51
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Chen Y, Ierapetritou M. A framework of hybrid model development with identification of plant‐model mismatch. AIChE J 2020. [DOI: 10.1002/aic.16996] [Citation(s) in RCA: 18] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Affiliation(s)
- Yingjie Chen
- Department of Chemical and Biomolecular Engineering University of Delaware Newark Delaware USA
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering University of Delaware Newark Delaware USA
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52
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Bhalode P, Ierapetritou M. A review of existing mixing indices in solid-based continuous blending operations. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.06.043] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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53
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Bhalode P, Ierapetritou M. Discrete element modeling for continuous powder feeding operation: Calibration and system analysis. Int J Pharm 2020; 585:119427. [PMID: 32473969 DOI: 10.1016/j.ijpharm.2020.119427] [Citation(s) in RCA: 16] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/17/2020] [Revised: 05/05/2020] [Accepted: 05/09/2020] [Indexed: 11/29/2022]
Abstract
Research emphases on extensive experimental studies and modeling efforts have been on the rise for the development of accurate predictive models of pharmaceutical unit operations and 'digital-twin' framework for continuous manufacturing lines. These exhaustive studies have been conducted at different process conditions to acquire comprehensive knowledge of effects of process parameters on the overall process dynamics. However, there still lacks a detailed understanding of material property effects of pharmaceutical powders on process operation. To address this issue, a discrete element modeling (DEM) approach combined with material calibration is applied for simulation of feeder unit to obtain particle-level insight into effects of material properties on feeder performance with focus on particle flow and powder mixing within the feeder unit. Bulk calibration is implemented to accurately represent powder material properties within the DEM framework. Different refill situations are simulated using DEM to observe powder mixing, measured at the outlet. Feeder DEM simulations are further applied to understand correlations of material properties on feeder operation. These studies provide a detailed physical insight and particle-scale information into the powder mechanics during powder feeding operation.
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Affiliation(s)
- Pooja Bhalode
- Department of Chemical and Biochemical Engineering, Rutgers University, Piscataway, NJ 08854, USA
| | - Marianthi Ierapetritou
- Department of Chemical and Biochemical Engineering, Rutgers University, Piscataway, NJ 08854, USA.
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54
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Escotet-Espinoza MS, Scicolone JV, Moghtadernejad S, Sanchez E, Cappuyns P, Van Assche I, Di Pretoro G, Ierapetritou M, Muzzio FJ. Improving Feedability of Highly Adhesive Active Pharmaceutical Ingredients by Silication. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09448-y] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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55
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Govender R, Abrahmsén-Alami S, Larsson A, Folestad S. Therapy for the individual: Towards patient integration into the manufacturing and provision of pharmaceuticals. Eur J Pharm Biopharm 2020; 149:58-76. [DOI: 10.1016/j.ejpb.2020.01.001] [Citation(s) in RCA: 31] [Impact Index Per Article: 7.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/11/2019] [Revised: 12/23/2019] [Accepted: 01/08/2020] [Indexed: 12/18/2022]
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56
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Impact of Particle and Equipment Properties on Residence Time Distribution of Pharmaceutical Excipients in Rotary Tablet Presses. Pharmaceutics 2020; 12:pharmaceutics12030283. [PMID: 32245219 PMCID: PMC7151020 DOI: 10.3390/pharmaceutics12030283] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2020] [Revised: 03/18/2020] [Accepted: 03/19/2020] [Indexed: 11/17/2022] Open
Abstract
Paddle feeders are devices commonly used in rotary tablet presses to facilitate constant and efficient die filling. Adversely, the shear stress applied by the rotating paddles is known to affect the bulk properties of the processed powder dependent on the residence time. This study focuses on the residence time distribution (RTD) of two commonly applied excipients (microcrystalline cellulose, MCC; dicalcium phosphate, DCP), which exhibit different flow properties inside rotary tablet presses. To realistically depict the powder flow inside rotary tablet presses, custom-made tracer powder was developed. The applied method was proven to be appropriate as the tracer and bulk powder showed comparable properties. The RTDs of both materials were examined in two differently scaled rotary tablet presses and the influence of process parameters was determined. To analyze RTDs independent of the mass flow, the normalized variance was used to quantify intermixing. Substantial differences between both materials and tablet presses were found. Broader RTDs were measured for the poorer flowing MCC as well as for the production scale press. The obtained results can be used to improve the general understanding of powder flow inside rotary tablet presses and amplify scale-up and continuous production process development.
