Use of a fluidized bed hammer mill for size reduction and classification: effects of process variables and starting materials on the particle size distribution of milled lactose batches.

The process capability of a fluidized bed hammer mill was investigated with respect to four process variables, namely, rotational speeds of beater system and classifier wheel, airflow rates and length of grinding zones, as well as the particle size and flow property of the starting materials. The size distributions of all the milled lactose batches could be fitted to the Rosin Rammler distribution (RRD) function. The characteristic particle size (De) and uniform coefficient (n), which were derived from the RRD function, complemented the size at the 99th percentile of the cumulative undersize distribution (D99) to characterize the lactose batches. Lower De and D99 values indicate a finer powder while a higher n value indicates a narrower size distribution. The beater speed played a critical role. Increasing the beater speed from 12000 to 21000 rpm generally resulted in an increase in n and a decrease in D99 values due to the greater amount of milling energy supplied. The particle size and flow property of the starting material also played an important role at beater speed of 12000 rpm, where the lowest amount of milling energy was supplied. When a higher amount of milling energy was provided, the effect of particle size of the starting material was less significant. The other process variables exerted varying effects. Increasing the classifier wheel speed from 5000 to 15000 rpm decreased the De and D99 and increased the n values of the milled lactose batches, provided sufficient milling energy was supplied to the lactose particles. Changing airflow rates from 80 to 90 m3/h generally resulted in larger De and D99 values and lower n values as the higher airflow rate provided greater airflow-induced kinetic energy that facilitated the passage of lactose through the classifier wheel. However, changing the long grinding zone to a short one did not significantly affect the De, D99 and n values of the milled lactose batches produced. Small lactose particles of narrow size distribution could be obtained using the fluidized bed hammer mill upon gaining a better understanding of the milling process.