Industrial pharmacy is a discipline which includes manufacturing, development, marketing and distribution of drug products including quality assurance of these activities
The reasons for the increasing of large scale manufacturing
Economic – As the scale of manufacturing batches increases so, proportionally, does the cost of production decreases
Accuracy – The larger the quantities of materials involved so, proportionally, is the accuracy of measurements increased
Greater scope – The increasing complexity of modern therapy has made it virtually impossible to prepare many medicaments on a small scale
1. Industrial pharmacy
8/22/20171
Industrial pharmacy is a discipline which includes
manufacturing, development, marketing and
distribution of drug products including quality
assurance of these activities
The reasons for the increasing of large scale
manufacturing
Economic – As the scale of manufacturing batches
increases so, proportionally, does the cost of
production decreases
Accuracy – The larger the quantities of materials
involved so, proportionally, is the accuracy of
measurements increased
2. The Fundamentals unit operations
8/22/20172
In a pharmaceutical industry a unit operation is a
basic step in a process
Eg. tablet processing: mixing, milling, drying
and sifting
It is convenient to break down the processes for the
manufacture of pharmaceutical products into unit
operations
those unit operations are not fundamental
All unit operations involve and are controlled, to a
greater or lesser extent, by one or more of the
following basic processes.
Fluid flow
3. Fluid flow
8/22/20173
Fluids are a form of matter that cannot achieve
equilibrium under an applied shear stress but
deform continuously, or flow, as shear stress is
applied.
Certain aspects of all the unit operations employ
the movement of a fluid through pipes or
between or around particles, etc
Mechanism of Fluid Flow
When a fluid flows through a pipe , the character
of the flow can vary according to the conditions
4. Reynolds’ experiment
8/22/20174
a long glass tube was connected to
a reservoir providing a constant
head of water, with the control
valve at the outlet so that the rate of
flow could be varied
In the inlet of the tube a jet was
inserted which allowed a colored
liquid to be injected into the center
of the tube for the visualization of
the flow behavior
5. Cont…
8/22/20175
When the velocity is low, the thread of colored liquid remains
undisturbed in the center of the water stream and moves steadily along
the tube, with out mixing, this condition is known as streamline or
laminar flow (a)
At moderate velocities, a point is reached (the critical velocity) at which
the thread begins to waver, although no mixing occurs. This is the
phase of transitional flow.
As the velocity is increased to high values eddies begin to occur in the
flow, so that the colored liquid mixes with the bulk of the water
immediately after leaving the jet. Since this is a state of complete
turbulence, the condition is known as turbulent flow.
6. Cont…
8/22/20176
Reynolds found that flow conditions were affected by four factors
Diameter of pipe
Velocity of fluid
Density of fluid
Viscosity of fluid
Re = ρvd/μ
where Re = Reynolds Number
ρ = density of fluid (kg/m3)
v = velocity of fluid (m/s)
d = diameter of pipe (m)
μ = viscosity of fluid (kg/m. s)
Reynolds number is just a number and it has no
7. Distribution of Velocities Across the Tube
8/22/20177
When a fluid flows along a tube, not all parts
are moving at the same velocity
The fluid in the center travels at the highest
velocity and that at the walls at the lowest
In laminar flow; Fluid in the centre can move
at highest velocity with frictional force causing
a continual decrease in the velocity towards
the walls
8. Boundary Lines
8/22/20178
whether flow in the tube is laminar or turbulent, the
velocity reaches very low values near the walls
ultimately, it becomes zero at the wall itself
Reynolds Number is proportional to the velocity
So similar decrease in the value of the local Re.
This means that there will be a change from
turbulence, through a transitional region to a
sluggish streamline region and finally, to a stationary
film on wall.
that boundary layers can never be eliminated
Increasing the velocity of the fluid over the surface
will reduce the thickness of the layer
9. 1.2 Heat Transfer
8/22/20179
Heat is a form of energy.