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57
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Bascone D, Galvanin F, Shah N, Garcia-Munoz S. Hybrid Mechanistic-Empirical Approach to the Modeling of Twin Screw Feeders for Continuous Tablet Manufacturing. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c00420] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Affiliation(s)
- Davide Bascone
- Centre for Process System Engineering, Department of Chemical Engineering, Imperial College London, London SW7 2AZ, United Kingdom
| | - Federico Galvanin
- Centre for Process System Engineering, Department of Chemical Engineering, University College London (UCL), London WC1E 6BT, United Kingdom
| | - Nilay Shah
- Centre for Process System Engineering, Department of Chemical Engineering, Imperial College London, London SW7 2AZ, United Kingdom
| | - Salvador Garcia-Munoz
- Eli Lilly and Company, Lilly Research Laboratories, Indianapolis, Indiana 46285, United States
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58
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Vanhoorne V, Vervaet C. Recent progress in continuous manufacturing of oral solid dosage forms. Int J Pharm 2020; 579:119194. [PMID: 32135231 DOI: 10.1016/j.ijpharm.2020.119194] [Citation(s) in RCA: 44] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/20/2019] [Revised: 02/28/2020] [Accepted: 02/29/2020] [Indexed: 12/28/2022]
Abstract
Continuous drug product manufacturing is slowly being implemented in the pharmaceutical industry. Although the benefits related to the quality and cost of continuous manufacturing are widely recognized, several challenges hampered the widespread introduction of continuous manufacturing of drug products. Current review presents an overview of state-of-the art research, equipment, process analytical technology implementations and advanced control strategies. Additionally, guidelines and regulatory viewpoints on implementation of continuous manufacturing in the pharmaceutical industry are discussed.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University.
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59
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Marques CM, Moniz S, de Sousa JP, Barbosa-Povoa AP, Reklaitis G. Decision-support challenges in the chemical-pharmaceutical industry: Findings and future research directions. Comput Chem Eng 2020. [DOI: 10.1016/j.compchemeng.2019.106672] [Citation(s) in RCA: 20] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
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60
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Alvarado-Hernández BB, Scicolone JV, Ortega-Zuniga C, Román-Ospino AD, Colón-Lugo YM, Aymat E, Sánchez E, Muzzio FJ, Romañach RJ. Method transfer of a near-infrared spectroscopic method for blend uniformity in a poorly flowing and hygroscopic blend. J Pharm Biomed Anal 2020; 180:113054. [PMID: 31881395 DOI: 10.1016/j.jpba.2019.113054] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/14/2019] [Revised: 12/12/2019] [Accepted: 12/18/2019] [Indexed: 10/25/2022]
Abstract
The challenges in transferring and executing a near-infrared (NIR) spectroscopic method for croscarmellose (disintegrant) in binary blends for a continuous manufacturing (CM) process are presented. This work demonstrates the development of a NIR calibration model and its use to determine the blending parameters needed for binary blends at a development plant and later used to predict CM process blends. The calibration models were developed with laboratory scale powder blends ranging from 4.32%-64.77 (%w/w) of croscarmellose and evaluated using independent test blends. The selected model was then transferred to the continuous manufacturing development site to determine the croscarmellose concentration for spectra collected in real-time. A total of 18 development plant runs were monitored using an in-line NIR spectrometer, however, these spectra showed high baseline variations. The baseline variations were caused by the poor flow of the material within the system. An inconsistent bias which varied from 2.51 to 14.95 (%w/w) was observed in the predictions of croscarmellose. High baseline spectra were eliminated and the bias was significantly reduced by 42-51%. Experiments at lower flow rate speeds did not show significant changes in baseline and bias values showed more consistency. The calibration model was then transferred to two NIR spectrometers installed at-line at the commercial site, where powder samples were collected at the beginning middle and end of each CM plant run. The NIR calibration model predicted disintegrant concentration from the powder samples. Results showed the bias values for the NIR (1) varied from 0.74 to 2.21 (%w/w) and NIR (2) from 0.28 to 3.39 (%w/w). Average concentration values for both equipments were very close to the reference concentration values of 43.18 and 50.98 (%w/w). The study showed the model was able to identify flow issues, identified as baseline shifts, that could be used to alert to problems in the powder bed that may warrant diversion from a production line. These powder flow problems such as air gaps and inconsistent powder bed height affected the NIR spectra collected at the development plant and provided results with high bias. A lower bias was obtained in samples collected at line after blending.
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Affiliation(s)
- Bárbara B Alvarado-Hernández
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemistry, The University of Puerto Rico at Mayaguez, Puerto Rico, 00681, United States
| | - James V Scicolone
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers University, NJ, Piscataway, 08854, United States
| | - Carlos Ortega-Zuniga
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemistry, The University of Puerto Rico at Mayaguez, Puerto Rico, 00681, United States; Janssen Supply Chain, Johnson & Johnson, Gurabo, Puerto Rico
| | - Andrés D Román-Ospino
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers University, NJ, Piscataway, 08854, United States
| | | | - Efrain Aymat
- Janssen Supply Chain, Johnson & Johnson, Gurabo, Puerto Rico
| | - Eric Sánchez
- Janssen Supply Chain, Johnson & Johnson, Gurabo, Puerto Rico
| | - Fernando J Muzzio
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers University, NJ, Piscataway, 08854, United States
| | - Rodolfo J Romañach
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemistry, The University of Puerto Rico at Mayaguez, Puerto Rico, 00681, United States.
