Drying Of

Pharmaceutical
Products
Presented To:
Mam Mehwish
Hussain
Presented By: Group 04

Definition Of Drying

It is the final removal of liquids from solids by thermal

vaporization, leaving a dry solid/mass
Drying is. . . . .
➢ The final stage in most of pharmaceutical processing
➢ Require/need special care
➢ Require regular checkup or monitoring
➢ It decide the fate of further processing

2
 Theory Of Drying

• When any material is exposed to the air at definite temperature

and humidity, It will gain or lose moisture until an equilibrium is
established.

• The moisture content of any material varies with temperature

and humidity of the air.
3

Theories of Drying
1. Heat and mass transfer theory.
2. Diffusion theory.
3. Capillary flow theory.
4. Surface evaporation theory.
5. Equilibrium moisture content theory.
 2. Diffusion Theory
➢ This theory focuses on the movement of
moisture from the interior of a material to
its surface. Moisture moves due to a
concentration gradient
➢ Fick’s Law of Diffusion is often used to
model how moisture migrates from the
interior of the material to the surface.
➢ Diffusion theory is especially relevant for
materials where moisture is trapped in a
porous structure, such as granules or
tablets.

3. Capillary Flow Theory

➢ In porous materials, moisture move through capillary forces. This
process is influenced by the size and structure of the capillaries within the
material.
➢ Capillary flow is dominant during the constant-rate period and early
stages of the falling-rate period.
➢ This theory is crucial for understanding drying behavior in
pharmaceutical powders and granules.
 Principle Of Drying

The drying of pharmaceutical products involves the removal of

moisture from a material using heat, driven by differences in vapor
pressure between the product surface and the surrounding
environment. This process is governed by heat transfer, mass
transfer, and evaporation.
• Heat Transfer: Heat is supplied to the product, typically through
conduction, convection, or radiation, to facilitate the evaporation
of moisture. The rate of heat transfer depends on the
temperature difference and material properties.

Principle Of Drying

Mass Transfer: Moisture moves from the interior of the material to

the surface, driven by diffusion (Fick's Law), and evaporates into
the surrounding environment. The diffusion rate is influenced by
the material's porosity and moisture content.

Evaporation: Moisture at the surface evaporates based on the vapor

pressure difference between the material and the air. Factors such
as temperature, air velocity, and humidity affect the rate of
evaporation.

8
 Principle Of Drying

Drying Stages:
➢ Constant Rate Period: Moisture is removed at a constant rate
from the surface.
➢ Falling Rate Period: As surface moisture decreases, evaporation
slows and becomes dependent on internal diffusion.
➢ Final Stage: Very slow moisture removal as bound moisture
diffuses outward.
Key Factors: Temperature, airflow, humidity, material properties
(e.g., particle size, porosity), and moisture content all influence the
drying process.
9

Principle Of Drying
Drying Methods: Common methods include convection drying,
vacuum drying, freeze-drying, and spray drying, each chosen based
on the material's characteristics.

Impact on Product Quality: Proper drying ensures stability and

prevents degradation of active ingredients. Excessive or improper
drying can affect bioavailability, dissolution rates, and microbial
safety.

10
 Drying Of Solids
Process:
•Involves heating the
solid to evaporate the
moisture. The rate of
drying depends on the
nature of the solid and
the drying conditions.
Applications:
•Used in food processing,
pharmaceuticals, and
chemical industrie
11

Cont...
Classification of Solids
• Granular/Crystalline Solids: Moisture is held in open pores and
spaces between particles, making it easy to remove. The drying
process is relatively straightforward.
• Amorphous Solids: Moisture is bound within the molecular structure,
making drying more challenging. It often requires lower
temperatures and specialized techniques.

