Slide 1: Fluid Bed Processing: Drying, Agglomeration and Particle Coating
AVEKA Group Fluid Bed Processing: Drying, Agglomeration and Particle Coating April 29, 2021 Particle Processing Services Toll Manufacturing Research & Development Innovative Solutions P R E S E N T E D B Y: W I L L I E H E N D R I C K S O N , C E O & F O U N D E R AVEKA
Slide 2: Presentation Outline
Presentation Outline • Overview of AVEKA • Particle processing 101 – the big 6 • Particle processing dilemmas • Drying methods • Agglomeration methods • Particle coating methods • Derek Geldart and powder flow/fluidization • Examples • Opportunities • Conclusions AVEKA
Slide 3: AVEKA Group Overview
• Particle technology company focused on contract manufacturing • Spin-off of 3M in 1994 • Comprised of 5 separate companies AVEKA • ISO certifications / food-grade certifications Group • Currently 290 employees Overview
Slide 4: Particle Processing: The Big Six
Particle Processing: The Big Six: • Characterization • Flow/Blending • Size Reduction • Drying • Agglomeration • Particle Coating AVEKA
Slide 5: What are Engineered Particles?
What are Engineered Particles? Tightly Adjusted Size Controlled Multicomponent Composition Complex Chemically or Functional Structure or Biologically Property Shape Active Controlled Release AVEKA
Slide 6: Processing Dilemmas
Processing Dilemmas • Available equipment dilemma • Volume/Scalability dilemma • Powder flow dilemma • Functionality dilemma AVEKA
Slide 7: Drying Technologies
Drying Technologies • Spray Drying • Tray Drying • Roll Drying • Fluid Bed Drying • Ring Drying • Turbulizers AVEKA
Slide 8: Agglomeration
Agglomeration Multiple techniques for particle formation • High Shear Agglomeration • Bella Mixer • Turbulizer • Fluid Bed – Spray Agglomeration • Extrusion Agglomeration AVEKA
Slide 9: Particle Coating
Particle Coating Multiple techniques for particle coating • Mixing • V-Blender • Ribbon Blender • Zig-zag Mixer • Fluid Bed – Wurster Coating • Tablet Coating • MAIC AVEKA
Slide 10: What Makes a Fluid Bed So Versatile
What Makes a Fluid Bed So Versatile • No Spray – Drying • Top Spray – Agglomeration, Coating • Bottom Spray – Coating • Tangential Spray - Coating
Slide 11: Geldart Particle Classification
Geldart Particle Classification Group B Sand-Like Group A Aeratable Group C Cohesive Group D Spoutable AVEKA
Slide 12: Functionality in Fluid Bed Processing
Functionality in Fluid Bed Processing • Water Activity • Powder Flow • Dedusting • Controlled Release • Wettability • Surface Modification • Surface Energy • Color AVEKA
Slide 13: The Examples…. Finally
The Examples…. Finally Drying of Particles ◦ Walnut Shells ◦ Encapsulated Oils ◦ Active Biologicals Agglomeration ◦ Food Powders for Wettability ◦ Food Powders for Improved Flow Particle Coating ◦ Color Change ◦ Controlled Release Statement of need How we approached the problem Why we chose fluid
Slide 14: Drying Using Fluid Beds
Drying The Result Using • PSD did not change during drying Fluid Beds Statement of challenge • Dry Bio-fiber • % moisture dropped from 9.2 to 2.8% in 30 minutes • Drying Walnut Shells • % moisture dropped from >40% to 2 % in 60 minutes AVEKA
Slide 15: What Went Wrong? The Reality
WHAT WENT THE REALITY WRONG? • Nothing • Fluid beds useful for wet • Fluid bed drying is useful cakes (10-70% moisture) for a variety of materials (density, shape, etc) AVEKA
Slide 16: Drying Using Fluid Beds
Drying The Result Using • Microbes had 90% Fluid Beds viability after drying Statement of challenge • Encapsulated beads were more spherical • Dry Encapsulated Beads with fluid bed drying and had stronger shells with fluid bed drying • Temperature sensitive • Very Fragile • Dry Live Microbe Matrices
Slide 17: What Went Wrong? The Reality
WHAT WENT THE REALITY WRONG? • Nothing • This process is standard • This is standard process at AVEKA instead of for temperature freeze drying for live sensitive materials at biologics AVEKA • Shape preservation much better with fluid beds AVEKA
Slide 18: Agglomeration Using Fluid Beds
Agglomeration The Result Using Dispersion Times Fluid Beds • Raw Material >90 sec • Fast Water Addition >90 sec Statement of challenge • Slow Water Addition 24 sec • Agglomerate Dairy • Low Water Addition 17 sec Powders to improve dispersibility by capillary absorption
Slide 19: What Went Wrong? The Reality
WHAT WENT THE REALITY WRONG? • Nothing • Process proven • Agglomeration shown to • Customer took in house produce better dissolution for processing for dairy products AVEKA
Slide 20: Agglomeration Using Fluid Beds
Agglomeration Particle Size Distributions (microns) Using D10 D10 D10 Fluid Beds Raw Material 15 50 113 Agglomerated with Water 87 202 380 Statement of challenge Agglomerated with Binder 75 174 324 • Improve spray dried material flow • Agglomeration with water • Agglomeration with added binder • Dec