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61
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Determining key parameters of continuous wet granulation for tablet quality and productivity: A case in ethenzamide. Int J Pharm 2020; 579:119160. [PMID: 32081803 DOI: 10.1016/j.ijpharm.2020.119160] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2019] [Revised: 01/29/2020] [Accepted: 02/16/2020] [Indexed: 11/24/2022]
Abstract
This paper aims to determine key parameters that affect tablet quality and productivity in continuous tablet manufacturing. Experiments were performed based on design of experiments using a continuous high-shear granulator and ethenzamide as the active pharmaceutical ingredient. To guide a systematic and comprehensive parameter analysis, a parameter framework was defined that comprised five input parameters on raw material properties and process parameters, 11 intermediate parameters on granule properties, and 11 output parameters on tablet quality and productivity. The interrelationships were analyzed statistically and were described as matrix functions. The liquid/solid ratio was the key parameter that affected circularity, density, and flowability as the granule properties, and disintegration and dissolution as the tablet quality. The maximum acceptable manufacturing rate that governs productivity was also affected by the liquid/solid ratio. Circularity was found to affect disintegration and dissolution. This result was specific to the setup of the study, but suggested development opportunities for a new process analytical technology system/quality-by-design application based on circularity. In addition, practical findings were obtained as follows: (1) high-speed manufacturing favored a lower liquid/solid ratio, and (2) high circularity slowed down disintegration/dissolution. This obtained knowledge will enhance the applicability of continuous technology in an actual manufacturing environment.
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62
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Wang Y, O'Connor T, Li T, Ashraf M, Cruz CN. Development and applications of a material library for pharmaceutical continuous manufacturing of solid dosage forms. Int J Pharm 2019; 569:118551. [DOI: 10.1016/j.ijpharm.2019.118551] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/16/2019] [Revised: 07/08/2019] [Accepted: 07/19/2019] [Indexed: 11/29/2022]
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63
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Moreno M, Liu J, Su Q, Leach C, Giridhar A, Yazdanpanah N, O’Connor T, Nagy ZK, Reklaitis GV. Steady-State Data Reconciliation Framework for a Direct Continuous Tableting Line. J Pharm Innov 2019; 14:221-238. [PMID: 36824482 PMCID: PMC9945915 DOI: 10.1007/s12247-018-9354-9] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Abstract
Purpose Reliable process monitoring in real-time remains a challenge for the pharmaceutical industry. Dealing with random and gross errors in the process measurements in a systematic way is a potential solution. In this paper, we present a process model-based framework, which for given sensor network and measurement uncertainties will predict the most likely state of the process. Thus, real-time process decisions, whether for process control or exceptional events management, can be based on the most reliable estimate of the process state. Methods Reliable process monitoring is achieved by using data reconciliation (DR) and gross error detection (GED) to mitigate the effects of random measurement errors and non-random sensor malfunctions. Steady-state data reconciliation (SSDR) is the simplest forms of DR but offers the benefits of short computational times. We also compare and contrast the model-based DR approach (SSDR-M) to the purely data-driven approach (SSDR-D) based on the use of principal component constructions. Results We report the results of studies on a pilot plant-scale continuous direct compression-based tableting line at steady-state in two subsystems. If the process is linear or mildly nonlinear, SSDR-M and SSDR-D give comparable results for the variables estimation and GED. SSDR-M also complies with mass balances and estimate unmeasured variables. Conclusions SSDR successfully estimates the true state of the process in presence of gross errors, as long as steady state is maintained and the redundancy requirement is met. Gross errors are also detected while using SSDR-M or SSDR-D. Process monitoring is more reliable while using the SSDR framework.
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Affiliation(s)
- Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Jianfeng Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Cody Leach
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Arun Giridhar
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Nima Yazdanpanah
- Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Thomas O’Connor
- Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
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64
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Tabora JE, Lora Gonzalez F, Tom JW. Bayesian probabilistic modeling in pharmaceutical process development. AIChE J 2019. [DOI: 10.1002/aic.16744] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/20/2023]
Affiliation(s)
- Jose E. Tabora
- Chemical & Synthetic Development, Product Development Bristol‐Myers Squibb Company New Brunswick NJ USA
| | - Federico Lora Gonzalez
- Chemical & Synthetic Development, Product Development Bristol‐Myers Squibb Company New Brunswick NJ USA
| | - Jean W. Tom
- Chemical & Synthetic Development, Product Development Bristol‐Myers Squibb Company New Brunswick NJ USA
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65
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Razuc M, Grafia A, Gallo L, Ramírez-Rigo MV, Romañach RJ. Near-infrared spectroscopic applications in pharmaceutical particle technology. Drug Dev Ind Pharm 2019; 45:1565-1589. [DOI: 10.1080/03639045.2019.1641510] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
Affiliation(s)
- M. Razuc
- Instituto de Química del Sur (INQUISUR), Universidad Nacional del Sur (UNS)-CONICET, Bahía Blanca, Argentina
- Departamento de Biología, Bioquímica y Farmacia, Universidad Nacional del Sur (UNS), Bahía Blanca, Argentina
| | - A. Grafia
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur (UNS)- CONICET, Bahía Blanca, Argentina
| | - L. Gallo
- Departamento de Biología, Bioquímica y Farmacia, Universidad Nacional del Sur (UNS), Bahía Blanca, Argentina
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur (UNS)- CONICET, Bahía Blanca, Argentina
| | - M. V. Ramírez-Rigo
- Departamento de Biología, Bioquímica y Farmacia, Universidad Nacional del Sur (UNS), Bahía Blanca, Argentina
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur (UNS)- CONICET, Bahía Blanca, Argentina
| | - R. J. Romañach
- Department of Chemistry, Center for Structured Organic Particulate Systems, University of Puerto Rico – Mayagüez, Mayagüez, Puerto Rico
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66
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Online Decision-Support Tool “TECHoice” for the Equipment Technology Choice in Sterile Filling Processes of Biopharmaceuticals. Processes (Basel) 2019. [DOI: 10.3390/pr7070448] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
In biopharmaceutical manufacturing, a new single-use technology using disposable equipment is available for reducing the work of change-over operations compared to conventional multi-use technology that use stainless steel equipment. The choice of equipment technologies has been researched and evaluation models have been developed, however, software that can extend model exposure to reach industrial users is yet to be developed. In this work, we develop and demonstrate a prototype of an online decision-support tool for the multi-objective evaluation of equipment technologies in sterile filling of biopharmaceutical manufacturing processes. Multi-objective evaluation models of equipment technologies and equipment technology alternative generation algorithms are implemented in the tool to support users in choosing their preferred technology according to their input of specific production scenarios. The use of the tool for analysis and decision-support was demonstrated using four production scenarios in drug product manufacturing. The online feature of the tool allows users easy access within academic and industrial settings to explore different production scenarios especially at early design phases. The tool allows users to investigate the certainty of the decision by providing a sensitivity analysis function. Further enrichment of the functionalities and enhancement of the user interface could be implemented in future developments.
