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Lou H, Ding L, Wu T, Li W, Khalaf R, Smyth HDC, Reid DL. Emerging Process Modeling Capabilities for Dry Powder Operations for Inhaled Formulations. Mol Pharm 2023; 20:5332-5344. [PMID: 37783568 DOI: 10.1021/acs.molpharmaceut.3c00557] [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] [Indexed: 10/04/2023]
Abstract
Dry powder inhaler (DPI) products are commonly formulated as a mixture of micronized drug particles and large carrier particles, with or without additional fine particle excipients, followed by final powder filling into dose containment systems such as capsules, blisters, or reservoirs. DPI product manufacturing consists of a series of unit operations, including particle size reduction, blending, and filling. This review provides an overview of the relevant critical process parameters used for jet milling, high-shear blending, and dosator/drum capsule filling operations across commonly utilized instruments. Further, this review describes the recent achievements regarding the application of empirical and mechanistic models, especially discrete element method (DEM) simulation, in DPI process development. Although to date only limited modeling/simulation work has been accomplished, in the authors' perspective, process design and development are destined to be more modeling/simulation driven with the emphasis on evaluating the impact of material attributes/process parameters on process performance. The advancement of computational power is expected to enable modeling/simulation approaches to tackle more complex problems with better accuracy when dealing with real-world DPI process operations.
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Affiliation(s)
- Hao Lou
- Drug Product Technologies, Process Development, Amgen, One Amgen Center Drive, Thousand Oaks, California 91320, United States
| | - Li Ding
- Drug Product Technologies, Process Development, Amgen, One Amgen Center Drive, Thousand Oaks, California 91320, United States
| | - Tian Wu
- Drug Product Technologies, Process Development, Amgen, One Amgen Center Drive, Thousand Oaks, California 91320, United States
| | - Weikun Li
- Drug Product Technologies, Process Development, Amgen, One Amgen Center Drive, Thousand Oaks, California 91320, United States
| | - Ryan Khalaf
- Drug Product Technologies, Process Development, Amgen, One Amgen Center Drive, Thousand Oaks, California 91320, United States
| | - Hugh D C Smyth
- College of Pharmacy, The University of Texas at Austin, 2409 West University Avenue, PHR 4.214, Austin, Texas 78712, United States
| | - Darren L Reid
- Drug Product Technologies, Process Development, Amgen, 360 Binney Street, Cambridge, Massachusetts 02142, United States
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2
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Fontalvo-Lascano MA, Alvarado-Hernández BB, Conde C, Sánchez EJ, Méndez-Piñero MI, Romañach RJ. Development and Application of a Business Case Model for a Stream Sampler in the Pharmaceutical Industry. J Pharm Innov 2022. [DOI: 10.1007/s12247-022-09634-0] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
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3
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Panikar S, Li J, Rane V, Gillam S, Callegari G, Kurtyka B, Lee S, Muzzio F. Integrating sensors for monitoring blend content in a pharmaceutical continuous manufacturing plant. Int J Pharm 2021; 606:120085. [PMID: 33737095 DOI: 10.1016/j.ijpharm.2020.120085] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/05/2020] [Revised: 10/14/2020] [Accepted: 11/08/2020] [Indexed: 10/21/2022]
Abstract
In a pharmaceutical manufacturing process, Critical Quality Attributes (CQAs) need to be monitored not only for the final product but also for intermediates. Blend uniformity of powders is one such attribute that needs to be measured to ensure the quality of the final product. Multiple in-line sensors were implemented within a Direct Compaction (DC) continuous tablet manufacturing line to monitor the blend content of the powders. In most cases, since the primary ingredient of interest is the active pharmaceutical ingredient (API), the concentration (potency) of the API was monitored/predicted over the course of manufacturing. For the calibration model building process, a unique setup involving dynamic powder spectral acquisition method was used. This setup was aimed at mimicking the powder flow characteristics within the manufacturing line, while at the same time utilizing a relatively small amount of powder. A Raman probe and a portable NIR were used concurrently at the exit of the blending process before the tableting stage. The performance of the two sensors and their respective models were evaluated in terms of accuracy, precision, operating range, measurement frequency, placement, reliability, robustness, and compared to predictions using gravimetric feed rates. Additionally, their performances were validated by off-line traditional analytical measurements.
