Helle Eliasen

Effects of binder rheology on melt agglomeration in a high shear mixer

Abstract Lactose monohydrate was melt agglomerated in an 8-l high shear mixer using Gelucire 50/13, Stearate 6000 WL 1644, or polyethylene glycol (PEG) 3000 as meltable binder. The impeller speed was varied at two levels, and massing time was varied at six levels. In order to obtain a similar agglomerate growth, a larger binder volume had to be used with Gelucire 50/13 than with Stearate 6000 WL 1644 and PEG 3000. The lower viscosity of Gelucire 50/13 gave rise to agglomerates of a wider size distribution and a higher porosity as well as more adhesion of mass to the bowl. A lower binder viscosity resulted in more spherical agglomerates at the low impeller speed.

Growth mechanisms in melt agglomeration with a low viscosity binder

Lactose monohydrate was melt agglomerated in an 8-l high shear mixer using stearic acid as meltable binder. The impeller speed was varied at six levels, and the temperature of the heating jacket was varied at three levels. The agglomerate growth mechanisms were found to be different from those observed in previous melt agglomeration experiments. This is attributed to the low viscosity of the molten stearic acid. A higher impeller speed and a higher jacket temperature resulted in an agglomerate growth that was markedly affected by comminution and accordingly gave rise to agglomerates of a wider size distribution and a higher porosity. A lower impeller speed and a lower jacket temperature resulted in smoother and more spherical agglomerates.

Electrostatic charging during a melt agglomeration process.

Lactose monohydrate was melt agglomerated in an 8-l high shear mixer using stearic acid, polyethylene glycol (PEG) 3000, and a mixture of stearic acid and glycerol monostearate as meltable binders. Electrostatic charging during processing at relative air humidities of 35 and 75%, respectively, was estimated from the voltage of a monitoring probe inserted into the mixer. Stearic acid produced a high level of electrostatic charges, whereas PEG 3000 gave rise to a markedly lower level. Addition of glycerol monostearate to the stearic acid reduced the level of electrostatic charges. A correlation was found between the resistivity of the binder and the level of electrostatic charges in the material. With the stearic acid and the binder mixture, the level of electrostatic charges was higher at a low air humidity. The amount of adhesion to the bowl was found to depend on the level of electrostatic charges.