size
size
reduction
reduction
Amena Akter
ID:202231240036
Introduction
Definition of Size Reduction
Size reduction is a fundamental unit operation in pharmaceutical
engineering in which the size of solid particles is reduced by the
application of mechanical forces such as compression, impact, attrition,
or cutting. It plays a critical role in improving drug formulation, processing,
and therapeutic effectiveness.
Objectives of
size reduction
Increase surface area to enhance dissolution rate
Improve bioavailability of poorly soluble drugs
Achieve uniform mixing and content uniformity
Facilitate extraction of active constituents
Improve drying efficiency
Obtain desired particle size for specific dosage forms
Advantages And
Disadvantages of size reduction
Increased surface area leads to faster dissolution
Improved absorption and bioavailability
Uniform blending of active ingredients and excipients
Enhanced extraction of crude drugs
Improved appearance and texture of pharmaceutical products
Disadvantages of Size Reduction
Heat generation may degrade thermolabile drugs
Loss of crystallinity or polymorphic changes
Poor flow properties when particles are too fine
Dust formation causing handling problems
Increased risk of oxidation and contamination
Factors affecting of
size reduction
Factors Affecting Size Reduction
Hardness: harder materials require more energy
Toughness: fibrous materials resist fracture
Brittleness: brittle materials fracture easily
Moisture content: excess moisture reduces efficiency
Softening temperature: low temperature materials melt easily
Feed size and mill speed
mechanisms of
size reduction
Compression: particles crushed between two rigid surfaces
Impact: particles broken by sudden force
Attrition: particles reduced by rubbing or friction
Cutting: particles sliced by sharp blades
method of size Types of size
reduction reduction equipment
Crushing: coarse size reduction
Crushers
using compressive force
Grinders
Grinding: fine size reduction by
Ultrafine grinders
impact or attrition
Cutting: used for fibrous or Cutting machines
tough materials
Milling: combination of
mechanisms for uniform size
components of size
reduction equipments
The components of size reduction equipment vary with design, but
the basic parts are:
[Link] Hopper: Holds and delivers material into the mill.
[Link] Reduction Chamber: Enclosed area where grinding or
cutting takes place.
[Link] Reduction Elements: Hammers, balls, rollers, knives, or jets
responsible for breaking particles.
[Link] or Classifier: Controls final particle size by allowing only
desired size to pass.
[Link] Mechanism: Motor, belts, or gears that supply power.
[Link] Outlet: Allows reduced material to exit the equipment.
[Link] or Housing: Supports and encloses the entire system.
Hammer mill
General Principle & Construction
Hammer mill operates mainly on the principle of impact, supported by attrition.
High-speed rotating hammers repeatedly strike the feed material. The kinetic
energy transferred from the hammers exceeds the material’s strength, causing
fracture. Further size reduction occurs due to collision between particles and
rubbing against the screen until particles become small enough to pass through
the perforations.
Hammer Mill – Construction, Operation, Uses, Pros & Cons
Construction: Feed hopper, rotating shaft with hammers, perforated screen,
motor.
→ →
Operation: Material enters hit by hammers reduced size passes through
screen.
Uses: Size reduction of dry materials, granules, crude drugs.
Advantages: Simple construction, continuous operation, high efficiency.
Disadvantages: Heat generation, not suitable for sticky or thermolabile materials.
Ball mill
Principle: Ball mill works on the combined principles of impact and attrition. During rotation, the grinding balls are
lifted and then fall under gravity, producing impact on the material. Simultaneously, sliding and rolling of balls
cause attrition, leading to gradual size reduction.
Construction: Horizontal rotating cylindrical shell, abrasion-resistant lining, grinding media (steel or ceramic
balls), motor, feed and discharge openings.
Ball Mill – Operation, Uses, Advantages & Disadvantages
Operation: Rotates at 60–80% of critical speed; balls cascade and grind material.