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Affiliation(s)
- Savitha Panikar
- Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, 08854 NJ, United States
| | - Jingzhe Li
- Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, 08854 NJ, United States
| | - Varsha Rane
- Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, 08854 NJ, United States
| | - Sean Gillam
- Kaiser Optical Systems, Inc., Ann Arbor, MI 48103, United States
| | - Gerardo Callegari
- Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, 08854 NJ, United States
| | - Bogdan Kurtyka
- Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Sau Lee
- Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Fernando Muzzio
- Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, 08854 NJ, United States.
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4
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Martínez-Cartagena PA, Sierra-Vega NO, Alvarado-Hernández BB, Méndez R, Romañach RJ. An innovative sampling interface for monitoring flowing pharmaceutical powder mixtures. J Pharm Biomed Anal 2020; 194:113785. [PMID: 33280992 DOI: 10.1016/j.jpba.2020.113785] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/11/2020] [Accepted: 11/17/2020] [Indexed: 10/22/2022]
Abstract
A chute was designed following the principles of the Theory of Sampling to minimize the variations in powder flow and provide all particles in the flowing blends with the same opportunity of being selected as a sample. The design also reduces the thickness of the chute to allow the analysis of a higher portion of the flowing blends by a near infrared spectrometer. The blends that flowed through the chute had Carr's index values that fluctuated between 23 and 25 percent, indicating passable flowability. A powder fowling evaluation demonstrated that there was no powder accumulation at the inspection window of the chute. The mass flow rate profiles indicated that the system achieves mass steady-state in approximately 30 s and a throughput of 30 kg/h which makes it suitable for continuous manufacturing operations. An in-line NIR calibration model was developed to quantify caffeine concentrations between 1.51 and 4.52 % w/w. The spectra obtained from each experiment had minimal baseline variation. The developed NIR method was robust to throughput changes up to approximately ±7 %. The test blends in the caffeine concentration range between 2.02 % w/w and 4.02 % w/w met the dose uniformity requirements of the Ph.Eur. 9.0, chapter 2.9.47. Variographic analysis was done to estimate the analytical and sampling errors which yielded values below 0.01 (%w/w)2. The obtained results showed that this chute could also be used in a continuous manufacturing line or other applications with flowing powders.
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Affiliation(s)
- Pedro A Martínez-Cartagena
- Department of Chemistry, University of Puerto Rico at Mayaguez Call Box 9000, Mayaguez, 00680, Puerto Rico
| | - Nobel O Sierra-Vega
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico
| | | | - Rafael Méndez
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico
| | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico at Mayaguez Call Box 9000, Mayaguez, 00680, Puerto Rico.
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5
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Sierra-Vega NO, Romañach RJ, Méndez R. Real-time quantification of low-dose cohesive formulations within a sampling interface for flowing powders. Int J Pharm 2020; 588:119726. [DOI: 10.1016/j.ijpharm.2020.119726] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/25/2020] [Revised: 07/29/2020] [Accepted: 07/31/2020] [Indexed: 11/27/2022]
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6
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Alvarado-Hernández BB, Sierra-Vega NO, Martínez-Cartagena P, Hormaza M, Méndez R, Romañach RJ. A sampling system for flowing powders based on the theory of sampling. Int J Pharm 2019; 574:118874. [PMID: 31837408 DOI: 10.1016/j.ijpharm.2019.118874] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/10/2019] [Revised: 11/10/2019] [Accepted: 11/12/2019] [Indexed: 12/16/2022]
Abstract
An innovative chute and stream sampler system for flowing powders has been developed and tested. The system is designed for representative sampling based on the principles of the Theory of Sampling (TOS). The sampling system was used in combination with near infrared (NIR) spectroscopy to determine the drug concentration of flowing powders. The system is comprised of three parts: a chute, a stream sampler and a sample collection port. The NIR spectra were obtained at the chute, before entering the sampler, and as the powder flowed through the stream sampler. Samples were also collected from the sample collection port to be analyzed using an ultraviolet-visible (UV-Vis) reference method to determine drug content. A total of eight pharmaceutical powder blends, ranging in concentration from 10.5(%w/w) to 19.5(%w/w) of caffeine, were used to test the sampling system. Materials were characterized before blends were made to provide information on flow properties. The throughput of the system was between 30 and 35 kg/h based on the flow properties of the blend. Drug concentration was effectively determined at the chute and stream sampler. The NIR calibration models showed low root mean squared errors of prediction, 0.65(%w/w) and 0.51(%w/w), for the chute and stream sampler respectively. The NIR calibration models also showed low bias values -0.36(%w/w) at the chute and 0.057(%w/w) at the stream sampler. Significant agreement was obtained between the results from the nondestructive NIR versus the destructive UV-Vis method. Variographic analysis was performed to estimate the analytical and sampling errors when determining the drug concentration at the chute and stream sampler respectively. The variographic analysis showed low analytical errors, 0.103(%w/w)2 and 0.181(%w/w)2 at the chute and stream sampler respectively. The analysis also showed that the minimum practical error (MPE) was around 0.2(%w/w)2 at both chute and stream sampler.
