How to avoid Powder Segregation during Powder sampling?

In the pharma, chemical, and food industries, product sampling is routinely performed to ensure that every batch meets the desired requirements. During the powder sampling process, product powder segregation is one of the common challenges incurred. When the sampling powder gets segregated, it affects the sampling process’s accuracy and precision.

In this blog, we discuss these problems and share strategies to overcome them. Keep reading further to learn more!

Common Challenges with Powder Segregation

The factors such as differences in particle size, shape, and density are the main causes of powder segregation. As the product powder segregates, it results in inconsistent sample composition, ultimately hindering the product quality.

Here are some of the major segregation challenges:

1. Density Segregation:

As the name suggests, the finer product particles settle at the bottom, while the coarser and denser particles remain on the top during handling and transportation. Thus producing non-homogeneous samples.

2. Airborne Segregation:

The Airborne Segregation of a powder sample occurs when the powders are fluidised with airflow rates, and the particles are separated based on size and density. This process causes the finer particles to become airborne and remain suspended in the air. Airborne segregation causes sampling errors when the samples are not handled or mixed carefully.

3. Sifting (Percolation)Segregation:

The sample powders get segregated when they are subjected to vibration or movement, during which the smaller particles filter through the larger ones. Sifting segregation occurs when fluidized beds and hoppers are used, affecting the sampling accuracy.

How to Mitigate Segregation Problems?

To ensure accurate and reliable powder sampling, you need to adhere to validation protocols and employ best practices. Following are the strategies you can implement to avoid powder segregation:

1. Selecting the right sampling method:

Random Sampling, Systematic Sampling, Composite sampling, and Dynamic Sampling are some of the most common methods used for powder sampling. Of these methods, the Dynamic Sampling method gives reliable and accurate results as the sample is captured from a moving stream to minimize the impact of segregation.

2. Using Validated Equipment:

The sampling device must meet Good Manufacturing Practices and be made of material that does not react with the powder to be analyzed.

Jetspray manufactures sampling devices that are simple, reliable and highly efficient. Every sampling port is designed to meet your industrial processes' requirements, providing accurate and representative samples without compromising the pressure or vacuum inside the equipment.

Its user-friendly design allows for thorough cleaning without needing to dismantle them, thereby minimizing any downtime delays. Jetspray ensures efficient sampling with every use.

Explore our list of products:

1. Sampling Ports for ANFDs, RCVDs, Reactors
2. Sampling Ports for FBD Bowl, Blenders, Bins
3. Sampling Ports for AutoCoaters
4. Sampling Ports for Small Systems & Process Piping

3. Follow Regulatory Standards:

It is of utmost importance to comply strictly with the stringent standards set by regulatory authorities like the FDA to avoid any product recall or hefty penalties. The Sampling Procedures must be well-documented to ensure traceability and reproducibility. In this digital era, leverage automated data recording systems to minimize human errors. Make use of statistical methods to validate every sample represents the batch.

4. Prevent Cross-Contamination:

In order to prevent cross-contamination, cleanroom protocols should be implemented, and a dedicated sampling tool for every type of product should be used. Training the personnel in best sampling practices is also essential to avoid handling errors. Opting for a closed-loop sampling system is advisable to minimize any contaminant contaminating the sample from the immediate environment.

5. Invest in Real-time Monitoring Systems:

An online sensor and analyzer can help detect segregation trends. With the help of a real-time monitoring system, you can correct any errors in no time. It also helps save resources.

Work With The BEST

Powder sampling is a crucial step in quality control. Though there are some major challenges, like segregation and validation concerns, you can mitigate them by implementing best practices and choosing the best sampling devices. Investing in the right technology helps you ensure regulatory compliance, accuracy and reliability in powder analysis.

Jetspray is a leading name in the process industry. We deliver cutting-edge solutions for Cleaning Systems, Sampling Systems, Industrial Spraying Systems, and Atomizers. Driven by indigenous innovation, we design and manufacture top-tier products that don’t just meet global standards—they set new benchmarks. Our solutions are built for reliability, boosting efficiency and performance across process industries.