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Hou P, Besenhard MO, Halbert G, Naftaly M, Markl D. A continuous micro-feeder for cohesive pharmaceutical materials. Int J Pharm 2024; 662:124528. [PMID: 39069146 DOI: 10.1016/j.ijpharm.2024.124528] [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: 05/19/2024] [Revised: 07/24/2024] [Accepted: 07/25/2024] [Indexed: 07/30/2024]
Abstract
Over the past decade, continuous manufacturing has garnered significant attention in the pharmaceutical industry. Still, numerous continuous unit operations need developments, such as powder blending and feeding at low and high throughputs. Especially the continuous and consistent feeding of solid drug substances and excipients at low feed rates remains challenging. This study demonstrates a micro-feeder capable of feeding poorly-flowing pharmaceutical powders at low feed rates. The system performance was investigated using three grades of pharmaceutical powder: croscarmellose sodium (cohesive), magnesium stearate (very cohesive), and an active ingredient, paracetamol (non-flowing). The results show that the micro-feeder can continuously and consistently feed powders at low flow rates (<20 g/h) with low variability (<10 % for non-flowing materials and < 5 % for cohesive materials). Notably, the micro-feeder achieves these results without any feedback control and remains unaffected by refilling, making it a truly versatile and industry-relevant solution. The study's results demonstrate that this micro-feeder system effectively tackles the challenge of consistent and accurate powder feeding at low rates.
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Affiliation(s)
- P Hou
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M O Besenhard
- Department of Chemical Engineering, University College London, London WC1E 7JE, UK
| | - G Halbert
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M Naftaly
- National Physical Laboratory, Teddington TW11 0LW, UK
| | - D Markl
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK.
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2
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Rangel-Gil RS, Nasrala-Álvarez JM, Romañach RJ, Méndez R. Blend uniformity monitoring in a continuous manufacturing mixing process for a low-dosage formulation using a stream sampler and near infrared spectroscopy. Int J Pharm 2024; 661:124478. [PMID: 39019300 DOI: 10.1016/j.ijpharm.2024.124478] [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: 04/24/2024] [Revised: 07/08/2024] [Accepted: 07/13/2024] [Indexed: 07/19/2024]
Abstract
Continuous manufacturing has the potential to offer several benefits for the production of oral solid dosage forms, including reduced costs, low-scale equipment, and the application of process analytical technology (PAT) for real-time process control. This study focuses on the implementation of a stream sampler to develop a near infrared (NIR) calibration model for blend uniformity monitoring in a continuous manufacturing mixing process. Feeding and mixing characterizations were performed for three loss-in-weight feeders and a commercial continuous mixer to prepare powder blends of 2.5-7.5 % w/w ibuprofen DC 85 W with a total throughput of 33 kg/h. The NIR spectral acquisition was performed after the mixing stage using a stream sampler for flowing powders. A continuous mixer shaft speed of 250 RPM was selected to operate the mixing process based on a variability analysis developed with in-line spectral data acquired using the stream sampler at 6 RPM. A partial least squares regression (PLS-R) model was performed and evaluated, yielding a root-mean-square error of prediction (RMSEP) of 0.39 % w/w and a bias of 0.05 % w/w. An independent experimental run conducted two days later revealed that the continuous mixing process and the NIR calibration model presented low day-to-day variation. The minimum practical error (MPE) and sill values through variographic analysis showed low variance associated with the sampling process using the stream sampler. Results demonstrated the promising capacity of the stream sampler coupled to an NIR probe to be implemented within continuous manufacturing processes for the real-time determination of API concentration.
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Affiliation(s)
- Raúl S Rangel-Gil
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico 00681, United States
| | - Juan M Nasrala-Álvarez
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico 00681, United States
| | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico at Mayaguez, Puerto Rico 00681, United States
| | - Rafael Méndez
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, Puerto Rico 00681, United States.
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3
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Janssen PHM, Fathollahi S, Dickhoff BHJ, Frijlink HW. Critical review on the role of excipient properties in pharmaceutical powder-to-tablet continuous manufacturing. Expert Opin Drug Deliv 2024:1-11. [PMID: 39129595 DOI: 10.1080/17425247.2024.2384698] [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: 05/15/2024] [Accepted: 07/22/2024] [Indexed: 08/13/2024]
Abstract
INTRODUCTION The pharmaceutical industry is gradually changing batch-wise manufacturing processes to continuous manufacturing processes, due to the advantages it has to offer. The final product quality and process efficiency of continuous manufacturing processes is among others impacted by the properties of the raw materials. Existing knowledge on the role of raw material properties in batch processing is however not directly transferable to continuous processes, due to the inherent differences between batch and continuous processes. AREAS COVERED A review is performed to evaluate the role of excipient properties for different unit operations used in continuous manufacturing processes. Unit operations that will be discussed include feeding, blending, granulation, final blending, and compression. EXPERT OPINION Although the potency of continuous manufacturing is widely recognized, full utilization still requires a number of challenges to be addressed effectively. An expert opinion will be provided that discusses those challenges and potential solutions to overcome those challenges. The provided overview can serve as a framework for the pharmaceutical industry to push ahead process optimization and formulation development for continuous manufacturing processes.
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Affiliation(s)
- Pauline H M Janssen
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, Groningen, The Netherlands
- Innovation & Technical Solutions, DFE Pharma, Goch, Germany
| | | | | | - Henderik W Frijlink
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, Groningen, The Netherlands
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4
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Bekaert B, Janssen P, Fathollahi S, Vanderroost D, Roelofs T, Dickhoff B, Vervaet C, Vanhoorne V. Batch vs. continuous direct compression - a comparison of material processability and final tablet quality. Int J Pharm X 2024; 7:100226. [PMID: 38235316 PMCID: PMC10792456 DOI: 10.1016/j.ijpx.2023.100226] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2023] [Revised: 12/06/2023] [Accepted: 12/18/2023] [Indexed: 01/19/2024] Open
Abstract
In this study, an in-depth comparison was made between batch and continuous direct compression using similar compression set-ups. The overall material processability and final tablet quality were compared and evaluated. Correlations between material properties, process parameters and final tablet properties were made via multivariate data analyses. In total, 10 low-dosed (1% w/w) and 10 high-dosed (40% w/w) formulations were processed, using a total of 10 different fillers/filler combinations. The trials indicated that the impact of filler type, drug load or process settings was similar for batch and continuous direct compression. The main differentiator between batch and continuous was the flow dynamics in the operating system, where properties related to flow, compressibility and permeability played a crucial role. The less consistent flow throughout a batch process resulted in a significantly higher variability within the tablet press (σCF) and for the tablet quality responses (σMass, σTS). However, the better controlled blending procedure prior to batch processing was reflected in a more consistent API concentration variability. Overall, the comparison showed the benefits of selecting appropriate excipients and process settings to achieve a specific outcome, keeping in mind some key differentiators between both processes.
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Affiliation(s)
- B. Bekaert
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - P.H.M. Janssen
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, Antonius Deusinglaan 1, 9713 AV Groningen, the Netherlands
- DFE Pharma, Klever Strasse 187, 47568 Goch, Germany
| | | | - D. Vanderroost
- GEA Process Engineering, Keerbaan 70, B-2160 Wommelgem, Belgium
| | - T. Roelofs
- DFE Pharma, Klever Strasse 187, 47568 Goch, Germany
| | | | - C. Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - V. Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
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5
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Leane M, Pitt K, Reynolds G, Tantuccio A, Moreton C, Crean A, Kleinebudde P, Carlin B, Gamble J, Gamlen M, Stone E, Kuentz M, Gururajan B, Khimyak YZ, Van Snick B, Andersen S, Misic Z, Peter S, Sheehan S. Ten years of the manufacturing classification system: a review of literature applications and an extension of the framework to continuous manufacture. Pharm Dev Technol 2024; 29:395-414. [PMID: 38618690 DOI: 10.1080/10837450.2024.2342953] [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: 02/08/2024] [Accepted: 04/10/2024] [Indexed: 04/16/2024]
Abstract
The MCS initiative was first introduced in 2013. Since then, two MCS papers have been published: the first proposing a structured approach to consider the impact of drug substance physical properties on manufacturability and the second outlining real world examples of MCS principles. By 2023, both publications had been extensively cited by over 240 publications. This article firstly reviews this citing work and considers how the MCS concepts have been received and are being applied. Secondly, we will extend the MCS framework to continuous manufacture. The review structure follows the flow of drug product development focussing first on optimisation of API properties. The exploitation of links between API particle properties and manufacturability using large datasets seems particularly promising. Subsequently, applications of the MCS for formulation design include a detailed look at the impact of percolation threshold, the role of excipients and how other classification systems can be of assistance. The final review section focusses on manufacturing process development, covering the impact of strain rate sensitivity and modelling applications. The second part of the paper focuses on continuous processing proposing a parallel MCS framework alongside the existing batch manufacturing guidance. Specifically, we propose that continuous direct compression can accommodate a wider range of API properties compared to its batch equivalent.
