Mechanical Milling & Particle Size Reduction Technologies

Mechanical milling technology is a highly effective method for reducing the particle size of pharmaceutical and other vital ingredients. This process typically achieves a Particle Size Distribution (PSD) ranging from 30 to 150 microns, meticulously balancing powder flowability and homogeneity, while simultaneously enhancing the dissolution rate of the processed material. The refined mechanical properties of the milled powder make it exceptionally suitable for applications such as direct compression, capsule filling, and granulation processes.

Munit employs various advanced mechanical milling technologies, including Pin Mills, Hammer Mills, and Quadro Co-mills. These machines utilise the impact of rigid bodies—such as pins, hammers, blades, or impellers—to precisely fracture particles into smaller sizes, thereby achieving a tightly controlled particle size distribution within a coarser range.

Pin Mill

The Alpine Hosokawa UPZ Fine Impact Mill, configured as a Pin Mill, is specifically designed for API milling. It achieves fine and consistent particle size reduction through high-speed rotor impacts and the controlled use of process gas, which also aids in heat dissipation to prevent product degradation. Key parameters like rotor speed and feed rate enable precise control over the final particle size distribution. The system incorporates HEPA-filtered air intake, pneumatic discharge, and facilitates easy product collection, ensuring clean and efficient operation.

Key Advantages: Delivers tight PSD in a range of 50-150 microns; excels in demanding milling conditions.

Hammer Mill

Our Hammer Mill design provides efficient milling for a wide array of pharmaceutical powders. Particle size reduction occurs through the mechanical impact of the rotor’s hammer bars. The desired particle size is achieved by selecting the appropriate screening grid hole diameter, through which the final collected particles are expelled. With adjustable parameters and the use of high-quality materials, our Hammer Mill design offers a reliable and highly effective milling solution.

Key Advantages: Capable of achieving PSD > 150 microns; suitable for demanding milling conditions.

Quadro Co-mill Technology

Primarily utilised for effective de-lumping and homogenisation of crude powders sourced from filter or vacuum tray dryers. Powder is fed into a conical sieve grid with precisely defined hole diameters and then gently pushed through by an impeller rotating at a controlled speed. This Co-milling process can serve as a standalone treatment or as a crucial pre-milling step to prepare powders for subsequent micronization activities.

Key Advantages: Provides effective soft de-lumping; ensures homogenisation of crude powder; offers adjustable process parameters for precise control; highly versatile as a standalone or pre-milling solution.

Overall, mechanical milling technology, as implemented by Munit, stands as a highly effective and efficient method for reducing particle size and significantly improving the characteristics of diverse materials across industries such as pharmaceuticals, food processing, and materials engineering.