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Affiliation(s)
| | - Nobel O Sierra-Vega
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico
| | - Pedro Martínez-Cartagena
- Department of Chemistry, University of Puerto Rico at Mayaguez, Call Box 9000, Mayaguez 00680, Puerto Rico
| | - Manuel Hormaza
- IBS Caribe INC., P.O. Box 8849, San Juan PR 00910, Puerto Rico
| | - Rafael Méndez
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico
| | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico at Mayaguez, Call Box 9000, Mayaguez 00680, Puerto Rico.
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7
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Sierra-Vega NO, Romañach RJ, Méndez R. Feed frame: The last processing step before the tablet compaction in pharmaceutical manufacturing. Int J Pharm 2019; 572:118728. [PMID: 31682965 DOI: 10.1016/j.ijpharm.2019.118728] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/23/2019] [Revised: 09/19/2019] [Accepted: 09/21/2019] [Indexed: 10/25/2022]
Abstract
The feed frame is a force-feeding device used in the die filling process. The die filling process is crucial within pharmaceutical manufacturing to guarantee the critical quality attributes of the tablets. In recent years, interest in this unit has increased because it can affect the properties of the powder blend and tablets, and because of the success in real time monitoring of powder blend uniformity potential for Process Analytical Technology as described in this review. The review focuses on the recent advances in understanding the powder flow behavior inside the feed frame and how the residence time distribution of the powder within the feed frame is affected by the operating conditions and design parameters. Furthermore, this review also highlights the effect of the paddle wheel design and feed frame process parameters on the tablet weight, the principal variable for measuring die filling performance.
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Affiliation(s)
- Nobel O Sierra-Vega
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, PR 00681, United States
| | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico at Mayaguez, PR 00681 United States
| | - Rafael Méndez
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, PR 00681, United States.
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8
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Raw Material Variability and Its Impact on the Online Adaptive Control of Cohesive Powder Blend Homogeneity Using NIR Spectroscopy. Processes (Basel) 2019. [DOI: 10.3390/pr7090568] [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
It is significant to analyze the blend homogeneity of cohesive powders during pharmaceutical manufacturing in order to provide the exact content of the active pharmaceutical ingredient (API) for each individual dose unit. In this paper, an online monitoring platform using an MEMS near infrared (NIR) sensor was designed to control the bin blending process of cohesive powders. The state of blend homogeneity was detected by an adaptive algorithm, which was calibration free. The online control procedures and algorithm’s parameters were fine-tuned through six pilot experiments and were successfully transferred to the industrial production. The reliability of homogeneity detection results was validated by 16 commercial scale experiments using 16 kinds of natural product powders (NPPs), respectively. Furthermore, 19 physical quality attributes of all NPPs and the excipient were fully characterized. The blending end time was used to denote the degree of difficulty of blending. The empirical relationships between variability of NPPs and the blending end time were captured by latent variable modeling. The critical material attributes (CMAs) affecting the blending process were identified as the particle shape and flowability descriptors of cohesive powders. Under the framework of quality by design (QbD) and process analytical technology (PAT), the online NIR spectroscopy together with the powder characterization facilitated a deeper understanding of the mixing process.
