Size Separation

Nidhi N. Patel,
Assistant Professor,
Parul University
 INTRODUCTION OF SIZE SEPARATION
• Size separation is a unit operation that involves the
separation of a mixture of various size particles into
two or more portions by means of screening
surfaces.
• Size separation is also known as sieving, sifting,
screening.
• It is a after process of size reduction, in which we
separate out the mixture of various size particles
into two or more portions by sieve or any other
processes.
 OBJECTIVES OF SIZE SEPARATION
• Size separation is useful in grading powders or granules. Any solid materials after size reduction
never give particles of the same size but contain particles of varying sizes. The size-reduced
particles are then passed through sieves to get fractions of the narrow size range.
• To control size variations in the materials. During tablet granulation the granules should be
within a narrow size range, otherwise, weight variation will take place during tablet punching.
• To determine particle size for the production of tablets and capsules.
• To improve mixing of powders.
• To improve the solubility and stability of particles during production.
• Quality control of raw materials.
• Useful in production of tablets, capsules, suspension, emulsion, ophthalmic preparations,
ointments, creams, etc.
 OFFICIAL STANDARDS FOR POWDERS
• The Indian Pharmacopoeia has laid down the standards for powders for pharmaceutical
purposes. The I.P. specifies five grades of powder which are as under :
1. COARSE POWDER- A powder of which all the particles pass through a sieve with nominal
mesh aperture of 1.7 mm (No. 10 sieve) and not more than 40.0 percent through a sieve
with nominal mesh aperture of 355 µm (No. 44 sieve) is called coarse powder.
2. MODERATELY COARSE POWDER- A powder of which all the particles pass through a sieve
with nominal mesh aperture of 710 µm (No. 22 sieve) and not more than 40.0 percent
through a sieve with nominal mesh aperture of 250 µm (No. 60 sieve) is called moderately
coarse powder.
3. MODERATELY FINE POWDER- If all the particles of a powder pass through a sieve with
nominal mesh aperture of 355 µm (No. 44 sieve) and not more than 40.0 per cent through
a sieve with nominal mesh aperture of 180 µm(No. 85 sieve), it falls in this group.
 OFFICIAL STANDARDS FOR POWDERS
4. FINE POWDER- In case all the particles
pass through a sieve with a nominal Official Standards of Grading of Powder
powders
mesh aperture of 180 µm (No. 85 sieve),
it is called fine powder. Powders Sieve NO.
5. VERY FINE POWDER - If all the particles
i) Very Coarse 10
of the powder pass through a sieve with
a nominal mesh aperture of 125 µm ii) Coarse 22
(No. 120 sieve), it is said to be very fine iii) Moderatory coarse 44
powder.
iv) Fine powder 85
v) Very fine powder 120
 OBJECTIVES / APPLICATION OF SIZE SEPERATION
▶ To determine particle size for the production of tablets and capsules.

▶ To improve mixing of powders.

▶ To improve the solubility and stability of particles during

production.

▶ To optimize feed rate, agitation, screening during production.

▶ Quality control of raw materials.

