The effect of droplet size and powder particle size on the mechanisms of nucleation and growth in fluid bed melt agglomeration

This study was performed in order to evaluate the effects of binder droplet size and powder particle size on agglomerate formation and growth in fluid bed spray agglomeration using a meltable binder. Three different lactose grades, 100, 125 or 350 mesh, were agglomerated using polyethylene glycol (PEG) 3000 at two different concentrations, 11.5 or 22% (volume/mass), and three spray droplet sizes, 30, 60 or 90 microm were applied. The ratio of droplet size/particle size was found to determine whether the mechanism of nucleation was distribution or immersion. Distribution was promoted by a low ratio, whereas immersion was promoted by a high ratio. Distribution as nucleation mechanism led to a more open agglomerate structure and immersion to a denser structure. When the nucleation phase was terminated, coalescence between rewetted nuclei or agglomerates was the growth mechanism with both preceding mechanisms of nucleation. A larger particle size of the lactose led to larger agglomerates. The difference in the effect on growth between the 30 and 60 microm droplets was generally low. The 90 microm droplets at 22% binder concentration offered a potential for uncontrollable growth giving rise to markedly larger agglomerates and a lower reproducibility than 30 and 60 microm droplets.     

Effects of interactions between powder particle size and binder viscosity on agglomerate growth mechanisms in a high shear mixer.

A study was performed in order to elucidate the effects of the interactions between powder particle size and binder viscosity on the mechanisms involved in agglomerate formation and growth. Calcium carbonates having mean particle sizes in the range of 5-214 microm and polyethylene glycols having viscosities in the range of approximately 50-100000 mPas were melt agglomerated in a high shear mixer. Agglomerate growth by nucleation and coalescence was found to dominate when agglomerating small powder particles and binders with a low viscosity. Increasing the binder viscosity increased the formation of agglomerates by immersion of powder particles in the surface of the binder droplets. With a larger powder particle size, an increasing binder viscosity was necessary in order to obtain an agglomerate strength being sufficient to avoid breakage. Due to a low agglomerate strength, a satisfying agglomeration of very large particles (214 microm) could not be obtained, even with very viscous binders. The study demonstrated that the optimum agglomerate growth occurred when the agglomerates were of an intermediate strength causing an intermediate deformability of the agglomerates. In order to produce spherical agglomerates (pellets), a low viscosity binder has to be chosen when agglomerating a powder with a small particle size, and a high viscosity binder must be applied in agglomeration of powders with large particles.     

Effects of physical properties of powder particles on binder liquid requirement and agglomerate growth mechanisms in a high shear mixer.

A study was performed in order to elucidate the effects of the physical properties of small powder particles on binder liquid requirement and agglomerate growth mechanisms. Three grades of calcium carbonate having different particle size distribution, surface area, and particle shape but approximately the same median particle size (4-5 microm), were melt agglomerated with polyethylene glycol (PEG) 3000 or 20,000 in an 8-l high shear mixer at three impeller speeds. The binder liquid requirement was found to be very dependent on the packing properties of the powder, a denser packing resulting in a lower binder liquid requirement. The densification of the agglomerates in the high shear mixer could be approximately predicted by compressing a powder sample in a compaction simulator. With the PEG having the highest viscosity (PEG 20,000), the agglomerate formation and growth occurred primarily by the immersion mechanism, whereas PEG 3000 gave rise to agglomerate growth by coalescence. Powder particles with a rounded shape and a narrow size distribution resulted in breakage of agglomerates with PEG 3000, whereas no breakage was seen with PEG 20,000. Powder particles having an irregular shape and surface structure could be agglomerated with PEG 20,000, whereas agglomerate growth became uncontrollable with PEG 3000. When PEG 20,000 was added as a powder instead of flakes, the resultant agglomerates became rounder and the size distribution narrower.     

Melt agglomeration with polyethylene glycol beads at a low impeller speed in a high shear mixer.

This study was performed in order to evaluate the possibility of obtaining spherical agglomerates with a high content of meltable binder by a melt agglomeration process in a high shear mixer. Lactose monohydrate was melt agglomerated with polyethylene glycol (PEG) 1500 or 6000 in a 10-l high shear mixer at an impeller speed of 400 rpm. The PEG 1500 was used as a size fraction of beads, and the PEG 6000 as a fine powder, a powder, unfractionated beads, and size fractions of beads. It was found to be possible to incorporate a high amount of PEG (28% m/m of the amount of lactose), because the rather low impeller speed applied in the present experiments caused less densification of the agglomerates. The fine powder of the PEG 6000 caused a complete adhesion of the mass to the bowl shortly after melting. A rapid agglomerate growth by coalescence was found to be the dominant growth mechanism when agglomeration was performed with the PEG 6000 powder. The PEG beads resulted in a slow and more controllable agglomerate growth, because the growth occurred primarily by an immersion of the lactose particles in the surface of the molten binder droplets. The initial shape of the agglomerates produced with the PEG beads was similar to the spherical shape of the beads. This shape could not be maintained during the process due to a breakage of the agglomerates caused by a hollow structure of the PEG beads.     

