As the name suggests, particle size reduction is all about breaking down large, solid particles into smaller particles.
particle size reduction is integral to many industries, including:
- Pharmaceuticals
- Food & Nutraceutical
- Chemicals
- Beauty & personal care
- Paints and coatings
- Mining and minerals
- Dairy
- Recycling
It is achieved by using high shear forces. The key to particle size reduction is uniformity. The final, reduced-sized particles should be uniformly sized to maintain consistency in the products for which they will be used. It is important to note that particle size reduction is not just about size reduction but also about altering specific key physiochemical properties of the raw material(s). This is essential for the success of the industrial process that creates emulsions and suspensions. By reducing particles to smaller sizes, manufacturers can improve several crucial aspects of their products such as the:
Efficacy
Quality
Functionality
Read on to learn more about the fundamentals, methods, and benefits of particle size reduction.
The importance of particle size reduction
- Improved product consistency
- When particle size is uniform, it results in consistent performance in chemical reactions and final product quality. Bigger chunks of particles or lumps adversely affect the taste and feel of a product.
- Better bioavailability
- In pharmaceuticals, smaller particle sizes enhance the dissolution rate. It means that once consumed, the active ingredients are more likely to be successfully absorbed by the body.
- Better absorption
- Since smaller-sized particles have a smaller surface area, they are more reactive. They tend to work better in catalytic reactions and absorption processes.
- Enhanced speed and flow
- Uniform-sized small particles tend to flow smoothly as opposed to bigger-sized particles. This helps in a more efficient flow of particles/substances from one place to another. It enhances handling, processing and even packaging.
Methods of Particle Size Reduction
There are several methods for particle size reduction, each with unique advantages and applications. Here are the most used methods:
- Mechanical Milling
- This method uses rotating or grinding tools to effectively crush, shear, and break particles. Some examples of mechanical mills include:
- Ball mills
- Hammer mills
- Jet mills
- Cone mills
- Various other types of milling machines
- Each of these equipment works on the principle of using mechanical forces. For example, hammer milling uses rotating hammers to crush and disintegrate materials and reduce their size.
- Grinding
- This method uses some sort of grinding media, like balls or discs, to pulverise materials through friction and impact.
- Ball mills and roller mills are common examples of particle size reduction grinding methods.
- Roll Compaction
- This method uses rollers to compress material and break it into smaller-sized particles.
- This method is particularly popular within the pharma and food industries.
- Ultrasonic Milling
- This method is a little advanced; it uses high-frequency sound waves to generate micro-cavitation. The process breaks particles into very, very small – nano-sized particles.
- This method is the most popular in advanced material sciences and nanotechnology.
- High-Pressure Homogenization
- In this method, high pressure is used to force materials through a narrow orifice and reduce its size.
- This method is popular in industries where consistent emulsions and suspensions are required.
Before choosing the right method for particle size reduction, manufacturers must consider a few factors. For example, it is important to understand the material properties. Various aspects of the particles play a vital role in the choice of the milling equipment. These include their:
- Hardness
- Brittleness
- Thermal sensitivity
One should also keep in mind the target size of the particle. For example, if one needs nano-sized particles, ultrasonic milling is the way to go.
Also Read: Understanding the Mechanics of AODD Pumps
Powder processing by Quadro
When it comes to particle size reduction, Quadro Engineering has been a known name across the globe. The brand has been offering a wide range of particle processing and size reduction equipment to a large number of pharmaceutical, food and chemical processing companies for over four decades.
Its flagship product – the conical mill called Comil®, came into existence in 1976 and has gone through several transformations to match the evolving global processing standards. Quadro’s size reduction equipment is backed with the highest level of application and technical support.
Quadro Comil is known to offer a fast, reliable method of particle size reduction while ensuring particles are of uniform size. Comil is built to last for decades while offering high performance and a contamination-free operation. Quadro’s team constantly endeavour to offer customised particle size reduction solutions based on the manufacturer’s requirements.
For example, for pharma manufacturers looking to increase their productivity across dry milling and wet conditioning applications, Quadro offers the best pharma sieve milling solution. For those who need a reliable solution for the deagglomeration or delumping of powders and granules, Quadro offers solutions that deagglomerate, pump and separate without excessive heat buildup or screen blockage while also maintaining the quality of fragile products.
To know more about Quadro Comil and other Quadro solutions, please check out their website today –
https://www.idexindia.in/quadro-powder-processing/