Pharmaceutical Powder Handling Equipment: Managing the OSD Processing Line

Manufacturing oral solid dosage (OSD) pharmaceuticals requires the controlled movement and processing of powder through multiple stages. From raw material receipt to tablet pressing or capsule filling, with containment, hygiene, and regulatory compliance maintained throughout. Each stage demands equipment that meets GMP requirements, supports validation, and minimises the risk of cross-contamination or operator exposure.

Hanningfield designs and manufactures a complete range of stainless steel equipment for OSD pharmaceutical powder handling, processing, and containment. Advanced Packaging Systems supplies Hanningfield equipment in New Zealand.

Hanningfield Capsule Conveyor

Raw Material Receipt and Sack Tipping

The OSD processing line typically begins with the receipt and unloading of raw materials from sacks, bags, or bulk containers. Hanningfield’s Sack Tip Station provides a controlled method for emptying sacks into a downstream conveyor or vacuum transfer system, with an integrated dust extraction hood protecting both the operator and the process environment during discharge. Feed bins are available for intermediate storage of powder prior to downstream processing, with optional agitators to prevent bridging.

Vacuum Transfer and Conveying

Once unloaded, powder must be conveyed from intake to processing equipment — often vertically, across multiple floors, and without risk of contamination or material loss. Hanningfield’s Uni-Vac vacuum conveyors transfer powder, granules, and other materials using a lean-phase vacuum system. The dust-tight sealed design prevents product contamination while protecting operators from exposure.

The Uni-Vac V-series uses a rolled and seam-welded hopper body and requires no compressed air, making it well suited to process rooms with height restrictions. The VC-series uses a vacuum generator and is available in fully pneumatic execution for ATEX environments. Both series support direct loading applications — including charging tablet presses, bin blenders, and IBCs — and can be configured with CIP/WIP, HEPA filtration, and level control. Throughput ranges from 50 kg/hr (V01 model) to 4,000 kg/hr (V100), with full validation documentation available to IQ/OQ standard.

Hanningfield Uni-Vac Vacuum Transfer System

Milling and Size Reduction

Many pharmaceutical powders require size reduction either to achieve a specified particle size distribution (PSD), break down raw material agglomerates, or reclaim powder from discarded product. The Hanningfield Uni-Mill conical mill is the established standard for pharmaceutical milling, available in both under-driven (U-series) and over-driven (B-series) configurations.

The U-series (M05-U through M30-U) uses a spacer-less design providing a pre-set optimal milling gap, with throughputs to 4,000 kg/hr and a lowest achievable particle size of approximately 150 microns (80 mesh). The B-series (M10-B through M60-B) uses a belt-driven impeller suited to heat-sensitive materials or high-throughput rugged applications, with throughputs to 7,200 kg/hr. Both series are constructed from 316L stainless steel with FDA-compliant seals, available in ATEX execution, and scalable from laboratory (M05-U) through pilot to full production.

For pre-milling of hard agglomerates — such as compacted Metformin or similar bulk materials — the BlockBuster lump breaker reduces large blocks to approximately 20 × 20 mm prior to cone milling, protecting the mill and increasing process throughput. For security screening and deagglomeration of friable materials, the Kwik-Sift centrifugal sifter provides throughputs to 23,000 kg/hr. Where a single unit combining milling and sifting is preferred, the Particle Sizing Solution (PSS) accepts interchangeable mill and sifter heads on one drive body, offering cost efficiency without compromising performance.

IBC-to-IBC milling — where a bin of unmilled powder discharges through the mill directly into a receiving IBC — is a standard configuration in contained OSD processing, minimising manual handling and operator exposure throughout.

Hanningfield Uni Mill

Blending

Following milling and sifting, blending creates uniform batches prior to compression or encapsulation. Hanningfield’s Uni-Blend bin blenders tumble IBCs or drums to achieve homogeneous mixing. The range covers batch sizes from 5 litres to 2,000 litres, in configurations including hoist-type, through-the-wall, fixed base, and mobile units. Controls can be supplied to 21 CFR Part 11 compliance for fully electronic batch records.

For smaller-volume applications, drum tumblers provide the same gentle tumbling action at up to 200 kg SWL, with variable RPM and optional batch data recording. Hanningfield’s IBCs — available from 150 to 2,000 litres, with custom sizes on request — are designed for the contained transport, storage, and handling of pharmaceutical powders, and can be specified with castors, corner stacking profiles, and lifting loops for forklift or hoist integration.

Feeding Downstream Equipment

Once blended, material must be transferred to tablet presses or capsule filling machines. Hanningfield’s Uni-Hoist lift systems are engineered for the safe and repeatable handling of IBCs, drums, and process machinery in hygienic GMP environments. The range spans light-duty (250 kg SWL) through to heavy-duty (2,000 kg SWL), with electric, pneumatic, or manual power options and a range of attachment configurations for different container types.

For capsule filling operations, the CapsuJet capsule conveying system transfers empty capsules from ground level into the filling machine hopper (C20 series, up to 300,000 capsules/hr) and filled capsules from the machine outlet to downstream containers (FCC series, up to 200,000 capsules/hr). The system operates on a low-pressure air conveying principle, with very low noise levels and virtually zero capsule damage.

Hanningfield Uni-Dust Type 40 Cyclone

Dust Capture and Containment

Tablet compression and encapsulation generate waste powder and dust that must be captured for operator safety and batch reconciliation. The Uni-Dust cyclone recovers waste powder with typical efficiency of 90–99.9%, without filters or moving parts. It is compatible with equipment from Fette, Manesty, Korsch, Zanasi, Bosch, Kilian, and other common process machine manufacturers, and can incorporate a manifold for simultaneous collection from dedusters and polishers. Recovered powder may be used for batch loss reconciliation or reintroduced to the process where protocol permits.

Hanningfield’s Sterivalves range — including butterfly, flexible butterfly, rotary dosing, and rotary crushing valve variants — provides contained flow control between pieces of equipment. Uni-Cap silicone dust caps and Uni-Connect compensator sleeves complete the containment solution, enabling flexible, dust-tight connections between process interfaces and accommodating minor misalignments during installation.

Hanningfield Uni-Hoist Drum Lifter

GMP Compliance and Validation

All Hanningfield equipment is manufactured from AISI 316L stainless steel (180 grit polish) for product-contact parts, with FDA-compliant seals throughout. ATEX-rated versions are available across the product range for use in potentially explosive environments. Hanningfield holds ISO 9001 and ISO 14001 accreditation and is a member of EHEDG and SHAPA. Full validation documentation — including Functional and Design Specifications, Factory Acceptance Tests, Site Acceptance Tests, and IQ/OQ protocols — is available for all equipment, together with 3.1 mill certificates to EN 10204.

Advanced Packaging Systems is the New Zealand distributor for the Hanningfield range. Contact the APS team to discuss equipment requirements for any stage of the OSD processing line.