Milling

Definition

A unit operation in which the materials are reduced into small pieces/coarse
particles/powder
Milling or comminution is the mechanical process of reducing particle size of
solids.
Comminution-A word derived from latin word minuere (less) to reduce

Sieve No: No. of holes per linear inch.

Mesh No: It indicates hole size

If hole size is small, then sieve number is increased and vice versa.

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 Reasons for size
reduction
Preparation of suspensions (Cake-Separation)
Mixing of solids
Solid/fluid separation (Suspension)
Granules size for tableting
Process factors (Dust, explosion risk)
Surface area
Mass transfer (Area expose)
Adsorption (Surface phenomenon)
Drug absorption

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 Techniques for Particle Size
Distribution and Measurement
1.Sieving. . . .
All the powder/material is passed through a number of mesh and separated until the
powder reach the final mesh.
The volume at each mesh is find and total volume is of the powder is calculated
Tyler Standard scale(tyler standard scale is based the size of opening 0.0029“ in a wire
cloth having 200 openings per linear inch)
United State Standard size of opening 1mm(18 mesh)
Limitations. . . .
Charges may effect the sieving process, so not the appropriate method
Humidity may also effect the particles separation
Particles Shape may effect passing through mesh

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2.Microscopy
Ordinary Microscope(0.4-150µ)
UV light and special lenses (lower limit extends to 0.1µ)
Ultra Microscope(0.01-0.2µ)
3.Sedimentation

4.Electrical Conductance Method

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Theory of Comminution
1.Flow Theory
A. Elastic Deformation
(Hooke’s law) Stress is proportional to strain
B. Yield Point
C. Plastic deformation
D. Fracture strength

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2.Griffith Theory of Cracks and Flaws
Flaw: It is any structural weakness that may develop to crack
under strain.
Griffith theory may be expressed as

Where =Tensile strength, =Young’s modulus

=The surface energy of the wall of crack
C=Critical Crack depth required for fracture

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Factors effecting size
reduction
Hardness (Hardness/brittle)
Toughness (Soft + tough)
Abrasiveness (Grinding contamination)
Stickiness (Resistance)
Slipperiness
Softening Temperature (Melting)
Material structure (Flake like particles)
Moisture content
Physiological effect (Potent drugs)
Purity (Grinding-contamination)
Feed to product size (Appropriate feeding)
Bulk density
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(Proper volume) UMAR FAROOQ
 Classification
equipment for milling:
By the way of milling:

1. Cutting machine
2. Attrition machine
3. Compression machine
4. Impact machine

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Classification equipment for
milling:

By the degree of comminution:

1. crushers:

for great, medium, fine milling;

2. mills:

for micro fine, superfine (colloid) milling.

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Classification equipment
for milling:
By the mechanism used to break the particles:

1. Disc
2. Ball
3. Rotor
4. Hammer
5. Rollers and others

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Requirements for the
milling process:
1. Substances must has initial its composition and
pharmacological properties during the milling process;
2. Periodically to remove enough milled particles from the
sphere of comminution;
3. Prevent formation of dust (sealed enclosures);
4. Appropriate moisture of material;
5. The use of sequence connected crushing-milling machines.

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Parameters for choosing
optimal type of machines:
1. Initial size of the material and desirable
size of final product
2. The total amount of material for milling
3. Physical and chemical properties of
material for milling

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 Energy
Mills
Size Reduction
Mechanisms
Cutting (Cutter/Knife Cutter Mill)
Compression (Roller Mill)
Impact (Hammer Mill)
Attrition (Roller Mill)
Combined Impact and Attrition (Ball Mill, Fluid Energy Mill, Wet Grinding)

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 Cutting
Cutter
Mills
Working. . . .
Sharp blades attached to a rotor and act against stationary knives
Container having mesh at the bottom and feeder for the materials
Knife moves with speed, cut the materials into pieces and that pass through the
exit/mesh , resulting uniform particles
Limitations. . . .
Used to obtained coarse powder/size material
Best for cutting roots, peels or woods prior to extration

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 Cutting
Cutter
Mills

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 Compressi
on
Roller Mill
Principle:
Working. . . .
Round shaped cylindrical rolls moving in opposite direction.
One roll move by mechanical force and the second move by free movement
Material is placed at nip and roll down, so material is cut by the fraction of rolls
Limitations. . . .
Used to for crushing cracking of seed prior to extraction of oils, soft tissues to help in
solvent penetration into tissues

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 Compressi
on
Roller
Mills

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 Impact
Hammer Mills(Fitz Patrick
Communitor)
Working. . . .
Consist of metal casing enclosed in central shaft, four hammers are attached to it cylindrical
rolls moving in opposite direction.
Lower end of the casing had a sieve where the required size particles passed by (Changeable)
Advantages. . . .
Rapid action
Product control by adjustment of speed
Continuous operation
Little chance of contamination
Disadvantages. . .
High speed lead to heating
Feeding require controlling - Blockade of mill lead to decrease in efficiency
Susceptible to damage by high speed
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 Impact
Hammer
Mills

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 Attrition
Roller
Mills
Working. . . .
Use both pressure and fraction for size reduction
Two to three rolls adjusted closed to each other

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 Combined Impact and
Attrition
Ball Mills
Working. . . .
Consist of metal ball enclosed in container
Based on the principal of falling down of balls due to gravitational force
Advantages. . . .
Used for wide variety of materials
Due to enclosed form, best for potent/toxic materials grinding
Can Produce very fine powders
Continuous operation
Suitable for both wet and dry grinding
Disadvantages. . .
Chances of contamination
Soft materials
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may cause sticking of balls/reduce
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movement
 Combined Impact and
Attrition
Ball Mills

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 Combined Impact and
Attrition
Fluid Energy
Mills
Working. . . .
Consist of pipes in container
Entry of high pressure air through nozzles/pipes that move materials
Due to high pressure turbulence occur, that results in impaction and attrition of particles
Advantages. . . .
Very small size particles are produced
Due to air flow, cooling effect is produced, best for heat sensitive materials
Size is reduced due to particles attrition and impaction, so no contamination chances
For sensitive materials, inert gases may be used
Method is suitable for very fine particles
Disadvantages. . .
Limited application/low capacity machine
Constant air supply required, so need extra machinery
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Can not be used for all types of materials
 Combined Impact and
Attrition
Fluid Energy
Mills

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 Thank You

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