It can only be transferred from a region of higher
temperature to a region of lower temperature
Many pharmaceutical unit operations like
distillation, drying, evaporation, sterilization etc
involve the application of heat
Heat is transferred by three mechanisms
Conduction: is the transfer of heat through a static
material by direct contact of particles of matter
is greater in solids, where atoms are in constant
contact
is limited to solids and to fluids that are ‘bound’ in
10. Cont…
8/22/201710
Convection: is the transfer of heat from one point to another
within a fluid (gas, liquid) by the mixing of one portion of the
fluid with another
In convection, the heat flow results from mixing or turbulence,
which can occur in fluids only
Radiation: is the transfer of heat energy through empty space
No medium is necessary for radiation to occur
12. Heat transfer by conduction
8/22/201712
Conduction is the most familiar and widely
understood mechanism of heat transfer
When heat is flowing under steady-state
conditions, the quantity of heat transferred is
given by:
13. 8/22/201713
k ,which is characteristic for any material, is known
as the coefficient of thermal conductivity
Thermal conductivities vary considerably, ranging
from metals that have high values to gases that
have the lowest values
Material Thermal conductivity
(J/sm°c)
Copper 379
Aluminum 242
Steel 43
Glass 1
Water 0.6
Air 0.03
14. 1.3 Mass transfer
8/22/201714
involves the movement of material from one
phase to another
Eg. in drying a wet solid, the liquid is
converted to vapor and carried away in that
form
when a drug is extracted with a solvent,
soluble material passes from the solid phase
into solution and is taken away in the liquid
phase
15. Solid fluid mass transfer
8/22/201715
Consider a crystal of a soluble material immersed in
a solvent in which it is dissolving
transport of the molecules of the dissolving solid will
take place in two stages
First the molecules move through the boundary layer
by molecular diffusion, with no mechanical
mixing
Once material has passed through the boundary
layer, mass transfer takes place by bulk movement of
the solution, known as eddy diffusion,
the controlling factor in the rate of solution of the
crystal will be the molecular diffusion through the
boundary layer
16. Cont…
8/22/201716
Eddy diffusion will not be considered further
since, in general, molecular diffusion is the
controlling process
Equation for mass transfer by molecular
diffusion
17. Factors affecting Solid fluid mass transfer
8/22/201717
Agitation, which reduces the thickness of the
boundary layers and disperses any local
concentrations of solution, so increasing the
concentration gradient.
Elevated temperatures which increase the diffusion
coefficient and decrease the viscosity of the liquid,
so reducing boundary layer thickness.
Size reduction of the solid, which increases the
area over which diffusion can occur.
18. Unit operations
8/22/201718
Unit operations:- are different processes and
equipments required in the manufacturing of
pharmaceuticals
Size reduction
Mixing
Drying
Filtration
Crystallization
19. Drying
8/22/201719
Removal of water or other liquid from a solution,
suspension or solid –liquid mixture to form a dry
solid
involves heat transfer and mass transfer
Drying and evaporation are distinguishable merely
by the relative quantities of liquid removed from the
solid
Purpose of drying/Application of Drying
In the preparation of granules
Stabilizes moisture sensitive materials :-Aspirin
& penicillin
20. Factors affecting drying
8/22/201720
The critical factor in drying operations is the
vapor - carrying capacity of the air, nitrogen,
or other gas stream passing over the drying
material
The vapor - carrying capacity determines both
rate and extent of drying
Heat sensitivity of the product
Physical characteristics of the product
Nature of solvent to be removed
21. Convective Driers for Wet Solid
8/22/201721
Tray Drier
Air flows in the direction of
the arrows over each shelf
in turn
The wet material is spread
on shallow trays resting
as the shelves
The required latent heat
of evaporation is
transferred convectively
from the air
Slow heat transfer=> slow
rate of drying
22. Dynamic Convective Driers
8/22/201722
Fluidized Bed
Drier(FBD)
There is an excellent
contact between the warm
drying air and the wet
particle
The material to be dried is
contained in a vessel, the
base of which is
perforated enabling a fluid
(air) to pass through the
