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Powder flow from an intermediate bulk container - Discharge predictions and experimental evaluation.

Håkan Wikström1, Johan Remmelgas1, Sara Solin2

  • 1Oral Product Development, Pharmaceutical Technology & Development, Operations & IT, AstraZeneca Gothenburg, Sweden.

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Summary

Understanding powder flow from Intermediate Bulk Containers (IBCs) is crucial for tablet manufacturing. A simple Erweka flow test effectively predicted full-scale IBC discharge rates, alongside a basic model using particle size and opening diameter.

Keywords:
Hopper designIntermediate bulk container (IBC)Pharmaceutical excipientsPowder flow properties

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Area of Science:

  • Pharmaceutical Manufacturing
  • Powder Technology
  • Chemical Engineering

Background:

  • Intermediate Bulk Containers (IBCs) are vital for powder handling in pharmaceutical manufacturing.
  • Efficient powder discharge from IBCs is critical for producing high-quality tablets.
  • Understanding powder flow behavior is essential for optimizing manufacturing processes.

Purpose of the Study:

  • To comprehensively characterize the flow behavior of pharmaceutical excipients during IBC discharge.
  • To predict the minimum non-arching outlet diameter and flow mode using Jenike's methodology.
  • To develop and validate a predictive model for IBC discharge rate.

Main Methods:

  • Characterization of excipient flow using Hausner ratio/Carr's index, Erweka flow test, FlowPro flow test, shear, and wall friction tests.
  • Utilizing FT4 powder rheometer experiments for detailed powder flow analysis.
  • Applying Jenike's hopper design methodology for predicting flow parameters.
  • Developing a simple model incorporating gravity and aerodynamic drag for discharge rate prediction.
  • Experimental verification of predicted discharge rates from a 20 L IBC with five common excipients.

Main Results:

  • The small-scale Erweka flow test demonstrated the highest accuracy in predicting full-scale IBC discharge.
  • A simplified model, dependent only on material particle size and discharge opening diameter, accurately predicted IBC discharge rates.
  • Comprehensive characterization provided insights into the flow behavior of selected excipients.

Conclusions:

  • The Erweka flow test is a reliable and effective method for predicting large-scale powder discharge from IBCs.
  • A straightforward predictive model based on particle size and outlet diameter can accurately estimate IBC discharge rates.
  • Optimizing IBC discharge is achievable through understanding powder rheology and employing predictive modeling.