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67
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Integrated continuous manufacturing in pharmaceutical industry: current evolutionary steps toward revolutionary future. Pharm Pat Anal 2019; 8:139-161. [DOI: 10.4155/ppa-2019-0011] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
Abstract
Continuous manufacturing (CM) has the potential to provide pharmaceutical products with better quality, improved yield and with reduced cost and time. Moreover, ease of scale-up, small manufacturing footprint and on-line/in-line monitoring and control of the process are other merits for CM. Regulating authorities are supporting the adoption of CM by pharmaceutical manufacturers through issuing proper guidelines. However, implementation of this technology in pharmaceutical industry is encountered by a number of challenges regarding the process development and quality assurance. This article provides a background on the implementation of CM in pharmaceutical industry, literature survey of the most recent state-of-the-art technologies and critically discussing the encountered challenges and its future prospective in pharmaceutical industry.
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68
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Su Q, Ganesh S, Moreno M, Bommireddy Y, Gonzalez M, Reklaitis GV, Nagy ZK. A perspective on Quality-by-Control (QbC) in pharmaceutical continuous manufacturing. Comput Chem Eng 2019; 125:216-231. [PMID: 36845965 PMCID: PMC9948678 DOI: 10.1016/j.compchemeng.2019.03.001] [Citation(s) in RCA: 68] [Impact Index Per Article: 13.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
Abstract
The Quality-by-Design (QbD) guidance issued by the US Food and Drug Administration (FDA) has catalyzed the modernization of pharmaceutical manufacturing practices including the adoption of continuous manufacturing. Active process control was highlighted recently as a means to improve the QbD implementation. This advance has since been evolving into the concept of Quality-by-Control (QbC). In this study, the concept of QbC is discussed, including a definition of QbC, a review of the recent developments towards the QbC, and a perspective on the challenges of QbC implementation in continuous manufacturing. The QbC concept is demonstrated using a rotary tablet press, integrated into a pilot scale continuous direct compaction process. The results conclusively showed that active process control, based on product and process knowledge and advanced model-based techniques, including data reconciliation, model predictive control (MPC), and risk analysis, is indispensable to comprehensive QbC implementation, and ensures robustness and efficiency.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Yasasvi Bommireddy
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA.,Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
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70
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Su Q, Bommireddy Y, Shah Y, Ganesh S, Moreno M, Liu J, Gonzalez M, Yazdanpanah N, O’Connor T, Reklaitis GV, Nagy ZK. Data reconciliation in the Quality-by-Design (QbD) implementation of pharmaceutical continuous tablet manufacturing. Int J Pharm 2019; 563:259-272. [PMID: 30951859 PMCID: PMC9976296 DOI: 10.1016/j.ijpharm.2019.04.003] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/01/2019] [Revised: 03/25/2019] [Accepted: 04/02/2019] [Indexed: 11/25/2022]
Abstract
Data provided by in situ sensors is always affected by some level of impreciseness as well as uncertainty in the measurements due to process operation disturbance or material property variance. In-process data precision and reliability should be considered when implementing active product quality control and real-time process decision making in pharmaceutical continuous manufacturing. Data reconciliation is an important strategy to address such imperfections effectively, and to exploit the data redundancy and data correlation based on process understanding. In this study, a correlation between tablet weight and main compression force in a rotary tablet press was characterized by the classical Kawakita equation. A load cell, situated at the exit of the tablet press chute, was also designed to measure the tablet production rate as well as the tablet weight. A novel data reconciliation strategy was proposed to reconcile the tablet weight measurement subject to the correlation between tablet weight and main compression force, in such, the imperfect tablet weight measurement can be reconciled with the much more precise main compression force measurement. Special features of the Welsch robust estimator to reject the measurement gross errors and the Kawakita model parameter estimation to monitor the material property variance were also discussed. The proposed data reconciliation strategy was first evaluated with process control open-loop and closed-loop experimental data and then integrated into the process control system in a continuous tablet manufacturing line. Specifically, the real-time reconciled tablet weight measurements were independently verified with an at-line Sotax Auto Test 4 tablet weight measurements every five minutes. Promising and reliable performance of the reconciled tablet weight measurement was demonstrated in achieving process automation and quality control of tablet weight in pilot production runs.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States.