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Affiliation(s)
- Michael Leane
- Drug Product Development, Bristol Myers Squibb, Moreton, UK
| | - Kendal Pitt
- Leicester School of Pharmacy, De Montfort University, Leicester, UK
| | - Gavin Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, AstraZeneca, Macclesfield, UK
| | - Anthony Tantuccio
- Technology Intensification, Hovione LLC, East Windsor, New Jersey, USA
| | | | - Abina Crean
- SSPC, the SFI Centre for Pharmaceutical Research, School of Pharmacy, University College Cork, Cork, Ireland
| | - Peter Kleinebudde
- Faculty of Mathematics and Natural Sciences, Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University Düsseldorf, Düsseldorf, Germany
| | - Brian Carlin
- Owner, Carlin Pharma Consulting, Lawrenceville, New Jersey, USA
| | - John Gamble
- Drug Product Development, Bristol Myers Squibb, Moreton, UK
| | - Michael Gamlen
- Chief Scientific Officer, Gamlen Tableting Ltd, Heanor, UK
| | - Elaine Stone
- Consultant, Stonepharma Ltd. ATIC, Loughborough, UK
| | - Martin Kuentz
- Institute for Pharma Technology, University of Applied Sciences and Arts Northwestern Switzerland, School of Life Sciences FHNW, Muttenz, Switzerland
| | - Bindhu Gururajan
- Pharmaceutical Development, Novartis Pharma AG, Basel, Switzerland
| | - Yaroslav Z Khimyak
- School of Pharmacy, University of East Anglia, Norwich Research Park, Norwich, UK
| | - Bernd Van Snick
- Oral Solids Development, Drug Product Development, JnJ Innovative Medicine, Beerse, Belgium
| | - Sune Andersen
- Oral Solids Development, Drug Product Development, JnJ Innovative Medicine, Beerse, Belgium
| | - Zdravka Misic
- Innovation Research and Development, dsm-firmenich, Kaiseraugst, Switzerland
| | - Stefanie Peter
- Research and Development Division, F. Hoffmann-La Roche AG, Basel, Switzerland
| | - Stephen Sheehan
- External Development and Manufacturing, Alkermes Pharma Ireland Limited, Dublin 4, Ireland
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6
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Kobayashi Y, Kim S, Nagato T, Oishi T, Kano M. Feed factor profile prediction model for two-component mixed powder in the twin-screw feeder. Int J Pharm X 2024; 7:100242. [PMID: 38601059 PMCID: PMC11004622 DOI: 10.1016/j.ijpx.2024.100242] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2023] [Revised: 03/14/2024] [Accepted: 03/28/2024] [Indexed: 04/12/2024] Open
Abstract
In continuous pharmaceutical manufacturing processes, it is crucial to control the powder flow rate. The feeding process is characterized by the amount of powder delivered per screw rotation, referred to as the feed factor. This study aims to develop models for predicting the feed factor profiles (FFPs) of two-component mixed powders with various formulations, while most previous studies have focused on single-component powders. It further aims to identify the suitable model type and to determine the significance of material properties in enhancing prediction accuracy by using several FFP prediction models with different input variables. Four datasets from the experiment were generated with different ranges of the mass fraction of active pharmaceutical ingredients (API) and the powder weight in the hopper. The candidates for the model inputs are (a) the mass fraction of API, (b) process parameters, and (c) material properties. It is desirable to construct a high-performance prediction model without the material properties because their measurement is laborious. The results show that using (c) as input variables did not improve the prediction accuracy as much, thus there is no need to use them.
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Affiliation(s)
- Yuki Kobayashi
- Department of Systems Science, Kyoto University, Yoshida-honmachi, Sakyo-ku, Kyoto 6068501, Kyoto, Japan
| | - Sanghong Kim
- Department of Applied Physics and Chemical Engineering, Tokyo University of Agriculture and Technology, 2-24-16 Naka-cho, Koganei, 1840012 Tokyo, Japan
| | - Takuya Nagato
- Research and Development Division, Powrex Corporation, 5-5-5 Kitagawara, Itami 6640837, Hyogo, Japan
| | - Takuya Oishi
- Research and Development Division, Powrex Corporation, 5-5-5 Kitagawara, Itami 6640837, Hyogo, Japan
- Department of Applied Chemistry, Tokyo University of Agriculture and Technology, 2-24-16 Naka-cho, Koganei, 1840012 Tokyo, Japan
| | - Manabu Kano
- Department of Systems Science, Kyoto University, Yoshida-honmachi, Sakyo-ku, Kyoto 6068501, Kyoto, Japan
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7
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Waněk A, Menarini L, Giatti F, Kubelka T, Consoli F, Funaro C, Stasiak P, Štěpánek F. Manufacturing process transfer to a 30 kg/h continuous direct compression line with real-time composition monitoring. Int J Pharm 2024; 656:124100. [PMID: 38609059 DOI: 10.1016/j.ijpharm.2024.124100] [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: 12/30/2023] [Revised: 04/06/2024] [Accepted: 04/07/2024] [Indexed: 04/14/2024]
Abstract
Transferring an existing marketed pharmaceutical product from batch to continuous manufacturing (CM) without changes in regulatory registration is a challenging task in the pharmaceutical industry. Continuous manufacturing can provide an increased production rate and better equipment utilisation while retaining key quality attributes of the final product. Continuous manufacturing necessitates the monitoring of critical quality attributes in real time by appropriate process analytical tools such as near infra-red (NIR) probes. The present work reports a successful transfer of an existing drug product from batch to continuous manufacturing process without changing the formulation. A key step was continuous powder blending, whose design and operating parameters including weir type, agitation rate, dynamic hold-up and residence time were systematically investigated with respect to process repeatability. A NIR-based multivariate data model for in-line composition monitoring has been developed and validated against an existing quality control method for measuring tablet content uniformity. A continuous manufacturing long-run with a throughput of 30 kg/h (approx. 128,000 tablets per hour), uninterrupted for 320 min, has been performed to test and validate the multivariate data model as well as the batch to continuous process transfer. The final disintegration and dissolution properties of tablets manufactured by the continuous process were found to be equivalent to those manufactured by the original batch process.
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Affiliation(s)
- Adam Waněk
- Zentiva, k.s., U Kabelovny 130, Prague 10, Czech Republic; Department of Chemical Engineering, University of Chemistry and Technology, Prague, Technická 5, Prague 6, Czech Republic
| | | | | | - Tomáš Kubelka
- Zentiva, k.s., U Kabelovny 130, Prague 10, Czech Republic
| | | | | | - Pawel Stasiak
- Zentiva, k.s., U Kabelovny 130, Prague 10, Czech Republic
| | - František Štěpánek
- Department of Chemical Engineering, University of Chemistry and Technology, Prague, Technická 5, Prague 6, Czech Republic.
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8
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Forster SP, Dippold E, Haser A, Emanuele D, Meier R. Integrated Continuous Wet Granulation and Drying: Process Evaluation and Comparison with Batch Processing. Pharmaceutics 2023; 15:2317. [PMID: 37765286 PMCID: PMC10537298 DOI: 10.3390/pharmaceutics15092317] [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: 08/08/2023] [Revised: 09/11/2023] [Accepted: 09/12/2023] [Indexed: 09/29/2023] Open
Abstract
The pharmaceutical industry is in the midst of a transition from traditional batch processes to continuous manufacturing. However, the challenges in making this transition vary depending on the selected manufacturing process. Compared with other oral solid dosage processes, wet granulation has been challenging to move towards continuous processing since traditional equipment has been predominantly strictly batch, instead of readily adapted to material flow such as dry granulation or tablet compression, and there have been few equipment options for continuous granule drying. Recently, pilot and commercial scale equipment combining a twin-screw wet granulator and a novel horizontal vibratory fluid-bed dryer have been developed. This study describes the process space of that equipment and compares the granules produced with batch high-shear and fluid-bed wet granulation processes. The results of this evaluation demonstrate that the equipment works across a range of formulations, effectively granulates and dries, and produces granules of similar or improved quality to batch wet granulation and drying.
