Granulation & Compaction
Design & Optimization of Granulation & Compaction Processes
This granulation/compaction workshop is an intense course drawing heavily on the interaction between powder properties and unit-operations, covering a variety of granulation and compaction processes as well as formulation techniques (fluid-beds, mixers, pans, tabletting, roll pressing, and extrusion).
The course emphasizes the marriage between formulation properties, characterization techniques, and engineering scale-up in controlling granule/compact quality. It features scale-up sessions for mixer and fluid-bed granulation, and demonstrations of the impact of stress transmission & lubrication on tabletting and compaction.
The workshop should be of interest to those involved in powder and pharmaceutical processing or formulation efforts for which granule and compact properties are critical.
Typical participants include those from pharmaceutical processing, excipient and chemical manufacture, food and consumer product production, and a variety of advanced material processes.
Course content will include principles of granulation and compaction; demonstrations of key agglomeration rate process phenomena (wetting, nucleation, granule growth and densification, granule breakage, and forming processes on compaction); design, scale-up & operation of various granulation processes and compaction techniques (fluid-beds, mixers, pans, tabletting, roll pressing, and extrusion).
Interactions between formulation properties and process equipment are particularly emphasized in the course. Characterization techniques relevant to granulation and compaction are discussed, including IGC, wet mass rheology and power, permeabilty characterization, fracture testing, Heistand and Heckel compaction testing, particle sizing, NIR chemical imaging, and effusivity.
Presentations of participant case studies and pre-course characterization of samples are also offered; contact us directly for further details. This course is based on latest advancements in size-enlargement theory based on the work of Dr. Ennis and colleagues as highlighted in Section 21: Solids Processing, Perry’s Chemical Engineers’ Handbook, 8th Ed, 2006; “The Science and Engineering of Granulation Processes,” Kluwer Academic Press, 2004; and “Theory of Granulation: An Engineering Perspective,” in Handbook of Pharmaceutical Granulation Technology, 2nd Ed., Marcel Dekker, 2005.
Sample Schedule:
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Day 1: |
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| 7:00 AM | Breakfast |
| 8:00 AM | Morning Lecture: Controlling granulation rate processes, Interaction of feed/ formulation properties & process operating variables, Wetting & nuclei formation, Characterization techniques based on Washburn & IGC, Spray flux regime map, Granule coalescence & growth. |
| 12:00 | Lunch |
| 1:00 PM | Afternoon Lecture: Granule growth (continued), Granule yield properties & deformability, Characterization techniques of wet mass rheology, Granule densification & bulk density, Regime map of granule growth, Granule breakage & attrition. |
| 4:00 | Afternoon Break |
| 5:30 | Dinner |
| 7:00 PM | Evening Session: Wrap-up, Powder flow characterization by shear cell, Characterization vendor presentations & hands-on testing.Shear cell & other characterization access for client samples. Offered on first come/first serve basis w/prior arrangements.(Requires prior MSDS review & approval with E&G Associates.) |
| 8:30 | Evening hors d’oeuvres & social time |
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Day 2: |
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| 7:00 AM | Breakfast |
| 8:00 AM | Morning Lecture: Design, scale-up & operation of agitative agglomeration processes: Fluid-Bed, Drum, Pan or Disc. Non-inertial growth and densification. Control of granule size and densification. The importance of spray flux to granule growth and bed weight to bulk density. Operational issues. Limiting granule size and population balances. |
| 12:00 | Lunch |
| 1:00 PM | Afternoon Lecture: Design, scale-up & operation of agitative agglomeration processes: High Shear Mixers. Competition between growth and densification in inertial regimes of growth. Growth regime map. Wet mass rheology and uses and limitations of power. |
| 4:00 | Afternoon Break |
| 5:30 | Dinner Course cook-out. |
| 7:00 PM | Evening Session: Optional case study discussion, Process Vendor Presentations & Hands-on Instrument BreakoutShear cell access for client samples. Offered on first come/first serve basis w/prior arrangements.(Requires prior MSDS review & approval with E&G Associates.) |
| 8:30 | Evening hors d’oeuvres & social time |
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Day 3: |
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| 7:00 AM | Breakfast |
| 8:00 AM | Morning Lecture: Compaction agglomeration processes: Roll Presses & Briquetting, Tabletting, Extrusion. Tabletting and roll press design based on powder properties. Powder flow characterization. Impact of wall and powder friction on stress transmission, die forces, and tablet ejection forces. Simulations. Additional compaction methods. Heistand indices, fracture mechanics, Heckle profiles, permeability. Fluidization methods of powder cohesion and permeability. |
| 12:00 | Lunch |
| 1:00 PM | Afternoon Lecture: Team design session. Scale-up of granulation & compaction processes. |
| 3:00 PM | Course conclusion |