| | - Yasasvi Bommireddy
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Yash Shah
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Jianfeng Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States,Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Nima Yazdanpanah
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Thomas O’Connor
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States,Corresponding authors. (Q. Su), (Z.K. Nagy)
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71
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Perçin ÖZKORUCUKLU S, Uka B, Yıldırım Baştemur G. Voltammetric Analysis of Cephalexin and Cefazoline in Pharmaceutical Formulation and Biological Samples. JOURNAL OF THE TURKISH CHEMICAL SOCIETY, SECTION A: CHEMISTRY 2019. [DOI: 10.18596/jotcsa.469028] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022] Open
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72
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Variographic analysis: A new methodology for quality assurance of pharmaceutical blending processes. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2019.02.010] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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73
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Abstract
The impact of the antibiotics in the environment is not well understood yet. Moreover, the total amount of antibiotics that are ending up in the environment as solid waste is not known and cannot be rigorously determined as many variables are influencing the determination of their concentration. The present article is focused on the estimation of the amount of non-prescribed antibiotics that are used in different European countries. Particular attention is paid to the class of beta-lactams, as they are responsible for a considerate share of the antimicrobial resistance. The primary purpose was the estimation of the quantity of non-prescribed antibiotics that might reach the environment as solid waste. For the present study, we used the ECDC and EUROSTAT reported data.
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74
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Ammarcha C, Gatumel C, Dirion J, Cabassud M, Mizonov V, Berthiaux H. Powder flow and mixing in a continuous mixer operating in either transitory or steady-state regimes: Mesoscopic Markov chain models. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.01.085] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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75
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Matsunami K, Nagato T, Hasegawa K, Sugiyama H. A large-scale experimental comparison of batch and continuous technologies in pharmaceutical tablet manufacturing using ethenzamide. Int J Pharm 2019; 559:210-219. [DOI: 10.1016/j.ijpharm.2019.01.028] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/02/2018] [Revised: 12/14/2018] [Accepted: 01/11/2019] [Indexed: 10/27/2022]
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76
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Escotet-Espinoza MS, Moghtadernejad S, Oka S, Wang Z, Wang Y, Roman-Ospino A, Schäfer E, Cappuyns P, Van Assche I, Futran M, Muzzio F, Ierapetritou M. Effect of material properties on the residence time distribution (RTD) characterization of powder blending unit operations. Part II of II: Application of models. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.12.051] [Citation(s) in RCA: 26] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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77
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Dülle M, Özcoban H, Leopold C. Analysis of the powder behavior and the residence time distribution within a production scale rotary tablet press. Eur J Pharm Sci 2018; 125:205-214. [DOI: 10.1016/j.ejps.2018.10.008] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/11/2018] [Revised: 09/28/2018] [Accepted: 10/08/2018] [Indexed: 10/28/2022]
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78
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Flow of granular materials in a bladed mixer: Effect of particle properties and process parameters on impeller torque and power consumption. ADV POWDER TECHNOL 2018. [DOI: 10.1016/j.apt.2018.07.022] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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79
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Characterizing drug product continuous manufacturing residence time distributions of major/minor excipient step changes using near infrared spectroscopy and process parameters. Int J Pharm 2018; 551:60-66. [DOI: 10.1016/j.ijpharm.2018.08.059] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/13/2018] [Revised: 08/10/2018] [Accepted: 08/31/2018] [Indexed: 11/16/2022]
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80
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Radcliffe AJ, Hilden JL, Nagy ZK, Reklaitis GV. Dropwise Additive Manufacturing of Pharmaceutical Products Using Particle Suspensions. J Pharm Sci 2018; 108:914-928. [PMID: 30308177 DOI: 10.1016/j.xphs.2018.09.030] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2018] [Revised: 09/05/2018] [Accepted: 09/14/2018] [Indexed: 11/16/2022]
Abstract
The principal method of drug delivery is by oral solid doses, the production of which often necessitates multiple post-crystallization unit operations to ensure content uniformity or enhance bioavailability. As an alternative to conventional dose production methods, applications of additive manufacturing technologies based on solvent- or melt-based formulations have demonstrated the potential for improvements to process efficiency, flexibility, and dosing precision. Here we explore the use of particulate suspensions in a dropwise additive manufacturing process as a method for dosing active ingredients in crystalline form, which may be difficult to achieve via powder processing due to poor flow properties. By employing a fluid-based method, powder flow issues are alleviated and adaptation of the process to new particles/crystals is facilitated by dimensional analysis. In this work, a feasibility study was conducted using 4 active ingredient powders, each with non-ideal particle properties, and 2 carrier fluids, in which the active ingredient does not dissolve, to formulate suspensions for dose manufacturing; drug products were analyzed to show reproducibility of dosing and to assess preservation of particle size through the process. Performance across particle types is affected by particle size and shape, and is related through effects on the rheological properties of the formulation.
