Needle-free ballistic powder delivery by applying Freeze Granulation you will be able to make microparticles with high insulin loading (nanosuspension) suitable for needle-free ballistic drug delivery. The resulting granules are homogeneous and robust with a diameter of around 50-150 µm, with a narrow size distribution and a high content of insulin.
Freeze Granulation of zeolite materials offers the possibility to produce very soft, spherical granules which show an excellent flowability. The granules can be compressed to compacts of high homogeneity and they are completely redispersable. Freeze Granulation is a granulation technique which combines the advantages of spray drying and freeze drying. Hard granules and agglomerates are prevented by this technique excluding capillary forces during drying.
Spray-freezing and freeze drying – Freeze Granulation
PowderPro AB develop, manufacture, market and sell equipment and know-how for Freeze Granulation, spray freezing and subsequent freeze drying (lyophilization or cryodesiccation). Freeze Granulation was developed in late 1980s at Swedish Ceramic Institute in Göteborg and it is also a development of Spray Freeze Drying (SFD) and Spray Freezing into Liquid (SFL).
Spray cooling or rather called spray freezing is the first step in the freeze granulation process where a suspension is atomized, sprayed with a nozzle, into a chamber with liquid nitrogen. The small droplets are then rapidly frozen with a minimum of ice crystal growth. The frozen material (granules) are then transferred to a freeze dryer where the ice is removed by sublimation, i e never go through a liquid state that ensure homogeneity preservation.
Below you can see an illustration of the Freeze Granulation process.
Nano ice formation in granules by Freeze Granulation process is a key factor for the unique homogeneity of particles and binders achieved in the resulting granules. This is especially important for nanopowders, fine particles and binders where migration of these could occur during conventional drying, like spray drying.
Freeze Granulation is today used for commercial production of homogeneous granules for the production of oxides used as a ceramic phosphor plate for white illumination in LED Lighting. By using Freeze Granulation of the powder and binder mixture, compared with spray drying, it is possible to manufacture a homogeneous phosphor plate with optimal properties for to generate a soft and warm white light from high power LEDs.
Freeze Granulation with ultrasonic atomisation of droplets
Freeze Granulation can be made using ultrasonic atomisation of spherical droplets. The resulting granules have a narrow granule size distribution and the granule size is in general smaller (average 120 micron) compared to a regular spray nozzle. The granulation speed is also slow with about 0.3 to 0.5 litre/h.
Transparent and translucent ceramics by Freeze Granulation
Freeze Granulation is today being used for commercial manufacturing of transparent and translucent ceramics. The main advantage is to achieve a homogeneous distribution of the starting material which will result in rapid reaction and sintering at low temperature where grain growth of the material will be avoided.
POWTECH 2013 – Nürnberg. Good and interesting meetings on powder processing and how Freeze Granulation can improve the homogeneity of the granules, for example nanomaterial like CNT – Carbon Nano Tubes.
Powder injection molding (PIM) and extrusion are powder shaping techniques that typically involve preparation of high viscous feedstock making it difficult to achieve full homogeneity. Especially if the powders are fine (submicron or nano) and/or if it is a composite material. By doing an initial preparation of a low viscous (based on water or organic) suspension the powders can be properly de-agglomerated, dispersed and homogenized. Other constituents aimed for the PIM or extrusion process can be added prior to freeze granulation. The result will be a homogenized, soft and dust free powder, easy to mix and disperse into a feedstock for PIM or extrusion at high powder concentration and homogeneity, promoting sintering and ultimate material performance.
PowderPro har i samarbete med Swerea IVF (då Svenska Keraminstitutet) under 1980-talet vidareutvecklat en alternativ granuleringsteknik – frysgranulering (Freeze Granulation) – vilken möjliggör konservering av homogeniteten från suspension till torrt granulat. Genom att spreja en pulversuspension ner i flytande kväve sker en momentan frysning av dropparna (granulerna). I den efterföljande frystorkningen sublimeras isen utan risk för segregeringseffekter som lätt sker vid konventionell torkning i luft. Resultatet blir sfäriska och friflytande granuler med optimal homogenitet lämpliga för t ex pressning av keramiska komponenter.
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