1

GEnie des Procds

Environnement
Agroalimentaire
UMR-CNRS 6144
TTC Tcchnn!ngy TraInIng Ccntcr
Wnrkshnp n 88, 21-23 JuIn 2005
Optimization of the Wurster Coating process Optimization of the Wurster Coating process
by accurate mass flow monitoring by accurate mass flow monitoring
5amIra E! MafadI, DcnIs Pnncc!ct 5amIra E! MafadI, DcnIs Pnncc!ct
BIncncapsu!atInn cngInccrIng Grnup
ENITIAA, Ruc dc !a GraudIrc, BP 82225
44322 Nantcs Ccdcx 3, Francc
c!mafadIcnItIaa-nantcs.fr
Trcnds In pnwdcrs functInnna!IzatInn Trcnds In pnwdcrs functInnna!IzatInn
Tons of powders today
Iioleclion Iioleclion
Sliucluie, conposilion Sliucluie, conposilion
ConlioIIed ieIease ConlioIIed ieIease
SlaliIily in sloiage SlaliIily in sloiage
DissoIulion, DissoIulion,
Iiee fIoving Iiee fIoving
2
MIxIng 5pray dryIng
Agg!nmcratInn Granu!atInn
CnatIng
PrIncIp!c nf thc cnatIng npcratInn PrIncIp!c nf thc cnatIng npcratInn
Coating
droplets
Particle
Pulverization Wetting Spreading and drying Formation of film
Thc Wurstcr Prnccss Thc Wurstcr Prnccss
+ Bnttnm spray cnatIng tcchnIquc,
+ CnatIng nf sn!Id partIc!cs
(mIcrnpartIc!cs, granu!atcs, pc!!cts nr
tab!cts),
+ UnIfnrm partIc!c cIrcu!atInn
+ UnIfnrm cnntInunus prnduct cnatIng
+ Excc!!cnt cnatIng qua!Ity
3
Thc Wurstcr Prnccss: PrIncIp!c Thc Wurstcr Prnccss: PrIncIp!c
- IIuidizalion and IailicIes
ciicuIalion
- IuIveiizalion of coaling
soIulion
- Diying and fiIn
foinalion
Thc Wurstcr Prnccss: PrIncIp!c Thc Wurstcr Prnccss: PrIncIp!c
4
Defluidization
Failure of the operation
Lost of coating polymer
Low efficiency
Prnb!cms Prnb!cms
Spiay diying AggIoneialion
Nozzle of pulverization
Fines particles
Agglomerates
Spray drying Agglomeration
Empirical use
HydrndynamIcs study HydrndynamIcs study
IIuidizalion:
To nake fine pailicIes oi soIids Iike fIuid ly passing a gas oi
Iiquid lhiough lhen.
IIuidized led IIuidized led Tianspoiled ed Tianspoiled ed
ReguIai ciicuIalion vilh a high concenlialion of pailicIes ReguIai ciicuIalion vilh a high concenlialion of pailicIes
inside lhe Wuislei lule inside lhe Wuislei lule
5
IndusliiaI oplinizalion IndusliiaI oplinizalion
Mp=3OOg
Mp=9OOg
- - SinpIe nelhod lul sliII enpiiic SinpIe nelhod lul sliII enpiiic
- - DifficuIl nelhod foi Iaige scaIe piIol. DifficuIl nelhod foi Iaige scaIe piIol.
- - No iepioduciliIily No iepioduciliIily
HydrndynamIcs study HydrndynamIcs study
P
annulaire
Pc
DeveIoped nelhod DeveIoped nelhod
IailicIes Concenlialion IailicIes Concenlialion
Ioiosily oi voidage Ioiosily oi voidage
Iiessuie diop Iiessuie diop
P =
p
gh(1)
IIuidizalion paianeleis: IIuidizalion paianeleis:
- - Aii fIov iale Aii fIov iale
- - alch size alch size
- - High gap High gap
HydrndynamIcs study HydrndynamIcs study
6

0
2
4
6
8
10
12
14
16
0 200 400 600 800 1000 1200
Temps (s)