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Affiliation(s)
| | | | - Abbe Haser
- Organon & Co., Inc., Jersey City, NJ 07302, USA
| | - Daniel Emanuele
- L.B. Bohle Maschinen und Verfahren GmbH, 59320 Ennigerloh, Germany
| | - Robin Meier
- L.B. Bohle Maschinen und Verfahren GmbH, 59320 Ennigerloh, Germany
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9
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Jones-Salkey O, Chu Z, Ingram A, Windows-Yule CRK. Reviewing the Impact of Powder Cohesion on Continuous Direct Compression (CDC) Performance. Pharmaceutics 2023; 15:1587. [PMID: 37376036 DOI: 10.3390/pharmaceutics15061587] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/03/2023] [Revised: 05/08/2023] [Accepted: 05/10/2023] [Indexed: 06/29/2023] Open
Abstract
The pharmaceutical industry is undergoing a paradigm shift towards continuous processing from batch, where continuous direct compression (CDC) is considered to offer the most straightforward implementation amongst powder processes due to the relatively low number of unit operations or handling steps. Due to the nature of continuous processing, the bulk properties of the formulation will require sufficient flowability and tabletability in order to be processed and transported effectively to and from each unit operation. Powder cohesion presents one of the greatest obstacles to the CDC process as it inhibits powder flow. As a result, there have been many studies investigating potential manners in which to overcome the effects of cohesion with, to date, little consideration of how these controls may affect downstream unit operations. The aim of this literature review is to explore and consolidate this literature, considering the impact of powder cohesion and cohesion control measures on the three-unit operations of the CDC process (feeding, mixing, and tabletting). This review will also cover the consequences of implementing such control measures whilst highlighting subject matter which could be of value for future research to better understand how to manage cohesive powders for CDC manufacture.
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Affiliation(s)
- Owen Jones-Salkey
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield SK10 2NA, UK
- School of Chemical Engineering, University of Birmingham, Birmingham B15 2TT, UK
| | - Zoe Chu
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield SK10 2NA, UK
- School of Chemical Engineering, University of Birmingham, Birmingham B15 2TT, UK
| | - Andrew Ingram
- School of Chemical Engineering, University of Birmingham, Birmingham B15 2TT, UK
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10
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C Dias R, Korhonen O, Ketolainen J, A Lopes J, Ervasti T. Flowsheet modelling of a powder continuous feeder-mixer system. Int J Pharm 2023; 639:122969. [PMID: 37084833 DOI: 10.1016/j.ijpharm.2023.122969] [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: 09/23/2022] [Revised: 03/28/2023] [Accepted: 04/15/2023] [Indexed: 04/23/2023]
Abstract
In this study, an integrated flowsheet model of the continuous feeder-mixer system was calibrated, simulated and compared against experimental data. The feeding process was first investigated using two major components (ibuprofen and microcrystalline cellulose (MCC)), in a formulation comprised of: 30 wt% of ibuprofen, 67.5 wt% MCC, 2 wt% of sodium starch glycolate and 0.5 wt% of magnesium stearate. The impact of a refill on feeder performance was experimentally evaluated for different operating conditions. Results showed that it had no influence on feeder performance. While simulations with the feeder model fairly reproduced the material behaviour observed in the feeder, unintended disturbances were underpredicted due to the model's low complexity. Experimentally, mixer's efficiency was assessed based on ibuprofen residence time distribution. Mean residence time pointed to a higher mixer's efficiency at lower flow rates. Blend homogeneity results showed that for the entire set of experiments, ibuprofen RSD <5%, irrespective of process variables. A feeder-mixer flowsheet model was calibrated, after regressing the axial model coefficients. The regression curves exhibited a R2 above 0.96, whereas the RMSE varied from 1.58x10-4 to 1.06x10-3 s-1 across all fitted curves. Simulations confirmed that flowsheet model captured the powder dynamics inside the mixer and qualitatively predicted the mixer's filtering ability against feeding composition fluctuations, as well as ibuprofen RSD in blend, in line with real experiments.
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Affiliation(s)
- Rute C Dias
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland; iMed.ULisboa, Faculty of Pharmacy, University of Lisbon, 1649-003 Lisbon, Portugal.
| | - Ossi Korhonen
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
| | - Jarkko Ketolainen
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
| | - João A Lopes
- iMed.ULisboa, Faculty of Pharmacy, University of Lisbon, 1649-003 Lisbon, Portugal
| | - Tuomas Ervasti
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
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11
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Beretta M, Kruisz J, Hörmann-Kincses TR, Magosi V, Guo M, Naderi M, Heupl S, Kastner J, Spoerk M, Paudel A. Assessment of Tribo-charging and Continuous Feeding Performance of Direct Compression Grades of Isomalt and Mannitol Powders. AAPS PharmSciTech 2023; 24:91. [PMID: 36977945 DOI: 10.1208/s12249-023-02552-5] [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: 12/14/2022] [Accepted: 03/06/2023] [Indexed: 03/30/2023] Open
Abstract
Tribo-charging is often a root cause of mass flow deviations and powder adhesion during continuous feeding. Thus, it may critically impact product quality. In this study, we characterized the volumetric (split- and pre-blend) feeding behavior and process-induced charge of two direct compression grades of polyols, galenIQ™ 721 (G721) for isomalt and PEARLITOL® 200SD (P200SD) for mannitol, under different processing conditions. The feeding mass flow range and variability, hopper end fill level, and powder adhesion were profiled. The feeding-induced tribo-charging was measured using a Faraday cup. Both materials were comprehensively characterized for relevant powder properties, and their tribo-charging was investigated for its dependence on particle size and relative humidity. During split-feeding experiments, G721 showed a comparable feeding performance to P200SD with lower tribo-charging and adhesion to the screw outlet of the feeder. Depending on the processing condition, the charge density of G721 ranged from -0.01 up to -0.39 nC/g, and for P200SD from -3.19 up to -5.99 nC/g. Rather than differences in the particle size distribution of the two materials, their distinct surface and structural characteristics were found as the main factors affecting their tribo-charging. The good feeding performance of both polyol grades was also maintained during pre-blend feeding, where reduced tribo-charging and adhesion propensity was observed for P200SD (decreasing from -5.27 to -0.17 nC/g under the same feeding settings). Here, it is proposed that the mitigation of tribo-charging occurs due to a particle size-driven mechanism.
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Affiliation(s)
- Michela Beretta
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/II, 8010, Graz, Austria
- Institute of Process and Particle Engineering, Graz University of Technology, 8010, Graz, Austria
| | - Julia Kruisz
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/II, 8010, Graz, Austria
| | | | - Viktoria Magosi
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/II, 8010, Graz, Austria
| | - Meishan Guo
- Surface Measurement Systems Ltd, Wembley, HA0 4PE, UK
| | - Majid Naderi
- Surface Measurement Systems Ltd, Wembley, HA0 4PE, UK
| | - Sarah Heupl
- University of Applied Sciences Upper Austria, Campus Wels, 4600, Wels, Austria
| | - Johann Kastner
- University of Applied Sciences Upper Austria, Campus Wels, 4600, Wels, Austria
| | - Martin Spoerk
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/II, 8010, Graz, Austria
| | - Amrit Paudel
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/II, 8010, Graz, Austria.
- Institute of Process and Particle Engineering, Graz University of Technology, 8010, Graz, Austria.
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12
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Kim SS, Castillo C, Cheikhali M, Darweesh H, Kossor C, Davé RN. Enhanced blend uniformity and flowability of low drug loaded fine API blends via dry coating: The effect of mixing time and excipient size. Int J Pharm 2023; 635:122722. [PMID: 36796658 DOI: 10.1016/j.ijpharm.2023.122722] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/29/2022] [Revised: 02/08/2023] [Accepted: 02/09/2023] [Indexed: 02/16/2023]
Abstract
Although previous research demonstrated improved flowability, packing, fluidization, etc. of individual powders via nanoparticle dry coating, none considered its impact on very low drug loaded blends. Here, fine ibuprofen at 1, 3, and 5 wt% drug loadings (DL) was used in multi-component blends to examine the impact of the excipients size, dry coating with hydrophilic or hydrophobic silica, and mixing times on the blend uniformity, flowability and drug release rates. For uncoated active pharmaceutical ingredients (API), the blend uniformity (BU) was poor for all blends regardless of the excipient size and mixing time. In contrast, for dry coated API having low agglomerate ratio (AR), BU was dramatically improved, more so for the fine excipient blends, at lesser mixing times. For dry coated API, the fine excipient blends mixed for 30 min had enhanced flowability and lower AR; better for the lowest DL having lesser silica, likely due to mixing induced synergy of silica redistribution. For the fine excipient tablets, dry coating led to fast API release rates even with hydrophobic silica coating. Remarkably, the low AR of the dry coated API even at very low DL and amounts of silica in the blend led to the enhanced blend uniformity, flow, and API release rate.
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Affiliation(s)
- Sangah S Kim
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Chelsea Castillo
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Mirna Cheikhali
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Hadeel Darweesh
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Christopher Kossor
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Rajesh N Davé
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA.
