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Jones-Salkey O, Nicusan AL, Windows-Yule CRK, Ingram A, Werner D, Clifford S, Reynolds GK. Application of Positron Emission Particle Tracking (PEPT) for the evaluation of powder behaviour in an incline linear blender for Continuous Direct Compression (CDC). Int J Pharm 2023; 645:123361. [PMID: 37673280 DOI: 10.1016/j.ijpharm.2023.123361] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/01/2023] [Revised: 08/11/2023] [Accepted: 08/31/2023] [Indexed: 09/08/2023]
Abstract
Positron Emission Particle Tracking (PEPT) is a non-invasive measurement technique which offers the ability to track the motion of individual particles with high temporal and spatial resolution, and thus build up an understanding of the bulk behaviour of a system from its microscopic (particle level) dynamics. Using this measurement technique, we have developed a series of novel metrics to better understand the behaviours of powders during the steady-state operation of a continuous blender system. Results are presented concerning the response of particle motion to processing parameters (mixing blade configuration and RPM), quantifying the motion in terms of predicted mixing performance. It was found that both increasing rpm and increasing hold-up mass (by selecting fewer transport blades and more mixing blades) provided improved mixing conditions. Interestingly, under specific conditions, there is evidence of convection-like mixing occurring at the interface of the transport and mixing region. This suggests the existence of a potential 'folding region' whereby powder is transported up the barrel (and away from the powder bulk bed) before being reconstituted back into the bulk mass. The results also provide valuable experimental data for the development, calibration and validation of future Discrete Element Method (DEM) simulations.
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Affiliation(s)
- O Jones-Salkey
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK.
| | - A L Nicusan
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - C R K Windows-Yule
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - A Ingram
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - D Werner
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - S Clifford
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
| | - G K Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
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Hybrid multi-zonal compartment modeling for continuous powder blending processes. Int J Pharm 2021; 602:120643. [PMID: 33901598 DOI: 10.1016/j.ijpharm.2021.120643] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/10/2021] [Revised: 04/03/2021] [Accepted: 04/21/2021] [Indexed: 02/02/2023]
Abstract
To modernize drug manufacturing, the pharmaceutical industry has been moving towards implementing emerging technologies to enhance manufacturing robustness and process reliability for production of regulation compliant drug products. Although different science and risk based technologies, like Quality-by-Design, have been used to illustrate their potential, there still exist some underlying obstacles. Specifically, for the production of oral solid drug products, an in-depth process understanding, and predictive modeling of powder mixing in continuous powder blenders is one such major obstacle and originates from the current limitations of the experimental and modeling approaches. Though first principle based discrete element modeling (DEM) approach can address the above issues, it can get very computationally intensive which limits its applications for predictive modeling. In the proposed work, we aim to address this limitation using a multi-zonal compartment modeling approach, which is constructed from DEM. The approach provides a computationally efficient and mechanistically informed hybrid model. The application of the proposed approach is first demonstrated for a periodic section of the blender, followed by its extension for the entire continuous powder blender and the obtained model predictions are validated. The proposed approach provides an overall assessment of powder mixing along axial and radial directions, which is an important requirement for the quantification of blend uniformity. Given the low computational cost, the developed model can further be integrated within the predictive flowsheet model of the manufacturing line.
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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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Konz AK, Windhab E. Experimental and computational study of a high speed pin mixer via PEPT, visualization and CFD. Chem Eng Sci 2016. [DOI: 10.1016/j.ces.2016.08.007] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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Gao Y, Boukouvala F, Engisch W, Meng W, Muzzio FJ, Ierapetritou MG. Improving Continuous Powder Blending Performance Using Projection to Latent Structures Regression. J Pharm Innov 2013. [DOI: 10.1007/s12247-013-9152-3] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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8
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Multi-dimensional population balance modeling and experimental validation of continuous powder mixing processes. Chem Eng Sci 2012. [DOI: 10.1016/j.ces.2012.06.024] [Citation(s) in RCA: 46] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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Gao Y, Muzzio FJ, Ierapetritou MG. A review of the Residence Time Distribution (RTD) applications in solid unit operations. POWDER TECHNOL 2012. [DOI: 10.1016/j.powtec.2012.05.060] [Citation(s) in RCA: 114] [Impact Index Per Article: 9.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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Boukouvala F, Niotis V, Ramachandran R, Muzzio FJ, Ierapetritou MG. An integrated approach for dynamic flowsheet modeling and sensitivity analysis of a continuous tablet manufacturing process. Comput Chem Eng 2012. [DOI: 10.1016/j.compchemeng.2012.02.015] [Citation(s) in RCA: 105] [Impact Index Per Article: 8.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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Comparison of flow microdynamics for a continuous granular mixer with predictions from periodic slice DEM simulations. POWDER TECHNOL 2012. [DOI: 10.1016/j.powtec.2012.01.021] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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