P

(
1
0
2

P
a
)
Annulus
0m
3
/h
21m
3
/h
96m
3
/h
128m
3
/h
52m
3
/h
155m
3
/h
S1
S2
S3
S4
172m
3
/h
Air
HydrndynamIcs study HydrndynamIcs study
VisuaIizalion of fIuidizalion slale: VisuaIizalion of fIuidizalion slale:
slale 2 slale 2 Lnd slale 2 Lnd slale 2
slale 3 slale 3
agilalion HnmngcnIzcd
f!uId bcd
Non
Honogenized
fIuid led
Iixed led AnnuIai led
Inlensive
lianspoil
Rcgu!ar
f!uIdIzatInn
Slail of
fIuidizalion
No lianspoil Inseil
Slale 4 Slale 3 Slale 2 Slale 1
OptImIzatInn nf aIrf!nw ratc OptImIzatInn nf aIrf!nw ratc
7
PartIc!c mntInn PartIc!c mntInn
Air
B
C C
D
A
4 iegions can le dislincl: 4 iegions can le dislincl:
Region A : AcceIeialion of pailicIes
Region : Ineunalic lianspoil
Region C : DeceIeialion of pailicIes
Region D : IIuidizalion of pailicIes
foining a led
p g p g D g p
p
p p
p
p
u u u u C d
z
u
m g m
dt
du
m = + + ). .( . . .
8
. . .
2
2

Zones A, el C :
Monenlun laIance equalion:
[ ]
g w D v d p
H D H g c Q . . . ) . . 2 .( .
2 / 1
=
) 1 (
D D p
D
D
S
M
H

=
=
M
p
Q
p

D
= (
A
+
B
+
C
)
PartIc!c mntInn PartIc!c mntInn
p
u
dt
dz
=
Zone D: (einouIIi equalion)
8
Air
B
C C
D
A
PartIc!c mntInn: mndc!Ing PartIc!c mntInn: mndc!Ing
\ Mcan partIc!c trajcctnry
RcsIdcncc tImc In cach
rcgInn
PartIc!c mass f!nw
PnrnsIty InsIdc thc
Inscrt
- PI!nt sIzc
- PartIc!cs prnpcrtIcs
- batch sIzc
- AIr f!nw ratc
- Gap hIgh
ModeI
PartIc!c pnsItInn PartIc!c pnsItInn
9
PartIc!c vc!ncIty PartIc!c vc!ncIty
10.42 9.70(93,1%) 0.37(3,55%) 0.24(2,30%) 0.11(1,05%) Mp=0.8kg
7.37 6.62(89,82
%)
0.40(5,43%) 0.24(3,25%) 0.11(1,5%) Mp=0.4kg
Cycle time
(s)
(D) (C) (B) (A)
Conditions
RcsIdcncc tImc RcsIdcncc tImc
DiopIels evapoialion
line
Coaling line
10
Wurstcr prnccss: Prnb!cms Wurstcr prnccss: Prnb!cms
Air
B
C C
D
A
MndIfIcatInn nf thc Wurstcr prnccss
dcsIgn
Largc rcsIdcncc tImc nf partIc!cs In
annu!ar bcd (rcgInn D)
Ovcrhcat nf partIc!cs In rcgInn D
LImItatInn nf thc prnccss whcn cnatIng
thcrmn-scnsItIvc matcrIa!s
Thc Wurstcr Prnccss: dcsIgn Thc Wurstcr Prnccss: dcsIgn
T <
(Pnncc!ct, TTC n55, 2002)
T > T >
T < T <
T < T <
11
- - IIuidizalion chaiacleiislics IIuidizalion chaiacleiislics
- - Tenpeialuie piofiIe Tenpeialuie piofiIe
- - Lffecl of piocess on ceII suivivaI Lffecl of piocess on ceII suivivaI
Thc Wurstcr Prnccss Thc Wurstcr Prnccss
T <
T > T >
T <
COMIARISON COMIARISON
MndIfIcd cquIpmcnt
Thc mndIfIcd Wurstcr Prnccss Thc mndIfIcd Wurstcr Prnccss
12
F!uIdIzatInn CharactcrIstIcs F!uIdIzatInn CharactcrIstIcs
mndIfIcd cquIpmcnt mndIfIcd cquIpmcnt
- -Prcssurc drnp accnrdIng tn aIr f!nw ratc Prcssurc drnp accnrdIng tn aIr f!nw ratc
S1: Iixed led S1: Iixed led S2: IIuidizalion slail S2: IIuidizalion slail
S3: Regular fluidization S3: Regular fluidization

