Investigation of an 11mm diameter twin screw granulator: Screw element performance and in-line monitoring via image analysis.

As twin screw granulation (TSG) provides one with many screw element options, characterization of each screw element is crucial in optimizing the screw configuration in order to obtain desired granule attributes. In this study, the performance of two different screw elements - distributive feed screws and kneading elements - was studied in an 11 mm TSG at different liquid-to-solid (L/S) ratios. The kneading element configuration was found to break large granules more efficiently, leading to narrower granule size distributions. While pharmaceutical industry shifts toward continuous manufacturing, inline monitoring and process control are gaining importance. Granules from an 11 mm TSG were analysed using the Eyecon™, a real-time high speed direct imaging system, which has been used to capture accurate particle size distribution and particle count. The size parameters and particle count were then assessed in terms of their ability to be a suitable control measure using the Shewhart control charts. d10 and particle count were found to be good indicators of the change in L/S ratio. However, d50 and d90 did not reflect the change, due to their inherent variability even when the process is at steady state.

Multipoint near-infrared spectrometry for real-time monitoring of protein conformational stability in powdered infant formula.

Powdered infant formula (PIF) can be the sole source of nutrition for babies and infants. Monitoring conformational changes in protein during manufacture of PIF is critical in order to maintain its nutritional value. This study presents the development of a calibration model for monitoring conformational changes in PIF protein by applying a novel multipoint near-infrared (NIR) spectrometry. NIR spectra were collected for PIF and PIF proteins, casein and whey protein isolate, before and after heat treatment. Results show that principal component analysis showed discrimination between native protein at room temperature and protein conformational changes caused at elevated temperature. Partial least squares regression analysis showed good calibration models with correlation coefficients ranging between 87% and 99% for the prediction of protein quality. This novel multipoint NIR spectrometry could serve as a simple in-line tool to rapidly monitor protein quality during processing stages, contributing to product nutritional value.

In-line implementation of an image-based particle size measurement tool to monitor hot-melt extruded pellets.

This work focuses on the implementation and application of an in-line particle measurement tool to monitor particle properties of hot-melt extruded pellets. A novel image analysis system (Eyecon) is used to analyze pellets with a size of approximately 1mm. The method is based on photometric stereo imaging, which is achieved by three different-colored light sources arranged circularly around the lens. Several implementations, whereby the product stream was led through the optical sampling volume, have been tested. The advantages and disadvantages of each implementation are discussed and evaluated. The most suitable implementation was applied to an extrusion run with constant throughput and different cutting frequencies resulting in different pellet sizes. A particle size distribution comparison between the image analysis system and an off-line reference particle analysis (QICPIC) showed good agreement although only a small fraction of the particles were analyzed in-line. Additionally, some illustrative examples for process development are given. With this approach the capability of hot-die face pelletizing to manufacture nearly-spherical pellets with a narrow size distribution is proven.