BÜCHI Labortechnik AG is a leading global supplier of spray drying systems for applications in research laboratories. In this project, an existing spray dryer for the production of inhalable particles from BÜCHI was optimized. The sub-processes of the atomization of the solution, the drying of the formed droplets or particles and the separation of the particles were examined theoretically and experimentally and then optimized.
The atomization and drying was analyzed via LDA/PDA laser measuring technology. With a parametric study, the optimum operating conditions for the production of the desired particles could be assessed. Another challenge is the separation of the particles in the gas cyclone. With the help of empirical models and numerical flow simulations, a new type of gas cyclone was developed for the separation of these ultra-fine particles. Compared to existing gas cyclones, this gas cyclone achieves 15%-30% higher separation efficiencies.
With the optimized spray dryer it is possible to produce inhalable particles with a yield of 90%. This enables a more cost-effective production of pharmaceutical active ingredients that results in drastically lower development costs for new types of medicaments.