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13
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Hou P, Besenhard MO, Halbert G, Naftaly M, Markl D. Development and implementation of a pneumatic micro-feeder for poorly-flowing solid pharmaceutical materials. Int J Pharm 2023; 635:122691. [PMID: 36764420 DOI: 10.1016/j.ijpharm.2023.122691] [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: 11/21/2022] [Revised: 01/31/2023] [Accepted: 02/02/2023] [Indexed: 02/11/2023]
Abstract
Consistent powder micro-feeding (<100 g/h) is a significant challenge in manufacturing solid oral dosage forms. The low dose feeding can well control the content consistency of the dosage forms, which improves drug efficiency and reduces manufacturing waste. Current commercial micro-feeders are limited in their ability to feed < 20 g/h of cohesive (i.e. powders of poor flowability) active pharmaceutical ingredients (API) and excipients (e.g. lubricants) with low fluctuation. To breach this gap, this study presents an advanced micro-feeder design capable of feeding a range of pharmaceutical-grade powders consistently at flow rates as low as 0.7 g/h with <20 % flow rate variation. This was possible due to a novel powder conveying concept utilising particle re-entrainment to minimise flow rate variations. This work details the design of this pneumatic micro-feeder and its excellent micro-feeding performance even for cohesive powders. The experimental studies investigated the influence of the process parameters (air pressure and air flow rate) and equipment configurations (insert size and plug position) on the feeding performance of different pharmaceutical-relevant powders, i.e., microcrystalline cellulose (MCC), croscarmellose sodium (CCS), crospovidone (XPVP) and paracetamol (APAP). It was shown that the system is capable of delivering consistent powder flow rates with good repeatability and stability.
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Affiliation(s)
- P Hou
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M O Besenhard
- Department of Chemical Engineering, University College London, London WC1E 7JE, UK
| | - G Halbert
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M Naftaly
- National Physical Laboratory, Teddington TW11 0LW, UK
| | - D Markl
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK.
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14
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Gamble JF, Akseli I, Ferreira AP, Leane M, Thomas S, Tobyn M, Wadams RC. Morphological distribution mapping: Utilisation of modelling to integrate particle size and shape distributions. Int J Pharm 2023; 635:122743. [PMID: 36804520 DOI: 10.1016/j.ijpharm.2023.122743] [Citation(s) in RCA: 6] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/23/2022] [Revised: 02/13/2023] [Accepted: 02/14/2023] [Indexed: 02/19/2023]
Abstract
The aim of this work was to develop approaches to utilize whole particle distributions for both particle size and particle shape parameters to map the full range of particle properties in a curated dataset. It is hoped that such an approach may enable a more complete understanding of the particle landscape as a step towards improving the link between particle properties and processing behaviour. A 1-dimensional principal component analysis (PCA) approach was applied to create a 'morphological distribution landscape'. A dataset of imaged APIs, intermediates and excipients encompassing particle size, particle shape (elongation, length and width) and distribution shape was curated between 2008 and 2022. The curated dataset encompassed over 200 different materials, which included over 150 different APIs, and approximately 3500 unique samples. For the purposes of the current work, only API samples were included. The morphological landscape enables differentiation of materials of equivalent size but varying shape and vice versa. It is hoped that this type of approach can be utilised to better understand the influence of particle properties on pharmaceutical processing behaviour and thereby enable scientists to leverage historical knowledge to highlight and mitigate risks associated to materials of similar morphological nature.
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Affiliation(s)
- John F Gamble
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral CH46 1QW, UK.
| | | | - Ana P Ferreira
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral CH46 1QW, UK
| | - Michael Leane
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral CH46 1QW, UK
| | | | - Mike Tobyn
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral CH46 1QW, UK
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15
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Elucidation of the powder flow pattern in a twin-screw LIW-feeder for various refill regimes. Int J Pharm 2023; 631:122534. [PMID: 36563797 DOI: 10.1016/j.ijpharm.2022.122534] [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: 08/08/2022] [Revised: 12/16/2022] [Accepted: 12/19/2022] [Indexed: 12/24/2022]
Abstract
The importance of residence time distribution modeling is acknowledged as a tool for enabling material tracking and control within a continuous manufacturing line in order to safeguard both product quality and production efficiency. One of the first unit-operations into a continuous direct compression line (i.e. CDC-line) worthwhile doing extensive RTD-analysis upon are the LIW-feeders since they dose the ingredients in a controlled way following the label claim and hence can directly influence critical quality attributes like content uniformity. An NIR measurement method was developed determining the RTD of selected powders at specific feeder settings. Step-change experiments using sodium saccharin as a tracer were conducted. In order to gain and in depth understanding of the material flow, spatial samples throughout the hopper were taken at predefined timepoints during the step change experiments. This revealed the presence of a bypass trajectory along the edges of the agitator, while in the center of the agitator an inner mixing volume in which the tracer concentration lags behind seemed to be present. Finally, a model based on a plug flow and continuous stirred tank reactor was evaluated. The fitted model was not able to capture this complex flow behavior and shows the need for an extended compartmental model distinguishing between a bypass trajectory formed by the agitator and an inner mixing volume.
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16
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Bekaert B, Van Snick B, Pandelaere K, Dhondt J, Di Pretoro G, De Beer T, Vervaet C, Vanhoorne V. Continuous direct compression: Development of an empirical predictive model and challenges regarding PAT implementation. Int J Pharm X 2022; 4:100110. [PMID: 35024605 PMCID: PMC8732775 DOI: 10.1016/j.ijpx.2021.100110] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/30/2021] [Revised: 12/21/2021] [Accepted: 12/23/2021] [Indexed: 11/21/2022] Open
Abstract
In this study, an empirical predictive model was developed based on the quantitative relationships between blend properties, critical quality attributes (CQA) and critical process parameters (CPP) related to blending and tableting. The blend uniformity and API concentration in the tablets were used to elucidate challenges related to the processability as well as the implementation of PAT tools. Thirty divergent ternary blends were evaluated on a continuous direct compression line (ConsiGma™ CDC-50). The trials showed a significant impact of the impeller configuration and impeller speed on the blending performance, whereas a limited impact of blend properties was observed. In contrast, blend properties played a significant role during compression, where changes in blend composition significantly altered the tablet quality. The observed correlations allowed to develop an empirical predictive model for the selection of process configurations based on the blend properties, reducing the number of trial runs needed to optimize a process and thus reducing development time and costs of new drug products. Furthermore, the trials elucidated several challenges related to blend properties that had a significant impact on PAT implementation and performance of the CDC-platform, highlighting the importance of further process development and optimization in order to solve the remaining challenges.
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Key Words
- #BP, Number of blade passes
- #RMB1, Number of radial mixing blades of the main blender
- API, Active pharmaceutical ingredient
- API_sd, Spray dried API
- BRT, Bulk residence time
- BU, Blend uniformity
- CDC, Continuous direct compression
- CDC-50
- CU, Content uniformity
- C_P, Caffeine anhydrous powder
- Continuous direct compression
- Continuous manufacturing
- DCP, Dicalcium phosphate / Emcompress AN
- FD, Fill depth
- HM1/HM2, Hold-up mass main blender/Hold-up mass lubricant blender
- Imp1, Impeller speed main blender
- LC, Percentage label claim
- MCF, Main compression force
- MCH, Main compression height
- MPT_μ, Metoprolol micronized
- MgSt, Magnesium stearate/Ligamed MF-2-V
- Multivariate data-analysis
- NIR, Near infrared
- PAT
- PAT, Process Analytical Technology
- PC, Principle component
- PCA, Principle component analysis
- PCD, Pre-compression displacement
- PCF, Pre-compression force
- PCH, Pre-compression height
- PH101, Microcrystalline cellulose / Avicel PH-101
- PH200, Microcrystalline cellulose / Avicel PH-200
- PLS, Partial least squares
- P_DP, Paracetamol dense powder
- P_P, Paracetamol powder
- P_μ, Paracetamol micronized
- Predictive modeling
- Q2, Goodness of prediction
- R2Y, Goodness of fit
- RMSEcv, Root mean squared error of cross validation
- RSDTW, Relative standard deviation of tablet weight
- SD100, Mannitol / Pearlitol 100 SD
- T80, Lactose / Tablettose 80
- T_P, Theophylline anhydrous powder
- rpm, Revolutions per minute
- σForce, Main compression force variability
- σPCD, Variability in pre-compression displacement
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Affiliation(s)
- B. Bekaert
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - B. Van Snick
- Oral Solid Dosage, Drug Product Development, Discovery Product Development and Supplies, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - K. Pandelaere
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - J. Dhondt
- Oral Solid Dosage, Drug Product Development, Discovery Product Development and Supplies, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - G. Di Pretoro
- Oral Solid Dosage, Drug Product Development, Discovery Product Development and Supplies, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - T. De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - C. Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - V. Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
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17
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Parameter optimization in a continuous direct compression process of commercially batch-produced bisoprolol tablets. Int J Pharm 2022; 628:122355. [DOI: 10.1016/j.ijpharm.2022.122355] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/22/2022] [Revised: 10/24/2022] [Accepted: 10/25/2022] [Indexed: 11/06/2022]
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18
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Predicting powder feedability: A workflow for assessing the risk of flow stagnation and defining the operating space for different powder-feeder combinations. Int J Pharm 2022; 629:122364. [DOI: 10.1016/j.ijpharm.2022.122364] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/24/2022] [Revised: 10/28/2022] [Accepted: 10/30/2022] [Indexed: 11/06/2022]
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19
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Shier AP, Kumar A, Mercer A, Majeed N, Doshi P, Blackwood DO, Verrier HM. Development of a predictive model for gravimetric powder feeding from an API-rich materials properties library. Int J Pharm 2022; 625:122071. [PMID: 35931397 DOI: 10.1016/j.ijpharm.2022.122071] [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: 02/02/2022] [Revised: 07/20/2022] [Accepted: 07/30/2022] [Indexed: 10/16/2022]
Abstract
A model was developed for predicting the feed factor profile of a powder, processed through a gravimetric feeder, as a function of material properties and process parameters. Predictive models proposed in existing literature have often used excipients and active pharmaceutical ingredients (APIs) with good powder flow characteristics in their development. In this work, a material properties library containing a large proportion of APIs, as well as excipients and co-processed blends, was used to build the model and enhance the prediction of feed factor profile for cohesive powders. Gravimetric feeder trials were performed at varying mass flow rates and screw geometries to determine the feed factor profiles. A semi-empirical exponential model, with parameters fmax, fmin, and β, was then used to fit the experimental feed factor profiles. Bayesian optimisation and Support Vector Regression (SVR) modelling techniques were utilised to optimise and predict the exponential model parameters as a function of material properties. The parameters found to strongly influence the model were particle size, bulk density, FFC and FT4 rheometer parameters. Results showed low prediction errors between the estimated and experimental data. The final model produces good estimations of the feed factor profile and requires minimal powder consumption.