Agglomerate formation and growth mechanisms during melt agglomeration in a rotary processor

The purpose of this study was to investigate the effect of the binder particle size and the binder addition method on the mechanisms of agglomerate formation and growth during melt agglomeration in a laboratory scale rotary processor. Lactose monohydrate was agglomerated with molten polyethylene glycol (PEG) 3000 by adding the PEG either as solid particles from the size fraction 0-250, 250-500, or 500-750 microm or as droplets with a median size of 25, 48, or 69 microm. It was found that the PEG particle size, the PEG droplet size, and the massing time significantly influenced the agglomerate size and size distribution. Agglomerate formation and growth were found to occur primarily by distribution and coalescence for the PEG size fraction 0-250 microm and mainly by the immersion mechanism for the PEG size fractions 250-500 and 500-750 microm. When the PEG was sprayed upon the lactose, the mechanism of agglomerate formation was supposed to be a mixture of immersion and distribution, and the agglomerate growth was found to occur by coalescence regardless of the PEG mean droplet size. Compared to high shear mixers and conventional fluid bed granulators, the mechanisms of agglomerate formation and growth in the rotary processor resembled mostly those seen in the fluid bed granulator.     

Effects of binder rheology on melt agglomeration in a high shear mixer

Lactose monohydrate was melt agglomerated in an 8-l high shear mixer using Gelucire 50/13, Stearate 6000 WL 1644, or polyethylene glycol (PEG) 3000 as meltable binder. The impeller speed was varied at two levels, and massing time was varied at six levels. In order to obtain a similar agglomerate growth, a larger binder volume had to be used with Gelucire 50/13 than with Stearate 6000 WL 1644 and PEG 3000. The lower viscosity of Gelucire 50/13 gave rise to agglomerates of a wider size distribution and a higher porosity as well as more adhesion of mass to the bowl. A lower binder viscosity resulted in more spherical agglomerates at the low impeller speed.     

Compression Shear Strength and Tableting Behavior of Microcrystalline Cellulose Agglomerates Modulated by a Solution Binder (Polyethylene Glycol)

Purpose. To investigate the possibility of modulating the compression shear strength of agglomerates by the incorporation of a solution binder and to study the subsequent effect on the deformation behavior and tablet forming ability of the agglomerates. Method. Various concentrations (0.5 to 10%) of polyethylene glycol were incorporated as a solution binder into microcrystalline cellulose agglomerates of different porosity (10 and 20%) and the shear strength of the agglomerates, as evaluated by the 1/b value of the Kawakita equation, and the permeability to air and tensile strength of tablets formed from them were determined. Results. Increased agglomerate porosity and concentration of polyethylene glycol reduced the 1/b values, which led to the formation of tablets with a lower permeability. A decreased tablet permeability corresponded to an increased tablet tensile strength except that the highest binder content was associated with a drop in the tablet tensile strength. Conclusions. The solution binder reduced the agglomerate shear strength, which was expressed as an increased degree of agglomerate deformation during compression. The latter seemed to be controlled by both agglomerate porosity and shear strength. The main role of the solution binder in improving the agglomerate compactability was to increase the degree of deformation of agglomerates during compression.     

Effect of a melt agglomeration process on agglomerates containing solid dispersions

The purpose was to produce solid dispersions of a poorly water-soluble drug, Lu-X, by melt agglomeration in a laboratory scale rotary processor. The effect of binder type and method of manufacturing on the dissolution profile of Lu-X was investigated. Lactose monohydrate and Lu-X were melt agglomerated with Rylo MG12, Gelucire 50/13, PEG 3000, or poloxamer 188. Either a mixture of binder, drug, and excipient was heated to a temperature above the melting point of the binder (melt-in procedure) or a dispersion of drug in molten binder was sprayed on the heated excipient (spray-on procedure). The agglomerates were characterized by DSC, XRPD, SEM, and EDX-SEM. The study showed that the agglomerates containing solid dispersions had improved dissolution rates compared to physical mixtures and pure drug. The melt-in procedure gave a higher dissolution rate than the spray-on procedure with PEG 3000, poloxamer 188, and Gelucire 50/13, whereas the opposite was found with Rylo MG12. This was explained by differences in mechanisms of agglomerate formation and growth, which were dominated by immersion with PEG 3000, poloxamer 188, and Gelucire 50/13, and by distribution and coalescence with Rylo MG12. The spray-on procedure resulted in a higher content of Lu-X in the core of the agglomerates when immersion was the dominating mechanism, and in a higher content in the agglomerate surface when distribution was dominating. The melt-in procedure resulted generally in a homogeneous distribution of Lu-X in the agglomerates. The compounds in the agglomerates were found primarily to be crystalline, and the dissolution profiles were unchanged after 12 weeks storage at 25 degrees C at 50% RH.     

