Predicting Dynamic Processes of Bulk Powder Behaviour Based on the Changes in Particles Physical and Chemical Properties

Aims:
The project will address manufacturability problems related to bulk behaviour of industrial powders. More specifically, it will examine the impact of the materials' physical and chemical surface properties on flowability, caking and performance. The aim is to gain an understanding of how a particular material can vary in its bulk powder behaviour despite being, prima facie, the same physicochemical form of the compound. Variations in bulk powder behaviour will be quantified and related to a deep understanding of the particle properties across all relevant length scales from molecular to macroscopic. These will then be correlated with manufacture and processing conditions.

Methodology Proposed for the Proposed Project (up to 200 Words)

The caking behaviour of pharmaceutical powders under controlled external conditions (applied stress, humidity and temperature) will be investigated. In particular, the changes in bulk volume and internal porosity of the samples (typically reduction) under the external conditions will be measured using x-ray tomography (at Leeds and Manchester) and the results will be correlated with the bulk strength, separately measured by the ball indentation technique. The information regarding changes in the physical property will be complemented by measurements of the chemical properties, particularly surface analysis using the environmental x-ray photoelectron spectroscopy.

Methodology:
In this work, ibuprofen (crystallised with different solvents) will be initially used as a model material to establish the research methodology, as ibuprofen has been shown to cake independently of relative humidity levels as well as to form agglomerates under dynamic vibrational conditions. Other model materials will also be used at later stage of the project to verify the methodology developed.

Potential Impact:
The project is relevant to all industries that use powder systems as it will offer fundamental understating into the nature of bulk behaviour issues such as powder caking and poor powder flow. It will also establish novel analytical capability to predict multiscale characterisation on how macroscopically observable powder behaviour relates to molecular and mesoscopic properties. The fundamental understanding and scientific knowledge in powder behaviour, as affected by the particle properties, would be highly beneficial for academia. In addition, implementing the knowledge in practical cases could have significant economic impact on the relevant industry, for instance where the trials and errors for improving the quality of high value products could be reduced.

Expected Deliverables:

a) A methodology to evaluate caking behaviour of pharmaceutical powders

b) In depth understanding and predictive tool for the caking and flow behaviours of active pharmaceutical powders based on particle morphology, surface chemistry and process conditions.

The CDT in Molecules to Product has the potential to make a real impact as a consequence of the transformative nature of the underpinning 'design and supply' paradigm. Through the exploitation of the generated scientific knowledge, a new approach to the product development lifecycle will be developed. This know-how will impact significantly on productivity, consistency and performance within the speciality chemicals, home and personal care (HPC), fast moving consumer goods (FMCG), food and beverage, and pharma/biopharma sectors.
UK manufacturing is facing a major challenge from competitor countries such as China that are not constrained by fixed manufacturing assets, consequently they can make products more efficiently and at significantly lower operational costs. For example, the biggest competition for some well recognised 'high-end' brands is from 'own-brand' products (simple formulations that are significantly cheaper). For UK companies to compete in the global market, there is a real need to differentiate themselves from the low-cost competition, hence the need for uncopiable or IP protected, enhanced product performance, higher productivity and greater consistency. The CDT is well placed to contribute to addressing this shift in focus though its research activities, with the PGR students serving as ambassadors for this change. The CDT will thus contribute to the sustainability of UK manufacturing and economic prosperity.
The route to ensuring industry will benefit from the 'paradigm' is through the PGR students who will be highly employable as a result of their unique skills-set. This is a result of the CDT research and training programme addressing a major gap identified by industry during the co-creation of the CDT. Resulting absorptive capacity is thus significant. In addition to their core skills, the PGR students will learn new ones enabling them to work across disciplinary boundaries with a detailed understanding of the chemicals-continuum. Importantly, they will also be trained in innovation and enterprise enabling them to challenge the current status quo of 'development and manufacture' and become future leaders.
The outputs of the research projects will be collated into a structured database. This will significantly increase the impact and reach of the research, as well as ensuring the CDT outputs have a long-term transformative effect. Through this route, the industrial partners will benefit from the knowledge generated from across the totality of the product development lifecycle. The database will additionally provide the foundations from which 'benchmark processes' are tackled demonstrating the benefits of the new approach to transitioning from molecules to product.
The impact of the CDT training will be significantly wider than the CDT itself. By offering modules as Continuing Professional Development courses to industry, current employees in chemical-related sectors will have the opportunity to up-skill in new and emerging areas. The modules will also be made available to other CDTs, will serve as part of company graduate programmes and contribute to further learning opportunities for those seeking professional accreditation as Chartered Chemical Engineers.
The CDT, through public engagement activities, will serve as a platform to raise awareness of the scientific and technical challenges that underpin many of the items they rely on in daily life. For example, fast moving consumer goods including laundry products, toiletries, greener herbicides, over-the-counter drugs and processed foods. Activities will include public debates and local and national STEM events. All events will have two-way engagement to encourage the general public to think what the research could mean for them. Additionally these activities will provide the opportunity to dispel the myths around STEM in terms of career opportunities and to promote it as an activity to be embraced by all thereby contributing to the ED&I agenda.