Particle Size Reduction Methods in Powders

Particle size reduction is critical to enhance powder properties such as flowability, compressability, stability, uniformity, and bioavailability of ingredients. A smaller particle size enables better absorption, thereby increasing the efficacy of powders, particularly in the pharmaceutical, food, and nutraceutical industries. 

Below, the various particle size reduction methods are explained, highlighting how spray drying is one of the most effective ways to reduce the powder particle size.  

Particle Size Reduction Methods 

The following table highlights some of the commonly used particle size reduction methods. 

Particle Size Reduction Methods
Method	Process	Particle size reduction
Milling	It involves the mechanical breakdown of particles through compression, impact, and attrition.  Depending on the desired particle size range, various milling techniques, such as ball milling, hammer milling, and jet milling, are used.	A few millimeters to hundreds of microns.
Microionization	It is a fine grinding of particles and involves fluid energy milling or air jet milling.  It is particularly useful to develop powders with ingredients that have low solubility and high potency.	Typically below 10 microns.
Homogenization	It involves passing a suspension through a channel at high pressure to create shear forces that break down particles into smaller sizes.  It is used to reduce particles within a fluid, resulting in smooth and uniform mixes.	From 0.1 μm to 10 μm in diameter.
Cryogenic particle size reduction	It is used for heat-sensitive ingredients and involves very low temperatures to make particles brittle and break them up to reduce their size.	Around 0.075 mm with a distribution below 0.1 mm.
Spray drying	It involves atomizing a raw liquid into tiny droplets, which are then rapidly dried by direct contact with hot air (or other gases), yielding particle products.	5 μm to 10 μm with different morphologies.

Spray Drying: A Preferred Particle Size Reduction Method  

Spray drying has emerged as a versatile technique for tailoring the particle size, morphology, encapsulation, and release kinetics of nutrient-loaded particles. Some of the key advantages of spray drying over other particle size reduction methods are: 

• High drying efficiency: The drying process is completed within 3-10 seconds. 

• Continuous, one-step operation: Spray drying’s high level of automation makes it suitable for industrial-scale production. 

• Compatibility with heat-sensitive products: This results in products with good dispersion, flowability, and solubility. 

• Cost-effectiveness: The process parameters can be optimized to produce particles with specific sizes, shapes, morphologies, and surface textures. 

How to Reduce the Particle Size of Powder with Advanced Powder Dynamics

At Advanced Powder Dynamics, we are redefining spray drying for particle size reduction. Unlike conventional spray drying, which relies on static atomization and can lead to uneven particle distribution, our patented Dynamic Atomization Technology (DAT) provides a more controlled environment for particle formation. This means smaller and more uniform powder particles are produced according to your needs.

By customizing key components such as nozzle geometry and nozzle operating parameters, as well as dryer operating parameters (air flow rate and pressure), we will help you achieve the exact particle size and consistency your powder needs.

Our in-house team of experts can help you:

• Optimize feed formulation for better particle breakdown
• Adjust atomization parameters to meet precise size specifications
• Fine-tune process parameters to ensure uniform particle morphology