Investigation of melt agglomeration process with a hydrophobic binder in combination with sucrose stearate

The melt agglomeration process of lactose powder with hydrogenated cottonseed oil (HCO) as the hydrophobic meltable binder was investigated by studying the physicochemical properties of molten HCO modified by sucrose stearates S170, S770 and S1570. The size, size distribution, micromeritic and adhesion properties of agglomerates as well as surface tension, contact angle, viscosity and specific volume of molten HCO, with and without sucrose stearates, were examined. The viscosity, specific volume and surface tension of molten HCO were found to be modified to varying extents by sucrose stearates which are available in different HLB values and melt properties. The growth of melt agglomerates was promoted predominantly by an increase in viscosity, an increase in specific volume or a decrease in surface tension of the molten binding liquid. The agglomerate growth propensity was higher with an increase in inter-particulate binding strength, agglomerate surface wetness and extent of agglomerate consolidation which enhanced the liquid migration from agglomerate core to periphery leading to an increased surface plasticity for coalescence. The inclusion of high concentrations of completely meltable sucrose stearate S170 greatly induced the growth of agglomerates through increased specific volume and viscosity of the molten binding liquid. On the other hand, the inclusion of incompletely meltable sucrose stearates S770 and S1570 promoted the agglomeration mainly via the reduction in surface tension of the molten binding liquid with declining agglomerate growth propensity at high sucrose stearate concentrations. In addition to being an agglomeration modifier, sucrose stearate demonstrated anti-adherent property in melt agglomeration process. The properties of molten HCO and melt agglomerates were dependent on the type and concentration of sucrose stearate added.     

Melt pelletization with polyethylene glycol in a rotary processor

The purpose of this study was to investigate the effect of the airflow, the binder concentration, the massing time, the friction plate rotation speed, and the surface structure of the friction plate on melt pelletization in a laboratory scale rotary processor. Lactose monohydrate was melt agglomerated with polyethylene glycol (PEG) 3000 as meltable binder. The study was performed as a full factorial design. An increase in agglomerate size was found when the binder concentration, the massing time, or the friction plate rotation speed was increased. The agglomerate size was also increased when increasing the shearing forces by using a friction plate with a different surface structure. The size distribution of the agglomerates was significantly narrowed when the binder concentration or the shearing forces caused by the friction plate were increased. An increase in the adhesion of material to the friction plate was found when the shearing forces of the friction plate were increased either by the rotation speed or by the surface structure. Generally, the rotary processor was found to be a suitable alternative to melt pelletization in a high shear mixer.     

The preparation of agglomerates containing solid dispersions of diazepam by melt agglomeration in a high shear mixer

The aim of this study was to prepare by melt agglomeration agglomerates containing solid dispersions of diazepam as poorly water-soluble model drug in order to evaluate the possibility of improving the dissolution rate. Lactose monohydrate was melt agglomerated with polyethylene glycol (PEG) 3000 or Gelucire 50/13 (mixture of glycerides and PEG esters of fatty acids) as meltable binders in a high shear mixer. The binders were added either as a mixture of melted binder and diazepam by a pump-on procedure or by a melt-in procedure of solid binder particles. Different drug concentrations, maximum manufacturing temperatures, and cooling rates were investigated. It was found to be possible to increase the dissolution rate of diazepam by melt agglomeration. A higher dissolution rate was obtained with a lower drug concentration. Admixing the binders by the melt-in procedure resulted in similar dissolution rates as the pump-on procedure. The different maximum manufacturing temperatures and cooling rates were found to have complex effects on the dissolution rate for formulations containing PEG 3000, whereas only minor effects of the cooling procedure were found with Gelucire 50/13. Gelucire 50/13 resulted in faster dissolution rates compared to PEG 3000.     