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9
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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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10
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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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11
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Stranzinger S, Faulhammer E, Li J, Dong R, Khinast JG, Zeitler JA, Markl D. Measuring bulk density variations in a moving powder bed via terahertz in-line sensing. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.11.106] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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12
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Stranzinger S, Faulhammer E, Li J, Dong R, Zeitler JA, Biserni S, Calzolari V, Khinast JG, Markl D. Predicting capsule fill weight from in-situ powder density measurements using terahertz reflection technology. INTERNATIONAL JOURNAL OF PHARMACEUTICS-X 2019; 1:100004. [PMID: 31517269 PMCID: PMC6733302 DOI: 10.1016/j.ijpx.2018.100004] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/26/2018] [Revised: 12/18/2018] [Accepted: 12/19/2018] [Indexed: 11/07/2022]
Abstract
The manufacturing of the majority of solid oral dosage forms is based on the densification of powder. A good understanding of the powder behavior is therefore essential to assure high quality drug products. This is particularly relevant for the capsule filling process, where the powder bulk density plays an important role in controlling the fill weight and weight variability of the final product. In this study we present a novel approach to quantitatively measure bulk density variations in a rotating container by means of terahertz reflection technology. The terahertz reflection probe was used to measure the powder density using an experimental setup that mimics a lab-scale capsule filling machine including a static sampling tool. Three different grades of α-lactose monohydrate excipients specially designed for inhalation application were systematically investigated at five compression stages. Relative densities predicted from terahertz reflection measurements were correlated to off-line weight measurements of the collected filled capsules. The predictions and the measured weights of the powder in the capsules were in excellent agreement, where the relative density measurements of Lactohale 200 showed the strongest correlation with the respective fill weight (R2=0.995). We also studied how the density uniformity of the powder bed was impacted by the dosing process and the subsequent filling of the holes (with excipient powder), which were introduced in the powder bed after the dosing step. Even though the holes seemed to be filled with new powder (by visual inspection), the relative density in these specific segments were found to clearly differ from the undisturbed powder bed state prior to dosing. The results demonstrate that it is feasible to analyze powder density variations in a rotating container by means of terahertz reflection measurements and to predict the fill weight of collected capsules.
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Affiliation(s)
- Sandra Stranzinger
- Research Center Pharmaceutical Engineering (RCPE), Inffeldgasse 13, 8010 Graz, Austria.,Graz University of Technology, Institute for Process and Particle Engineering, Inffeldgasse 13, 8010 Graz, Austria
| | - Eva Faulhammer
- Research Center Pharmaceutical Engineering (RCPE), Inffeldgasse 13, 8010 Graz, Austria
| | - Jingyi Li
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Philippa Fawcett Drive, CB3 0AS Cambridge, UK
| | - Runqiao Dong
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Philippa Fawcett Drive, CB3 0AS Cambridge, UK
| | - J Axel Zeitler
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Philippa Fawcett Drive, CB3 0AS Cambridge, UK
| | - Stefano Biserni
- MG2, Via del Savena, 18. I-40065 Pian di Macina di Pianoro, Bologna, Italy
| | - Vittorio Calzolari
- MG2, Via del Savena, 18. I-40065 Pian di Macina di Pianoro, Bologna, Italy
| | - Johannes G Khinast
- Research Center Pharmaceutical Engineering (RCPE), Inffeldgasse 13, 8010 Graz, Austria.,Graz University of Technology, Institute for Process and Particle Engineering, Inffeldgasse 13, 8010 Graz, Austria
| | - Daniel Markl
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, UK.,EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation, University of Strathclyde, 99 George Street, G1 1RD Glasgow, UK
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13