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Affiliation(s)
- Andrew J Radcliffe
- Department of Chemical Engineering, Purdue University, West Lafayette, Indiana.
| | - Jon L Hilden
- Eli Lilly and Company, Lilly Corporate Center, Indianapolis, Indiana
| | - Zoltan K Nagy
- Department of Chemical Engineering, Purdue University, West Lafayette, Indiana
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81
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Schmidt A, de Waard H, Moll KP, Kleinebudde P, Krumme M. Simplified end-to-end continuous manufacturing by feeding API suspensions in twin-screw wet granulation. Eur J Pharm Biopharm 2018; 133:224-231. [PMID: 30291963 DOI: 10.1016/j.ejpb.2018.09.026] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/03/2018] [Revised: 09/25/2018] [Accepted: 09/25/2018] [Indexed: 11/26/2022]
Abstract
This study focussed on investigating the coupling of continuous manufacturing of drug substance and continuous manufacture of drug product. An important step in such an integrated end-to-end continuous manufacturing was envisioned by dosing the API as suspension into a twin-screw wet granulation process. To achieve this goal, a model drug substance (ibuprofen) was fed as a concentrated aqueous suspension (50% w/w) into a twin-screw granulator and compared against traditional solid feeding of the model drug substance to meet a target ibuprofen load of 60% w/w in the formulation. Granulation and compaction behaviour were evaluated to determine the impact of feeding API as suspension in twin-screw wet granulation on the critical quality attributes of the drug product. It was demonstrated that the ibuprofen suspension feed is comparable with the ibuprofen dry blend feed in twin-screw wet granulation. Next to enabling end-to-end continuous manufacturing, API suspension feed in twin-screw wet granulation could afford a number of additional advantages including manufacturing efficiency by removing the drying step for API, or overcoming processing issues linked to the bulk properties of the API powder (e.g. flowability).
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Affiliation(s)
- Adrian Schmidt
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, 40225 Duesseldorf, Germany; Novartis AG, Novartis Campus, 4002 Basel, Switzerland
| | - Hans de Waard
- Novartis AG, Novartis Campus, 4002 Basel, Switzerland
| | | | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, 40225 Duesseldorf, Germany
| | - Markus Krumme
- Novartis AG, Novartis Campus, 4002 Basel, Switzerland.
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82
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Residence time distribution of a continuously-operated capsule filling machine: Development of a measurement technique and comparison of three volume-reducing inserts. Int J Pharm 2018; 550:180-189. [DOI: 10.1016/j.ijpharm.2018.08.017] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/30/2018] [Revised: 08/08/2018] [Accepted: 08/11/2018] [Indexed: 01/20/2023]
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83
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Resilience and risk analysis of fault-tolerant process control design in continuous pharmaceutical manufacturing. J Loss Prev Process Ind 2018; 55:411-422. [PMID: 36777050 PMCID: PMC9912099 DOI: 10.1016/j.jlp.2018.07.015] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Abstract
The shift from batch to continuous manufacturing, which is occurring in the pharmaceutical manufacturing industry has implications on process safety and product quality. It is now understood that fault-tolerant process control of critical process parameters (CPPs) and critical quality attributes (CQAs) is of paramount importance to the realization of safe operations and quality products. In this study, a systematic framework for fault-tolerant process control system design, analysis, and evaluation of pharmaceutical continuous oral solid dosage manufacturing is proposed. The framework encompasses system identification, controller design and analysis (controllability, stability, resilience, etc.), hierarchical three-level control structures (model predictive control, state estimation, data reconciliation, etc.), risk mapping, assessment and planning (Risk MAP) strategies, and control performance evaluation. The key idea of the proposed framework is to identify the potential risks associated with the control system design itself, the material property variations, and other process uncertainties, under which the control strategies must be evaluated. The framework is applied to a continuous direct compaction process, specifically the feeding-blending subsystem, wherein the major source of variance in the process operation and product quality arises. It is demonstrated, using simulations and experimentally, that the process operation failures and product quality variations in the feeding-blending system can be mitigated and managed through the proposed systematic fault-tolerant process control system design and risk analysis framework.
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84
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Material tracking in a continuous direct capsule-filling process via residence time distribution measurements. Int J Pharm 2018; 550:347-358. [PMID: 30172751 DOI: 10.1016/j.ijpharm.2018.08.056] [Citation(s) in RCA: 22] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/26/2018] [Revised: 08/23/2018] [Accepted: 08/28/2018] [Indexed: 01/13/2023]
Abstract
Continuous production of pharmaceuticals requires traceability from the raw material to the final dosage form. With that regard, understanding the residence time distribution (RTD) of the whole process and its unit operations is crucial. This work describes a structured approach to characterizing and modelling of RTDs in a continuous blender and a tamping pin capsule filling machine, including insights into data processing. The parametrized RTD models were interconnected to model a continuous direct capsule-filling process, showing the batch transition as well as the propagation of a 2 min feed disturbance throughout the process. Various control strategies were investigated in-silico, aiding in the selection of optimal material diversion point to minimize the material waste. Additionally, the RTD models can facilitate process design and optimization. In this work, adaptions to the capsule filling machine were made and their influence on the RTD was examined to achieve an optimal machine setup.
