Micro-compounding explained

Micro-compounding is the mixing or processing of polymer formulations in the melt on a very small scale, typically several milliliters. It is popular for research and development because it gives faster, more reliable results with smaller samples and less investment cost. Its applications include pharmaceutical, biomedical, and nutritional areas.

Overview

Micro-compounding is typically performed with a tabletop, twin screw micro-compounder, or micro-extruder with a working volume of 5 or 15 milliliters. With such small volumes, it is almost impossible to have sufficient mixing in a continuous extruder. Therefore, state-of-the-art micro-compounders have a batch mode (recirculation) and a conical shape.

The L/D of a continuous twin screw extruder is mimicked in a batch micro-compounder by the recirculation mixing time, which is controlled by a manual valve. With this valve, the recirculation can be interrupted to unload the formulation in either a strand or an injection moulder, a film device or a fiber line. Typical recirculation times are one to three minutes, depending on the ease of dispersive and distributive mixing of the formulation.

Benefits

Micro-compounding can now produce films, fibers, and test samples (rods, rings, tablets) from mixtures as small as 5 ml in less than ten minutes. By the small footprint, less lab space is needed than for a parallel twin screw extruder.[1] [2] [3] [4] [5] One micro-extruder, developed to test the improvement of bioavailability of poorly soluble drugs or realize sustained release of dispersed or dissolved active ingredients, has options to easily fill and clean. [6] [7] [8] [9] [10]

Notes and References

  1. Qizheng Dou, Xiaomin Zhu, Karin Peter, Dan E. Demco, Martin Möller, Claudiu Melian, J. Sol-Gel Sci Technol (2008) 48: 51-60
  2. 10.1016/j.polymer.2006.10.013 . Properties and morphology of nanocomposites based on styrenic polymers, Part II: Effects of maleic anhydride units . 2006 . Stretz . H.A. . Paul . D.R. . Polymer . 47 . 26 . 8527–8535 .
  3. 10.1002/pc.20392 . Microcompounding of organoclay–ABS/PA6 blend-based nanocomposites . 2008 . Ozkoc . Guralp . Bayram . Goknur . Tiesnitsch . Johan . Polymer Composites . 29 . 4 . 345–356 .
  4. 10.1002/pc.20846 . Production of poly(lactic acid)/Organoclay nanocomposite scaffolds by microcompounding and polymer/Particle leaching . 2010 . Ozkoc . Guralp . Kemaloglu . Sebnem . Quaedflieg . Martin . Polymer Composites . 31 . 4 . 674–683 .
  5. 10.1002/app.27460 . Effects of microcompounding process parameters on the properties of ABS/Polyamide-6 blends based nanocomposites . 2008 . Özkoç . Güralp . Bayram . Göknur . Quaedflieg . Martin . Journal of Applied Polymer Science . 107 . 5 . 3058–3070 .
  6. Markus Thommes, APV Drug Delivery Focus Group Newsletter - 1/2012
  7. Pharmaceutical Extrusion Technology, ed. Isaac Ghebre-Sellassie, Charles Martin, Drugs and the Pharmaceutical Sciences, Volume 133, Informa Healthcare, 2007
  8. V. M. Litvinov, S. Guns, P. Adriaensens, B. J. R. Scholtens, M. P. Quaedflieg, R. Carleer, and G. Van den Mooter, Solid State Solubility of Miconazole in Poly[(ethylene glycol)-g-vinyl alcohol] Using Hot-Melt Extrusion., Mol. Pharmaceutics, 2012, 9 (10), pp 2924–2932DOI: 10.1021/mp300280k
  9. Toshiro Sakai, presentation APV Experts‘ Workshop on Hot Melt Extrusion – Ludwigshafen, 6th November, 2012
  10. Toshiro Sakai and Markus Thommes, J.Pharmacy and Pharmacology 2013; DOI: 10.1111/jphp.12085

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