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Scale-Up

17. Scale-Up. you need product for testing. you need product for marketing. you must learn to work on a large scale. have you ever cleaned a 1000 m 3 spray dryer?. How to Scale Up. lab recipe. process diagram. get equipment. scale-down design. scale up. optimize lab recipe. scale up.

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Scale-Up

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  1. 17 Scale-Up you need product for testing you need product for marketing you must learn to work on a large scale have you ever cleaned a 1000 m3 spray dryer?

  2. How to Scale Up lab recipe process diagram get equipment scale-down design scale up optimize lab recipe scale up product for testing product and plant design

  3. CH2OH O OH HO HO HOCH2 O O HO CH2 OH nav 10 O HOCH2 O HO CH2OH OH Inulin as a Binder? polysaccharide powder from chicory roots sweet, non-fattening, healthy in foods other markets? could we use inulin as binder-filler for tablets?

  4. Process Diagram chicoryroot wash cut pulp extract heat water proteins purify salts concentrate water hotair spray dry air post dry inulinpowder

  5. Binders Compared binders Dicalcium Phosphate Mannitol Inulin MCC property — + 0 flow properties 0 ++ ++ ++ binding strength 0 ++ + + mixing properties + ++ ++ + stability 0 can we make small amounts of good product? can we make large amounts of the same product?

  6. A Good Powder hollow spheres good flow : large particles non-sticking 154 m

  7. Particle Sizes mass fraction smaller than d the particles have a size-distribution frequency distribution

  8. Tablet Strength tablet strength, N little effect of lubrication(very good) 200 non-lubricated 100 lubricated 0 10 000 20 000 0 compaction force, N

  9. Binding and Lubrication filler (inulin) lubricant (MgSt) fracturing fresh surface poor binding good binding patented

  10. Scale Up Requirements well-dried particles spherical particles defined hollowness defined size (distribution) the same on the two scales

  11. inulin solution Spray Dryer hot air drying drops air air heat blower wheel atomizer cyclone inulin powder

  12. Scaling Up (or Down) small machine: as small as practical large machine: large throughput given different design of atomizers they should make the same product same drops same drying

  13. Inside the Dryer 1 5 1 wheel ejects drops 3 2 4 2 drops retarded 3 drops in air jet 4 particles dry (outside) 5 particles hit wall largest drops must be dry before they reach the wall 6 6 constant temperature

  14. Drop Formation feed atomizer spray film hollow sphere  100 m s-1 skin drop vaporising water draws inulin to the skin

  15. Drop Size limitations load per vane height number of vanes maximum drop size smallest wheel diameter

  16. Flow Considerations D/2 time available depends on: distance D/2 ejection velocity circulation rate small machine: minimize vav and D large machine: move drops quickly for capacity

  17. Small and Large these give approximately the same product

  18. Other Differences pro-analyse ingredients technical column packing filter aid auxiliaries catalyst between lab and plant batch process continuous start-up time-scale procedures safety cleaning

  19. Other Equipment same feed filter same medium scaling-up same fluxes same turbulence 'large enough' mixer same dissipation as mixer crystallizer control nucleation control impurities! is continuous extruder operate adiabatically

  20. Summary lab recipe process diagram get same product: lab and large scale get equipment optimize in the lab scale-down design start producing optimize lab recipe scale up product for testing product and plant design

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