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85
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Is the adjustment of the impeller speed a reliable attempt to influence granule size in continuous dry granulation? ADV POWDER TECHNOL 2018. [DOI: 10.1016/j.apt.2018.02.029] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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86
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Boumya W, Laghrib F, Lahrich S, Farahi A, Achak M, Bakasse M, El Mhammedi M. Electrochemical behavior study of salicylic acid following azo dye formation with 2,4-dinitrophenylhydrazine: Analytical evaluation. SOUTH AFRICAN JOURNAL OF CHEMICAL ENGINEERING 2018. [DOI: 10.1016/j.sajce.2018.01.002] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Indexed: 11/15/2022] Open
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87
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A Systematic Framework for Data Management and Integration in a Continuous Pharmaceutical Manufacturing Processing Line. Processes (Basel) 2018. [DOI: 10.3390/pr6050053] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
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88
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Investigations on the residence time distribution of a three-chamber feed frame with special focus on its geometric and parametric setups. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.03.019] [Citation(s) in RCA: 21] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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89
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Rehrl J, Karttunen AP, Nicolaï N, Hörmann T, Horn M, Korhonen O, Nopens I, De Beer T, Khinast JG. Control of three different continuous pharmaceutical manufacturing processes: Use of soft sensors. Int J Pharm 2018; 543:60-72. [DOI: 10.1016/j.ijpharm.2018.03.027] [Citation(s) in RCA: 49] [Impact Index Per Article: 8.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2017] [Revised: 02/26/2018] [Accepted: 03/14/2018] [Indexed: 11/30/2022]
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90
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Pauli V, Elbaz F, Kleinebudde P, Krumme M. Methodology for a Variable Rate Control Strategy Development in Continuous Manufacturing Applied to Twin-screw Wet-Granulation and Continuous Fluid-bed Drying. J Pharm Innov 2018. [DOI: 10.1007/s12247-018-9320-6] [Citation(s) in RCA: 21] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
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91
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Nicolaï N, De Leersnyder F, Copot D, Stock M, Ionescu CM, Gernaey KV, Nopens I, De Beer T. Liquid‐to‐solid ratio control as an advanced process control solution for continuous twin‐screw wet granulation. AIChE J 2018. [DOI: 10.1002/aic.16161] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/16/2023]
Affiliation(s)
- Niels Nicolaï
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
- Dept. of Data Analysis and Mathematical Modelling, BIOMATH, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Fien De Leersnyder
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
| | - Dana Copot
- Dept. of Electrical Energy, Metals, Mechanical Constructions and Systems, Research Group on Dynamical Systems and ControlGhent University, Technologiepark 914Zwijnaarde 9052 Belgium
| | - Michiel Stock
- Dept. of Data Analysis and Mathematical Modelling, KERMIT, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Clara M. Ionescu
- Dept. of Electrical Energy, Metals, Mechanical Constructions and Systems, Research Group on Dynamical Systems and ControlGhent University, Technologiepark 914Zwijnaarde 9052 Belgium
| | - Krist V. Gernaey
- Dept. of Chemical and Biochemical Engineering, CAPEC‐PROCESS Research CenterTechnical University of Denmark, Building 229Kgs. Lyngby 2800 Denmark
| | - Ingmar Nopens
- Dept. of Data Analysis and Mathematical Modelling, BIOMATH, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Thomas De Beer
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
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92
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Munteanu FD, Titoiu AM, Marty JL, Vasilescu A. Detection of Antibiotics and Evaluation of Antibacterial Activity with Screen-Printed Electrodes. SENSORS 2018; 18:s18030901. [PMID: 29562637 PMCID: PMC5877114 DOI: 10.3390/s18030901] [Citation(s) in RCA: 52] [Impact Index Per Article: 8.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 01/30/2018] [Revised: 03/12/2018] [Accepted: 03/15/2018] [Indexed: 12/19/2022]
Abstract
This review provides a brief overview of the fabrication and properties of screen-printed electrodes and details the different opportunities to apply them for the detection of antibiotics, detection of bacteria and antibiotic susceptibility. Among the alternative approaches to costly chromatographic or ELISA methods for antibiotics detection and to lengthy culture methods for bacteria detection, electrochemical biosensors based on screen-printed electrodes present some distinctive advantages. Chemical and (bio)sensors for the detection of antibiotics and assays coupling detection with screen-printed electrodes with immunomagnetic separation are described. With regards to detection of bacteria, the emphasis is placed on applications targeting viable bacterial cells. While the electrochemical sensors and biosensors face many challenges before replacing standard analysis methods, the potential of screen-printed electrodes is increasingly exploited and more applications are anticipated to advance towards commercial analytical tools.
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Affiliation(s)
- Florentina-Daniela Munteanu
- Faculty of Food Engineering, Tourism and Environmental Protection, "Aurel Vlaicu" University of Arad, Elena Dragoi, No. 2, Arad 310330, Romania.
| | - Ana Maria Titoiu
- International Centre of Biodynamics, 1B Intrarea Portocalelor, Bucharest 060101, Romania.
| | - Jean-Louis Marty
- BAE Laboratory, Université de Perpignan via Domitia, 52 Avenue Paul Alduy, 66860 Perpignan, France.
| | - Alina Vasilescu
- International Centre of Biodynamics, 1B Intrarea Portocalelor, Bucharest 060101, Romania.