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Corredor CC, Vikstrom C, Persson A, Bu X, Both D. Development and Robustness Verification of an At-Line Transmission Raman Method for Pharmaceutical Tablets Using Quality by Design (QbD) Principles. J Pharm Innov 2018. [DOI: 10.1007/s12247-018-9334-0] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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14
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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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15
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Parr MK, Schmidt AH. Life cycle management of analytical methods. J Pharm Biomed Anal 2018; 147:506-517. [DOI: 10.1016/j.jpba.2017.06.020] [Citation(s) in RCA: 53] [Impact Index Per Article: 8.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/14/2017] [Revised: 06/10/2017] [Accepted: 06/12/2017] [Indexed: 11/30/2022]
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16
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Alam MA, Shi Z, Drennen JK, Anderson CA. In-line monitoring and optimization of powder flow in a simulated continuous process using transmission near infrared spectroscopy. Int J Pharm 2017; 526:199-208. [DOI: 10.1016/j.ijpharm.2017.04.054] [Citation(s) in RCA: 29] [Impact Index Per Article: 4.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/30/2017] [Revised: 04/19/2017] [Accepted: 04/22/2017] [Indexed: 11/29/2022]
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17
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Wang H, Barona D, Oladepo S, Williams L, Hoe S, Lechuga-Ballesteros D, Vehring R. Macro-Raman spectroscopy for bulk composition and homogeneity analysis of multi-component pharmaceutical powders. J Pharm Biomed Anal 2017; 141:180-191. [PMID: 28448887 DOI: 10.1016/j.jpba.2017.04.003] [Citation(s) in RCA: 29] [Impact Index Per Article: 4.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/20/2016] [Revised: 03/30/2017] [Accepted: 04/04/2017] [Indexed: 11/25/2022]
Abstract
A new macro-Raman system equipped with a motorized translational sample stage and low-frequency shift capabilities was developed for bulk composition and homogeneity analysis of multi-component pharmaceutical powders. Different sampling methods including single spot and scanning measurement were compared. It was found that increasing sample volumes significantly improved the precision of quantitative composition analysis, especially for poorly mixed powders. The multi-pass cavity of the macro-Raman system increased effective sample volumes by 20 times from the sample volume defined by the collection optics, i.e., from 0.02μL to about 0.4μL. A stochastic model simulating the random sampling process of polydisperse microparticles was used to predict the sampling errors for a specific sample volume. Comparison of fluticasone propionate mass fractions of the commercial products Flixotide® 250 and Seretide® 500 simulated for different sampling volumes with experimentally measured compositions verified that the effective sample volume of a single point macro-Raman measurement in the multi-pass cavity of this instrument was between 0.3μL and 0.5μL. The macro-Raman system was also successfully used for blend uniformity analysis. It was concluded that demixing occurred in the binary mixture of l-leucine and d-mannitol from the observation that the sampling errors indicated by the standard deviations of measured leucine mass fractions increased during mixing, and the standard deviation values were all larger than the theoretical lower limit determined by the simulation. Since sample volume was shown to have a significant impact on measured homogeneity characteristics, it was concluded that powder homogeneity analysis results, i.e., the mean of individual test results and absolute and relative standard deviations, must be presented together with the effective sample volumes of the applied testing techniques for any measurement of powder homogeneity to be fully meaningful.
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Affiliation(s)
- Hui Wang
- Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2G8, Canada
| | - David Barona
- Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2G8, Canada
| | - Sulayman Oladepo
- Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2G8, Canada; Department of Chemistry, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia
| | | | - Susan Hoe
- Pearl Therapeutics Inc., Redwood City, CA, USA
| | | | - Reinhard Vehring
- Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2G8, Canada.
