The Problem

A leading pharmaceutical firm was in the process of validating a new tablet product, which begins with several ingredients being added to a tumble blender. The blended material is then discharged into multiple bins. Initial tests during scale-up showed high active ingredient percentages in the tablets produced from the material which discharged last from each bin.

Jenike & Johanson was contacted to assist in determining the cause of the problem and to recommend a solution. Typical areas of concern with such a process include the tumble blender, the portable containers, the transfer chute from the portable container, and the press feed hopper below the chute.

Jenike & Johanson's Solution

Jenike & Johanson recommended flow properties tests to be conducted on four variations of the formulation to determine their handling and segregation characteristics.

During the filling of the bin, segregation occurred which resulted in fine particles accumulating near the perimeter of the bin. During free-fall into a container, particles tend to separate from each other, with fine particles forming dust clouds. When the falling stream impacts the pile, it can become aerated, and generate more dust. It was determined that the best solution was to eliminate the dusting, and hence segregation, by reducing the drop height from the blender to the portable bin, using a retractable letdown tube. Jenike & Johanson engineers developed the concept, then designed and built the PharmaSok™ filling system.

The Result

Tests with the PharmaSok™ showed a dramatic reduction in the observed dust normally generated during container filling. Assays performed on the tablets showed them to be within specification.

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