In situ monitoring of powder blending by non-invasive Raman spectrometry with wide area illumination.

A 785nm diode laser and probe with a 6mm spot size were used to obtain spectra of stationary powders and powders mixing at 50rpm in a high shear convective blender. Two methods of assessing the effect of particle characteristics on the Raman sampling depth for microcrystalline cellulose (Avicel), aspirin or sodium nitrate were compared: (i) the information depth, based on the diminishing Raman signal of TiO(2) in a reference plate as the depth of powder prior to the plate was increased, and (ii) the depth at which a sample became infinitely thick, based on the depth of powder at which the Raman signal of the compound became constant. The particle size, shape, density and/or light absorption capability of the compounds were shown to affect the "information" and "infinitely thick" depths of individual compounds. However, when different sized fractions of aspirin were added to Avicel as the main component, the depth values of aspirin were the same and matched that of the Avicel: 1.7mm for the "information" depth and 3.5mm for the "infinitely thick" depth. This latter value was considered to be the minimum Raman sampling depth when monitoring the addition of aspirin to Avicel in the blender. Mixing profiles for aspirin were obtained non-invasively through the glass wall of the vessel and could be used to assess how the aspirin blended into the main component, identify the end point of the mixing process (which varied with the particle size of the aspirin), and determine the concentration of aspirin in real time. The Raman procedure was compared to two other non-invasive monitoring techniques, near infrared (NIR) spectrometry and broadband acoustic emission spectrometry. The features of the mixing profiles generated by the three techniques were similar for addition of aspirin to Avicel. Although Raman was less sensitive than NIR spectrometry, Raman allowed compound specific mixing profiles to be generated by studying the mixing behaviour of an aspirin-aspartame-Avicel mixture.

Non-invasive monitoring of the mixing of pharmaceutical powders by broadband acoustic emission.

Broadband acoustic transducers, including an intrinsically safe device, were assessed for non-invasive monitoring of aspirin, citric acid or Avicel mixing in a bench scale convective blender. The frequency information content of the acoustic emission (AE) spectra depends on the response characteristics of the transducers, which vary depending on the design. As acoustic waves generated from the impact of particles propagated through and around the glass mixing vessel, comparable spectra were obtained from different locations on the glass. The intensity of AE increased as the impeller speed, mass of powder or density of the particles was increased. AE also increased with particle size, with a relatively greater increase in intensity at lower frequencies. Mixing profiles were generated in real time from the change in the integrated intensity over selected frequency ranges on addition of aspirin to Avicel; the AE signal initially increased and then came to a plateau as the mixture became homogeneous. The average plateau signal was plotted against concentration for three different particle size ranges of aspirin in Avicel; for aspirin concentrations <21% m/m the increase in the AE was relatively small with no discernable effects of the aspirin particle size; however, for >21% m/m aspirin, there was a proportionally greater increase in AE, and particle size effects were more obvious. The study has shown that AE is relatively easy to measure non-invasively during powder mixing, but has poorer sensitivity than NIR spectrometry for detection of effects caused by addition of secondary compounds, especially at smaller particle sizes.

Effects of particle size and cohesive properties on mixing studied by non-contact NIR.

A scaled-down convective blender was used along with non-invasive NIR spectrometry to study the mixing of citric acid, aspirin, aspartame or povidone with microcrystalline cellulose. NIR mixing profiles were generated in real time using measurements at the 2nd overtone wavelength of the added compounds. Trends demonstrated previously for aspirin were confirmed for additions of citric acid: the magnitude of the 2nd overtone NIR measurements is less affected by changes in particle size than that of the 1st overtone; the peak-to-peak noise of the 2nd overtone NIR mixing profile increases with the particle size of the added compound. The study has demonstrated the usefulness of continuous NIR measurements for rapid evaluation of the mixing process when deciding the best particle size of microcrystalline cellulose to mix with compounds of different particle shape and cohesive properties. Smaller particle sizes of microcrystalline cellulose (53-106 microm) were better for aspirin (212-250 microm), whereas larger particles (212-250 microm) were better for aspartame (212-250 microm). The characteristics of the compounds also need to be considered when deciding the order of addition of secondary compounds when mixed with microcrystalline cellulose. The time required to achieve a uniform mixture was much less when povidone was added before aspirin, rather than vice versa.

Real-time monitoring of powder mixing in a convective blender using non-invasive reflectance NIR spectrometry.

A convective blender based on a scaled down version of a high shear mixer-granulator was used to produce binary mixtures of microcrystalline cellulose (Avicel) and aspirin, citric acid, aspartame or povidone. Spectra of stationary Avicel or aspirin powder provided an indication of the information depth achieved with the NIR spectrometer used in the study, and confirmed previously reported effects of particle size and wavenumber. However, it was demonstrated that for 10% w/w aspirin in Avicel, the information depth at the C-H second overtone of aspirin (about 2.4 mm) was unaffected by changes in the particle size of aspirin and was determined by the major component. By making non-invasive NIR measurements as powders were mixed, it was possible to illustrate differences in the mixing characteristics of aspirin, citric acid, aspartame or povidone with Avicel, which were related to differences in the cohesive properties of the particles. Mixing profiles based on second overtone signals were better for quantitative analysis than those derived from first overtone measurements. It was also demonstrated that the peak-to-peak noise of the mixing profile obtained from the second overtone of aspirin changed linearly with the particle size of aspirin added to Avicel. Hence, measurement of the mixing profile in real time with NIR spectrometry provided simultaneously the opportunity to study the dynamics of powder mixing, make quantitative measurements and monitor possible changes in particle size during blending.

Monitoring of a heterogeneous reaction by acoustic emission.

The feasibility of monitoring the reaction of itaconic acid and 1-butanol by non-invasive acoustic emission measurements has been assessed. A piezoelectric transducer with a resonant mode at 90 kHz was attached to the external wall of a 1 L jacketed glass reactor. Acoustic emission from the oil jacket, stirrer and toluene was insignificant in comparison to that produced by the itaconic acid particles, which was transmitted through the glass walls and heating oil to the transducer. The transducer responded to acoustic emission from itaconic acid up to approximately 300 kHz, with the region around 90 kHz having the highest sensitivity. The effect of particle concentration and size on the acoustic emission generated has also been investigated, with higher concentrations and larger particles giving the greater signals. The detection limit for itaconic acid particles was 14 g dm(-3) of toluene. The effect of 1-butanol concentration and temperature on the progression of reactions was monitored using acoustic emission. It was possible to detect differences in the rate and extent of the reaction under different conditions, and also to identify when a combination of the concentration and/or size of itaconic acid particles had reached a steady state. However, it was not possible to differentiate between changes in particle size and concentration using the resonant transducer.