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18
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Tewari J, Strong R, Boulas P. At-line determination of pharmaceuticals small molecule's blending end point using chemometric modeling combined with Fourier transform near infrared spectroscopy. SPECTROCHIMICA ACTA. PART A, MOLECULAR AND BIOMOLECULAR SPECTROSCOPY 2017; 173:886-891. [PMID: 27816889 DOI: 10.1016/j.saa.2016.10.013] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/06/2016] [Revised: 10/09/2016] [Accepted: 10/15/2016] [Indexed: 06/06/2023]
Abstract
This article summarizes the development and validation of a Fourier transform near infrared spectroscopy (FT-NIR) method for the rapid at-line prediction of active pharmaceutical ingredient (API) in a powder blend to optimize small molecule formulations. The method was used to determine the blend uniformity end-point for a pharmaceutical solid dosage formulation containing a range of API concentrations. A set of calibration spectra from samples with concentrations ranging from 1% to 15% of API (w/w) were collected at-line from 4000 to 12,500cm-1. The ability of the FT-NIR method to predict API concentration in the blend samples was validated against a reference high performance liquid chromatography (HPLC) method. The prediction efficiency of four different types of multivariate data modeling methods such as partial least-squares 1 (PLS1), partial least-squares 2 (PLS2), principal component regression (PCR) and artificial neural network (ANN), were compared using relevant multivariate figures of merit. The prediction ability of the regression models were cross validated against results generated with the reference HPLC method. PLS1 and ANN showed excellent and superior prediction abilities when compared to PLS2 and PCR. Based upon these results and because of its decreased complexity compared to ANN, PLS1 was selected as the best chemometric method to predict blend uniformity at-line. The FT-NIR measurement and the associated chemometric analysis were implemented in the production environment for rapid at-line determination of the end-point of the small molecule blending operation.
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Affiliation(s)
- Jagdish Tewari
- Pharmaceutical Analytical Department, Biogen, 115 Broadway, Cambridge, MA 02142, United States.
| | - Richard Strong
- Pharmaceutical Analytical Department, Biogen, 115 Broadway, Cambridge, MA 02142, United States
| | - Pierre Boulas
- Pharmaceutical Analytical Department, Biogen, 115 Broadway, Cambridge, MA 02142, United States
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19
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Near infrared spectroscopic calibration models for real time monitoring of powder density. Int J Pharm 2016; 512:61-74. [DOI: 10.1016/j.ijpharm.2016.08.029] [Citation(s) in RCA: 40] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/15/2016] [Revised: 07/20/2016] [Accepted: 08/13/2016] [Indexed: 11/19/2022]
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20
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Zhang L, Mao S. Application of quality by design in the current drug development. Asian J Pharm Sci 2016; 12:1-8. [PMID: 32104308 PMCID: PMC7032183 DOI: 10.1016/j.ajps.2016.07.006] [Citation(s) in RCA: 101] [Impact Index Per Article: 12.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2016] [Revised: 07/07/2016] [Accepted: 07/31/2016] [Indexed: 11/15/2022] Open
Abstract
Quality by Test was the only way to guarantee quality of drug products before FDA launched current Good Manufacturing Practice. To clearly understand the manufacture processes, FDA generalized Quality by Design (QbD) in the field of pharmacy, which is based on the thorough understanding of how materials and process parameters affect the quality profile of final products. The application of QbD in drug formulation and process design is based on a good understanding of the sources of variability and the manufacture process. In this paper, the basic knowledge of QbD, the elements of QbD, steps and tools for QbD implementation in pharmaceutics field, including risk assessment, design of experiment, and process analytical technology (PAT), are introduced briefly. Moreover, the concrete applications of QbD in various pharmaceutical related unit operations are summarized and presented.
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Affiliation(s)
- Lan Zhang
- Shenyang Pharmaceutical University, No.103, Wenhua Road, Shenyang 110016, China
| | - Shirui Mao
- Shenyang Pharmaceutical University, No.103, Wenhua Road, Shenyang 110016, China
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Boiret M, Chauchard F. Use of near-infrared spectroscopy and multipoint measurements for quality control of pharmaceutical drug products. Anal Bioanal Chem 2016; 409:683-691. [PMID: 27422646 DOI: 10.1007/s00216-016-9756-9] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/05/2016] [Revised: 05/23/2016] [Accepted: 06/30/2016] [Indexed: 11/30/2022]
Abstract
Near-infrared (NIR) spectroscopy is a non-destructive analytical technique that enables better-understanding and optimization of pharmaceutical processes and final drug products. The use in line is often limited by acquisition speed and sampling area. This work focuses on performing a multipoint measurement at high acquisition speed at the end of the manufacturing process on a conveyor belt system to control both the distribution and the content of active pharmaceutical ingredient within final drug products, i.e., tablets. A specially designed probe with several collection fibers was developed for this study. By measuring spectral and spatial information, it provides physical and chemical knowledge on the final drug product. The NIR probe was installed on a conveyor belt system that enables the analysis of a lot of tablets. The use of these NIR multipoint measurement probes on a conveyor belt system provided an innovative method that has the potential to be used as a new paradigm to ensure the drug product quality at the end of the manufacturing process and as a new analytical method for the real-time release control strategy. Graphical abstract Use of near-infrared spectroscopy and multipoint measurements for quality control of pharmaceutical drug products.
