This paper describes a collaborative theoretical and experimental research effort to investigate both the atomization dynamics of non-Newtonian liquids as well as the performance of coaxial atomizers utilized in pharmaceutical tablet coating. In pharmaceutically relevant applications, the coating solutions being atomized are typically complex, non-Newtonian fluids which may contain polymers, surfactants and large concentrations of insoluble solids in suspension. The goal of this investigation was to improve the understanding of the physical mechanism that leads to atomization of viscous and non-Newtonian fluids and to produce a validated theoretical model capable of making quantitative predictions of atomizer performance in pharmaceutical tablet coaters. The Rayleigh-Taylor model developed by Varga et al. has been extended to viscous and non-Newtonian fluids starting with the general dispersion relation obtained by Joseph et al. The theoretical model is validated using droplet diameter data collected with a Phase Doppler Particle Analyzer for six fluids of increasing rheological complexity. The primary output from the model is the Sauter Mean Diameter of the atomized droplet distribution, which is shown to compare favorably with experimental data. Critical model parameters and plans for additional research are also identified.

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A tablet film-coating model for aqueous- and/or organic-based systems is shown to predict exhaust stream conditions thereby facilitating process optimization and scale-up. This coating model uses the First Law of Thermodynamics and conservation of mass principles to complete a material-energy balance on the coating unit operation for a closed, non-isolated system. Heat loss from the coating pan is incorporated into the model through a parameter called a heat loss factor (HLF) that is directly related to the heat transfer coefficient and pan surface area. For a mixed organic-aqueous coating formulation, the outlet air temperature and humidity are most notably affected by the coating composition and the inlet drying air temperature, which controls the evaporative cooling rate. The coating solution temperature and inlet air relative humidity do not significantly influence the exhaust air temperature, Tair,out. The HLF was determined to be 24 to 62 cal/min degrees C for the LDCS-20 to HCT-30, 360 cal/min degrees C for the HCT-60, 0 cal/min degrees C for the HC-130L and 945 to 1322 cal/min degrees C for the Accela-Cota-48 to Compulab-36 coating pans. This model successfully predicts Tair,out within 3 degrees C for a given coating pan, and within 6 degrees C scaling up from one to 220 kg pans for both organic- and aqueous-based coatings. The model is also useful for probing process and formulation variable sensitivity critical to establishing process robustness.

No abstract

A tablet film-coating model for aqueous- and/or organic-based systems is shown to predict exhaust stream conditions thereby facilitating process optimization and scale-up. This coating model uses the First Law of Thermodynamics and conservation of mass principles to complete a material-energy balance on the coating unit operation for a closed, non-isolated system. Heat loss from the coating pan is incorporated into the model through a parameter called a heat loss factor (HLF) that is directly related to the heat transfer coefficient and pan surface area. For a mixed organic-aqueous coating formulation, the outlet air temperature and humidity are most notably affected by the coating composition and the inlet drying air temperature, which controls the evaporative cooling rate. The coating solution temperature and inlet air relative humidity do not significantly influence the exhaust air temperature, Tair,out. The HLF was determined to be 24 to 62 cal/min degrees C for the LDCS-20 to HCT-30, 360 cal/min degrees C for the HCT-60, 0 cal/min degrees C for the HC-130L and 945 to 1322 cal/min degrees C for the Accela-Cota-48 to Compulab-36 coating pans. This model successfully predicts Tair,out within 3 degrees C for a given coating pan, and within 6 degrees C scaling up from one to 220 kg pans for both organic- and aqueous-based coatings. The model is also useful for probing process and formulation variable sensitivity critical to establishing process robustness.