bed of the solid from the
bottom
23. Advantages of Fluidized Bed Drying
8/22/201723
Efficient heat and mass transfer. This
attributes to
Short drying time (20-30 min)
Good for thermolibile materials
Drying occurs from the surface of the individual
particles
No migration of soluble API & Expients
The temperature of the fluidizing bed is uniform
throughout and can be controlled precisely
Turbulence cause attrition – More spherical free
flowing particles
The container can be mobile, good for material
24. Disadvantages of FBD
8/22/201724
Turbulence – Excessive attrition
Production of too much dust –> too fine –> flow
problem
– >segregation
Generation of static electricity
Mixture of air with organic materials (starch and
lactose) can cause explosion
The danger is increased if the fluidizing material
contains volatile solvents such as isopropyl
alcohol
Therefore, adequate electrical earthing is
25. Conductive Drying of wet solids
8/22/201725
The wet solid is in thermal contact with a hot surface
and heat transfer mainly occurs by conduction
Vacuum Oven
Consists of a jacketed Vessels sufficiently strong in
construction to with stand vacuum and steam pressure in
the jacket
Operating pressure can be as low as 0.03-0.06 bar,H2O
boils at25-350c
[[[
Commonly used in pharma R & D`s
Advantages:
For thermolibile products
Minimum oxidation
26. Radiation drying of wet solid
8/22/201726
Microwave (MW) Radiation
Microwave radiation in the Wave length of 10nm-
1nm penetrates much better than IR
More application in pharma than IR dries does
Microwaves are produced by an electronic
devices known as magnetron
When MW falls on substances of suitable electronic
structure (Polar molecules e.g. water), the electrons
in molecules attempt to resonate in sympathy with
the radiation and the resulting molecular friction
which in turn causes generation of heat
27. Advantage of MW drying
8/22/201727
Rapid drying at fairly low Temp.
Thermal efficiency is high
most of the MW is absorbed by the liquid
No heating of the air
The bed is stationary avoiding the problem of dust
generation
Solute migration is reduced as there is uniform
heating of the wet mass.
Equipment is highly efficient and refined
All product and operators safety have been
incorporated
CGMP compliant
Drying end point detection is possible
28. Disadvantages of MW drying
8/22/201728
Smaller batches sizes are used as compared to FBD
Safety issues.
Care should be taken to shield operators from the MW
radiation
which can cause damage to the eyes and testes
29. Driers for Dilute solutions and suspensions
8/22/201729
Objective
To spread the liquid to a large surface area for heat and
mass transfer and to provide an efficient means of
collecting the dry solid
Two main types are used
Spreading the liquid to a thin film on a drum
Dispersing the liquid to a spray of small droplets
30. Drum driers
8/22/201730
consists of a drum 0.75-1.5m
in diameter and 2-4m in length
It is heated internally by steam
The liquid is applied to the
surface of the drum and
spread to a film
This is usually performed by
Deeping the drum in the
feeding pan
Drying rate is controlled by
Manipulating the speed of the
drum
Manipulating Temp.
The product is scraped from
31. Advantages of the drum drier
8/22/201731
gives rapid drying =>rapid heat and mass transfer
The equipment is compact less space than spray
drier
Heating time is short (a few sec)
The drum can be enclosed in vacuum =>the drying
Temp. can be reduced
The product is obtained in flake form which is
convenient for many purposes
32. Disadvantages
8/22/201732
Operation conditions are critical i.e. it is
necessary to impose careful control on
Feed rate
Film thickness
Speed of drum
Drum Temperature
Pharmaceutical applications
Drying of starch products
Ferrous salt
Suspensions of Zn oxide
33. Spray Driers
8/22/201733
Provides a larger surface area for heat and mass
transfer
Works by atomizing the liquid to small droplets
The liquid is sprayed into a stream of hot air
Each droplet dries to an individual solid particles
Mechanism of drying
The air enters the chamber tangentially and rotates the
drying droplets around the chamber to increase their
residence time
The air is heated by heat exchangers
Dust carried over in the air is recovered by cyclone
separator of filter
Physical characteristics of spray dried products
35. Advantages of the spray Drying process
8/22/201735
Rapid drying (fraction of sec)
Evaporation is rapid =>the droplets do not attain
high Temp.
