AVEKA Group MASTERING THE PROCESSING METHODS OF ENGINEERED - - PowerPoint PPT Presentation

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AVEKA Group MASTERING THE PROCESSING METHODS OF ENGINEERED - - PowerPoint PPT Presentation

Mar 01, 2023 266 likes •569 views

AVEKA Group MASTERING THE PROCESSING METHODS OF ENGINEERED PARTICLES MAY 13, 2020 PA RT I C L E P RO C ES S I N G S E RV I C ES TO L L M A N U FAC T U R I N G R ES EA RC H & D E V E LO P M E N T I N N O VAT I V E S O LU T I O N S

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SLIDE 1

AVEKA Group

MASTERING THE PROCESSING METHODS OF ENGINEERED PARTICLES

MAY 13, 2020

PA RT I C L E P RO C ES S I N G S E RV I C ES TO L L M A N U FAC T U R I N G R ES EA RC H & D E V E LO P M E N T I N N O VAT I V E S O LU T I O N S

AVEKA

PRESENTED BY: WILLIE HENDRICKSON, CEO & FOUNDER

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SLIDE 2

Presentation Outline

Overview of AVEKA What are engineered particles? How do you approach making engineered particles? General processing methods to consider Practical challenges Separation example Coating example Atomization example Conclusions

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SLIDE 3

AVEKA Group Overview

  • Particle technology company focused on

contract manufacturing

  • Spin-off of 3M in 1994
  • Comprised of 5 separate companies
  • ISO certifications / food-grade

certifications

  • Currently 290 employees
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SLIDE 4

AVEKA’s Vision

AVEKA

AVEKA’s Vision Building the legacy of leadership and innovation in manufacturing solutions for particle technology AVEKA’s Mission Our team of employee owners will deliver custom solutions, quality manufacturing, and excellent customer service for the benefit of our customers, employees and communities.

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SLIDE 5

The AVEKA Group

  • 75 people
  • Corporate Headquarters
  • R&D, Manufacturing, Specialty Process Suites

AVEKA Inc

  • 96 people – Fredericksburg, Iowa
  • Large scale manufacturing
  • Spray Drying, Hammer Milling, Fluid Bed Drying, Tumble Coating,

Agglomeration AVEKA Manufacturing

  • 50 people – Cresco, Iowa
  • Food Processing
  • Spray Drying, Prilling, Drum Drying, Extraction, Wet Blending

Cresco Food Technologies

  • 40 people – Waukon Iowa
  • Value Added Food Processing
  • Spray Drying, Roll Drying, Microfiltration/Nanofiltration, Specialty Separations

AVEKA Nutra Processing

  • 15 People – Cottage Grove, Minnesota
  • Industrial Materials, Abrasives, Ceramics, Minerals
  • Jet Milling and Classification

AVEKA CCE Technologies

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SLIDE 6

AVEKA

Particle Characterization

Particle size analysis

  • Particles 1 nm to 2+ mm
  • Particle size distribution (PSD)
  • Sonic sieving
  • Rototap

Imaging

  • Optical microscopy
  • Scanning electron microscopy (SEM) with EDS

Surface area analysis True density analysis

  • Helium pycnometry

Formulation analysis

  • High performance liquid chromatography

(HPLC)

  • Thermogravimetric analysis (TGA)
  • Spectrophotometer
  • Differential scanning calorimetry (DSC)

Flow characteristics

  • Freeman FT4
  • Zeta potential analysis (ZP)
  • Rheological analysis
  • Moisture and solids analysis (MSA)
  • Karl Fisher
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SLIDE 7

What are Engineered Particles?

  • Size controlled
  • Multicomponent
  • Tightly adjusted composition
  • Complex structure or shape
  • Functional property
  • Chemically or biologically active
  • Controlled release
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SLIDE 8

It’s All About Knowing the Trick

CARL FRIEDRICH GAUSS NORA, ORRIN, LAINA YATES

AVEKA

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SLIDE 9

AVEKA

PARTICLE TECHNOLOGY TRICKS (EXAMPLES)

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SLIDE 10

Particle Knowledge Sources

▪Academic literature ▪Patent literature ▪General reading ▪You Tube ▪How it’s made

AVEKA

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SLIDE 11

What Do You Need to Know?

Chemistry Properties

M.p., b.p., solubility, pH, density

Functional Properties

Particle size, viscosity, powder flow

Financial Considerations

Cost, volumes, profitability

What equipment do you have available?