12
 Classification Of
Dryers
Based on solid handling (static bed dryer-moving bed-fluidized bed).
Based on heat transfer (direct dryers-Indirect-IR or radiant heat).
• Dryers for Dilute Solutions and Suspensions
The objective of these dryers is to spread the liquid to a large
surface area for heat and mass transfer for collecting the dry solid.
• Two main types are used:
The first, spreading the liquid to a thin film.
The second, dispersing the liquid to a spray of small droplets.
13

Classification Of Dryer

14
Classification Of Dryer

• Classification of dryer based on method of Solid handling

Material not agitated

(STATIC BED DRYERS)

Batch types Continous type

Tray and Truck Dryer Vaccum shelf dryer Freeze dryers Drum Dryers’ Belt Dryers Tunnel Dryers Festoon Dryers

15

16
General Methods Of Drying

1. Natural Air Drying

- Utilizes ambient air to remove moisture.
- Commonly used for drying agricultural products and certain foods.
- Cost-effective but dependent on weather conditions.

2. Supercritical Drying (Superheated Steam Drying)

- Involves using superheated steam to dry materials.
- Efficient for industrial applications.
- Can achieve high drying rates and uniform moisture removal.

3. Freeze Drying
- Freezes the material and then reduces the surrounding pressure to allow the
frozen water to sublimate. 17

- Ideal for preserving sensitive materials like pharmaceuticals and food.

Fluidized Bed Dryer

Principle
The fluidized bed system operates by passing a stream of air or
gas through solid particles, causing them to behave like a fluid.
This allows for efficient heat and mass transfer, as the particles
are suspended and move freely, enhancing uniformity in
processes such as drying, granulation, and coating.

18
 Types of Fluidized Bed System

The fluidized-bed dryer available for use in the pharmaceutical

industry are of two types:
• Vertical fluidized-bed system
• Horizontal fluidized-bed system

19

Working of Vertical Fluidized

Bed System

20
 Working of Horizontal
Fluidized Bed System

21

Fluidized Bed System

Working

• Feed Material: Solid particles (e.g., powders or granules) are introduced

into the bed.
• Fluidizing Air/Gas: Air or gas is blown through the bed from the bottom,
causing the particles to become suspended.
• Processing: Depending on the application, heated air is used for drying, or
a binder is sprayed for granulation.
• Exit: The processed material exits the system, with airflow passing through
filters or cyclones to remove airborne particles.
22
 Advantages

• Efficient Heat & Mass Transfer: Enhanced contact between

particles and air leads to faster and more uniform drying,
granulation, or coating.
• Uniformity: Ensures consistent product quality with even
temperature and moisture distribution.
• Scalability: Can be easily scaled from laboratory to industrial
production.
• Multi-Functionality: Suitable for drying, granulation, coating, and
pelletization.

23

Disadvantages

• High Cost: High capital and operating costs, especially for energy
and maintenance.
• Energy Consumption: Significant energy is required to circulate
large volumes of air.
• Handling Cohesive Powders: Difficult to fluidize materials with poor
flow properties.
• Maintenance: Wear on equipment from continuous circulation of
particles.

24
 Pneumatic Dryer/System

Principle

Pneumatic dryers use high-velocity hot gas to dry

materials. Wet material is injected into the gas stream,
where it's dispersed and dries quickly due to rapid
heat transfer. The dried material is then separated
from the gas.

25

Working Of Pneumatic Dryer

26
 Working Of Pneumatic Dryer

• Pneumatic dryers, also known as flash dryers, are widely used in

the pharmaceutical industry due to their efficiency in drying heat-
sensitive materials like antibiotics, enzymes, and vitamins.
1. Feeding:
Wet material is fed into the dryer, where it's dispersed into the hot
gas stream.
2. Flash Drying:
The high-velocity gas rapidly dries the particles.|
3. Separation:
Dried particles are separated from the gas stream using a cyclone
or filter. 27

Advantage

• Speed:
Fast drying times minimize heat damage to sensitive materials.
• Continuous Operation:
Ensures consistent product quality and high throughput.
• Versatility:
Suitable for various particle sizes and shapes.

Disadvantage

• Energy Consumption:
High-velocity gas requires significant energy.
• Potential for Particle Degradation: High gas speeds can damage
fragile particles.
• Noise: The high-velocity gas stream can generate noise. 28
 Spray Dryer

Principle

Spray drying transforms a liquid into a powder by

atomizing it into fine droplets and drying them with hot
air.