good for thermolibile products
High bulk density=> rapid dissolution due to
increased surface area
Uniform and controlled particle size
The product is free flowing as the particles are
spherical in shape
Low labor costs. No human handling
36. Disadvantages
8/22/201736
The equipment is very bulky
Thermal efficiency is low as the air is still hot when it
leaves the drier
Pharmaceutical Application
Gelatin
Starch
Some powdered antibiotics for reconstitution into
syrup
Particles in 1-7mm can be dried and used in DPI
(dry powder inhalers)
Can be operated with inert gases for 02 sensitive
37. Freeze drying (lyophilization)
8/22/201737
Many products of pharmaceutical lose their viability
in the liquid state and readily deteriorate if dried in
air at normal atmospheric pressures
It works by freezing the material and then reducing
the surrounding pressure and adding enough heat to
allow the frozen water in the material to sublime
directly from the solid phase to gas
38. Advantages
8/22/201738
1. Drying takes place at low Temp., so that enzymes
action is inhibited and chemical decomposition,
particularly hydrolysis, is minimized
2. The solution is frozen such that the final dry product
occupy the same volume as the original solution
3. Fast solubility due to high porosity
4. The process takes place under high vacuum; there
is little chance for oxidation
39. Disadvantage
8/22/201739
1. Very hygroscopic substance.
The products should be dried in their final
containers and sealed in situ
2. The process is very slow and uses complicated
plants and not universal method.
Uses
For drying of Biological products
Such as Antibiotics, blood products and
vaccines, and enzyme preparations
40. Size Reduction
8/22/201740
is the mechanical process of reducing the particle
size of a substance to smaller pieces, to coarse
particles, or to powder
Various terms have been used synonymously with
size reduction depending on the product, the
equipment, and the process
Crushing , Grinding, Milling, Pulverization and
Dispersion
particle size affects a number of characteristics in
the manufacturing process
controlling the particle size helps assure that the
milled material will be consistent and repeatable
41. the most common reasons for reducing material sizes
8/22/201741
Create appropriate particle sizes for subsequent
processing or end use
Color - uniform particles assure batch-to-batch colo
consistency /less chance for mottling/
Improve material blending and prevent segregation
by making different sized products with similar particle
size distributions
Increase the material’s surface area to improve a
material’s solubility
Examples:- decrease particle size of griseofulvin
decreased oral dosage regimen half.
To facilitate drying of wet masses
reduces the distance the moisture must travel to
42. Factors affecting size reduction
8/22/201742
Hardness
Hard materials are difficult to comminute
Toughness
It is often more important than hardness, so that a soft
but tough material may present more problems in size
reduction than a hard but brittle substance.
Ex. - Rubber - Fibrous drugs
Rubber are capable of absorbing large amount of
energy through elastic and plastic deformation
Such materials can be milled by cooling
Stickiness
It may cause difficulty in size reduction, since a material
acts as a lubricant & lowers efficiency of the grinding
surfaces.
Example:- Grinding of gummy or resinous
43. Cont…
8/22/201743
Softening Temperature
The heat during size reduction processes softens and
melts materials with a low melting point.
Ex. – Synthetic gums and resins
- Heat-sensitive drugs may be degraded or even
charred
Moisture content
An increase in moisture can decrease the rate of size
reduction to a specified product size
The presence of more than 5% water hinder comminution
and often produces a sticky mass upon milling
Only a small amount of energy put into a milling
operation actually effect size reduction (2%)
44. Methods for size reduction
8/22/201744
There are four main methods of effecting size
reduction
Cutting:- the material is cut by means of a sharp
blade or blades
Compression:- the material is crushed by
application of pressure
Impact:- material is hit by an object moving at a
high speed or it strikes a stationary surface and
the material is broken down into small places
Attrition:- the pressure is applied to the material
as in the case of compression, but the surfaces
are in motion relative to each other.
45. Cutting
8/22/201745
The cutter mill consists of a series of knives attached on
a horizontal rotary which act against a series of
stationary knives attached to the mill casing.
