Powder Handling Systems for Pharmaceutical Manufacturing

Powder handling systems in pharmaceutical manufacturing directly influence blend homogeneity. Matcon IBC Blending uses tumble mixing and diffusion mixing to create content uniformity that is equivalent to other blending methods such as conta blenders.  

Using the Cone Valve technology inside each IBC, powders are transferred without risk of segregation, particle stratification, or uncontrolled flow. When feeding to Tablet Presses, the blend that was created during blending is discharged carefully, keeping actives and excipients fully mixed. This results in improved dose accuracy, high product quality, and confidence in meeting regulatory expectations for content uniformity. 

Well‑designed systems support GMP compliance by offering predictable, repeatable handling and reduced operator intervention. 

Key powder properties in pharmaceutical manufacturing determine the selection and design of powder handling and blending equipment.

Powder flowability, particle size, bulk density and moisture content all affect how powders behave in handling and processing equipment. Flowability influences whether powders discharge consistently or are prone to issues such as bridging, ratholing or uncontrolled flow. Moisture content and hygroscopic behaviour affect cohesion and flow stability.

Particle size and size distribution, along with bulk density affect blend uniformity and the risk of segregation during transfer and discharge. Large particles can rise up in the mix through percolation effects, whilst fines will move downwards under the sifting effect.

Understanding these characteristics allows equipment to be specified with the correct discharge geometry, mass‑flow transfer rate and blending method, giving you consistent and repeatable pharmaceutical production.

An intermediate bulk container IBC is a portable, enclosed stainless steel container used to store, transport, and process powder throughout the manufacturing process. In pharmaceutical manufacturing, IBCs are widely used for transferring materials between operations such as dispensing, blending, granulation, milling, and tablet compression while maintaining product quality and operator safety.

IBCs are used in pharmaceutical powder handling because they offer: 

Improved Containment IBCs help prevent the release of potent or hazardous powders into the manufacturing environment, protecting operators and reducing the risk of cross-contamination.

Enhanced Product Quality By keeping materials enclosed throughout processing, IBCs minimise exposure to moisture, airborne contaminants, and handling errors that could affect product integrity.

Greater Manufacturing Efficiency IBCs can be moved directly between process equipment, reducing manual handling steps, cleaning requirements, and production downtime.

Regulatory Compliance Contained powder handling supports GMP (Good Manufacturing Practice) requirements by improving traceability, cleanliness, and process control.

Reduced Product Loss Closed transfer systems help maximise yield by minimising spillage and dust generation during material movement.

An IBC is typically charged with powder at one stage of production and then transports that powder to the next process step, where it is connected directly to the downstream equipment using a contained discharge system. The container can be moved safely around the facility and docked to different process machines without exposing the product to the surrounding environment.

Matcon IBC systems incorporate Cone Valve technology, which promotes mass-flow discharge and helps prevent common powder handling issues such as segregation, rat-holing, and inconsistent flow. This enables manufacturers to achieve more reliable product quality, greater process efficiency, and improved containment throughout pharmaceutical production.

Yes, Matcon IBC systems are used across both oral solid dosage and active pharmaceutical ingredient manufacturing.  For OSD production, the IBCs are used to transport material between dispensing, blending, granulation, tablet compressions, coating and primary packing.

For API manufacturing, Matcon Cone Valve IBCs have the ability to handle solvent-rich wet cake solids as well as dry free-flowing powders. As API systems tend to be highly specific to each facility, Matcon works closely with each customer to design the right solution.

Yes, Matcon provides full aftermarket support including preventative maintenance, spare parts supply, and on-site engineering assistance. The Matcon aftermarket team works with pharmaceutical manufacturers to keep systems running at peak performance.

Planned maintenance programmes help reduce the risk of unexpected downtime, which is particularly important in regulated pharmaceutical environments where any unplanned stoppage can affect batch records and compliance timelines.

Visit the Matcon Aftermarket support page for more information.