SIZE REDUCTION OF SOLID

Group No. :3
CANTOS, JOMAR
RAGONTON, KIM ARVIN JUSTIN
SILANG, WILLIAM
INTRODUCTION
Size reduction is a process of reducing large solid
unit masses vegetables or chemical substances
into small unit masses, coarse particles or fine
particles. Size reduction is commonly employed in
pharmaceutical industries. It is the process of
reduction of large solid units into small units.
Size reduction process is also referred to as
Comminution, grinding, diminution or
pulverisation .
OBJECTIVES OF UNDERSTANDING SIZE
REDUCTION
1. Size reduction leads to increase of surface area.
2. Pharmaceutical capsules, insufflations (i.e.
powders
inhaled directly into the lungs), suppositories and
ointments require particles size to be below 60 mm
size.
3. To increase the therapeutic effectiveness of
certain drugs
by reducing the particle size.
4. Size reduction produces particles in narrow size
range.
Mixing of powders with narrow size range is easier.
5. The mixing of several solid ingredients is easier
and more
uniform if the ingredients are reduced to same
particle
size.
6. Pharmaceutical suspensions require finer particle
size. It
reduces rate of sedimentation.
7. The stability of emulsions is increased by decreasing the
size of the oil globules.
8. All the ophthalmic preparations and preparations meant
for external application to the skin must be free from
gritty particles to avoid irritation of the area to which they
are applied.
9. The rate of absorption of a drug depends on the dosage
form, route of administration and particle size. The
smaller the particle size, quicker and greater will be rate
of absorption.
10. The physical appearance of ointments, pastes
and creams
can be improved by reducing its particle size
PROCESS OF SIZE REDUCTION::

Process of size reduction: Size reduction may be

achieved by two methods:
1. Precipitation method
Mechanical method Precipitation method:
Substance + solvent Mixture + another solvent
Precipitation of material reduced size ( e.g. calcium
carbonate, yellow mercuric oxide, bulk drugs etc.)
2. Mechanical process
Substance + mechanical force (grinding
equipments like Ball mill, Colloid mill etc.) reduced
size ( e.g. Dry grinding in tables and capsules, Wet
grinding in suspension, emulsion and ointments
etc.)
ADVANTAGES/ APPLICATIONS/SIGNIFICANCE
AND OBJECTIVES OF SIZE REDUCTION:

Content uniformity Uniform flow Effective

extraction of drugs
Effective drying Improved physical stability

Improved dissolution rate Improved rate of

absorption
DISADVANTAGES OF SIZE REDUCTION:
Drug degradation
Poor mixing Contamination
Size Reduction
Equipment :
Size reduction equipment is divided into
crushers, grinders, ultrafine grinders, and
cutting machines. Crusher do the heavy work of
breaking large pieces of solid material into
small lumps. A primary crusher operates on
run-of -mine material accepting anything that
comes from mine face and breaking it into 150
to 250 mm lumps. A secondary crusher reduces
these lumps into particles perhaps 6mm in
size.
Grinders reduce crushed feed to powder. The product from
an intermediate grinder might pass a 40-mesh screen; most
of the product from a fine grinder would pass a 200-mesh
screen with a 74m m opening. An ultrafine grinder accepts
feed particles no larger than 6mm and the product size is
typically 1 to 5m m. Cutters give particles of definite size
and shape, 2 to 10mm in length.
The principal types of size-
reduction machines are as
follows:
A. Crushers (coarse and fine)

Jaw crushers

Gyratory crushers

Crushing rolls

B. Grinders (intermediate and

fine)

Hammer mills;
impactors

Rolling-compression
mills
 Attrition mills

Tumbling mills

C. Ultrafine grinders

Hammer mills with

internal
classification

Fluid-energy mills

Agitated mills

D. Cutting machines

Knife cutters; dicers;