Size reduction occurs by fracture of particles between
the two sets of knives which have a clearance of a few
millimeters
Application
To produce a coarse degree of size reduction of dried
granulation prior to tableting
To mill fibrous crude drugs such as roots or barks prior
to extraction
47. Compression
8/22/201747
Size reduction range 10-100μm
Direct-pressure milling occurs when a particle is
crushed or pinched between two hardened surfaces
Two rotating bars or one rotating bar and a stationary
plate generally produce this milling action
Used in small scale by using a mortar and pestle
In large scale there are:
End runner mill- a weighted pestle is turned by
friction of material passing beneath it- a mortar rotates
under the powder
Edge runner mill -a pestle rotates against a bed of
powder
48. Alternative technique/Roller Mill/
8/22/201748
Compression mill which uses two cylindrical rollers
mounted horizontally and rotated about their long axes
In rollers, one of the rollers is rotating and the other one
is rotated by friction.
This are not like ointment mills where both rolls are
driven at different speed and size reduction occurs by
attrition
The commonest method in the pharmaceutical industry
USE - used for crushing, such as cracking the seeds
of fixed oils to aid solvent penetration in extraction
49. Attrition milling (1-100μm)
8/22/201749
Is used for the Size reduction of solids in
suspensions, pastes and ointments
Roller Mill
Two or more metal rolls are mounted horizontally with
an adjustable gap which can be as small as 20 μm
The rollers rotate at different speeds so that the
material is sheared as it pass though the gap
The material is transformed from the slower to the
faster roll
The material (milled) is removed by scraper
50. Impact milling (1-10000μm)
8/22/201750
A hammer mill
A hammer mill consists of a four or more hammers
hinged on a central shaft which is enclosed in a rigid
metal case
During milling, the hammer swing out radially from
the central shaft
As size reduction continues the inertia of particles
hitting the hammer reduces and sequentially fracture
is less probable
Hence, hammer mill tend to produce powders with
narrow size distribution
53. Cont …
8/22/201753
Example-2 Alternative Technique (Vibration
Milling)
Uses a drum where 80% of the content is filled with
porcelain or steel balls
During milling, the whole body of the mill is vibrated
and size reduction occurs by repeated impaction
Comminuted particles fall through a screen at the
base of the mill
The efficiency of vibration milling is greater than
that of the conventional ball mill
54. Combined impact and attrition Method
8/22/201754
Ball mill
Both impact and attrition methods are used
Consists of a hollow cylinder containing balls (30-
50%) of its space
The amount of material in a mill is considerable
important
Speed of ball mill has a considerable effect on
grinding
At low speed – balls will slide or roll over each
other
56. Advantages of ball mill
8/22/201756
It is capable of grinding a wide variety of materials
It can produce very fine powders
It is economical and simple to operate
It can be used for batch or continuous operation
It can be used in completely enclosed form, which
makes it especially suitable for use with toxic
materials
Disadvantages
Contamination may happen because of wearing of
balls and partially from casing.
Soft materials may stick on the sizes of the mill.
57. Fluid Energy Mill
8/22/201757
Utilizes particle impaction and attrition
Consists of a hallow tube with a diameter of 20-200mm
A fluid (air) is injected as a high pressure jet through
nozzles at the bottom of the loop
The high velocity of the air gives rise to zones of
turbulence into which solid particles are fed
The high kinetic energy of air causes the particles to
impact with each other
A particle size classifier is incorporated so that particles
are retained in the tube until sufficiently milled
58. Advantages Fluid energy mill
8/22/201758
The particle size of the product is smaller than that
produced by any other method of size reduction
Is used for thermolabile substances because the
cooling effect counteracts the heat generated by milling
There is no abrasion of mill so virtually no
contamination of the product
For very sensitive materials it is possible to use inert
gases
Having a classifier as an integral part of the system
permits close control of particle size and of particle size
distribution
Use:- used for obtaining very fine powders, e.g.