Impact of a non-meltable additive on melt agglomeration with a hydrophobic meltable binder in high-shear mixer

The present study aims to investigate the behavior of melt agglomeration with a low-viscosity hydrophobic meltable binder by using a non-meltable additive. The size, crushing strength, and pore size distribution of resultant agglomerates, the rheological, surface tension, and wetting properties of the molten binder, as well as, the flow characteristics of preagglomeration powder blend were determined. The use of additive showed contradictory agglomerate growth-promoting and -retarding effects on the molten binder surface tension and the interparticulate frictional forces. Critical concentration effects of additive corresponded to threshold transition of agglomeration-promoting to -retarding behavior were discussed.     

Impact of a Non-meltable Additive on Melt Agglomeration with a Hydrophobic Meltable Binder in High-Shear Mixer

The present study aims to investigate the behavior of melt agglomeration with a low-viscosity hydrophobic meltable binder by using a non-meltable additive. The size, crushing strength, and pore size distribution of resultant agglomerates, the rheological, surface tension, and wetting properties of the molten binder, as well as, the flow characteristics of preagglomeration powder blend were determined. The use of additive showed contradictory agglomerate growth-promoting and -retarding effects on the molten binder surface tension and the interparticulate frictional forces. Critical concentration effects of additive corresponded to threshold transition of agglomeration-promoting to -retarding behavior were discussed.     

Effects of powder particle size and binder viscosity on intergranular and intragranular particle size heterogeneity during high shear granulation.

A study was performed in order to elucidate the effects of powder particle size and binder viscosity on intergranular and intragranular particle size heterogeneities. Granules were produced by melt granulation in a high shear mixer from each of four calcium carbonates having mean particle sizes in the range of 5.5-63.1 microm. Each of three polyethylene glycols (PEGs) having viscosities in the range of approximately 40-14,000 mPas were applied as meltable binders. The size distribution of the calcium carbonate particles in three granule size fractions (125-250, 355-500, and 800-1000 microm) was measured after disintegration of the granules. Intragranular particle size heterogeneities were evaluated qualitatively by means of scanning electron microscopy. A preferential growth of the smaller particles was found to give rise to a higher content of small particles in large granules when calcium carbonates with mean particle sizes of 11.7, 34.5, and 63.1 microm were granulated with a binder of low viscosity. The use of a binder of medium or high viscosity leads to a marked reduction of these heterogeneities. A preferential growth of larger particles was seen when calcium carbonates with mean particle sizes of 5.5 and 11.7 microm were granulated with a highly viscous binder. The use of a binder with low or medium viscosity resulted in an increased homogeneity. Intragranular particle size heterogeneities were primarily seen when 5.5 and 11.7 microm calcium carbonate particles were granulated with a highly viscous binder.     

The influence of povidone K17 on the storage stability of solid dispersions of nimodipine and polyethylene glycol.

Previous studies revealed that solid dispersions containing nimodipine and polyethylene glycol 2000 can be effectively prevented from recrystallization by adding povidone K17. These systems are characterized by a high dissolution rate and a remarkable supersaturation of the drug in the dissolution media. It is still unknown if these characteristics are achievable with all polyethylene glycol and povidone mixtures. The objective of the present study is to find out, whether povidone K17 has to be dissolved in melted polyethylene glycol during the preparation process of solid dispersions by the melting method in order to avoid recrystallization of the drug and to ensure storage stability. Solid dispersions consisting of 20% (m/m) nimodipine, 16% (m/m) povidone K17 and 64% (m/m) of six different mixtures of polyethylene glycol 2000 and 8000 were prepared by the melting method and investigated by dissolution testing, thermal analysis and X-ray diffraction. As the solubility of povidone K17 in polyethylene glycol 2000 is about 70% at 65 degrees C and decreases with increasing molecular weight of the polyethylene glycol, mixtures containing different amounts of dissolved povidone K17 are obtained by varying the mixing ratio of polyethylene glycol 2000 and 8000. Recrystallization is inhibited in the formulations, containing mainly polyethylene glycol 2000 whereas recrystallization occurs in systems consisting predominantly of polyethylene glycol 8000. These results show clearly that dissolution of povidone in melted polyethylene glycol is a prerequisite in order to prevent recrystallization.     

An investigation into the effect of formulation variables and process parameters on characteristics of granules obtained by in situ fluidized hot melt granulation

The aim of this study was to investigate the influence of binder content, binder particle size, granulation time and inlet air flow rate on granule size and size distribution, granule shape and flowability, as well as on drug release rate. Hydrophilic (polyetilenglycol 2000) and hydrophobic meltable binder (glyceryl palmitostearate) were used for in situ fluidized hot melt granulation. Granule size was mainly influenced by binder particle size. Binder content was shown to be important for narrow size distribution and good flow properties. The results obtained indicate that conventional fluid bed granulator may be suitable for production of highly spherical agglomerates, particularly when immersion and layering is dominant agglomeration mechanism. Granule shape was affected by interplay of binder content, binder particle size and granulation time. Solid state analysis confirmed unaltered physical state of the granulate components and the absence of interactions between the active and excipients. Besides the nature and amount of binder, the mechanism of agglomerate formation seems to have an impact on drug dissolution rate. The results of the present study indicate that fluidized hot melt granulation is a promising powder agglomeration technique for spherical granules production.     

