(161a) Powder Characterization as Tool for Successful Product Development

Solid materials and solid consumer products are widespread in industry as well as in our daily life. A predominant portion of the materials is handled as solids, for example typical chemical intermediates in process industry or detergent powders in households. Looking on the entire process chain of such materials, not only a proper monitoring of the bulk solids properties during the manufacturing process and subsequent bulk solids handling is of relevance. Powder characterization is also of considerable importance during product and process design. During development of new substances or molecules which are intended to be handled in a solid form, it is important to know already at an early stage what product properties have to be expected. Frequently an easy handling is interfered with negative physical properties of the raw materials, as hygroscopic behavior, low melting point or stickiness. To overcome these difficulties, chemical modifications in the molecule structure are to be considered or suitable additives have to be identified. In any case these unfavorable physical and chemical product properties require additional efforts and multiply the complexity of processing. If complex product mixtures or product applications have to be considered, the selection of suitable formulation components in most cases has to be done experimentally which calls for a wide product knowledge. Effective small-scale screening methods which are capable of flexible adaptation to the specific problem areas represent a substantial tool during this development phase. For example, methods for assessment of hygroscopicity, impact of increased temperatures or chemical stability are of substantial interest. After having decided on a target product composition, additional powder characterization tests as flowability, time consolidation, etc. complete the picture and establish the basis for process and equipment design. On basis of practical examples the approach to develop individual solutions for different problem areas is demonstrated.