Size reduction and the importance of particle size

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Rich Robatzek, Product Manager, Sturtevant

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Size reduction and the importance of particle size

  1. 1. Size Reduction and the Importance of Low Particle Size
  2. 2. Who Am I? Rich Robatzek – Product Manager, Sturtevant Inc.  Business development manager for the Micronizer® jet mill product line.  Extensive background as a Sales Manager contributing to the growth and profitability of manufacturing companies  More than 20 years of industrial sales experience, growing sales territories, leading sales teams and developing new business.  Experience in food, pharmaceutical, and consumer good industries
  3. 3. Sturtevant - Perfecting Particle Size Perfecting Service Over 60% of our sales are repeat customers • All operations are under one roof which results in fast, reliable problem solving • open, full service testing facility to test each customer’s specific material and understand the grinding characteristics • An experienced field team is available for startup and field service. Perfecting Experience Thousands of installations, 60 years of micronizing • The original Micronizer® company • Sturtevant employees average over 20 years of service • Customer driven innovations including more sizes, varieties and accessories than any other jet mill manufacturer Perfecting Reliability 130 years of family operated, US manufacturing • Sturtevant President W. Sturtevant English, Jr. is the fifth generation of family management • Made in the USA means Sturtevant’s Center of Excellence and all product knowledge is domestic and easy to access • Installations in over 50 countries with every major manufacturer requiring fine grinding
  4. 4. Crushing / Grinding Methods • Impact • Compression • Shear • Attrition
  5. 5. What is Micronization? Micronization is the process of reducing a solid materials average particle size to low micron and sub micron particle sizes.
  6. 6. Why is Micronization Important in Industry? • Control of rate of dissolution and absorption • Control of chemical reactions. • Control of physical characteristics
  7. 7. Why is Micronization Important in Industry? • Control optical properties. • Product Preparations. • Efficiency – Your competitive advantage.
  8. 8. Benefits of Micronized Particles • Higher Surface Area • Tight Particle Size Distribution • Uniform Size, Spherical Shape • Better Control Properties of Powders, • (suspension, dispersion & absorption) • More Predictable Performance of Powders
  9. 9. Total Surface Area vs Particle Diameter for Spherical Objects 0 10000 20000 30000 40000 50000 60000 70000 0 10 20 30 40 50 60 70 80 90 TotalSurfaceArea(in2) Diameter (µm) 0.5 µm = 500 Nm 1 µm = 1,000 Nm 2 µm = 2,000 Nm 5 µm = 5,000 Nm 10 µm = 10,000 Nm
  10. 10. Tight Particle Size Distribution d50 d90d10 Ultra Fines Grit Micronized PSD Similar d50 Median But Lower Mean (Average) Less Grit/Less Ultrafines
  11. 11. Uniform Spherical Particles Wide PSD – Irregular Particles Tight PSD – Uniform Spherical Particles Before Micronizing (-50 microns) After Micronizing (-10 microns)
  12. 12. Principals of Operation
  13. 13. Factors of Grindability • Brittle vs. Resilient • Crystalline • Fibrous or Polymeric • Feed Particle Size • Typically 75-150 Microns • Max 800 Microns • Multi-Element Formulation • Moisture or Cohesive
  14. 14. How Feed Rate Affects Particle Size Distribution Cosmetic Powders Feed: d100 = 416 µm, d90 = 29 µm, d50 = 6.0 µm, d10 = 1.3 µm Test No. 11: d100 = 15 µm, d90 = 6.0 µm, d50 = 2.7 µm, d10 = 1.0 µm Test No. 12: d100 = 20 µm, d90 = 7.5 µm, d50 = 3.2 µm, d10 = 1.1 µm
  15. 15. Pharmaceuticals Advantageous for Ease of Cleaning, No Contamination & Small Batches • Orals, Injectables, Inhalers, Topicals, etc. • Antibiotics • Amino Acids • Steroids • Vitamins
  16. 16. Pharmaceuticals Dolasetron Mesylate for Nausea Ibuprophen Feed d50=25 µm Test 1 d50=1.5 µm Test 2 d50=2.1 µm
  17. 17. Advantageous for High Surface Area • Greater Coverage, Consistent Color in Paints • TiO2, Carbon Black, Iron Oxide • Finer than hammer mill • No oversize grit • Very smooth products Pigment
  18. 18. Iron Oxide Pigment
  19. 19. Cosmetics Advantageous for Silky Texture, No Heat • Eye Shadow, Blush, Lipstick, Eye Liners • Finer than hammer mill • No oversize grit • Very smooth products
  20. 20. Cosmetic Powder Feed: d90 = 17.2 µm, d50 = 5.84 µm, d10 = 1.56 µm Test 1: d90 = 7.17 µm, d50 = 3.41 µm, d10 = 1.17 µm
  21. 21. Agricultural Chemicals Advantageous for Heat Sensitive Powders • Herbicides, Pesticides, Insecticides, Fungicides • No temperature rise • Powder dissolves easily • No spray nozzle clog
  22. 22. Agricultural Chemicals Herbicide used in the Agricultural Industry Feed: d100 = 665 µm, d90 = 81.6 µm, d50 = 8.51 µm, d10 = 1.43 µm Test 1: d100 = 21.1 µm,d90 = 8.59 µm, d50 = 2.90 µm, d10 = 0.56 µm
  23. 23. Ceramics Advantageous for Abrasive Powders • No contamination in electronics & dental implants • Aluminum Oxide, Zirconium Oxide, Glass • No moving parts • Ceramic wear liners • No lubrication • No oversize grit
  24. 24. Foods & Additives Advantageous for Ease of Cleaning, No Contamination & No Heat • Sugar/Sweeteners/Salts (instant soups, sodas) • Proteins (baby formulas) • Gelatin/Sodium Cellulose (thickeners)
  25. 25. 11 Micronizer Sizes
  26. 26. Fineness Vs Energy Equipment Product HP lb/hr lb/hr per HP Jaw Crusher 1/2”- 2” 10 6K – 20K 600-2000 Pin Mill 45-75 µm 20 2K – 4K 100-200 ACM 20-45 µm 35 200 – 2K 6-60 Jet Mill 0-20 µm 40 10 – 100 0.25-2.5
  27. 27. Production System 1 2 3 1) Feeder 2) Micronizer® 3) Bag House 4) Product Collector 4 Up to 42” diameter 6,000 lbs/hr
  28. 28. Q&A Rich Robatzek Micronizer® Product Manager Office: 978-829-1418 Cell: 617-615-7176 rrobatzek@sturtevantinc.com Micronizer® is a registered trademark of Sturtevant Inc.
  29. 29. Perfecting Particle Size since 1883

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