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

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.