PARTICLE COATING, TASTE MASKING & PELLETIZATION
PARTICLE COATING, TASTE MASKING &PELLETIZATIONPARTICLE COATING CONTENTS: Introduction Applications Types of coating: Wet particle coating Dry particle coating Particle coating techniques: WET PARTICLE COATING TECHNIQUES:a) MICROENCAPSULATION:1. Air suspension coating.I.Top spray coatingII. Electrostatic fluidized bed coatingIII. Bottom spray coating:A. Wurster coaterB. Precision coaterIV. Tangential or rotating fluidized bed coatingV. Novel rotating fluidized bed coater2. Solvent evaporation technique.3. Coacervation and phase separation technique: By temperature change. By incompatible polymer addition. By non solvent addition By salt addition By polymer polymer interaction By solvent evaporation4.5.6.7.8.9.Spray dryingPrilling or melt sprayingCentrifugation processInterfacial polymerization.Pan coating.Melt dispersion technique.b) 1.2.3.VAPOR COATING OF POWDERS:Fluidized bed chemical vapor coatingDRY PARTICLE COATING EQUIPMENTS:Magnetically assisted impaction coatingRotating fluidized bed coatingHybridizer A NEW AND VERSATILE COATING METHOD OF PARTICLES AT ROOMTEMPERATURE
INTRODUCTION:Coating of particles is an important unit operation in the pharmaceutical industry.There are numerous applications of coating, including drug layering, modifiedrelease coating, physical and chemical protection, aesthetic purposes, tastemasking, and enhanced identification of drugsAPPLICATIONS OF PARTICLE COATING: Particle coating are widely used in following industries:1) Pharmaceuticals, Powder2) Food3) Cosmetics4) Biochemical5) Dyestuff6) Toner7) Fertilizer8) Ceramics9) ElectromaterialsParticle coating can change the properties of target particles:PHYSICAL PROPERTIES:IMPORTANCE:(BASED ON DOSAGE FORMS)1) Particle size distribution POWDERS,TABLETS,CAPSULES,SUSPENSIONS2) NS3) Solid phase reactivityPOWDERS4) Hydrophilic/hydrophobic SUSPENSIONS,SOLUTIONSproperties5) WettabilitySUSPENSIONS,SOLUTIONS6) DispersibilitySUSPENSIONS7) FlowabilityPOWDERS,TABLETS,CAPSULES8) Electrostatic/electric/ma lScharacteristicsORGANOLEPTICPROPERTIES:1) Colouring2) ONS TIONSTYPES OF COATING : Wet particle coating Dry particle coating WET PARTICLE COATING:Involves use of either aqueous or non aqueous solution. Currently industrial standard for nanoparticle coating Drawbacks WPC solution may be volatile and toxic
Requires post treatment and waste processing increases costAn innovative method to replace the wet coating process is to directly coat fineparticles on target particles (dry particle coating) using strong mechanical forces. DRY PARTICLE COATING:Dry particle coating is used to create new-generation materials by combiningdifferent powders having different physical and chemical properties to formcomposites, which show new functionality or improve the characteristics of knownmaterials. Materials with relatively large particle size (1–200 μm) form a core andthese core (host) particles are mechanically coated with fine submicron (guest)particles; no liquid of any kind (solvents, binders or water) is required.In this technology, powdered coating materials are directly coated onto solid dosageforms without using any solvent, and then heated and cured to form a coat. As aresult, this technology can overcome such disadvantages caused by solvents inconventional liquid coating as serious air pollution, high time- and energyconsumption and expensive operation cost encountered by liquid coating.Eg:- Improvement in the flow properties of a cohesive lactose powder by intensivemechanical dry coating.Adv. of dry particle coating:o New particles may have completely different functionality or muchimproved propertieso Much reduced use of high-priced or rare materialso Process is environmentally cleano Water soluble powders can now be coated without compromising thesample. PARTICLE COATING TECHNIQUES: MICROENCAPSULATION:Microencapsulation is a process of applying relatively thin coating to small particlesof solids, droplets of liquids and dispersions, using various coating agents, such asgelatin, povidone, hydroxyethyl cellulose, ethyl cellulose, bees wax, carnauba waxand shellac.It is a versatile & precise coating technique used to encapsulate individual particles.This proces results in individual particles of a drug substance being enveloped into amembrane.The type & level of membrane applied is determined by release rate requirements,organoleptic features & the dosage form application.Microencapsulation also increases the stability of the drug. It can be accomplishedby a variety of methods, including Air suspension coating. Solvent evaporation technique. Coacervation and phase separation technique.o By temperature change.o By incompatible polymer addition.o By non solvent additiono By salt additiono By polymer polymer interactiono By solvent evaporation Spray drying and spray congealing Centrifugation process Interfacial polymerization. Pan coating.