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Affiliation(s)
- Andrew P Shier
- Worldwide Research and Development, Pfizer Inc, Sandwich, Kent, UK.
| | | | - Amy Mercer
- Worldwide Research and Development, Pfizer Inc, Sandwich, Kent, UK
| | - Naimah Majeed
- Worldwide Research and Development, Pfizer Inc, Groton, CT, USA
| | - Pankaj Doshi
- Worldwide Research and Development, Pfizer Ltd, Mumbai, India
| | | | - Hugh M Verrier
- Worldwide Research and Development, Pfizer Inc, Sandwich, Kent, UK
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20
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Effect of batch-to-batch variation of spray dried lactose on the performance of feeders. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117776] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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21
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Stauffer F, Boulanger E, Pilcer G. Sampling and diversion strategy for twin-screw granulation lines using batch statistical process monitoring. Eur J Pharm Sci 2022; 171:106126. [DOI: 10.1016/j.ejps.2022.106126] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/30/2021] [Revised: 12/21/2021] [Accepted: 01/12/2022] [Indexed: 11/03/2022]
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22
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Kreiser MJ, Wabel C, Wagner KG. Impact of Vertical Blender Unit Parameters on Subsequent Process Parameters and Tablet Properties in a Continuous Direct Compression Line. Pharmaceutics 2022; 14:pharmaceutics14020278. [PMID: 35214014 PMCID: PMC8879867 DOI: 10.3390/pharmaceutics14020278] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/09/2021] [Revised: 01/14/2022] [Accepted: 01/20/2022] [Indexed: 12/10/2022] Open
Abstract
The continuous manufacturing of solid oral-dosage forms represents an emerging technology among the pharmaceutical industry, where several process steps are combined in one production line. As all mixture components, including the lubricant (magnesium stearate), are passing simultaneously through one blender, an impact on the subsequent process steps and critical product properties, such as content uniformity and tablet tensile strength, is to be expected. A design of experiment (DoE) was performed to investigate the impact of the blender variables hold-up mass (HUM), impeller speed (IMP) and throughput (THR) on the mixing step and the subsequent continuous manufacturing process steps. Significant impacts on the mixing parameters (exit valve opening width (EV), exit valve opening width standard deviation (EV SD), torque of lower impeller (TL), torque of lower impeller SD (TL SD), HUM SD and blend potency SD), material attributes of the blend (conditioned bulk density (CBD), flow rate index (FRI) and particle size (d10 values)), tableting parameters (fill depth (FD), bottom main compression height (BCH) and ejection force (EF)) and tablet properties (tablet thickness (TT), tablet weight (TW) and tensile strength (TS)) could be found. Furthermore, relations between these process parameters were evaluated to define which process states were caused by which input variables. For example, the mixing parameters were mainly impacted by impeller speed, and material attributes, FD and TS were mainly influenced by variations in total blade passes (TBP). The current work presents a rational methodology to minimize process variability based on the main blender variables hold-up mass, impeller speed and throughput. Moreover, the results facilitated a knowledge-based optimization of the process parameters for optimum product properties.
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Affiliation(s)
- Marius J. Kreiser
- Product and Process Development, Pfizer Manufacturing Deutschland GmbH, 79108 Freiburg, Germany; (M.J.K.); (C.W.)
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany
| | - Christoph Wabel
- Product and Process Development, Pfizer Manufacturing Deutschland GmbH, 79108 Freiburg, Germany; (M.J.K.); (C.W.)
| | - Karl G. Wagner
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany
- Correspondence:
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23
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Peterwitz M, Gerling S, Schembecker G. Challenges in tracing material flow passing a loss-in-weight feeder in continuous manufacturing processes. Int J Pharm 2022; 612:121304. [PMID: 34800615 DOI: 10.1016/j.ijpharm.2021.121304] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/08/2021] [Revised: 11/11/2021] [Accepted: 11/13/2021] [Indexed: 12/31/2022]
Abstract
Loss-in-weight feeders are an integral part of most continuous manufacturing processes, ensuring a constant mass flow. The feeders cause a significant degree of back-mixing in such lines. Understanding back-mixing is essential for the treatment of disturbances. However, feeders refilled semi-continuously contradict the common theory assuming steady-state. This study aims at understanding dynamic back-mixing and related phenomena. Low filling levels of a feeder are investigated using a fluorescent tracer. These investigations prove an impact of the addition of material probably caused by a non-uniform draw-in of the screws and dead material in the hopper. In turn, the dead material accounts for up to 50 % of the material in the hopper. Possible evidence of dead zones at higher filling levels and in feeders from literature are discussed additionally. Steady-state models from literature are extended to represent the observations and back-mixing at all filling levels. This extension reduces the root-mean-squared deviation of the model from the experimental data by 41%. The model predicts different responses to similar disturbances depending on the filling. This state-dependent back-mixing and the observed dead zones are challenging for diverting non-conforming material and material traceability. Therefore, these phenomena should be considered in selecting and operating feeders.
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Affiliation(s)
- Moritz Peterwitz
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany; Invite GmbH, Otto-Bayer-Straße 32, D-51061 Cologne, Germany
| | - Sina Gerling
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
| | - Gerhard Schembecker
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany.
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24
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Peterwitz M, Jodwirschat J, Loll R, Schembecker G. Tracking raw material flow through a continuous direct compression line Part I of II: Residence time distribution modeling and sensitivity analysis enabling increased process yield. Int J Pharm 2022; 614:121467. [PMID: 35032576 DOI: 10.1016/j.ijpharm.2022.121467] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/05/2021] [Revised: 12/30/2021] [Accepted: 01/08/2022] [Indexed: 11/30/2022]
Abstract
Continuous manufacturing (CM) offers advantages in quality and space-time yield compared to common batch manufacturing. However, higher yield losses due to the start-up procedure make a broad application uneconomical. This work discusses the possibility of reducing yield losses by adjusting the degree of back-mixing. Back-mixing of nonconforming material from disturbances or start-up will result in the contamination of subsequent material. Therefore, higher degrees of back-mixing cause the discharge of additional material. Choosing an advantageous setting of operational parameters may be a simple way to change the degree of back-mixing. Based on direct compression, this work demonstrates the identification of promising parameters. Therefore, step-change experiments using color-marked material in the feeder, blender, and tablet press quantify the impact of three operational parameters per device. Models for the devices and the entire process result from those measurements. Subsequently, a global variance-based sensitivity analysis identifies the most influential parameters. As a result, adjusting the minimal filling level of the feeder and the rotational feed frame speed of the tablet press reduces back-mixing by more than 30%. At high costs of the raw materials, the resulting savings can significantly improve the economic performance of CM compared to batch manufacturing.
