sponsoredPowder Induction Biopharmaceutical Processes Accelerating Powder Dissolution: Advances in In-Line Mixing for Bioprocessing

Sponsored by

ILC Dover SA

In-line powder induction revolutionizes media and buffer preparation: Conventional tank mixers slow down production in the biopharmaceutical industry, are prone to lump formation, and often achieve only incomplete particle wetting. A new in-line system solves this bottleneck through a highly efficient, closed-loop Venturi powder induction.

Efficient powder dissolution and mixing remain critical bottlenecks in biopharmaceutical manufacturing, directly influencing batch consistency, yield, and process scalability. Traditional vessel-based approaches often struggle with agglomeration, incomplete wetting, and long dissolution times, particularly for low-density or poorly wetting powders, resulting in variability and extended cycle times.

Recent performance data presented in the ILC Dover whitepaper on EZJetFlo™ demonstrate how in-line, Venturi-based powder dissolution can significantly improve these operations.

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Due to the high flow velocity, agglomerates are torn apart while simultaneously every particle surface is wetted in fractions of a second. The system operates in a closed-loop recirculation mode, where liquid acceleration generates a vacuum (~ –900 mbar) to entrain powders directly into a high-velocity turbulent stream, enabling immediate wetting and dispersion. The flow dynamics using this system are significantly more consistent and assure a streamlined process that yields operational improvements.

Fast and Efficient Solution Thanks to Negative Pressure

Experimental results at 900 L scale highlight the impact of controlled hydrodynamics on both powder induction and mixing efficiency. Powder delivery rates were strongly influenced by flow conditions, with a ~25 percent increase in feed rate observed when pump speed increased from 61 percent to 71 percent, confirming the direct relationship between outflow rate and Venturi-driven suction performance. Across all tested materials, including NaOH, glucose, and starch, stable powder feeding was achieved without clogging or operational interruption.

Mixing performance was equally significant. For highly soluble systems such as NaOH, pH measurements showed an almost instantaneous shift from neutral (~pH 6) to strongly alkaline (~pH 12), indicating rapid dissolution and homogeneous distribution without the need for additional mechanical agitation. Complementary dispersion studies further demonstrated that >99.5 percent of solids were dissolved within 2–3 minutes, with minimal retained particles (<0.5 percent on a 60 mesh screen), even for more challenging formulations.

Over 99.5 Percent Solubility in Record Time

These results confirm that high-efficiency in-line mixing can reduce dependence on tank agitation, shorten batch times, and improve reproducibility. The system simplicity reduces maintenance time and energy costs creating gains in sustainability. In addition, the fully closed, single-use configuration eliminates cleaning requirements and significantly reduces cross-contamination risks, aligning with current GMP and Annex 1 expectations.

As detailed in the whitepaper, such integrated powder induction and mixing approaches provide a robust, scalable solution for modern bioprocessing, combining measurable performance gains with improved process control and operational efficiency.

For a detailed technical evaluation and full performance dataset, readers are encouraged to consult the whitepaper “Enhancing Biopharmaceutical Production Through Advanced Mixing: Boosting Performance with EZJetFlo™ Technology,” authored by Paulo Bento and Scott Patterson. The paper provides in-depth analysis of hydrodynamic behavior, powder induction performance, and mixing efficiency across representative bioprocess applications, offering valuable insights for engineers and process specialists seeking to optimize media and buffer preparation workflows.

Discover how EZJetFlo™ can accelerate your performance on www.ILCDover.com

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