Melt dispersion technique. FLUIDIZED BED COATING:(AIR SUSPENSION COATER)In fluidized bed powder coating, heated parts are either dipped directly into acontainer of fluidized powder or passed through an electrically charged cloud ofpowder, which is created above a container of fluidized powder.Heating parts for use in a fluidized bed powder coating operation:conventional gas fire convection ovens are most common. However, electric and gasir and other methods work fine as well, depending upon part dimensions. The maingoal is to preheat the part above the melting point of the coating so the film thicknesswill build when submerged in the coater.induction heaters are used as well,especially on long, continuous parts. Characterization of fluid beds:- gas/liquid(low velocity)gas/liquidliquidgasgasgas1. Fixed bed2. Minimum fluidization3. Smooth fluidization4 .bubbling fluidization5. Axial slugging6. Flat sluggingThere are different characteristics of fluid beds depending on the velocity of streamof air: Initially bed remains static but as we pass air in the chamber it becomesfluidized in the air stream The point at which bed becomes just fluidized is known as incipientfluidization The velocity of particle in the bed under this condition is too low for efficientcoating
Increasing the air volume results in wider fluidization range known as bubblingfluidization , in which bed can be defined as containing 2 phases, a particulatephase, containing particles & air & a bubble phase ,which contains excess air.Can the fluidized bed process be used with both thermoset andthermoplastic powder coatings?Yes. However, thermosets are rarely used and much more complicated due tothe heat buildup in the fluid bed coater, which can cause the powder to crosslink in the coater. Thermoplastics are much more forgiving in this manner.Drawbacks associated with the fluidized bed process:color changes can be difficult. Where practical, one should use a dedicatedbed for each color.Coating of fine particles are performed using MINI GLATT FLUIDIZEDBED. TOP SPRAY COATING:Most widely used in pharmaceutical industryWith top spray coating in the fluid bed ,particles are fluidized in the flow ofheated air which is introduced via base plate.coating liquid is sprayed intofluid bed from above against the air flow by means of a nozzle. Drying takesplace as particles continue to move upwards in the air flow.small droplets & alow viscosity of the spray medium ensure uniform distribution.Coating in continuous fluid bed is particularly suitable for protective coatings/colour coatings where product throughput rates are high.Depending on the application ,the system is sub-divided into pre-heatingzones, spray zones & drying zones.The dry, coated particles are continuously extracted. ELECTROSTATIC FLUIDIZED BED COATING:-An electrostatic fluidized bed is essentially a fluidized bed with a high voltage dc gridinstalled above the porous plate to charge the finely divided particles. Once charged,the particles are repelled by the grid, and they repel each other, forming a cloud ofpowder above the grid. These electrostatically charged particles are attracted to andcoat products that are at ground potential.The advantages of electrostatic fluidized bed coating is that preheating of parts isgenerally not necessary and small products, can be coated uniformly and quickly.The disadvantages are that the product size is limited and inside corners have lowfilm thickness owing to the well known faraday cage effect.DIFFERENCE BETWEEN FBD & EFBDFbd:-with fluid bed coating, the part has to be preheated, immersed in the coatingand then flowed out.Efbd:- electrostatically assisted fluidized bed coating does not dip the part into thepowder, it generates a cloud of charged particles (much like a conventionalelectrostatic gun) through which a heated or an unheated part passes. It generallyapplies a thin coat vs. The thicker coat from fluidized bed coating.Does the pre-heating stage make fluidized bed a more expensive process thanelectrostatic spray?