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SLIDE 12

Processing Dilemmas

▪Available equipment dilemma ▪Spray drying dilemma ▪Mass balance dilemma ▪Scalability dilemma

AVEKA

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SLIDE 13

Particle Processing Tools

▪ GRANULATION ▪ DRYING ▪ ATOMIZATION ▪ GRINDING ▪ COATING ▪ SEPARATION

AVEKA

Spray Drying

▪ 5-120 micron particle size ▪ 10-60% solids (slurries or solutions) ▪ 1-200 cps Liquid viscosity ▪ Particles can be solid or hollow

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SLIDE 14

The Examples…. Finally

Cellulose Fiber Separation

  • Water holding enhancement

Encapsulation of Omega-3 Oils

  • Reduced oxidation and odor

Monodisperse Particles

  • Medical device testing

❖Statement of need ❖How we approached the problem ❖What went right ❖What went wrong

AVEKA

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SLIDE 15

Preparation

  • f Cellulose

Fiber from Corn Bran

The Solution

  • Starch:1-10%
  • Protein: 1-8%
  • Oils: 0-2%
  • Ash: 1-6%
  • Water: 1-10%
  • Fiber: 80-90%
  • Cellulose: 25-30%
  • Hemicellulose: 60-70%
  • Lignin: 1-6%

Statement of challenge

  • Scale-up proven

process

  • Produce high

concentration of cellulose fiber with high water holding property

AVEKA

Corn Bran Starting Material Composition Starch 1-10% Protein 1-8% Oils 0-2% Ash 1-6% Water 1-10% Fiber 80-90%

  • Cellulose

25-30%

  • Hemicellulose

60-70%

  • Lignin

1-6%

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SLIDE 16

Process and Cellulose Images

▪Slurry in Water ▪Remove digested starch and fats ▪Add caustic to solubilize hemicellulose and lignin ▪Centrifuge and dry

AVEKA

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SLIDE 17

WHAT WENT WRONG?

  • Yields were poor
  • Process incredible

inconsistent

  • Water holding results

were inconsistent

THE SOLUTION

  • Analyze
  • Understand

AVEKA

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SLIDE 18

TGA of Cellulose and Hemicellulose

Wood Cellulose Hemicellulose

AVEKA

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SLIDE 19

TGA of Corn Bran and Purified Cellulose

Corn Bran Processed Cellulose

AVEKA

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Preparation of Microencapsul ated Omega-3 Fish Oil

Statement of challenge

  • No known method for

protecting Omega-3

  • ils from oxidation
  • Overcome oxygen

disfusion through cell wall

  • Consider biomimicry

The Solution

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Proposed Structure

Oil core Organelle shell Alginate shell Carbohydrate/protein/fiber shell Fat/fiber shell

Oil Core

AVEKA

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WHAT WENT WRONG?

  • Multilayer structure

was made using atomization and spray drying methods followed by coating process

  • Results were as good as

industry standards – not better

THE SOLUTION

  • Change materials
  • Improve on oleosin

usage

AVEKA

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SLIDE 23

Preparation of Monodisperse Wax Beads

Statement of challenge

  • 4mm monodisperse

beads needed for bio assay end use

  • Need to be sterile
  • Need to be tight size

and weight

  • Minimal waste of raw

material

The Solution

  • Prilling process
  • Underwater formation and cooling
  • New atomization method needed
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Particles from Liquids: Prilling

  • Spherical particles (10-2000 micron)
  • Up to 50% active loading
  • Matrix: phytosterols, hydrogenated oils, PLA
  • Actives: oils, flavors, particles, CMC, biocides
  • Throughputs: 1 – 2000 lb/hr

Raylei leigh gh Break akup up

AVEKA

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Microencapsulation via Prilling

▪ Process Parameters ▪

Melts not solutions(50- 200 °C)

▪

Melt viscosities < 300 cps

▪

Atomizers

▪

Drip

▪

Spinning disk

▪

Two-fluid

▪

Single fluid

▪

Chamber temperature

▪

Throughput (1-5000 kg/hr)

▪ Product Parameters ▪

Particle size (10-5000 µm)

▪

Matrix particle with 5-50% active inclusions

AVEKA

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SLIDE 26

Cold water Melted wax Wax beads cool and forms spheres when floating up in the water (~lava lamp) since they are less dense than the water Large nozzle to make 4 mm beads Collect from top

Underwater Prilling

AVEKA

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SLIDE 27

Under Water Prilling Process

AVEKA

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SLIDE 28

Underwater Prilling Results

AVEKA

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SLIDE 29

WHAT WENT WRONG?

  • Under water prilling

process produced beads in the correct size and consistency

  • Water inclusion (holes)

were not expected

THE SOLUTION

  • Vacuum drying worked
  • Customer went to

another technology due to timing

AVEKA

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SLIDE 30

AVEKA

Summary

  • Knowing the tricks and applying

them are Critical

  • Multiple methods should be

considered for every problem

  • It is hard to analyze and know too

much

R&D / Lab-Scale Testing Pilot Testing Full Scale Manufacturing Value Added Product Partnerships

  • Contact Information:
  • Willie Hendrickson
  • whendrickson@aveka.com
  • 651-730-1729