29

Working Of Spray Dryer

30
Working Of Spray Dryer

1. Feed Preparation:
The liquid feed, containing the substance to be dried (e.g., a solution,
slurry, or suspension), is prepared and pumped into the atomizer.
2. Atomization:
The liquid feed is atomized into a fine mist of tiny droplets. This is
achieved through:
Pressure nozzles: The liquid is forced through a small orifice at high
pressure, breaking it into droplets.
Rotary atomizers: A high-speed rotating disk or wheel throws the
liquid off its surface, creating a fine spray.
3. Contact with Hot Gas:
The atomized droplets are introduced into a drying chamber filled with hot
air or gas. This hot gas can be generated by various methods, such as 31

burning fuel or using electrical heaters.

Working Of Spray Dryer

4. Drying:
As the droplets come into contact with the hot gas, the solvent (usually
water) rapidly evaporates from their surfaces. This rapid evaporation
causes the droplets to shrink and solidify into dry particles.
5. Separation:
The dried powder particles are separated from the exhaust gas stream.
This is typically done using:
Cyclone separators: The gas stream is spun, causing the heavier
particles to be thrown to the outer wall and collected.
Bag filters: The gas stream is passed through filters that trap the
particles.
6. Collection:
The collected powder is further processed as needed, such as milling or 32

sieving, to achieve the desired particle size and properties.

 Advantage

• Rapid Drying
• Controllable Particle Size: The particle size and distribution of
the powder can be controlled by adjusting the atomization
process.
• High Production Capacity
• Versatility: Suitable for a wide range of pharmaceutical products,
including antibiotics, enzymes, vitamins, and vaccines.

33

Disadvantage

• High Energy Consumption

• Heat Degradation
• Initial Investment: Spray dryers are expensive to purchase and
install.
• Noise: The process can generate significant noise.

34
 Freeze Dryer

Principle

Freeze drying, also known as lyophilization, is a dehydration process

that involves freezing the material and then reducing the pressure
around it. This creates an environment where water in the frozen state
sublimates directly into vapor, bypassing the liquid phase. Sublimation
is the transition of a substance directly from the solid to the gaseous
state without passing through the intermediate liquid state.
35

Stages Of Freeze Drying:

Pre-freezing: Material is frozen by keeping the material below or at−20°C.
Pre-freezing the material before application of vacuum avoids foaming.

Vacuum: Rotary pumps on small scale, and ejector pumps on large-scale, are
used to reduce the pressure sufficiently.

Primary drying: During primary drying the latent heat of sublimation must be
provided and the vapour removed. Primary drying stage by sublimation can
remove the unbound water.

Secondary drying: It is used to remove bound water or traces of water left

after primary drying. The temperature is raised (up to 50°C) or desiccantis used
to carry secondary drying.
 Working Of Freeze Dryer

37

Working Of Freeze Dryer

• Freezing: The material to be dried is initially frozen. This can be

achieved by placing the material in a freezer or using a chilled shelf
within the freeze dryer itself.
• Primary Drying (Sublimation): Vacuum is created within the chamber,
significantly lowering the pressure.Heat is applied to the frozen
material, typically through the shelves or by radiation.The frozen water
within the material sublimates directly into vapor due to the low
pressure.The water vapor is removed from the chamber by a vacuum
pump or condenser.
• Secondary Drying (Desorption): After the majority of the ice has
sublimated, the temperature is slightly increased.This removes any
residual water that is bound to the material (unfrozen water).
38
 Advantage

• Minimal Shrinkage and Distortion: Since the material does not

pass through a liquid phase during drying, it retains its original
shape and structure.
• Preservation of Heat-Sensitive Materials
• Long Shelf Life
• Rehydration: Freeze-dried products can be easily rehydrated by
adding water, restoring their original form and properties.

39

Disadvantage

• Slow Process
• High Equipment Cost.
• Energy Consumption

40
 Group Members
➢ M. Kashif Ali
➢ M. Usman Hassan
➢ Muhammad Zubair
➢ Amir Nazakat
➢ M. Mudassir
➢ Sohail Sikandar
➢ Shahmeer Khokhar

42