Generally not. The overall thermal requirements for both coating methods arebasically the same. Obviously, fluidized bed coating uses more heat prior to coating,and electrostatic spray uses more heat after coating, but these usually net out.Some other benefits of fluidized bed powder coating:there is generally less waste since it’s a 100% transfer efficient coating method.When compared to electrostatic spray, capital investment in equipment and ongoingmaintenance is most always lower. It’s basically a low-tech coating method, andonce coating parameters are established, there are not that many things that can gowrong. It is by far the most efficient method of applying thick film coatings. WURSTER COATER:(BOTTOM SPRAY COATING)Wurster coaters are bottom spray fluid bed coaters that have been extensively usedin the pharmaceutical industry for coating of small particulates. They offer excellentheat and mass transfer within the product bed and are able to form uniform coats.however, their use has been limited by the propensity of the particles toagglomerate during the coating the precision coater(B) is similar to the wurstercoater (A)except for its mode of air distribution.The air distribution plate in the precision coater consists of a perforated plateconnected to the swirl accelerator. The swirl accelerator functions to swirl andaccelerate the inlet air to impart spin and high velocity to the particles as they transitthrough the partition column where coating takes place. This process can change thefluid dynamics of the particles.In bottom spray fluid bed processes, the area of the air distribution plate directlyunder the partition column has more perforated area than the periphery region of theair distribution plate, resulting in a higher central air velocity through the partitioncolumn. This creates a region of lower pressure that draws in particles by theventuri’s effect and lifts particles up the partition column (up-bed zone) according toBernoulli’s law. As such, particles from the product bed enter the partition column(horizontal transport zone) and decelerate in the expansion chamber (decelerationzone)—falling outwards freely in an inverted u-shape trajectory back onto theproduct bed staging area (down-bed zone).The particles then reenter the partition column though the partition gap and repeatthe fountain-like cyclic flow. Particles receive coating droplets during the passagethrough the spray zone within the partition column, and this cycle is repeated untilthe desired coating level is achieved.Fluid dynamics was found to be important in controlling product quality andproductivity in bottom spray fluid bed coaters.
TANGENTIALLY/ROTATING FLUIDIZED BED COATING:Ideal for coatings with high solid content.The product is set into spiral motion by means of rotating base plate ,whichhas air fed into the powder bed at its edge.Spray nozzle is arranged tangentially to the rotor disc @ sprays concurrentlyinto the powder bed.Very thick film layers can be applied by means of rotor method. NOVEL ROTATING FLUIDIZED BED COATER:Fine particle coating has been conducted by using a novel rotating fluidized bedcoater. The coater consists of a plenum chamber and a horizontal porous cylindricalair distributor, which rotates around its axis of symmetry inside the plenum chamber.Cohesive fine cornstarch was used as core particle and an aqueous solution ofhydroxypropylcellulose (hpc-l) was sprayed onto the cornstarch to generate a filmcoating. Fine particle coating was conducted under various coating levels (wt.% hpcl) and the particle size distribution of the coated particles, release rate of an aqueouspigment (food blue no. 1), which had been pre-coated onto the initial cornstarch, andthe degree of agglomeration were investigated. The relationship between the coatinglevel and the physical properties of the coated particles was analyzed. The resultsindicated that coating of cohesive fine cornstarch with hpc-l could be achieved,producing a favorable prolonged release property with almost maintaining theindividual single particle. COACERVATION PHASE SEPARATION:The general outline of the processes consists of three steps carried out undercontinuous agitation.1. Formation of three immiscible chemical phases.2. Disposition of the coating, and3. Rigidization of the coatinga. By thermal change: phase separation of the dissolved polymer occurs in theform of immiscible liquid droplets, and if a core material is present in thesystem, under proper polymer concentration, temperature and agitationconditions, the liquid polymer droplets coalesce around the dispersed core
material particles, thus forming the embryonic microcapsules. As thetemperature decreases, one phase becomes polymer-poor (themicroencapsulation vehicle phase) and the second phase. (the coatingmaterial phase) becomes polymer-rich.Eg:- microencapsulation of ibuprofenb. By incompatible polymer addition: it involves liquid phase separation of apolymers coating material and microencapsulation can be accomplished byutilizing the incompatibility of dissimilar polymers existing in a commonsolvent.c. By non-solvent addition: a liquid that is a non-solvent for a given polymer canbe added to a solution of the polymer to induce phase separation. Theresulting immiscible liquid polymer can be utilized to effect microencapsulationof an immiscible core material.d. By salt addition: there are two types of coacervation: simple and complex.Simple coacervation involves the use of only one colloid, e.g. Gelatin in water,and involves removal of the