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Affiliation(s)
- Moritz Peterwitz
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany; Invite GmbH, Otto-Bayer-Straße 32, D-51061 Cologne, Germany
| | - Janis Jodwirschat
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
| | - Rouven Loll
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
| | - Gerhard Schembecker
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
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25
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Bekaert B, Van Snick B, Pandelaere K, Dhondt J, Di Pretoro G, De Beer T, Vervaet C, Vanhoorne V. In-depth analysis of the long-term processability of materials during continuous feeding. Int J Pharm 2022; 614:121454. [PMID: 35026314 DOI: 10.1016/j.ijpharm.2022.121454] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/29/2021] [Revised: 12/24/2021] [Accepted: 01/05/2022] [Indexed: 10/19/2022]
Abstract
This study determined the feasibility of long-term continuous powder feeding and its effect on the overall process performance. Additionally, quantitative relationships were established between material properties, process settings and screw feeding responses during gravimetric feeding. Twelve divergent raw materials were processed over longer periods using a GEA Compact Feeder integrated in a continuous direct compression line (ConsiGma™ CDC-50). The resulting gravimetric feeding responses were combined with the material properties and process settings into an overall PLS model. The model elucidated the impact of the material descriptors for density; powder flow; particle size; compressibility; permeability and wall friction angle on the feeding process. Furthermore, long-term processing of the materials exhibited challenges related to the processability and refill consistency where a significant impact of the compressibility and cohesive/adhesive properties of the materials was observed. Overall, this approach provided insights into the feasibility of long-term continuous feeding which is not possible through 'short-term' feeding trials. Additionally, throughout this study, the need for material-specific adjustments of the feeding and refill equipment was highlighted.
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Affiliation(s)
- B Bekaert
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - B Van Snick
- Oral Solid Dosage, Drug Product Development, Discovery Product Development and Supplies, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - K Pandelaere
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - J Dhondt
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - G Di Pretoro
- Oral Solid Dosage, Drug Product Development, Discovery Product Development and Supplies, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - V Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium.
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26
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Impact of blend properties and process variables on the blending performance. Int J Pharm 2021; 613:121421. [PMID: 34954006 DOI: 10.1016/j.ijpharm.2021.121421] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/29/2021] [Revised: 12/18/2021] [Accepted: 12/20/2021] [Indexed: 11/22/2022]
Abstract
In this study, quantitative relationships were established between blend properties, process settings and blending responses via multivariate data-analysis. Four divergent binary blends were composed in three different ratios and processed at various throughputs and impeller speeds. Additionally, different impeller configurations were tested to see their impact on the overall blending performance. During each run, feeder mass flows were compared with the API concentration (BU) in order to investigate the dampening potential of the blender. The blender hold-up mass (HM), mean residence time (MRT), strain on the powder (#BP) and BU variability (RSDBU) were determined as blending descriptors and analyzed via PLS-regression. This elucidated the correlation between process settings (i.e. throughput and impeller speed) and blending responses, as well as the impact of blend properties on MRT and RSDBU. Furthermore, the study revealed that HM does not need to be in steady state conditions to assure a stable BU, while it became clear that long/large feeder deviations can only be dampened by the blender when using dedicated impeller configurations. Overall, this study demonstrated the generic application of the blender, while the developed PLS models could be used to predict the blender performance based on the blend properties.
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Fathollahi S, Kruisz J, Sacher S, Rehrl J, Escotet-Espinoza MS, DiNunzio J, Glasser BJ, Khinast JG. Development of a Controlled Continuous Low-Dose Feeding Process. AAPS PharmSciTech 2021; 22:247. [PMID: 34642863 PMCID: PMC8510936 DOI: 10.1208/s12249-021-02104-9] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2021] [Accepted: 07/31/2021] [Indexed: 11/30/2022] Open
Abstract
This paper proposes a feed rate control strategy for a novel volumetric micro-feeder, which can accomplish low-dose feeding of pharmaceutical raw materials with significantly different powder properties. The developed feed-forward control strategy enables a constant feed rate with a minimum deviation from the set-point, even for materials that are typically difficult to accurately feed (e.g., due to high cohesion or low density) using conventional continuous feeders. Density variations observed during the feeding process were characterized via a displacement feed factor profile for each powder. The characterized effective displacement density profile was applied in the micro-feeder system to proactively control the feed rate by manipulating the powder displacement rate (i.e., computing the feed rate from the powder displacement rate). Based on the displacement feed factor profile, the feed rate can be predicted during the feeding process and at any feed rate set-point. Three pharmaceutically relevant materials were used for the micro-feeder evaluation: di-calcium phosphate (large-particle system, high density), croscarmellose sodium (small-particle system, medium density), and barium sulfate (very small-particle <10 μm, high density). A significant improvement in the feeding performance was achieved for all investigated materials. The feed rate deviation from the set-point and its relative standard deviation were minimal compared to operations without the control strategy.
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Determination of a quantitative relationship between material properties, process settings and screw feeding behavior via multivariate data-analysis. Int J Pharm 2021; 602:120603. [PMID: 33862133 DOI: 10.1016/j.ijpharm.2021.120603] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/03/2021] [Revised: 04/08/2021] [Accepted: 04/09/2021] [Indexed: 11/21/2022]
Abstract
In this study, a quantitative relationship between material properties, process settings and screw feeding responses of a high-throughput feeder was established via multivariate models (PLS). Thirteen divergent powders were selected and characterized for 44 material property descriptors. During volumetric feeder trials, the maximum feed capacity (FCCmax), the relative standard deviation on the maximum feed capacity (RSDFCmax), the short term variability (STRSD) and feed capacity decay (FCdecay) were determined. The gravimetric feeder trials generated values for the mass flow rate variability (RSDLC), short term variability (STRSD) and refill responses (Vrefill and RSDrefill). The developed PLS models elucidated that the material properties and process settings were clearly correlated to the feeding behavior. The extended volumetric feeder trials pointed out that there was a significant influence of the chosen screw type and screw speed on the feeding process. Furthermore, the process could be optimized by reducing the feeding variability through the application of optimized mass flow filters, high frequency vibrations, independent agitator control and optimized top-up systems. Overall, the models could allow the prediction of the feeding performance for a wide range of materials based on the characterization of a subset of material properties greatly reducing the number of required feeding experiments.
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Loss-in-weight feeding, powder flow and electrostatic evaluation for direct compression hydroxypropyl methylcellulose (HPMC) to support continuous manufacturing. Int J Pharm 2021; 596:120259. [PMID: 33486020 DOI: 10.1016/j.ijpharm.2021.120259] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2020] [Revised: 01/06/2021] [Accepted: 01/10/2021] [Indexed: 11/23/2022]
Abstract
Minimizing variability in the feeding process is important for continuous manufacturing since materials are fed individually and can impact the final product. This study demonstrates the importance of measuring powder properties and highlights the need to characterize the feeding performance both offline with multiple refills and in the intended configuration for the continuous manufacturing equipment. The standard grade hydroxypropyl methylcellulose (HPMC) had material buildup on the loss-in-weight feeder barrel from triboelectric charging and resulted in more mass flow excursions and failed refills which were not observed with the direct compression grades. The location of the electrostatic buildup changed when the feeder was connected to a hopper instead of feeding offline into a collection bucket. Overall, the direct compression HPMC exhibited better flow which resulted in more accurate loss-in-weight feeding with less excursions from the target mass flow and all refills were completed in the first attempt. The improvements with the direct compression HPMC would be beneficial when running any continuous process (wet granulation, roller compaction, or direct compression) or other processes where loss-in-weight feeding is utilized, such as melt extrusion or twin screw granulation.
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Sacher S, Heindl N, Afonso Urich JA, Kruisz J, Khinast JG. A solution for low-dose feeding in continuous pharmaceutical processes. Int J Pharm 2020; 591:119969. [PMID: 33068692 DOI: 10.1016/j.ijpharm.2020.119969] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/15/2020] [Revised: 10/07/2020] [Accepted: 10/08/2020] [Indexed: 11/18/2022]
Abstract
Continuous feeding of small quantities of powder is increasingly applied in pharmaceutical manufacturing. With that regard, what is crucial is not only the feasibility, but also the accuracy and stability. To enable stable processing, low amounts of various agents, e.g., lubricants, can be used. Even more important is the exact dosage of highly potent active pharmaceutical ingredients (APIs), which require feed rates within the range of grams per hour. Conventional feeders cannot supply powder at such rates, especially when the material properties are challenging. In this work, a novel micro-feeder was integrated into a continuous manufacturing line and its capability to supply API at feed rates down to one gram per hour was tested. The micro-feeder system is based on the principle of active volumetric displacement: a piston pushes the powder out of the cartridge upwards to the end of a plate, where a scraper places it into the process inlet. In this study, a hot melt extrusion process was used, during which the API was dissolved in a polymer matrix. Samples of the strand were analysed with regard to their content by means of HPLC. The results showed that the novel micro-feeder system can feed powder with good accuracy and reproducibility, indicating its high potential for continuous process implementation.
