MAKING EXCELLENT ACTIVATED CARBON THAT FIXES THE COMMON PROBLEMS OF ACTIVE PACKAGING

Activated carbon, also known as charcoal, is widely used as an adsorbent in the pharmaceutical industry to eliminate toxins, odours, and noxious gases from packaged goods. This is due to its amorphous, highly porous composition, which allows for a wide surface area for gas and reactive organic molecule adsorption.

Manufacturers and distributors use activated charcoal for their packaging because it is particularly useful in conjunction with other ingredients, such as desiccants, for moisture and odour regulation.

Active carbon is made in a particular manner.

Coconut shells, peat, ash, coal, and fruit stones are only a few of the ingredients that can be used to make activated carbon. During activation, however, both of these materials contain differing degrees of pore size and distribution. Coconut shell contains a very pure and effective source of activated carbon that appears to be denser with a larger number of micro-pores, according to ChemBro Packaging. Furthermore, ChemBro Packaging has been able to produce non-dusting pouches by incorporating coconut shell into the manufacturing process. Because of our focus on consistency, we're able to have a superior product that protects formulators and suppliers from consumer concerns related to dusting problems. Furthermore, coconut shells are a very renewable and natural option.

The raw material is thermally decomposed in the first phase of the production process, resulting in a carbonaceous mass with many tiny pores. This base material is ‘activated' in the second stage by being steam-heated to temperatures of up to 1,100 degrees Celsius.

ChemBro's activated carbon has a lattice structure with a network of micro-pores, making for a large adsorption surface region. Physical adsorption draws toxic gases and odours to this structure, where they retain until equilibrium is achieved between adsorbed molecules and those that are either freely dispersed and holding moisture or steam. Chemisorption happens as new chemical bonds form between the adsorbates and the activated carbon surface.

Characteristics of activated carbon that make it suitable for successful packaging

• Huge surface area – The layered composition of activated carbon creates a surface area of 200 to 2,000 m2/gm – a spoonful is equal to the entire surface area of a football field, suggesting that tiny volumes can be effective in successful packaging.
• Activated carbon is thermally and PH-stable over a wide range of PHs and temperatures. It functions equally well for acidic or alkaline liquids, making it incredibly strong and dependable. Steam activated carbon is stable above the temperature of activation.
• Inert – Since activated carbon is inert in nature, it does not cause active ingredients to decompose. As a result, the probability of unfavourable interactions between the sorbent and the medication is significantly reduced, and drug effectiveness is maintained.
• Activated carbon is especially effective in packaging where free moisture can reduce the adsorption potential of other sorbents due to its non-polar and hydrophobic nature. This ensures it can be safely mixed with other desiccants for improved efficacy and use in complex situations.
• By its own essence, activated carbon is an exceptional adsorbent, with a yield of 95-98 percent. In practice, variables such as the raw material, activation mechanism, and adsorbate concentration can affect the yield.

Real-world uses of activated carbon

These examples of how activated carbon has been used to overcome real-life pharmaceutical packaging problems illustrate the outstanding properties of activated carbon in tackling odour issues:

Metformin – This diabetic treatment has a strong odour, so strong that certain people refuse to obey the prescribed dose schedule. Although extended formulations of the drug have resulted in lower odour levels, activated carbon in packaging can help avoid odour build-up before opening.

Degradation produced by formaldehyde/formic acid – Drug degradation can occur as formaldehyde and formic acid react in excipients. Activated carbon has been shown in studies to slow down the degradation of gelatine and to help with stability problems caused by gelatine cross-linking.

Activated carbon in combination with other active packaging materials

Since activated carbon is safe to mix with other desiccants and gas absorbers, active packaging formulations may be tweaked for increased efficacy in specific applications. Below are a few examples of potential combinations:

Silica gel is a type of silica gel that is used to make Silica gel, a microporous type of silicon dioxide, that has long been used to successfully regulate moisture. Though activated carbon is non-polar, silica gel contains hydroxyl groups that allow free moisture to be absorbed. Both are non-toxic, making this a good match for nutraceuticals.

• Bentonite clay – A layered composition provides a wide surface area for water adsorption on both the outer and inner surfaces of this calcium-rich and cost-effective montmorillonite desiccant. Bentonite clay is a naturally occurring, non-toxic clay that is suitable for use in medicinal materials. Since activated carbon has low desiccant properties, mixing it with bentonite clay results in moisture and odour control that is efficient.
• Oxygen absorber – These compounds, as their name indicates, decrease the volume of free oxygen in manufactured goods. Although oxygen absorbers are not known as desiccants, they may guard against oxidative oxidation by using iron, which interacts with free oxygen to create rust. This is particularly useful for reducing odour, volatile gases, and oxygen in the packaging when combined with activated charcoal.
• Molecular sieve – In pharmaceuticals and health products, this synthetic zeolite sorbent is used to regulate odour and gas. It has a high affinity for hydrocarbons and organics, similar to activated charcoal. A molecular sieve, unlike non-polar activated carbon, has aggressive moisture control properties, making it an excellent alternative for overall moisture and odour control. On the drawback, it isn't ideal for applications that necessitate subtle moisture control.

Clearly, activated carbon is an outstanding option for odour and gas protection in successful packaging on its own. When paired with other active packaging components, however, it becomes a truly efficient and flexible alternative for the active packaging industry, ensuring that products meet the end-user with reduced consistency and effectiveness loss.

Ask our technical sales agent now for the perfect activated carbon solution for your active packaging needs!