associated water from around the dispersedcolloid by agents with a greater affinity for water, such as various alcohols andsalts. The dehydrated molecules of polymer tend to aggregate withsurrounding molecules to form the coacervate. Complex coacervationinvolves the use of more than one colloid. Gelatin and acacia in water aremost frequently used, and the coacervation is accomplished mainly by chargeneutralization of the colloids carrying opposite charges rather than bydehydration.E. By polymer-polymer interaction: the interaction of oppositely charged polyelectrolytes can result in the formation of a complex having such reducesolubility that phase separation occurs.F. By solvent evaporation: the processes are carried out in a liquid manufacturingvehicle. The microcapsule coating is dispersed in a volatile solvent, which isdispersed in volatile solvents, which is immiscible with the liquidmanufacturing vehicle phase. A core material to be microencapsulated isdissolved or dispersed in the coating polymer solution. With agitation, the corematerial mixture is dispersed in the liquid manufacturing vehicle phase toobtain the appropriate size microcapsule. The mixture is then heated ifnecessary to evaporate the solvent for the polymer. In the case in which thecore material is dissolved in the coating polymer solution, matrix typemicrocapsules are formed. The solvent evaporation technique to productmicrocapsules is applicable to a wide variety of core materials. The corematerials may be either water soluble or water insoluble materials.Advantages: To encapsulate water immiscible liquids This technology produce single capsules of 20-80 µm diameter that contains80 – 90% wt core material
Disadvantages: The mechanical and barrier properties of dry capsules are sensitive tomoisture. SPRAY DRYING:Spray drying often is used as an coating technique by the food and other industries.A substance to be coated (the load) and a coating material are homogenized as asuspension in water (the slurry). The slurry is then fed into a spray drier, usually atower heated to temperatures well over the boiling point of water.As the slurry enters the tower, it is atomized. Partly because of the high surfacetension of water and partly because of the hydrophobic/hydrophilic interactionsbetween the coating material , the water, and the load, the atomized slurry formsmicelles. The small size of the drops (averaging 100 micrometers in diameter)results in a relatively large surface area which dries quickly. As the water dries, thecoating material forms a hardened shell around the load. PRILLING/MELT SPRAYING:Prilling, also known as spray congealing, spray chilling, or melt atomization, is theprocess of atomizing molten liquids or mixtures and cooling the resultant droplets toform prills or beads that are the final product.In general, any material that is solid at room temperature and stable in the moltenstate with a relatively low viscosity can be used in this process.Examples of materials that have been successfully processed this way include lowmolecular weight polymers, phytosterols, waxes, fats, hydrogenated vegetable oils,and hydrated salts such as alum. While high melting materials such as metals,glasses and ceramics are routinely processed commercially, this requires specialheaters and atomizing sources, so these materials are not typically processed on atoll basis. Materials that are easy to prill generally have melting points below 200degrees c and melt viscosities lower than 200 cps.Prilling offers a number of unique benefits in creating free-flowing powders fromsolids. First, prilling is a relatively inexpensive process for converting moltenmaterials into a solid, easy to handle form. Second, the typical output consists ofspherical particles, although the final form can vary from fibers to rods to spheresdepending on the melt viscosity. Third, a wide range of final sizes are possibledepending on the atomization method and the starting material. A particle size outputof 10 to 3,000 microns is readily obtainable. Fourth, throughputs of 2,000 lbs/hourand higher with the above size distribution are easy to obtain. Finally, the processcan be used with blended materials very easily.Eg:1) Glimepiride microcapsules were successfully prepared using spraycongealing technique.2) Hot-melt coating technique is used for controlled release of propranololhydrochloride pellets.
CENTRIFUGATION:The liquid material to be coated is extruded through the nozzle of the inner tube intothe coating fluid contained in the outer tube. Initially, the fluid extrudes as a rodsurrounded by the coating fluid, but the rod ultimately breaks up into droplets, whichare then immersed, in the coating fluid. As the extruded droplets pass through thenozzle orifice of the outer tube, the coating fluid forms a surface coat, which encasesthe extruded particle. This is then passed through hardening bath where coated particles arestrengthened.The centrifugation method is capable of producing microcapsules in the 100200 µm range. INTERFACIAL POLYMERIZATION: This is usually accomplished by emulsifying the liquid containing the firstreactant (dispersed phas
The advantages of electrostatic fluidized bed coating is that preheating of parts is generally not necessary and small products, can be coated uniformly and quickly. The disadvantages are that the product size is limited and inside corners have low film thickness owing to the well known faraday cage effect. DIFFERENCE BETWEEN FBD & EFBD
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