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93
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Process analytical technology in continuous manufacturing of a commercial pharmaceutical product. Int J Pharm 2018; 538:167-178. [DOI: 10.1016/j.ijpharm.2018.01.003] [Citation(s) in RCA: 73] [Impact Index Per Article: 12.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2017] [Revised: 12/17/2017] [Accepted: 01/01/2018] [Indexed: 11/18/2022]
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94
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Ganesh S, Moreno M, Liu J, Gonzalez M, Nagy Z, Reklaitis G. Sensor Network for Continuous Tablet Manufacturing. INTERNATIONAL SYMPOSIUM ON PROCESS SYSTEMS ENGINEERING 2018; 44:2149-2154. [PMID: 36790945 PMCID: PMC9923509 DOI: 10.1016/b978-0-444-64241-7.50353-0] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/31/2023]
Abstract
The progress in the mechanistic understanding of the unit operations and the availability of multiple sensor technologies enable the inline implementation of data reconciliation and gross error detection methods in continuous pharmaceutical manufacturing. In this work, we demonstrate the benefits of accurate real-time monitoring of the process state in a continuous tableting process, with case studies representative of common situations in pilot-plant or manufacturing line implementation.
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Affiliation(s)
- Sudarshan Ganesh
- School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Mariana Moreno
- School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Jianfeng Liu
- School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Zoltan Nagy
- School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Gintaras Reklaitis
- School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA,
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95
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Jolliffe HG, Diab S, Gerogiorgis DI. Nonlinear Optimization via Explicit NRTL Model Solubility Prediction for Antisolvent Mixture Selection in Artemisinin Crystallization. Org Process Res Dev 2017. [DOI: 10.1021/acs.oprd.7b00289] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Hikaru G. Jolliffe
- Institute for Materials and Processes (IMP), School of
Engineering, University of Edinburgh, The King’s Buildings, Edinburgh EH9 3FB, United Kingdom
| | - Samir Diab
- Institute for Materials and Processes (IMP), School of
Engineering, University of Edinburgh, The King’s Buildings, Edinburgh EH9 3FB, United Kingdom
| | - Dimitrios I. Gerogiorgis
- Institute for Materials and Processes (IMP), School of
Engineering, University of Edinburgh, The King’s Buildings, Edinburgh EH9 3FB, United Kingdom
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96
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Abstract
Abstract
Process intensification (PI) is a rapidly growing field of research and industrial development that has already created many innovations in chemical process industry. PI is directed toward substantially smaller, cleaner, more energy-efficient technology. Furthermore, PI aims at safer and sustainable technological developments. Its tools are reduction of the number of devices (integration of several functionalities in one apparatus), improving heat and mass transfer by advanced mixing technologies and shorter diffusion pathways, miniaturization, novel energy techniques, new separation approaches, integrated optimization and control strategies. This review discusses many of the recent developments in PI. Starting from fundamental definitions, microfluidic technology, mixing, modern distillation techniques, membrane separation, continuous chromatography, and application of gravitational, electric, and magnetic fields will be described.
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Affiliation(s)
- Frerich J. Keil
- Institute of Chemical Reaction Engineering , Hamburg University of Technology , 21073 Hamburg , Germany
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97
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Process analysis and optimization of continuous pharmaceutical manufacturing using flowsheet models. Comput Chem Eng 2017. [DOI: 10.1016/j.compchemeng.2017.02.030] [Citation(s) in RCA: 57] [Impact Index Per Article: 8.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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98
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Ganesh S, Troscinski R, Schmall N, Lim J, Nagy Z, Reklaitis G. Application of X-Ray Sensors for In-line and Noninvasive Monitoring of Mass Flow Rate in Continuous Tablet Manufacturing. J Pharm Sci 2017; 106:3591-3603. [DOI: 10.1016/j.xphs.2017.08.019] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/19/2017] [Revised: 08/11/2017] [Accepted: 08/23/2017] [Indexed: 10/18/2022]
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99
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Su Q, Moreno M, Giridhar A, Reklaitis GV, Nagy ZK. A Systematic Framework for Process Control Design and Risk Analysis in Continuous Pharmaceutical Solid-Dosage Manufacturing. J Pharm Innov 2017. [DOI: 10.1007/s12247-017-9297-6] [Citation(s) in RCA: 28] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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100
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García-Muñoz S, Butterbaugh A, Leavesley I, Manley LF, Slade D, Bermingham S. A flowsheet model for the development of a continuous process for pharmaceutical tablets: An industrial perspective. AIChE J 2017. [DOI: 10.1002/aic.15967] [Citation(s) in RCA: 55] [Impact Index Per Article: 7.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
| | | | | | | | - David Slade
- Process Systems Enterprise Ltd; 26-28 Hammersmith Grove, London W6 7HA U.K
| | - Sean Bermingham
- Process Systems Enterprise Ltd; 26-28 Hammersmith Grove, London W6 7HA U.K
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