Slide 21: Aeration (Reference Materials)
Aeration (Reference Materials) • General theory: as air is forced through a powder bed, the resistance to flow decreases (fluidization of powder beds) • Gold-standard powders • Flow energy decreases small amount • Mostly insensitive to changes over this range of air flow speeds AVEKA AVEKA
Slide 22: Aeration (Agglomerated Samples)
Aeration (Agglomerated Samples) • Agglomerated powders all start with lower flow energy (1 exception) • Response to increased air flow is linear, not big drop • The water content does not appear to be a big factor here • Flow has changed to something closer to gold standard (lower flow energy, but s
Slide 23: Permeability (Reference Materials)
Permeability (Reference Materials) • General theory: the more difficult it is for air to pass through a powder, the higher the pressure drop (shows efficiently packed powders) • Gold-standard powders • Near-zero pressure drop for all • Air passes freely through these powders AVEKA
Slide 24: Permeability (Agglomerated Samples)
Permeability (Agglomerated Samples) • All agglomerated powders • Near-zero pressure drop for all • Air passes freely through these powders • Match gold standard • Differentiation of the test samples difficult at this resolution AVEKA AVEKA
Slide 25: What Went Wrong? The Reality
WHAT WENT THE REALITY WRONG? • Nothing • Process improvements • Fluid bed material still being looked at for was less dusty production • Fluid bed material flowed better than spray dried material, but not better than flake material AVEKA
Slide 26: Coating Using Fluid Beds
Results Coating Using Fluid Beds • Statement of challenge • Coating of ground seed for flavor delivery • Minimal agglomeration • Functional coating ~20% Fluid Bed Coating • Comparison to Tablet Coating tablet coating AVEKA
Slide 27: What Went Wrong? The Reality
WHAT WENT THE REALITY WRONG? • Nothing • Process went to • Fluid Bed was more better production coating than tablet coating • Less agglomeration AVEKA
Slide 28: Particles from Liquids: Prilling
Particles from Liquids: Prilling Rayleigh Breakup • Spherical particles (10-2000 micron) • Up to 50% active loading • Matrix: phytosterols, hydrogenated oils, PLA • Actives: oils, flavors, particles, CMC, biocides • Throughputs: 1 – 2000 lb/hr AVEKA
Slide 29: Coating Using Fluid Beds
Coating The Material Using Fluid Beds Statement of challenge • Coating of Colored Prills for color change upon melting • Fat Prill • Water Soluble Dye • Titania Coating in starch
Slide 30: Color Changing Result
Color Changing Result ENCAPSULATION 101 Dough Shell Perfection vs. Diffusivities Baked AVEKA
Slide 31: What Went Wrong? The Solution
WHAT WENT THE WRONG? SOLUTION • Dye leaked through • Microencapsulation 101 coating in dough matrix • Switch to water insoluble dye • Add another layer AVEKA
Slide 32: Coating Using Fluid Beds
Coating The Result Using Fluid Beds Uncoated Statement of challenge Creatine • Coat Creatine with Shellac for stomach bypass and release in small intestine • Shellac well known enteric coating (pH dependent solubility) Coated Creatine 30% • Test for release at pH 1 and 7 as a function of time
Slide 33: Creatine Release
Creatine Release Creatine release as a function of time at two levels of pH 3.20.07 Data 100.00 90.00 80.00 70.00 —e— 11740105 (30% shedac shell wiw} Saco —B— 1140/8 (30% shelinc shel w/w) 50.00 a 11780105 (30% shedac shell wiw } 4000 % creatine release —— 1180/8 (30% shelinc shel w/w) 30.00 2000 10
Slide 34: The Reality: What Went Wrong?
THE REALITY WHAT WENT WRONG? • Coating process was good but drying was flawed AVEKA
Slide 35: So What Did I Leave Out?
So What Did I Leave Out? MAJOR USES OF FLUID BEDS EQUIPMENT VARIATIONS • Pharmaceutical Agglomeration • Batch vs. continuous fluid beds • Food Agglomeration for • Spray drying/fluid bed combined dispersibility and dedusting systems • Success for controlled release of • Final drying fluid bed coated
Slide 36: Fluid Bed Processing Thoughts
Fluid Bed Processing Thoughts RESOURCES IDEAS FOR THE FUTURE International Fine Particle Fluidization of nanoparticles: Research Institute (IFPRI) www.ifpri.net Using magnetic fields ◦ USP 7,658,340 Jim Litster University of Sheffield (James.litster@sheffield.ac.uk) Using microjets ◦ USP 8,439,283 K
Slide 37: Summary
Summary Value Added • Fluid bed processing is versatile Product • Drying Partnerships • Agglomeration • Coating Full Scale Manufacturing • Process conditions and materials are critical • It is hard to analyze too much Pilot Testing • Contact Information: • Willie Hendrickson R&D / Lab-Scale • aveka@