Unit Op-12

SIZE REDUCTION
Size reduction
Is a process of reducing large solid unit masses -
vegetables or chemical substances into small unit
masses
Is also referred to as comminution/grinding
When the particle size of solids is reduced by
mechanical means it is known as Milling.
The size reduction operation can be divided into two
major categories depending on whether the material is
a solid or a liquid.
If the material is solid, the process is called grinding and
cutting, if it is liquid, emulsification or atomization
Objectives of size reduction
To increase of surface area Pharmaceutical capsules,
insufflations (i.e. powders inhaled directly into the
lungs), suppositories and ointments require particles
size to be below 60 mm size.
To increase the therapeutic effectiveness of certain

drugs by reducing the particle size.
Size reduction produces particles in narrow size range.
Mixing of powders with narrow size range is easier
and uniform.
Pharmaceutical suspensions require finer particle size.
It reduces rate of sedimentation.
Mechanism of size reduction
Impact – this involve hammer or bar at high speed
(hammer mill).
Compression- particle crushed b/w rollers by the

application of force (roller mill).
Cutting – the material cut by a sharp blade (cutter

mill)
Attrition - arising from particles scraping against one

another or rubbing action (fluid energy mill)
Laws governing size reduction
Griffith theory -The amount of force to be applied depends
on the crack length.
Kick's law- Work required to reduce the size of a given

quantity of material is constant for the same reduction
ratio regardless of the original size.
Rittinger's law -Work used for particulate size reduction is

directly proportional to the new surface produced.
Bond's law -Work used to reduce particle size is

proportional to the square root of the diameter of the
particle produced.
Factors affecting Size Reduction
Selection of mill - It is related to feed, milled product,
safety and economics
Factors related to nature of raw materials affecting size

reduction
Hardness - It is easier to break soft material than hard

materials
Fibrous - These are tough in nature. A soft, tough

material has more difficulty than a hard, brittle
substance.
Factors affecting Size Reduction…
Elastic / Sticky - Become soft during milling. eg: synthetic
gums, waxes, resins. Low melting substances should be
chilled before milling. These are milled using hammer,
colloid or fluid energy mill.
Melting point - Waxy substances, fats and oils are

softened during size reduction due to heat generated.
This is avoided by cooling the mill and the substance.
Hygroscopic - Certain substances absorb moisture

content rapidly. This wet mass hampers the milling
process. eg: Potassium carbonate. Closed system such as
porcelain ball mill is used
Hammer Mill
Principle: Operates on the principle of impact between
rapidly moving hammers mounted on rotor and the
stationary powder material.
Parts Consists of a metal casing, enclosing a central shaft,

to which 4 or more swinging hammers are attached.
Lower part of casing consists of a screen, through which
material can pass and collected in a suitable receiver
Construction & Working
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.
Construction & Working…
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 1000 to 2500 revolutions

per minute (rpm) for the reduction of the large sized
particles. High speed rotor uses 10000 rpm speed.
Uses
Brittle material is best fractured by impact from
blunt hammers.
Fibrous material is best reduced by cutting edges
Advantages a 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 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 a hammer mill
Heat build up 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

Ball Mill
Principle It operates on the principle of impact and
attrition between the rapidly moving balls and the
powder material, both enclosed in a hollow cylinder.
Parts Consists of a hollow cylinder mounted on a

metallic frame such that it can be rotated along its
longitudinal axis.
Cylinder contains balls occupying 30–50 % of mill

volume. Weight of ball is constant; Size depends on the
feed quantity and diameter of mill.
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.
Installation, operation and labour costs are low.

Advantages of Ball mill:
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.
Disadvantages:
The ball mill is a very noisy machine.
Ball mill is a slow process.
Soft, fibrous material cannot be milled by

ball mill.

Unit Op-12

Uploaded by

Copyright:

Available Formats

Unit Op-12

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Unit Op-12

Uploaded by

Copyright:

Available Formats

SIZE REDUCTION

To increase the therapeutic effectiveness of certain

Compression- particle crushed b/w rollers by the

Cutting – the material cut by a sharp blade (cutter

Attrition - arising from particles scraping against one

Kick's law- Work required to reduce the size of a given

Rittinger's law -Work used for particulate size reduction is

Bond's law -Work used to reduce particle size is

Factors related to nature of raw materials affecting size

Hardness - It is easier to break soft material than hard

Fibrous - These are tough in nature. A soft, tough

Melting point - Waxy substances, fats and oils are

Hygroscopic - Certain substances absorb moisture

Parts Consists of a metal casing, enclosing a central shaft,

The hammers swings on the ends or fixed to the central

The rotor is rotates at a high speed inside the drum

This are mainly operated at 1000 to 2500 revolutions

They are easy to install and operate, the operation is

There is little contamination of the product with metal

The particle size of the material to be reduced can be

Heat build up during milling is more, therefore,

Hammer mills cannot be employed to mill sticky,

The screens may get clogged

Parts Consists of a hollow cylinder mounted on a

Cylinder contains balls occupying 30–50 % of mill

At low speeds, the ball roll over each other and

Thus, in the ball mill, impact or attrition or both are

Installation, operation and labour costs are low.

Ball mill is used for both wet and dry grinding

Toxic substances can be ground, as the cylinder

The ball mill is a very noisy machine.

Ball mill is a slow process.

Soft, fibrous material cannot be milled by

You might also like