▶ Useful in production of capsules, suspension, emulsion, ophthalmic

tablets,
preparations, ointments, creams, etc
 Mechanism of size separation
• Screening is a method of separating particles according to size alone.
• The basic technique involved in passing the particles through a series of sieves of uniform size.
• In this the particles drop through the openings due to gravity.
• Coarse particles can drop easily through large openings, but it is difficult to screen the fine
powders.
• This process can be made easy by inducing some type of motion (movement) to the particles.
• Size separation is basically assisted by three methods.
1. Agitation
2. Brushing
3.Centrifugal force
• These modes of shaking help to shake the material so that sieving will be quick and entire sieve
can be utilised.
 MECHANISM OF SIZE SEPARATION
1. Agitation
• Oscillation – This sieve is mounted in a frame that oscillates back and forth. It is a
simple method but the material may roll on the surface of the sieve. i.e. reciprocal
motion.
• Vibration – Movement of sieve is through vibration. The sieve is vibrated at high speed
by means of an eccentric device either electrically or mechanical. The rapid vibration is
imparted to the particles on the sieve which helps to pass the powdered material through
it.
• Gyration – Movement of sieve is clockwise or anti clockwise. In this method, a system
is made so that sieve is on rubber mounting and connected to an eccentric fly wheel.
This gives a rotary movement of small amplitude to sieve which in turn gives spinning
motion to the particles that helps to pass them through a sieve.
 MECHANISM OF SIZE SEPARATION
2. Brushing
• In this case, a brush is used to move the particles on the surface of the sieve and to
keep the meshes clear. The brush is rotated in the middle in the case of a circular
sieve.one example is brush sifter. This is used for size separation of greasy or sticky
powders such as waxes and soaps.
3. Centrifugation
• In this method, a high-speed rotor is fixed inside the vertical cylindrical sieve, so that
on rotation of the particles are thrown outwards by centrifugal force. The currents of
air generated by mean of jet of air into the equipment, which helps in separating the
particles. Example: cyclone separator and air separator.
 SIEVES
• Sieves are constructed from wire cloth with square
meshes, wires of brass, bronze, stainless steel or any
other suitable material.
• The wires should not be coated or plated.
• There must be no any reaction between the material
of the sieve and the substance which is being sifted
from it.
 Type of sieves
• The primary considerations for sieves are given to the size and shape of aperture opening. Square
meshes are arranged as per the specifications.
• Sieves commonly used in pharmaceutical processing include:
• Woven wire sieves
• Bolting cloth sieves
• Closely spaced bars (screens)
• Punched plates
• Woven wire sieves:
• wire woven sieves are general purpose sieves and widely used in the pharmacy practice.
• The type of woven wire sieves are:
• Plain weave
• Twilled weave
 Type of sieves
• Bolting cloth sieves:
• silk, nylon and cotton are generally woven from twisted multi-strand fibres.
• Nylon cloths are generally designated by their micrometer opening and available in different grades.
• Bar screens:
• Bar screens are generally used in handling large and heavy piece of materials.
• The bars are fixed in parallel position and held by cross bars and spacers.
• Bars which taper in thickness from one end to the other are recommended, because they tend to
avoid blinding grizzlies use these type of screens.
• Punched plates (perforated screens):
• These are used for coarse sizing.
• The screens are prepared by using a metal sheet of varying thickness with perforated holes.
• The holes may be round, oval, square ,or rectangular.
 Standards of sieves, Dimensions and notations
a) Tyler standard sieve series (in USA)
b) US standard sieve series ( in USA)
c) British standard sieve series ( in UK)
d) German DIN (Deutsche industrienormein) (in Germany and Europe)
e) IP standard sieve series ( in India)
f) International test sieve series ( ISO) (World wide)
• Tyler and US standards can be interchangeable, since the difference between the two
standards is less than the allowable tolerance in weaving of the screens.
• These are also known as test sieves.
 Standards of sieves, Dimensions and notations
• Sieves used for pharmacopoeia testing must match with the specifications:
• Numbers of sieve
• Nominal size of aperture
• Nominal diameter of the wire
• Approximate percentage sieving area
• Aperture tolerance average size
 MACHINES USED IN SIZE SEPARATION
• Sieve shaker
• Cyclone separator
• Air separator
• Bag filter
• Elutriation tank
 SIEVE SHAKER
• PRINCIPLE OF SIEVE SHAKER :
• The principle of sieve shaker is based upon vibration, agitation, or
gyration.
• The efficiency of sieving by sieve shaker depends on the particles size
distribution, sieve load, the method of sieve shaking, the dimension and
shape of the particle, and the ratio of the open area of sieve to total
area.
• The powdered drug is separated according to its particle size using a
number of sieves in nest.
 SIEVE SHAKER
• CONSTRUCTION OF SIEVE SHAKER :
• It is a machine with different sizes of sieve. At first
there is very coarsest sieve and at last there is very
finest sieve.
• There are two pipes in which the sieves are fixed.
• One pan which is called as receiver that is
connected in the bottom of the sieves. In which we
get very fine powder or the product.
• There is one on switch with the help of that the
machine is operated and also there is timer button
with the help of that time can be set.
 SIEVE SHAKER
• WORKING OF SIEVE SHAKER :
• The powder to be screened is kept on the uppermost sieve and is capped and
bolted.
• The machine's timer is set to the desired time (Usually 20 mins) and operated at
desired speed.
• The vibrations cause oscillations resulting in passing of material from one sieve to
another.
• After a given time the machine is stopped, the metal frame is loosed and screens are
separated to collect the material.
 SIEVE SHAKER
• Uses of sieve shaker :
• Used for separation different size of particles at same time.
• Advantages of sieve shaker :
• Inexpensive, Simple & rapid in use.
• We can separate out many size of drug particles at a same time.
• Disadvantages of sieve shaker :
• Lower limit of particle size is 50 micrometer..
• It is used only as small scales.
 CYCLONE SEPARATOR
• PRINCIPLE OF CYCLONE SEPARATOR :
• It is based on the principle of centrifugation.
• In cyclone separator, centrifugal force is used to separate the solids from
fluids. The separation process depends not only on the particle size, but also
on the density of particles. Depending on the fluid velocity, the cyclone
separator can be used to separate Fluid outlet all types of particles.
• CONSTRUCTION OF CYCLONE SEPARATOR :
• The construction of a cyclone separator is shown in Figure.
• It consists of a short vertical, cylindrical vessel with a conical base. The upper
part of the vessel is fitted with a Solids outlet tangential inlet. The outlet
(solid outlet) is arranged at the base.
• Fluid outlet is provided at the centre of the top portion, which extends
inwardly into the separator. Such an arrangement prevents the air short-
circuiting directly from the inlet to the outlet of the fluid.
 CYCLONE SEPARATOR
• WORKING OF CYCLONE SEPARATOR :
• The solids to be separated are suspended in a stream of gas (usually air). Such a feed
is introduced tangentially at a very high velocity, so that rotary movement takes
place within the vessel.
• centrifugal force and vertexing throws the solids to the walls.
• As the speed of air diminishes, the particles fall to the conical base and are
discharged through the solid outlet.
 CYCLONE SEPARATOR
• USES OF CYCLONE SEPARATOR :
• It is used to separate solid from gases.
• It is also used to size separation of solid in liquids.
• ADVANTAGES OF CYCLONE SEPARATOR :
• Cheap in cost.
• Low maintenance.
• Suitable for high temperatures.
• Do not require much space.
• DISADVANTAGES OF CYCLONE SEPARATOR :
• Difficult for when handling very fine particles.
• Not suitable for sticky substances.
 AIR SEPARATOR
• Principle:
• In air separator, centrifugal force is used to separate solids.
• The air environment is obtained by means of rotating disc and blades. To improve the separation,
stationary blades are used. By controlling these blades and the speed of the rotation, it is possible to
vary the size at which separation occurs.
 AIR SEPARATOR
• Construction:
• The construction of an air separator is shown in
Figure. It consists of a cylindrical vessel with a
conical base.
• The feed inlet is fitted to the upper part of the
vessel.
• The rotating disc and rotating blades are
attached to the central shaft to produce air
environment.
• At the base of the vessel, two outlets are
provided; one for fine particles and the other for
heavy particles.
 Working:

