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This sprayer was designed to apply low spray volumes as very coarse spray droplets.
Highest coating crystallinity resulted at high current, low spray distance and low carrier gas flow rate.
A low spray rate and a high pan speed improved the coating uniformity at both scales.
Secondary phases were also observed at low spray rate of 2 ml/min.
At low spray rates, the temperature of the coating pan did not affect the roughness of the coated tablets.
The DoE models both revealed the same CPP: a low drum load, high drum speed, low spray rate and high run duration were beneficial for coating uniformity.
Low variabilities could be achieved using low spray rates and high rotation speeds and they were independent from the tablet batch sizes in the studied factor space.
Low spray unsteadiness and good atomization performance can be obtained when the diameter of incline aeration holes increased at ALR of 10%.
High crystallinity resulted at high current and low spray distance due to the presence of bulk crystalline material and recrystallization of amorphous material.
The observed differences in population-level effects and recovery patterns ranged from no observable effects in the low spray-drift and low sensitivity scenario to severe reduction of abundances in the high spray-drift and high sensitivity scenario.
Coating thickness was determined by the number of particles and the degree of flattening on impact, and was highest at high current, low gas flow rate, high powder feed rate and low spray distance.
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