Uses: Fine grinding of drugs, pigments, suspensions.
Advantages: Produces very fine powder, suitable for wet & dry grinding.
Disadvantages: Time consuming, heat generation, possible contamination.
Fluid Energy Mill – Principle &
Construction
Principle: Fluid energy mill operates on the principle of high-velocity fluid energy.
Compressed air or steam is introduced at very high speed, accelerating particles to
collide with each other. Size reduction occurs due to particle-to-particle impact
rather than mechanical grinding, making the process suitable for heat-sensitive
materials.
Construction: Grinding chamber, air/steam inlet nozzles, feed injector, classifier,
outlet.
Fluid Energy Mill – Operation, Uses, Pros & Cons
Operation: Particles are fed into the chamber where high‑velocity air streams accelerate
them. Particle‑to‑particle collision causes size reduction; a classifier separates fine
particles.
Uses: Micronization of potent drugs, antibiotics, steroids, thermolabile substances.
Pros: No moving parts, negligible heat generation, excellent particle size.
Cons: High energy consumption, costly operation, and low production rate.
Rotary cutter mill
Rotary Cutter Mill – Principle & – Operation, Uses, Advantages &
Construction Disadvantages
Principle: Rotary cutter mill works on Operation: Material enters through hopper
the principle of cutting and shearing.
Sharp rotating blades cut the material
→ cut repeatedly by rotating knives→
reduced size passes through screen.
against stationary knives. The cutting
force exceeds the tensile strength of
Uses: Size reduction of fibrous and tough
fibrous materials, resulting in clean materials like roots, leaves, barks, gums.
and controlled size reduction with Advantages: Minimal heat generation,
minimal generation of fines. uniform particle size, suitable for fibrous
Construction: Feed hopper, drugs.
rotating cutter blades, stationary Disadvantages: Not suitable for hard or
knives, perforated screen, motor, brittle materials, blades need frequent
discharge outlet. sharpening.
Rollar Mill
A roller mill is a size reduction equipment in which materials are crushed and reduced in size by compression
between two or more rotating rollers.
The material is drawn between rotating rollers, and the compressive force applied exceeds the crushing
strength of the particles, causing them to break into smaller sizes. Minimal attrition may also occur.
Construction
Feed hopper – feeds material uniformly
Two or more rollers – usually made of steel or porcelain
Adjustable gap – controls final particle size
Drive system – motor, gears, belts
Discharge chute – collects crushed material
Frame/housing – supports the system
Operation
[Link] is fed through the hopper.
[Link] rotate in opposite directions.
[Link] is pulled into the gap between rollers.
[Link] reduces particle size.
[Link] material exits through the discharge outlet.
Size reduction -
Energy theories
Energy theories explain the relationship between the energy required and the extent of size reduction.
1. Rittinger’s Law
States that energy required for size reduction is directly proportional to the new surface area
generated.
Suitable for fine grinding operations.
∝
Equation: E (1/D2 − 1/D1)
Application: Ball mill, fluid energy mill.
2. Kick’s Law
States that energy required is proportional to the size reduction ratio.
Assumes energy needed per unit mass is constant.
Suitable for coarse crushing operations.
∝
Equation: E ln(D1/D2)
Application: Crushers.
3. Bond’s Law
Intermediate law between Rittinger’s and Kick’s laws.
Energy required is proportional to the change in particle diameter.
Widely used in industrial practice.
∝
Rittinger’s Law: Energy new surface area formed (fine grinding)
∝
Kick’s Law: Energy size reduction ratio (coarse crushing)
Bond’s Law: Intermediate law; widely used in practice
Project Overview
Advantages
Simple and efficient operation
Produces uniform particle size
Low dust formation
Less heat generation
Easy to clean and maintain
Disadvantages
Not suitable for sticky or fibrous materials
Limited to coarse size reduction
Wear of rollers over time
Mechanism Involved
Compression (main)
Minor attrition
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