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Affiliation(s)
- Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria.
| | - Nikolaus Heindl
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | | | - Julia Kruisz
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Johannes G Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
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Fathollahi S, Sacher S, Escotet-Espinoza MS, DiNunzio J, Khinast JG. Performance Evaluation of a High-Precision Low-Dose Powder Feeder. AAPS PharmSciTech 2020; 21:301. [PMID: 33141336 PMCID: PMC7609424 DOI: 10.1208/s12249-020-01835-5] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/29/2020] [Accepted: 09/29/2020] [Indexed: 01/23/2023] Open
Abstract
Abstract Highly potent active pharmaceutical ingredients (APIs) and low-dose excipients, or excipients with very low density, are notoriously hard to feed with currently available commercial technology. The micro-feeder system presented in this work is capable of feeding low-dose rates of powders with different particle sizes and flow properties. Two different grades of lactose, di-calcium phosphate, croscarmellose sodium, silicon dioxide, a spray-dried intermediate, and an active ingredient were studied to vary material properties to test performance of the system. The current micro-feeder system is a volumetric feeder combined with a weighing balance at the outlet that measures feeder output rates. Feeding results are shown as a so-called “displacement-feed factor” curve for each material. Since the powder mass and volume are known in the micro-feeder system, in this work, we characterized an observed density variation during processing via a “displacement-feed factor” profile for each of the fed powders. This curve can be later used for calibrating the system to ensure an accurate, constant feed rate and in addition predicting feeding performance for that material at any feed rate. There is a relation between powder properties and feeding performance. Powders with finer particles and higher compressibility show densification during their feeding process. However, powders with larger particles and lower compressibility show both “densification” and “powder bed expansion,” which is the manifestation of dilation and elastic recovery of particles during the micro-feeding process. Through the application of the displacement-feed factor, it is possible to provide precise feeding accuracy of low-dose materials. Graphical abstract ![]()
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Investigation into powder tribo-charging of pharmaceuticals. Part I: Process-induced charge via twin-screw feeding. Int J Pharm 2020; 591:120014. [PMID: 33122114 DOI: 10.1016/j.ijpharm.2020.120014] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/24/2020] [Revised: 10/19/2020] [Accepted: 10/20/2020] [Indexed: 11/23/2022]
Abstract
Powder feeding is a crucial unit operation in continuous manufacturing (CM) of pharmaceutical products. Twin-screw feeders are typically employed to ensure the accurate mass flow of pharmaceutical materials throughout the production process. Here, contact and separation of particles can give rise to electrostatic charges, affecting feeder performance and final product quality. The knowledge of the material charging tendency would therefore be beneficial for both formulation and process design. At the early stage of product development, only a limited amount of material is available and the propensity of the powders to charge needs to be assessed on lab test equipment, which not necessarily represent the material state during processing. In this study, the tribo-charging behaviour of a set of common pharmaceutical materials (i.e., microcrystalline cellulose, D-mannitol, paracetamol and magnesium stearate) was experimentally evaluated. To this end, powder materials were let to flow over the stainless-steel pipes of the GranuCharge™ instrument. The resulting charge was compared to the one acquired during twin-screw feeding. In both cases, paracetamol exhibited the highest charging tendency followed by D-mannitol and microcrystalline cellulose and last by magnesium stearate. A good correlation was found for charge values obtained for both methods, despite the different tribo-charging mechanisms involved in the two set-ups. However, these differences in experimental set-ups led to diverse magnitudes and, in one case, polarity of charge. Additionally, an extensive material characterization was performed on the selected powders and results were statistically analyzed to identify critical material attributes (CMAs) affecting powder tribo-charging. A strong correlation was obtained between the measured charge and inter-particle friction. This indicated the latter as one of the most influencing material characteristic impacting the powder tribo-charging phenomenon of the selected materials.
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33
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Process Control of Drug Product Continuous Manufacturing Operations—a Study in Operational Simplification and Continuous Improvement. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09498-2] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
Abstract
Abstract
Purpose
The purpose of this manuscript is to demonstrate that implementation of gravimetric measurements provides the same assurance of product quality and process control as spectroscopic measurements (1) for control of drug content in a fixed-dose combination (FDC) tablet and (2) for identification of non-conforming material.
Methods
A wet granulation continuous tableting line was used to make the FDC drug product batches. Comparative data was generated for ten batches using near-infrared (NIR) spectroscopy for core tablets, and gravimetric in-process control measurements (IPCs) applied to the ratio control of intra- and extra-granular blend (IG and EG). HPLC reference data were collected to further demonstrate uniformity at each stage of the production process, including IG, final blend, and core tablets. All possible sources of variation not directly detectable by the gravimetric measurements were considered and quantified.
Results
The two IPC measurement techniques showed excellent agreement where both were within 2% of the target drug concentrations and within 2% of each other for the ten comparative batches. The NIR was more sensitive to material and process variations than the gravimetric IPCs; thus, it was more variable within and across batches. Gravimetric IPCs were demonstrated as an effective replacement for spectroscopic measurements for continuous tableting operations, capable of ensuring on target manufacturing and detection of non-conforming material.
Conclusions
As pharmaceutical companies continue to push toward operational simplicity and sustainable manufacturing processes, soft-sensor and gravimetric controls as alternatives to their spectroscopic counterparts will be applied more broadly for process monitoring and control.
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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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Ervasti T, Niinikoski H, Mäki-Lohiluoma E, Leppinen H, Ketolainen J, Korhonen O, Lakio S. The Comparison of Two Challenging Low Dose APIs in a Continuous Direct Compression Process. Pharmaceutics 2020; 12:pharmaceutics12030279. [PMID: 32244950 PMCID: PMC7151305 DOI: 10.3390/pharmaceutics12030279] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2020] [Revised: 03/13/2020] [Accepted: 03/18/2020] [Indexed: 11/18/2022] Open
Abstract
Segregation is a common problem in batch-based direct compression (BDC) processes, especially with low-dose tablet products, as is the preparation of a homogenous mixture. The scope of the current work was to explore if a continuous direct compression (CDC) process could serve as a solution for these challenges. Furthermore, the principle of a platform formulation was demonstrated for low dose tablets. The combination of filler excipients and the API in the formulation used was suitable for direct compression, but also prone to induce segregation in BDC process. The CDC process was found to be very promising; it was shown that tablets with the desired quality parameters could be manufactured successfully with both of the APIs studied. Powder analysis indicated that the APIs display some fundamental differences in their physical properties, which was also reflected in powder mixture properties and, hence, eventually in processing. However, process parameters, especially mixer impeller speed, were not found to have any significant influence on end product quality. The study suggests that a CDC process can be a viable solution to resolve the challenges described. Moreover, manufacturing by using a universal platform formulation seems to be a feasible way for producing low-dose tablets.
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Affiliation(s)
- Tuomas Ervasti
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
- Correspondence: ; Tel.: +358403553252
| | - Hannes Niinikoski
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
| | | | - Heidi Leppinen
- Orion Pharma Oyj, 02200 Espoo, Finland; (E.M.-L.); (H.L.); (S.L.)
| | - Jarkko Ketolainen
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
| | - Ossi Korhonen
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
| | - Satu Lakio
- Orion Pharma Oyj, 02200 Espoo, Finland; (E.M.-L.); (H.L.); (S.L.)
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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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37
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Demonstration of the Feasibility of Predicting the Flow of Pharmaceutically Relevant Powders from Particle and Bulk Physical Properties. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09433-5] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
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38
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Hsiao WK, Hörmann TR, Toson P, Paudel A, Ghiotti P, Stauffer F, Bauer F, Lakio S, Behrend O, Maurer R, Holman J, Khinast J. Feeding of particle-based materials in continuous solid dosage manufacturing: a material science perspective. Drug Discov Today 2020; 25:800-806. [PMID: 31982395 DOI: 10.1016/j.drudis.2020.01.013] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2019] [Revised: 12/17/2019] [Accepted: 01/16/2020] [Indexed: 11/16/2022]
Abstract
The pharmaceutical industry today is experiencing a paradigm shift from batch to continuous manufacturing, which promises greater flexibility to target diverse populations, as well as more-consistent product quality to ensure best efficacy. However, shifting to continuous processing means that even basic process steps, such as feeding, can become unexpected but are crucially important. In this review, we will present the fundamental differences between dispensing (batch) and feeding (continuous) and how they impact the formulation design space. We will further outline our rational development approach, applicable to continuous unit operations in general, which includes standardized material and process characterization, as well as predictive modeling based on advanced, multidomain simulation tools.