59. SIZE SEPARATION
8/22/201759
In pharmaceutical industry, the control of particle size
and size range has great importance
Standards for sieves
There are different standards of sieves for
standardization of particles size of powders
Number of sieves:- this is the number of meshes in a
length of 25.4 mm (1 inch), in each direction, parallel to
the wires
thus a number 10 sieve has 10 meshes in 2.54cm in
each direction
Nominal size of aperture:- this is the distance
between the wires, so that it represents the length of the
side of the square aperture
60. Size separation by sieving
8/22/201760
There are several techniques for encouraging particles
to separate into their appropriate size fractions
efficiently
Agitation methods
A. Oscillation:- The sieve is mounted in a frame that
oscillated back and forth
B. Vibration:- the mesh is vibrated at high speed,
often by means of an electrical device
Brushing methods
A brush can be used to move the particles on the
surface of the sieve and to keep the meshes clear.
61. Cont …
8/22/201761
Centrifugal methods
This type of sieve used a vertical cylindrical sieve
with a high speed rotor inside the cylinder, so the
particles are thrown outwards by centrifugal force
Wet sieving
Wet sieving is more efficient than the equivalent dry
process, particles being suspended readily and
passing easily through the sieve with less blinding of
the meshes.
62. Mixing
8/22/201762
is a process in which two or more components in a
separate or roughly mixed condition are treated so that
each particle lies as nearly as possible in contact with a
particle of each of the other ingredients
Purposes of pharmaceutical mixing
To ensure even distribution of the API
To ensure even appearance
To ensure the release of the drug at the correct site
and at the desired rate
63. Types of Mixtures
8/22/201763
There are three types of mixing based on their
behavior:-
Positive mixtures
These mixtures are formed when two or more miscible
liquids are mixed together by diffusion process.
Irreversible mixing would take place.
Negative mixtures
Hence insoluble solids are mixed with the vehicle to form
a suspension or two immiscible liquids are mixed to form
emulsion.
require energy for their formation
The components of which will separate unless work is
continually expanded on them.
64. Cont…
8/22/201764
Neutral Mixtures
Here mixing of pastes, ointments takes place.
When two powders are mixed, then it forms a
neutral mixtures
Components of the mixture have no tendency to
mix spontaneously, nor do they segregate when
mixed
They are static in their behavior
65. Mechanisms of solid mixing
8/22/201765
Convective mixing
Arises when there is the transfer of relatively large group
of particles from one part of the powder bed to another as
might occur when a mixture blade or paddle moves
through the mix
In order to achieve a random mix an extended mixing time
is required
Shear mixings
When a layer of material moves / flow over another layer
66. Cont..
8/22/201766
Diffusion mixing
When the powder bed is forced to move or flow
This is because the powder particles will become
less tightly packed and there is an increase in the
voids space between them
Under this circumstance, there is a potential for the
particles to fall under gravity through the void
created
results in low rate of mixing
N.B all three mixing mechanisms are likely to occur
in a certain mixing operation
67. Mechanisms of Mixing for Liquids
8/22/201767
Bulk transport
involves the movement of a relatively large amount
of materials from one position in the mix to another
It tends to produce a large degree of mixing fairly
quickly
Turbulent mixing
Arises from the haphazard movement of molecules
when forced to move in a turbulent manner
Molecular diffusion
Occurs with miscible fluid whenever a concentration
gradient exists and will eventually produce a well
mixed product
68. Powder Segregation /demixing/
8/22/201768
Segregation is the opposite effect to mixing i.e.
components tend to separate out
is very important in pharmaceutical preparations
as it causes a non random mixing
Effects of segregation
Increased content variation
Un acceptable variation in weight
Processing difficulties
Non uniform drug release rate
69. Causes of powder segregation
8/22/201769
Particle size effect
It is the main cause of segregation
a. Percolation segregation
Smaller particles tend to fall through the void between
larger ones and moves to the bottom of the mass.
