not solutions(50- 200 °C) ▪ Melt viscosities < 300 cps ▪ Atomizers ▪ Drip ▪ Spinning disk ▪ Two-fluid ▪ Single fluid ▪ Chamber temperature ▪ Throughput (1-5000 kg/hr) ▪ Product Parameters ▪ Particle size (10-5000 µm) ▪ Matrix particle with 5-50% active inclusions AVEKA
- 26. Cold water Melted wax Wax beads cool and forms spheres when floating up in the water (~lava lamp) since they are less dense than the water Large nozzle to make 4 mm beads Collect from top Underwater Prilling AVEKA
- 29. WHATWENT WRONG? • Under water prilling process produced beads in the correct size and consistency • Water inclusion (holes) were not expected THE SOLUTION • Vacuum drying worked • Customer went to another technology due to timing AVEKA
- 30. AVEKA Summary •Knowing the tricks and applying them are Critical •Multiple methods should be considered for every problem •It is hard to analyze and know too much R&D / Lab-Scale Testing PilotTesting Full Scale Manufacturing Value Added Product Partnerships • Contact Information: • Willie Hendrickson • whendrickson@aveka.com • 651-730-1729