Suspensions manufacture

Studies of polymorphs in recent years have pointed out the effects of polymorphism on solubility and, more specifically, on dissolution rates. The aspect of polymorphism that is of particular concern to the parenteral formulator is physical stability of the product [8]. Substances that form polymorphs must be evaluated so that the form used is stable in a particular solvent system. Physical stresses that occur during suspension manufacture may also give rise to changes in crystal form [9]. 

Brief mention should be made of the important topic of aerosols, more or less stable suspensions of liquid or solid particles in a gas. The manufacture... 

Manufacturing processes have been improved by use of on-line computer control and statistical process control leading to more uniform final products. Production methods now include inverse (water-in-oil) suspension polymerization, inverse emulsion polymerization, and continuous aqueous solution polymerization on moving belts. Conventional azo, peroxy, redox, and gamma-ray initiators are used in batch and continuous processes. Recent patents describe processes for preparing transparent and stable microlatexes by inverse microemulsion polymerization. New methods have also been described for reducing residual acrylamide monomer in finished products. 

Commercially, SAN is manufactured by three processes emulsion, suspension, and continuous bulk. 

There are three commercial processes for manufacturing ABS emulsion, mass, and mass-suspension. 

The scale-up of filtration centrifuges is usually done on an area basis, based on small-scale tests. Buchner funnel-type tests are not of much value here because the driving force for filtration is not only due to the static head but also due to the centrifugal forces on the Hquid in the cake. A test procedure has been described with a specially designed filter beaker to measure the intrinsic permeabiHty of the cake (7). The best test is, of course, with a small-scale model, using the actual suspension. Many manufacturers offer small laboratory models for such tests. The scale-up is most reHable if the basket diameter does not increase by a factor of more than 2.5 from the small scale. 

The discovery of PTFE (1) in 1938 opened the commercial field of perfluoropolymers. Initial production of PTFE was directed toward the World War II effort, and commercial production was delayed by Du Pont until 1947. Commercial PTFE is manufactured by two different polymerization techniques that result in two different types of chemically identical polymer. Suspension polymerization produces a granular resin, and emulsion polymerization produces the coagulated dispersion that is often referred to as a fine powder or PTFE dispersion. 

PVDE is manufactured using radical initiated batch polymerization processes in aqueous emulsion or suspension operating pressures may range from 1 to 20 MPa (10—200 atm) and temperatures from 10 to 130°C. Polymerization method, temperature, pressure, recipe ingredients, the manner in which they are added to the reactor, the reactor design, and post-reactor processing are variables that influence product characteristics and quaUty. 

There are two principal PVC resins for producing vinyl foams suspension resin and dispersion resin. The suspension resin is prepared by suspension polymerization with a relatively large particle size in the 30—250 p.m range and the dispersion resin is prepared by emulsion polymerization with a fine particle size in the 0.2—2 p.m range (245). The latter is used in the manufacture of vinyl plastisols which can be fused without the appHcation of pressure. In addition, plastisol blending resins, which are fine particle size suspension resins, can be used as a partial replacement for the dispersion resin in a plastisol system to reduce the resin costs. 

A Gaussian distribution of particle size is the result of copolymer manufactured by suspension polymerization. A jetting process produces beads with more uniform particle size. The uniformity coefficient is a numerical method of indicating closeness of all beads to the same size. 

The organic peroxides and peroxide compositions produced commercially are those that can be manufactured, shipped, stored, and used safely. Organic peroxides can be thermally and mechanically desensitized by wetting or by dilution with suitable solvents, iaert soHd fillers, or iasoluble Hquids (suspension of soHd peroxides ia Hquid plasticizers or water, and emulsions of Hquid peroxides ia water). 

Manufacture. Phosphoms pentachloride is manufactured by either batch or continuous processing. In the former, the phosphoms trichloride usually dissolves in carbon tetrachloride before being treated with chlorine. A mixture of ca one part of phosphoms trichloride to one part of carbon tetrachloride is introduced to a water-jacketed vessel that contains an efficient stirrer and a tight cover with a redux condenser. The chlorine is passed into the vessel below the Hquid level, and crystals of phosphoms pentachloride form in the Hquid. When the reaction is completed, the suspension of crystals of phosphoms pentachloride in the carbon tetrachloride is drawn out of the vessel and the crystals are filtered and then dried by circulating hot water through the jacket of the filter. The clarified carbon tetrachloride is returned to the reaction vessel. 

The second difficulty, degradation, required the development of a two-step polyamidation process following salt formation (157). During salt formation, tetramethylenediammonium adipate salt is formed in water solution at approximately 50% concentration or at a higher concentration in a suspension. As in nylon-6,6 manufacture, this salt solution, when diluted, permits easy adjustment of the stoichiometry of the reactants by means of pH measurement. 

Acrylonitrile—Butadiene—Styrene. ABS is an important commercial polymer, with numerous apphcations. In the late 1950s, ABS was produced by emulsion grafting of styrene-acrylonitrile copolymers onto polybutadiene latex particles. This method continues to be the basis for a considerable volume of ABS manufacture. More recently, ABS has also been produced by continuous mass and mass-suspension processes (237). The various products may be mechanically blended for optimizing properties and cost. Brittle SAN, toughened by SAN-grafted ethylene—propylene and acrylate mbbets, is used in outdoor apphcations. Flame retardancy of ABS is improved by chlorinated PE and other flame-retarding additives (237). 

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