Example - during vibration, Stirring or poring
b. Trajectory segregation
During mixing larger particles will tend to have greater
kinetic energy imparted to them and therefore will tend
to move greater distance than smaller particles before
come to rest
70. 8/22/201770
C. Elutriation segregation/Dusting out/
When a material is discharged from a container, very
small particles dust in a mix may tend to be blown
upward by turbulent air current as the mass tumbles
and remains suspended in the air
Particle –density effect
If component are of different density, the more dense
materials will have a tendency to move downward even
if the particles size are similar
Particle shape
Spherical particles exhibit the greatest flow ability and
are therefore more easily mixed, but they also
segregate more easily than non spherical particles
71. Approach to Rectify Segregation
8/22/201771
Selection of particle size fractions
E.g. sieving to remove fins or lumps to achieve drug
and excipients within narrow particles size
distribution range
Milling of components followed by sieving
To reduce particle size range
Controlled crystallization
Selection of excipients which have densities similar
to the API
Avoid vibration /proper material handling/
Use of filling machine hopers designed so that
72. Powder mixing equipment
8/22/201772
Tumbling mixer equipments
Used for mixing /blending of granules of free flowing
powders
There are many designs
Examples :Double cone mixers, Twin shells ,Cube
mixers , y- cone mixers, Drum mixers
Too high mixer speed
Will cause the material to be held on the wall by the
centrifugal force
Too low mixer speed
Will generate insufficient bed expansion and little
shear mixing
74. 8/22/201774
High speed mixer granulator( Rapid mixer
granulators)(RMG)
It both mixes and granulates
Fluidized Bed mixers
Used for mixing of powders prior to granulation
Agitator mixers
Eg -ribbon mixers
75. Mixing of Miscible Liquids and Suspensions
8/22/201775
Propeller mixer
It has angled blade which cause the fluid to circulate in
both axial and radial directions
Turbine Mixer
Used for more viscous fluids
The impeller has four flat blades surrounded by
perforated inner and
outer diffuser rings
77. Mixing of Semi solids
8/22/201777
The problem with semi solids is that they are
not free flowing
For this reason, mixers with rotating
elements and narrow clearance between
themselves and mixing vessels wall
they must produce a high degree of shear
mixing
Sigma blade mixer /- mixer/
79. Clarification (Filtration)
8/22/201779
Filtration is process that involves the removal or
separation of a solid from a fluid or a fluid from
another fluid
The preparation of pharmaceutical dosage forms
frequently requires the separation of particles from a
fluid
Objectives
Sparkling liquid that is free of
Crystalline precipitates or amorphous
Colloidal hazes
Insoluble liquid drops
Removal of microbes or sterilization
80. Terminologies in Filtration
8/22/201780
Filters: - the porous (permeable) material that
separates particles from the liquid passes through it
Residue: - solids retained in the filter
Effluent filtrate:-the classified liquid
Cake filtration:- The solid forms a cake on the medium
and if the recovery of this cake is required the process is
called cake filtration
Clarification: - When the solid to be filleted is not
exceeding 1.0% and the filtrate is the primary product
Ultra filtration- separation of inter molecular liquid from
solids by the use of pressure in on a semi permeable
81. Principles of Filtration
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It is more of an art than a science
The flow of liquid through a filter follows the basic rules
that govern flow of any liquid through a medium offering
resistance
The rate of flow may be expressed as
Rate = driving force
Resistance
The rate is expressed as volume per unit time & the
driving force as a pressure differential
Rate of filtration:- ( dv) (area of filter) x (pressure
difference)
( dt) (Viscosity) x (resistance of
82. Factors Affecting Filtration rate
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The area available for filtration (A)
The pressure difference across the filter bed (filler
medium and any cake formed)
The viscosity of the fluid passing through the filter i.e.
the filtrate( μ pas) increase viscosity =>greater
resistance for movement
The thickness of the filter medium and any deposited
cake (L)
Increased Cake = >decreased rate of filtration
83. Mechanisms of Filtration
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Straining (sieving)
the pores are smaller than the particles to be filtered,
and this results the particles to be retained on the filter
medium.
