Twin-screw continuous mixing: Effect of mixing elements and processing parameters on properties of aerosol powders

Twin-screw continuous mixing was used to prepare aerosol powders containing 1% budesonide, 0.3% magnesium stearate, and 98.7% α-lactose monohydrate. The effect of mixing configuration was studied using three screw profiles containing either a combing element, 30° forward kneading element, or a 60° forward kneading element. The impact of screw speed, feed rate, and multiple passes through the mixer on powder quality was investigated. The impact of specific energy on aerosol performance was dependent on the mixing configuration, and high energy input was detrimental to FPF for the 30° kneading element. Control of content uniformity was demonstrated by varying the mixing element in the screw profile. Passing the material through the mixer multiple times improved the aerosol performance. The robust and tunable nature of twin-screw mixing makes it a process well suited for continuous manufacturing of aerosol powders. [Display omitted] •The mixing process is robust above a critical specific throughput.•Excessive mixing shear can reduce aerosol performance due to press on forces.•More aggressive mixing elements in the screw profile improve content uniformity.•Aerosol performance improves with multiple passes through the mixer.•Increased mixing time reduces drug agglomerates to improve FPF.