slitters
SIZE REDUCTION EQUIPMENT
A hammer mill is essentially a steel drum
containing a vertical or horizontal rotating shaft or
drum on which hammers are mounted.
The hammers swings on the ends or fixed to the
central rotor.
The rotor is rotates at a high speed inside the drum
while material is fed into a feed hopper.
The material is put into the hopper which is
connected with the drum.
The material is powdered to the desired size due
to fast rotation of hammers and is collected under
the screen.
This are mainly operated at 2500
rpm or 1000 to 2500 rpm for the
reduction of the large sized
particles. High speed rotor uses
10000 rpm speed.
ADVANTAGES OF HAMMER MILL
It is rapid in action, and is capable of grinding many
different types of materials.
They are easy to install and operate, the operation is
continuous.
There is little contamination of the product with metal
abraded from the mill as no surface move against each
other.
The particle size of the material to be reduced can be
easily controlled by changing the speed of the rotor,
hammer type, shape and size of the screen.
 DISADVANTAGES
Heat buildup during milling is more,
therefore, product degradation is
possible.
Hammer mills cannot be employed to
mill sticky, fibrous and hard materials.
The screens may get clogged.
Wearing of mill and screen is more with
abrasive materials.
 BALL MILL
These are also knows as tumbling mills.
Principle: The ball mill works on the principle
of impact between the rapidly moving balls
and the powder material, both enclosed in a
hollow cylinder.
Working: At low speeds, the ball roll over each
other and attrition (rubbing action) will be the
predominate mode of action. Thus, in the ball
mill, impact or attrition or both are responsible
for the size reduction.
 ADVANTAGES:
It can produce very fine powder.
Ball mill is used for both wet and dry grinding
processes.
Toxic substances can be ground, as the cylinder is
closed system.
Rod or bars can also be used as grinding media.

(example: Sticky material are size reduced) In ball mill,

installation, operation and labour costs are low.

 DISADVANTAGES:
The ball mill is a very noisy
machine.
Ball mill is a slow process.
Soft, fibrous material cannot be
milled by ball mill.
ROLLER MILL
ROLLER MILL
ROLLER MILL
 PRINCIPLE
Colloidal mill works on the principle of rotor-stator.
The size reduction is affected due to shearing, when
the material is passed between the narrow gap of
milling surfaces of rotor and stator. A rotor turns at
high speeds of 3000 - 20000rpm. The high levels of
hydraulic shear applied to the process liquid disrupt
structures in the fluid.
Higher shear rates leads to smaller droplets of 1
micron. Based on a rotor rotating at high speed and
very close to a conical stator, the particle size is done
by modifying the gap between the rotor and the stator
COLLOIDAL MILL
Subject : Mechanical Operation
( 2150502 )
Topic : Size Reduction

Presented By :

Akash Patel : 130190105064

Ankit Patel : 130190105065

Dimple Patel : 130190105067

Divyesh Patel : 130190105068

Size
Reduction
Commonly Used Method For
Size Reduction:
Compression

Impact

Attrition

Cutting
Principle For Size
Reduction:
Criteria For Size
Reduction
An Ideal Crusher Would, Have a large
Capacity, Require a Small Power Input
Per Unit Of Product; and Yield a Product
of the Single Size Distribution Desired.

Energy and power requirement

in size reduction :
The cost of power is a major expensive in
crushing and grinding, so the factor that
control this cost are important.
Crushing Efficiency :
Empirical Relationship of
Rittingers Law & Kicks Law
The work required in crushing is
proportional to the new surface created.
This is equivalent to the statement that
the crushing efficiency is constant and,
for a giving machine and material, is
independent of the sizes of feed and
product. If the sphericities F a (before
size reduction) and F b (after size
reduction) are equal and the machine
efficiency is constant, the Rittingers
law can be written as
Where Kr is Rittingers
Co-efficient.
Bond Crushing
law & Work Index :
The work required to form particles of
size Dp from very large feed is
proportional to the square root of the
surface-to-volume ratio of the
product, sp/vp. Since F s = 6/Dp, it
follows that

where Kb is a constant that

depends on the type of machine and
on the material being crushed.
Kicks Law :
the work required for crushing
a given mass of material is constant
for the same reduction ratio, that is
the ratio of the initial particle size to
the finial particle size

Where P is power required, m

is a feed rate of Crusher, DS2 is a
average particle diameter before
crushing, DS1 is average particle
diameter after crushing,
Kk is Kicks Co-efficient.
 The Work Index Wi, Is define
as the gross energy required in KWH
per tone to reduce a very large feed to
such a size that 80%of the product
passes a 100 m screen. If Dp is in
millimeters, P in Kw, and m in tone
per hour, then

If 80% of the feed passes a

mesh size of Dpa millimeters and 80%
of the product a mesh
of Dpb millimeters, it follows that