MATERIALS AND SOLIDS PROCESSING
Better particle characterisation means better processing
Fast and cost-effective particle characterisation leads to more consistent and less expensive manufacturing for the chemical industry. Eugene McCarthy reports.
Une caractérisation rapide des particules et avec un bon rapport coût- efficacité permet une production plus constante et moins coûteuse pour l’industrie chimique. Selon Eugene McCarthy.
Schnelle und kostengünstige Partikelcharakterisierung führt zu einer konsistenteren und günstigeren Herstellung in der chemischen Industrie. Eugene McCarthy berichtet.
M
ettler Toledo has launched its new inline particle system characterisation tool ParticleTrack
E25. Modifying focused beam reflectance technology (FBRM) for use in settings where pneumatic motors are impractical, the fully electric ParticleTrack E25 measures aqueous particle and droplet systems for the chemical and other industries. This probe-based technology eliminates
sampling’s measurement variability for simpler, faster and more cost-effective system characterisation, as well as the more consistent and less expensive manufacturing outcomes it promotes (Fig. 1). Based on traditional FBRM technology
yet requiring no air/gas supply, this robust FBRM probe allows real-time product-quality optimisation, greater formulation stability, and enhanced processing whether particle systems are being observed in two-litre beakers, 20,000-litre vessels, or pipeline flow. This versatility and ease-of-use is helping to put FBRM technology in the hands of labs and production environments in industries where it has historically been considered a luxury. Now, those working in non-explosive
environments in almost any industry can access FBRM’s ability to optimise processes in real-time. This includes FBRM advances such as the ability to detect and correct for particles that are ‘stuck’ to the probe and enhanced measurement consistency over a wider dynamic range. These improvements maximise sensitivity and data integrity and encourage more intuitive data analysis. ParticleTrack E25 is ideal for measuring
modern manufacturing processes such as crystallisation and precipitation; homogenisation and emulsification; and solid/ liquid or liquid/solid separations including flocculation, coalescence, and flotation. In a separate development, Mettler Toledo
has published its latest, free, downloadable white paper. ‘Recent advances for seeding a crystallisation process: a review of modern techniques’ explores crystallisation experiments that, coupled with advanced seeding techniques and real-time in situ process feedback, provide results which significantly improve yields and reduce manufacturing costs. Seeding has become a critical and widely- used step to optimise crystallisation behaviour,
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process efficiency, and product quality. However, a non-ideal seeding protocol can result in inconsistent filtration rates, drying times, yields, bulk density, flow properties and particle size distribution - any of which can disrupt downstream processing, potentially resulting in costly rework or even expensive product loss. The white paper details both general
seeding theory and use of inline particle measurement tools such as FBRM, particle vision and measurement (PVM), and ATR- FTIR (ReactIR). Results include significantly improved fine particle counts which eliminated the need for post-crystallisation milling. In practical application, this benefit has been shown to shorten production schedules for faster time-to-market - an essential ingredient in cost-effective chemical and pharmaceutical manufacturing in today’s highly competitive global marketplace.
Granulation processes The Parsum in-line particle sizing probe from Malvern Instruments is proving its value as a process analytical technology (PAT) instrument in granulation research being conducted at Ghent University in Belgium. Professor Thomas De Beer’s PAT
group at the university is successfully using the instrument to continuously monitor granulation processes and to develop effective automated strategies for process control. The PAT group focuses on identifying
robust and relevant PAT tools for the chemical and pharmaceutical industries. The team researches how these can be applied to improve manufacturing efficiency. Granulation trials have shown that real-time particle size measurements, in combination with other analytical data, support consistent production of granules to a defined specification. De Beer said: “In our research we look
at all aspects of PAT. We focus not only on assessing different technologies and instrumentation for monitoring, but on applying the resulting data to process control. Using Parsum we have tracked the evolution of particle size in real time during fluidised bed granulations. The data provide detailed information during design of experiment studies and enable us to develop models for real-time batch evaluation. These models help drive effective automated process control and
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