In pharmaceutical production, agglomerates often form in the preliminary stages – especially in mixtures of powders and liquids. For the further process, these lumps must be broken up and the raw materials reduced in size; this process is called active substance deagglomeration.
Why an agitator alone is not enough
A conventional agitator cannot reliably break up agglomerates. Modern process plants with integrated, powerful agitation and homogenising systems, on the other hand, are ideally suited to this task.
Their rotor/stator system reduces solids optimally and at the same time increases the surface area of the powder in the liquid. This produces agglomerate-free solutions within a few minutes.
Benefits of active substance deagglomeration
Breaking up the agglomerates makes the entire particle surface accessible to the liquid. This brings several advantages:
- active ingredients dissolve faster and more evenly
- suspensions become more homogeneous
- dosing accuracy increases
- for poorly soluble active ingredients, a finer particle size can improve the dissolution rate and thus bioavailability
True micronisation down to a few micrometres usually requires jet mills, bead mills or high-pressure homogenisers. The rotor/stator homogeniser mainly handles deagglomeration, wetting and dispersion.
FAQ: Active substance deagglomeration
What is active substance deagglomeration?
Breaking up agglomerates and lumps that form when powdered actives are mixed with liquids. The goal is a fine, uniform distribution of every single particle.
Why is a standard agitator not sufficient?
An agitator produces hardly any shear. Agglomerates remain and powder nests form. Only the high shear in the rotor-stator gap of a homogeniser breaks them up reliably.
What are the benefits of good deagglomeration?
Shorter dissolving and process times, homogeneous active distribution, higher dosing accuracy and a larger effective particle surface, which can improve dissolution rate and bioavailability.
How are powders best incorporated?
By vacuum powder induction directly into the shear zone of the homogeniser below the liquid level, so every particle is wetted immediately.
Does SEEFRIED offer deagglomeration solutions?
Yes, with process consulting, trial planning and suitable homogenising mixers, also used.