In sectors where fine powder processing is a key element, such as pharmaceuticals, foods and materials, uniformity is even more critical. Differences in the powder blends may result in product infidelities, loss of potency or yield and sacrifice regulatory compliance. And that’s why testing for blend uniformity and flow properties is essential. An essential part of the QC in these contexts is assessing material separation during manipulation and transport.
When mixing powders, discrepancies in various aspects such as size, shape, or density can result in unintentional segregation. This problem is further pronounced during the operation, such as transporting, supplying, or vibration. To address these issues, manufacturers provide testing in the form of “handling” inspections. Tests range from identifying how likely a formulation is to split under normal processing conditions, such as a powder segregation test.
Various techniques are employed for different applications, from visual inspection to automated systems that record concentration changes following artificial motion. This sort of calculation helps development engineers to modify formulations and design hardware early in the process.
Performing a routine segregation analysis can reduce the occurrence of product failures and waste. Minor changes, such as modifying particle size distribution or adjusting the method of discharging, can indeed show dramatic benefits to blend uniformity.
A well-executed powder segregation test can provide confidence in batch uniformity as well as facilitate a scalable production process. And as processes mature, it becomes increasingly important to keep the same material behaviour from the lab to the factory floor. The earlier we notice the tendency of segregation, the more time and energy we will save.
Whether you are tuning up a new recipe or troubleshooting a problem with an existing product, segregation testing can bring you one step closer to achieving both process continuity and product quality.
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