Centrifugal air-assisted melt agglomeration for fast-release "granulet" design

Conventional melt pelletization and granulation processes produce round and dense, and irregularly shaped but porous agglomerates respectively. This study aimed to design centrifugal air-assisted melt agglomeration technology for manufacture of spherical and yet porous "granulets" for ease of downstream manufacturing and enhancing drug release. A bladeless agglomerator, which utilized shear-free air stream to mass the powder mixture of lactose filler, polyethylene glycol binder and poorly water-soluble tolbutamide drug into "granulets", was developed. The inclination angle and number of vane, air-impermeable surface area of air guide, processing temperature, binder content and molecular weight were investigated with reference to "granulet" size, shape, texture and drug release properties. Unlike fluid-bed melt agglomeration with vertical processing air flow, the air stream in the present technology moved centrifugally to roll the processing mass into spherical but porous "granulets" with a drug release propensity higher than physical powder mixture, unprocessed drug and dense pellets prepared using high shear mixer. The fast-release attribute of "granulets" was ascribed to porous matrix formed with a high level of polyethylene glycol as solubilizer. The agglomeration and drug release outcomes of centrifugal air-assisted technology are unmet by the existing high shear and fluid-bed melt agglomeration techniques.     

Effect of off-bottom clearance on properties of pellets produced by melt pelletization

This study examines the influence of off-bottom clearance on size and size distribution of pellets produced during melt pelletization at different postmelt impeller speeds and binder concentrations using lactose and polyethylene glycol. Melt pelletization of lactose powder 450 M in an 8-liter highshear mixer, the floor of which was made of polytetrafluoroethylene (PTFE), was carried out with polyethylene glycol 3000 as the meltable binder. Erosion of the PTFE floor of the mixer occurred with time of use and this caused a change in the off-bottom clearance. The findings showed that with a wider clearance, the size distribution of pellets was wider and pellets were much larger. These changes were the results of changes in the mixing intensity and impact frequency of the mass in relation to the eddies formed within the off-bottom clearance. The changes were not associated with the reduction in the circulating material load by entrapment into the off-bottom clearance. In the melt pelletization process, the quality of product was higher if the clearance was kept to a minimum. The off-bottom clearance was best measured at the beginning of each pelletization run because the PTFE floor of the mixer was prone to erosion.     

Melt pelletization in a high shear mixer. V. Effects of apparatus variables

Effects of two different sets of impeller blades on melt pelletization of lactose with polyethylene glycol (PEG) 3000 were investigated in an 8 litre high shear mixer. Results obtained in the 8 litre mixer were compared with previous results from a 50 litre high shear mixer of the same type. In the 8 litre mixer curved impeller blades were found to give rise to a high power input and smooth pellets of a spherical shape, whereas plane impeller blades caused a lower power input and irregular agglomerates. Agglomerate growth was found to be different in mixers of different scale. This difference was primarily ascribed to differences in movement of the mass, power input and product temperature.     

An investigation into the production of paracetamol solid dispersions in PEG 4000 using hot stage differential interference contrast microscopy

The melting and crystallisation behaviour of paracetamol dispersions in polyethylene glycol (PEG) 4000 has been studied using differential interference contrast microscopy fitted with a hot stage. The effects of thermally cycling physical mixes of the two components have been studied with particular reference to the effects of the presence of molten PEG 4000 on the melting behaviour of the model drug. The effects of the drug particle size, the maximum temperature of heating and the holding time at the maximum temperature on the solid dispersion structure have been investigated, with profound changes in structure being observed depending on the manufacturing protocol used. In particular, higher maximum temperatures and holding times with lower drug particle sizes promoted greater dissolution of the drug into the molten PEG. In the majority of systems observed, the remaining paracetamol particles simply persisted as the system was cooled. However, for certain systems, involving high drug loadings and extended holding times and temperatures in the liquid state, the drug recrystallised over a 24-h period to form a fine dispersion within the carrier. The study has therefore demonstrated the usefulness of hot stage microscopy as a method of directly observing the processes involved during the manufacture of solid dispersions and has also indicated that changing the manufacturing protocol may have a profound effect on the structure of the dispersion.