• The disc and blades- Rotating disc are allowed to rotate by means of a motor.
• These produce a current of air as shown by the arrows.
• The sample powder is introduced through the feed inlet.
• The feed falls on the rotating disc.
• The fine particles are picked up and carried into space, where air velocity is
sufficiently reduced.
• The fine particles are dropped and are ultimately collected at the outlet meant for
the fine particles.
• The heavy particles which fall downward, are removed at the outlet meant for heavy
particles.
 uses
• Air separators are often attached to the ball mill or hammer mill to separate and
return over sized particles for further size reduction.
 BAG FILTER
• Principle:
• In a bag filter, size separation of fines (or dust) from the milled powder is
achieved in two steps.
• In the first step, the milled powder is passed through a bag filter (cloth)
by applying the suction on the opposite side of the feed entry. This
facilitates the separation.
• In the next step, pressure is applied in order to shake the bags so that
powder adhering to the bag falls off, which is collected from the conical
base.
 BAG FILTER
• Construction:
• It consists of a number of bags made of cotton or wool fabric. These are
suspended in a metal container.
• A hopper is arranged at the bottom of the filter to receive the feed. At the
top of the metal container, a provision is made for the exhaust.
• Adjacent to this, a bell crank lever arrangement is made to bring the
filters to normal atmospheric conditions.
BAG FILTER:
 BAG FILTER
• Working:
• The working of the bag filter consists of two steps.
• In the first step, the feed is separated from air by passing it through the
cloth bags.
• In the subsequent step, the bags are shaken to collect the fines that are
adhered to the bags. These two steps follow in succession and are
controlled at different intervals with the help of a bell crank lever
arrangement.
 BAG FILTER
• These changes occur at intervals of a few minutes.
• Filtering period: The exhaust fan positioned at the top keeps the bags under less pressure than
atmospheric pressure. The gas containing fine particles (or dust) enters the hopper, as shown with
arrows in Figure, and passes up. The gas feed passes through the fabric of bag.
• During this process, the fines (or dust) are retained in the bags, while the gas reaches the top of the
casing. Because of air, the bag remains taut during filtering operation.
• Shaking period: Since vacuum is cut off in the chamber, air from outside enters the casing and passes
through the bags.
• This results in violent shaking of the bags, so that the dust and fine particles are displaced from the
bags and falls into the conical base.
• It is then removed at intervals. Such devices are entirely automatic in their action and can be
designed to affect very large filtering surface per unit floor space.
 ELUTRIATION TANK
• Principle:
• It is based on the principle of sedimentation.
• Construction/working
• The dry powder or paste made by levigation is kept in an elutriating tank. It is mixed with a large
quantity of water.
• The solid particles are distributed uniformly in the liquid during stirring.
• Then the particles are allowed to settle.
• Depending on the density, the solid particles may either settle down or remain suspended in water.
• Samples are withdrawn at different heights through the outlets.
• The powders are dried and thus various size fractions are collected.
ELUTRIATION TANK
 ELUTRIATION TANK
• USES
• Separation of particle of different particle size.
• Advantages:
• Separation is quick as compared to other methods.
• Disadvantages:
• Sometimes the suspension of solid particle has to diluted which may not be desired
in certain cases.