Aromaz Pte Ltd Characterisation of Powder Premix Flowability Analysis HW

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Characterisation of Powder Premix Flowability

Company: Aromaz Pte Ltd

Aromaz Pte Ltd is a nutraceutical powder processing and manufacturer for both supermarket and food services products. Recently, there is a huge demand for nutraceutical, superfood and clean label products in the market. As such, there is a need to reduce or eliminate the use of anti-caking agent in products. On the other hand, as a manufacturer, it is crucial for products to have good powder flowability as it affects the machinability and rate of production for powder sachet packing. The project aims to characterise powder premix flowability and understand how processing conditions and ingredients in the formulation affect the powder flowability.

Objectives:

1) To characterise powder flowability of various powder categories using shear cell for texture analyser.

2) To build a flowability chart and understand how the formulation and ingredients (acid, sugar and salt) interaction affect the powder flowability and machinability in production packing (DOE).

3) To understanding how powder processing (granulation, liquid plating, dry blending) and particle size affects powder flowability.

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Explanation & Answer

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Running head: POWDER FLOWABILITY

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Characterization of Powder Premix Flowability
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POWDER FLOWABILITY

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Background
According to Chen and Roberts (2018), powder flowability is a term used about the flow
properties of the powder. In this case, there is a continuum in the categorization of powder
flowability that ranges from non-flowing on the one end to free-flowing on the other end.
Freeman, Brockbank, and Sabathier (2017) argue that it is important to consider granular and
powder systems as constituting a multiphase continuum. In this case, the behavior of such a
continuum is largely due to the individual properties of the particles as well as the powder
properties. These include shape, size, moisture content, as well as surface texture. Additionally,
the multiphase continuum is also affected by several external factors, including the history of
consolidation and humidity.
Also, temperature acts as a crucial external factor. Elsewhere, Fitzpatrick and Ahrne
(2005) argue that powder flow refers to powder particle displacement due to the influence of
certain directional forces. Such a force could be mechanical, the gravity of vibratory force. In
case the powder demonstrates resistance to such displacement, we talk of its powder strength.
Several inter-particle forces contribute towards powder strength (Geldart, Harnby & Wong,
1984). Such resistance is mainly due to adhesive forces between powders particles which are
determined by three forces namely, van der Walls forces, as well a liquid bridge forces.
However, each of these forces is determined by the nature of the powder particles. If the powder
particle is dry, the inter-particle forces are associated with van der Walls forces. This force is
determined by the distance from one body to another. If this distance happens to be very small,
then the force is quite significant. On the other hand, liquid bridge forces are associated with
capillary forces.

POWDER FLOWABILITY

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Powder flowability can also be affected by environmental factors, including humidity,
aeration, as well as consolidation. These have been shown to impact the moisture content of
certain powders. Others affect the friction and cohesiveness (Janjatović et al., 2012). The
inability to maintain flowability at optimum levels implies that the ingredients can absorb
humidity from the atmosphere. The added moisture affects the powder particles so that they stick
or adhere to each other, leading to solid lumps. As a result, the products manufactured from such
a powder are of poor quality given the potential for the ingredients to oxidize. To overcome such
a challenge, it is important to add anti-caking agents.
Before powder gets used in any industrial setting, there is the need for calibration of the
equipment to be in tune with the varying density and size of the powder particles (Geldart et al.,
1984)... Consequently, powder flowability will also be affected by the equipment of storage or
use, alongside its physical properties. In the pharmaceutical industry, for example, powder
handling takes place in such processes as compaction, blending, as well as fluidization.
The aforementioned forces can hinder powder flow, but they can equally facilitate in its
flow. However, the level to which such factors influence powder flowability is dependent on
various physical attributes of the powder particles, such as shape, size, and density. Additionally,
powder flow is also impacted by surface tension and geometry (Gioia, 1980). To improve
powder flowability, an anti-adherent must be added in the right proportion. It aids in reducing or
moderating the cohesive and adhesive forces that affect its attributes. The angle of repose of a
powder, in addition to its bulk density, acts as a useful parameter for determining flowability. In
this case, bulk density refers to powder mass relative to its total volume.