0
2
4
6
8
10
12
14
0 50 100 150 200 250 300 350 400 450
Time (s)
P
r
e
s
s
u
r
e

d
r
o
p

(
m
B
a
r
)
50m
3
/h
122m
3
/h
152m
3
/h
90m
3
/h
175m
3
/h
0m
3
/h
S1
S2
S3
F!uIdIzatInn CharactcrIstIcs F!uIdIzatInn CharactcrIstIcs
VIsua!IzatInn VIsua!IzatInn
CnnvcntInna! cquIpmcnt CnnvcntInna! cquIpmcnt MndIfIcd cquIpmcnt MndIfIcd cquIpmcnt
13
F!uIdIzatInn CharactcrIstIcs F!uIdIzatInn CharactcrIstIcs
Cnnc!usInn Cnnc!usInn
T <
T > T >
T <
Bcttcr stabI!Ity Bcttcr stabI!Ity nf f!uIdIzatInn prnccss nf f!uIdIzatInn prnccss
(hnmngcnIzcd cnatIng) (hnmngcnIzcd cnatIng)
CnnvcntInna! cquIpmcnt MndIfIcd cquIpmcnt
Tcmpcraturc prnfI!c Tcmpcraturc prnfI!c
CnnvcntInna! cquIpmcnt CnnvcntInna! cquIpmcnt
30
35
40
45
50
55
60
65
70
0 50 100 150 200 250
Time (s)
T
e
m
p
e
r
a
t
u
r
e

(

C
)
Wurster outlet
Wurster inlet
Annular bed
Air chamber
T
T
T
T
14
Tcmpcraturc prnfI!c Tcmpcraturc prnfI!c
MndIfIcd cquIpmcnt MndIfIcd cquIpmcnt
30
35
40
45
50
55
60
65
70
0 50 100 150 200 250
Time (s)
T
e
m
p
e
r
a
t
u
r
e

(

C
)
Wurster outlet
Wurster inlet
Annular Bed
Air chamber
T
T
T
T
Tcmpcraturc prnfI!c Tcmpcraturc prnfI!c
Cnnc!usInn Cnnc!usInn
T <
T > T >
T <
AvnId Ovcrhcat nf partIc!cs In annu!ar bcd AvnId Ovcrhcat nf partIc!cs In annu!ar bcd
(thcrmnscnsItIvc matcrIa!s) (thcrmnscnsItIvc matcrIa!s)
CnnvcntInna! cquIpmcnt MndIfIcd cquIpmcnt
15
DryIng nf mIcrnnrganIsms DryIng nf mIcrnnrganIsms
Prnccdurc Prnccdurc
Coaled pailicIes
ConvenlionaI
equipnenl
Modified
equipnenl
5urvIva! Ratc (%)
DIssn!utInn nf thc cnatIng
&
EnumcratInn nn MR5 agar
SoIulion of Skin niIk
and Suciose
Prcoic|ics s|rain
DryIng nf mIcrnnrganIsms DryIng nf mIcrnnrganIsms
5urvIva! ratc 5urvIva! ratc
5urvIva! ratc nf L. cascI and L.acIdnphI!us durIng dryIng 5urvIva! ratc nf L. cascI and L.acIdnphI!us durIng dryIng
Probiotic strain
Survival rate with
the conventional
equipment
(%)
Survival rate with
the modified
equipment
(%)
Increase of
the final cell
concentration
(%)
L. casei Lc1 40.1 6.9 53.6 7.2 34
L. acidophilus R0052 7.6 1.3 15.3 1.4 102
16
T <
T > T >
T <
Mnrc gcnt!c npcratIng cnndItInns Mnrc gcnt!c npcratIng cnndItInns
(cc!! survIva!) (cc!! survIva!)
DryIng nf mIcrnnrganIsms DryIng nf mIcrnnrganIsms
Cnnc!usInn Cnnc!usInn
Cnnc!usInns Cnnc!usInns
- - Hydiodynanic sludy Hydiodynanic sludy
\ \ DeveIopnenl of nev nelhod lo DeveIopnenl of nev nelhod lo
conlioI conlioI fIuidizalion paianeleis fIuidizalion paianeleis
\ \ Oplinizalion of fIuidizalion Oplinizalion of fIuidizalion
- - ModeIing of pailicIe nolion ModeIing of pailicIe nolion
\ \ Residence line Residence line
\ \ IailicIe concenlialion IailicIe concenlialion
- - Inpiovenenl of lhe Wuislei piocess Inpiovenenl of lhe Wuislei piocess
\ \ Diying lheinosensilives naleiiaIs Diying lheinosensilives naleiiaIs