Energy-based analysis of cone milling process for the comminution of roller compacted flakes

Cone mill is commonly used for the milling of wet and dry agglomerates in the pharmaceutical industry as it is capable of producing milled granules with desired size characteristics. The aim of this study was to evaluate the various cone mill process parameters in terms of milling rate and energy consumption for the comminution of roller compacted flakes. A placebo formulation containing microcrystalline cellulose, lactose and magnesium stearate was used to evaluate the milling performance. Results of this study showed that higher milling rate was obtained with the combination of higher impeller speed, teethed round sidearm impeller and grater screen surface profile. Either one of the later two parameters when present in any mill setting was found to be capable of shortening the residence time of flakes inside the milling chamber, thus resulting in a higher milling rate. On the other hand, selection of appropriate screen surface profile and impeller speed was very important at lowering the effective specific energy consumption during milling. Grater screen surface profile and impeller speed between 2000 and 2400 rpm were found to act synergistically as the best combination for an energy sparing process. Impeller sidearm shape was found to have no significant effect on energy consumption.