POWDER FLOWABILITY

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An increase in the size of a particle is often accompanied by a change in the force that
acts of such particles. In the case of very small particles, these might experience restricted flow
since the gravitational forces match the cohesive forces between them. Surface forces are usually
common in particle sizes of 1000 µm. Powder behavior then rests in the difference between these interaction forces
(Emery et al., 2009). The flow properties of a powder are also determined by the shape. In the
case of an irregular shape, the flow properties tend to be poor owing to a high surface area.
The surface properties associated with a particle are also influenced by moisture content.
Specifically, absorbed moisture contributes towards the granule formulation further affecting
flow. However, the impact of moisture of powder flowability differs and is determined by the
level of porosity or packing associated with the powder bed.

POWDER FLOWABILITY

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Various problems could occur and which have the potential to restrict the flow of powder
in such types of equipment as press hoppers or bins. In the case of a cohesive powder, there is
the risk of the formation of an arch contributing towards an erratic flow. Alternatively, the
powder might not flow at all (Stasiak &Molenda, 2012). If a rathole disintegrates impulsively,
we are likely to experience uncontrolled discharge or what is known as flooding. Arching
happens if there is the formation of a bridge or arch on top of the outlet bin. Consequently, this
restricts additional material discharge. If there is mechanical locking of particles, effectively
leading to the arch formation, we talk of an interlocking arch. What this means is that the outlet
size is smaller in comparison with the size of the particles being released. To establish if this
problem will take place, we can make use of the powder flow properties. They require being
dealt with during scale-up, to avoid the problem. Specifically, the cohesive strength associated
with a powder acts as a determinant of the outlet size needs. As the cohesive force increase, so
does the possibility of arching.
To assess powder flow, we estimate the time that a certain mass of powder takes to flow
via a funnel of a given size. Additionally, one can also pour powder on a flat surface and then
determine the angle of repose (Freman et al., 2017). This is the angle that forms between the
powders’s one surfaces relative to the flat surface. An angle repose that is associated with
granulated powder does not exceed 40°. Another aspect that affects powder flow is bulk density.
It refers to the weight of a loose powder, relative to its volume. It acts as an indirect determinant
of powder flow.
Powder flow normally encounters numerous challenges. Some of these challenges are
discussed below.
Zero flow

POWDER FLOWABILITY

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Usually, a powder ought to flow freely. However, lack of flow could be as a result of
various factors, including the irregular shape of the powder material and humidity. Come
materials are also coated and this too affects their flow (Stasiak & Molenda, 2012). Additionally,
the material may not flow due to its high moisture content.
Low flow
It is the result of having the feeder being obstructed. A misalignment in the feeder can
also contribute towards low flow.
Gradually reducing flow
One of the characteristics of problems associated with powder flow is that they do not
happen abruptly. Rather, there is a gradual decline in the flow rate until eventually, it stops. Such
gradual reduction inflows can be the result of materials having stuck to the feeder owing to what
is known as the static buildup. To overcome this problem, the feeder frame requires being
grounded. This helps to overcome static. Alternatively, the feeder can be coated.
Material flooding
During the production process, material flooding can happen in case of material overflow
following the shutting of the process. Consequently, the product experiences some
inconsistencies. To overcome this problem, it may be necessary that a valve is installed at the
point of discharge.
Formulated powders are of interest to researchers who are on the lookout for solutions to
enhance their flow properties and hence aid in its transportation. As noted earlier, moisture
contributes towards the flowability of the powder. Consequently, the association of moisture and
powder formulated has attracted the attention of various researchers. Based on the prevailing
humidity, there is the likelihood of the formation of a liquid bridge between powder particles.

POWDER FLOWABILITY

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Such liquid bridges are in turn associated with increased powder cohesion (Stasiak & Molenda,
2012). Consequently, there is a resultant reduction in powder flowability. Sensitivity to moisture
hinges on surface properties of the particle under study. It may be necessary to conduct
hydrophobic and hydrophilic treatments as a means of altering powder sensitivity. Moreover, the
particle surface can be changed through lactose coating. However, the ...


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