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Oliva A, Monzón C, Santoveña A, Fariña JB, Llabrés M. Development of an ultra high performance liquid chromatography method for determining triamcinolone acetonide in hydrogels using the design of experiments/design space strategy in combination with process capability index. J Sep Sci 2016; 39:2689-701. [PMID: 27184267 DOI: 10.1002/jssc.201600273] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/07/2016] [Revised: 04/28/2016] [Accepted: 05/05/2016] [Indexed: 11/06/2022]
Abstract
An ultra high performance liquid chromatography method was developed and validated for the quantitation of triamcinolone acetonide in an injectable ophthalmic hydrogel to determine the contribution of analytical method error in the content uniformity measurement. During the development phase, the design of experiments/design space strategy was used. For this, the free R-program was used as a commercial software alternative, a fast efficient tool for data analysis. The process capability index was used to find the permitted level of variation for each factor and to define the design space. All these aspects were analyzed and discussed under different experimental conditions by the Monte Carlo simulation method. Second, a pre-study validation procedure was performed in accordance with the International Conference on Harmonization guidelines. The validated method was applied for the determination of uniformity of dosage units and the reasons for variability (inhomogeneity and the analytical method error) were analyzed based on the overall uncertainty.
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Affiliation(s)
- Alexis Oliva
- Departamento de Ingeniería Química y Tecnología Farmacéutica, Facultad de Ciencias de la Salud-Sección Farmacia, Universidad de La Laguna, Tenerife, Spain
| | - Cecilia Monzón
- Departamento de Ingeniería Química y Tecnología Farmacéutica, Facultad de Ciencias de la Salud-Sección Farmacia, Universidad de La Laguna, Tenerife, Spain
| | - Ana Santoveña
- Departamento de Ingeniería Química y Tecnología Farmacéutica, Facultad de Ciencias de la Salud-Sección Farmacia, Universidad de La Laguna, Tenerife, Spain
| | - José B Fariña
- Departamento de Ingeniería Química y Tecnología Farmacéutica, Facultad de Ciencias de la Salud-Sección Farmacia, Universidad de La Laguna, Tenerife, Spain
| | - Matías Llabrés
- Departamento de Ingeniería Química y Tecnología Farmacéutica, Facultad de Ciencias de la Salud-Sección Farmacia, Universidad de La Laguna, Tenerife, Spain
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Nie L, Dai Z, Ma S. Enhanced Accuracy of Near-Infrared Spectroscopy for Traditional Chinese Medicine with Competitive Adaptive Reweighted Sampling. ANAL LETT 2016. [DOI: 10.1080/00032719.2016.1143479] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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Romañach RJ. Near Infrared Spectroscopy: From Feasibility to Implementation in the Pharmaceutical Industry. ACTA ACUST UNITED AC 2016. [DOI: 10.1255/nirn.1582] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/01/2022]
Abstract
Near infrared (NIR) spectroscopy will play an increasingly important role in pharmaceutical processes as the quality of pharmaceutical products is progressively defined on the basis of their performance and pharmaceutical quality control is transformed to meet this challenge. This new quality control will require a thorough understanding of the sources of error in NIR methods, an understanding that starts with fundamentals such as the physics of diffuse reflectance and the Theory of Sampling, and progresses to working with pharmaceutical engineers to implement online predictions and control of pharmaceutical operations. This article outlines the research areas that need to be integrated to advance the implementation of NIR spectroscopy in the pharmaceutical industry.
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Affiliation(s)
- Rodolfo J. Romañach
- Engineering Research Center for Structured Organic Particulate Systems (ERC-SOPS), Department of Chemistry, University of Puerto Rico-Mayaguez Campus, PO Box 9000, Mayaguez, PR 00681, USA
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