Clamp Down on Clumping

First understand what’s really causing the problem.

By Tom Blackwood, Healthsite Associates

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Poor flow is one of the most common problems encountered in handling or storing solids. With liquids you open the valve and (hopefully) material runs out. With solids you often have to pray before opening the valve. Wouldn’t it be nice to have an inexpensive well-established test method or procedure that would allow you to predict whether a fine powder will flow after a given time interval?

Often test methods take too long and generate results that are qualitative and very subjective. Also, material may be limited and quantitative test procedures are very expensive. If your plant has been working with solids you’re probably familiar with this scenario. The basic issue is a balance of cost versus usable results. Clumping is a complicated issue that’s difficult to quantify; so it’s no surprise that finding a meaningful test is difficult. In most cases, clumping is unpredictable. However, a generalized procedure can be used to solve a clumping problem after it has occurred.

By clumping we really mean unintended agglomeration. While some types of agglomeration are desirable, e.g., to reduce dustiness or make a material easier to handle, most clumping isn’t appreciated. The last thing you need in a pharmaceutical plant is for a bulk bag of acetaminophen to come in as a solid block (as has happened). Clumping is such a tricky issue due to its many causes. Before you can select a test method or procedure, you need to determine the root cause of clumping. Sometimes that can identify a solution without further testing.

Causes of Clumping
The 10 most common sources of agglomeration in bulk solids are:

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