Example – Removal of bacteria and fibers from parental
preparation
Impingement -A liquid following pattern is disturbed
eg. Used mainly for removal of materials from gases
Entanglement
If the filter medium consists of a cloth with a nap or is a
porous , then particles become entangled in the mass of
fibers
84. Filtration Equipment
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•Equipment selection
Equipment should
Allow a fast filtration rate
Minimize production cost
Cheap to buy and to run
Be easily cleanable
Be resistant to corrosion
Be capable of filtering large volumes
85. Industrial Filtration Equipments
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Gravity Filter
Filter that relay solely on gravity generate low
operating pressure
They are very simple and cheap and used in
laboratories
Are common in water treatment Ex - Sand filter
Vacuum Filters
The rotary Vacuum Filter
is continuous in operation and has a system for
removing the cake
up to 2m in diameter and 3.5m in length with a
filtration area of 20m2
Used for continuous filtration of slurry containing 15-
87. Advantages
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1. It is automatic and continuous in operation
2. It has a large capacity
3. Varied speed of rotation enables the cake thickness
to be controlled
Disadvantage
1. It is complex and expensive
2. Ancillary equipments like
vacuum pump
Vacuum receivers
Slurry pumps are required
3. Less satisfactory for solids that forms impermeable
cake
88. Pressure filters
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The product is fed to the filter at a high pressure
Most commonly used for processing of pharmaceuticals
I. The Meta filter
The filter operates by pumping in the slurry under
pressure
Advantages
1. High strength and no fear of bursting
2. No filter medium (stainless steel). This makes it
economical
Application
The small surface area restricts the amount of solid that
can be
collected.
89. Cartridge filter
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Commonly used in the
preparation of
pharmaceutical products
It poses a very large
filtration surface area in a
small unit and is easy and
cheap to operate
The cartridge is then fitted
in a metal supporting
cylinder and the product is
pumped under pressure
into one end of the
90. Air Filtration (High Efficiency Particulate Air (HEPA) filter)
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HEPA is a type of highly efficient filtration media that
removes microscopic particles from air which
passes through the filter
The most efficient HEPA filter removes 99.7% of
particles with a size of 0.3η that enter the filter.
Such particles include tobacco smoke, household
dust, and pollen.
ULPA filters, or "Ultra-HEPA" filters, are designed to
trap 99.999%
Usually Microban is used in HEPA filters which is
used to treat the HEPA filter
91. 8/22/201791
In most industries HEPA filters work along with
Dehumidifiers or humidity controllers and also along
with steam line and chillers which controls the
temperature in such cases the system is termed as
Heating, Ventilation and Air conditioning system
(HVAC system)
93. Crystallization
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Crystallization refers to the formation of solid crystals
from a homogeneous solution
It is essentially a solid-liquid separation technique
The processes by which a crystal forms are called
nucleation and growth.
Nucleation is the formation of a small mass on to which
a crystal can grow.
Growth is the addition of more solute molecules to the
nucleation site
In order for crystallization to take place a solution must
be "supersaturated“
Supersaturation refers to a state in which the solvent
contains more dissolved solute
94. Cont…
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Primary nucleation is the first step in crystallization.
Simply defined, it's the growth of a new crystal
The second chief mechanism in crystallization is called
secondary nucleation requires "seeds" or existing
crystals to achieve crystal growth
The four most common methods of reaching
supersaturation in industrial processes are:
Cooling (with some exceptions) Ce2(SO4)3
Solvent Evaporation
Drowning :addition of a nonsolvent to the solution
which decreases the solubility of the
solid
Chemical Reaction: alter the dissolved solid to
96. Equipment Used in Crystallization
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Tank Crystallizers
the oldest and most basic method of crystallization
saturated solutions are allowed to cool in open
tanks
After crystallization, the mother liquor is drained and
the crystals are collected
The crystallization is essentially just "allowed to
happen“
Heat transfer coils and agitation can be used
high operating costs
97. Forced Circulating Liquid Evaporator-Crystallizer
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These crystallizers combine crystallization and
evaporation
The circulating liquid is forced through the tube side of
a steam heater
The heated liquid flows into the vapor space of the
crystallization vessel
flash evaporation occurs, reducing the amount of
solvent in the solution
The supersaturated liquor flows down through a tube,
then up through a fluidized area of crystals and liquor
where crystallization takes place via secondary
nucleation.
Larger product crystals are withdrawn while the liquor
is recycled, mixed with the feed, and reheated.