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Affiliation(s)
- Wen-Kai Hsiao
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com)
| | - Theresa R Hörmann
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); Graz University of Technology, Graz, Austria
| | - Peter Toson
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Amrit Paudel
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); Graz University of Technology, Graz, Austria
| | - Patrizia Ghiotti
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); UCB Pharma S.A., Brussels, Belgium
| | - Fanny Stauffer
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); UCB Pharma S.A., Brussels, Belgium
| | - Finn Bauer
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); Merck KGaA, Darmstadt, Germany
| | - Satu Lakio
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); Orion Pharma, Espoo, Finland
| | - Olaf Behrend
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach, Germany
| | - Reto Maurer
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); F. Hoffmann-La Roche Ltd, Basel, Switzerland
| | - James Holman
- European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); GEA Group, Wommelgem, Belgium
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; European Consortium of Continuous Pharmaceutical Manufacturing (eccpm.com); Graz University of Technology, Graz, Austria.
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Szabó E, Démuth B, Galata DL, Vass P, Hirsch E, Csontos I, Marosi G, Nagy ZK. Continuous Formulation Approaches of Amorphous Solid Dispersions: Significance of Powder Flow Properties and Feeding Performance. Pharmaceutics 2019; 11:E654. [PMID: 31817454 PMCID: PMC6955740 DOI: 10.3390/pharmaceutics11120654] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/07/2019] [Revised: 11/28/2019] [Accepted: 12/03/2019] [Indexed: 12/14/2022] Open
Abstract
Preparation and formulation of amorphous solid dispersions (ASDs) are becoming more and more popular in the pharmaceutical field because the dissolution of poorly water-soluble drugs can be effectively improved this way, which can lead to increased bioavailability in many cases. During downstream processing of ASDs, technologists need to keep in mind both traditional challenges and the newest trends. In the last decade, the pharmaceutical industry began to display considerable interest in continuous processing, which can be explained with their potential advantages such as smaller footprint, easier scale-up, and more consistent product, better quality and quality assurance. Continuous downstream processing of drug-loaded ASDs opens new ways for automatic operation. Therefore, the formulation of poorly water-soluble drugs may be more effective and safe. However, developments can be challenging due to the poor flowability and feeding properties of ASDs. Consequently, this review pays special attention to these characteristics since the feeding of the components greatly influences the content uniformity in the final dosage form. The main purpose of this paper is to summarize the most important steps of the possible ASD-based continuous downstream processes in order to give a clear overview of current course lines and future perspectives.
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Affiliation(s)
| | | | | | | | | | | | | | - Zsombor K. Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, H-1111 Budapest, Hungary; (E.S.); (B.D.); (D.L.G.); (P.V.); (E.H.); (I.C.); (G.M.)
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40
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Peng Y, Zhao K, Yang Y, Pu H, Sun Y, Liu N, Liu Y, Xie S, Luo J. Highly precise and efficient powder feeding system based on gravimetric feedback. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.06.043] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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41
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Dahlgren G, Tajarobi P, Simone E, Ricart B, Melnick J, Puri V, Stanton C, Bajwa G. Continuous Twin Screw Wet Granulation and Drying-Control Strategy for Drug Product Manufacturing. J Pharm Sci 2019; 108:3502-3514. [PMID: 31276686 DOI: 10.1016/j.xphs.2019.06.023] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/03/2018] [Revised: 06/16/2019] [Accepted: 06/26/2019] [Indexed: 01/28/2023]
Abstract
The use of continuous manufacturing has been increasing within the pharmaceutical industry over the last few years. Continuous direct compression has been the focus of publications on the topic to date. The use of wet granulation can improve segregation resistance, uniformity, enhance density, and flow properties for improved tabletability, or improve stability of products that cannot be manufactured by using a direction compression process. This article focuses on development of appropriate control strategies for continuous wet granulation (especially twin screw wet granulation) through equipment design, material properties and manufacturing process along with areas where additional understanding is required. The article also discusses the use of process analytical technologies as part of the control and automation approach to ensure a higher assurance of product quality. Increased understanding of continuous wet granulation should result in increased utilization of the technique, thereby allowing for an increase in diversity of products manufactured by continuous manufacturing and the benefits that comes with a more complex process such as wet granulation compared with direct compression process.
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Affiliation(s)
| | | | - Eric Simone
- Agios Pharmaceuticals Inc., Cambridge, Massachusetts 02139
| | | | | | - Vibha Puri
- Genentech, Inc., San Francisco, California 94080
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42
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Sensitivity of a continuous hot-melt extrusion and strand pelletization line to control actions and composition variation. Int J Pharm 2019; 566:239-253. [DOI: 10.1016/j.ijpharm.2019.05.046] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/26/2019] [Revised: 05/14/2019] [Accepted: 05/15/2019] [Indexed: 11/20/2022]
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43
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Schaller BE, Moroney KM, Castro-Dominguez B, Cronin P, Belen-Girona J, Ruane P, Croker DM, Walker GM. Systematic development of a high dosage formulation to enable direct compression of a poorly flowing API: A case study. Int J Pharm 2019; 566:615-630. [PMID: 31158454 DOI: 10.1016/j.ijpharm.2019.05.073] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2019] [Revised: 05/13/2019] [Accepted: 05/30/2019] [Indexed: 10/26/2022]
Abstract
In this work, the transfer of oral solid dosage forms, currently manufactured via wet granulation, to a continuous direct compression process was considered. Two main challenges were addressed: (1) a poorly flowing API (Canagliflozin) and (2) high drug loading (51 wt%). A scientific approach was utilised for formulation development, targeting flow and compaction behaviour suitable for manufacturing scale. This was achieved through systematic screening of excipients to identify feasible formulations. Targeted design of experiments based on factors such as formulation mixture and processing parameters were utilised to investigate key responses for tablet properties, flow and compaction behaviour. Flow behaviour was primarily evaluated from percentage compressibility and shear cell testing on a powder flow rheometer (FT4). The compaction behaviour was studied using a compaction simulator (Gamlen). The relationships between tablet porosity, tensile strength and compaction pressure were used to evaluate tabletability, compactibility and compressibility to assess scale-up. The success of this design procedure is illustrated by scaling up from the compaction simulator to a Riva Piccola rotary tablet press, while maintaining critical quality attributes (CQAs). Compactibility was identified as a suitable scale-up relationship. The developed procedure should allow accelerated development of formulations for continuous direct compression.
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Affiliation(s)
- Barbara E Schaller
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland.
| | - Kevin M Moroney
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland; MACSI, Department of Mathematics and Statistics, University of Limerick, Limerick, Ireland
| | | | - Patrick Cronin
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland
| | - Jorge Belen-Girona
- Johnson & Johnson Supply Chain, Product Supply - Manufacturing Engineering and Technology, USA
| | - Patrick Ruane
- Johnson & Johnson Supply Chain, Product Supply - Manufacturing Engineering and Technology, USA
| | - Denise M Croker
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland
| | - Gavin M Walker
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland
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Bostijn N, Van Renterghem J, Vanbillemont B, Dhondt W, Vervaet C, De Beer T. Continuous manufacturing of a pharmaceutical cream: Investigating continuous powder dispersing and residence time distribution (RTD). Eur J Pharm Sci 2019; 132:106-117. [DOI: 10.1016/j.ejps.2019.02.036] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/18/2019] [Revised: 02/28/2019] [Accepted: 02/28/2019] [Indexed: 01/09/2023]
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Yadav IK, Holman J, Meehan E, Tahir F, Khoo J, Taylor J, Benedetti A, Aderinto O, Bajwa G. Influence of material properties and equipment configuration on loss-in-weight feeder performance for drug product continuous manufacture. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.01.071] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/29/2022]
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46
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Karttunen AP, Wikström H, Tajarobi P, Fransson M, Sparén A, Marucci M, Ketolainen J, Folestad S, Korhonen O, Abrahmsén-Alami S. Comparison between integrated continuous direct compression line and batch processing - The effect of raw material properties. Eur J Pharm Sci 2019; 133:40-53. [PMID: 30862514 DOI: 10.1016/j.ejps.2019.03.001] [Citation(s) in RCA: 22] [Impact Index Per Article: 4.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2018] [Revised: 02/27/2019] [Accepted: 03/02/2019] [Indexed: 11/26/2022]
Abstract
There is a current trend in pharmaceutical manufacturing to shift from traditional batch manufacture to continuous manufacturing. The purpose of this study was to test the ability of an integrated continuous direct compression (CDC) line, in relation to batch processing, to achieve consistent tablet quality over long processing periods for formulations with poor flow properties or with a tendency to segregate. The study design included four industrially relevant formulations with different segregation indices and flow properties induced through different grades of the Active Pharmaceutical Ingredient (API), paracetamol, and major filler as well as varying the amount of API. The performance metrics investigated were content, uniformity of content, tablet weight, and tablet strength. The overall process stability over time was significantly improved with the CDC line as compared to the batch process. For all the formulations with a high API content, the CDC line provided better or equal uniformity of content and tablet weight as compared to batch. The CDC line was especially efficient in providing a stable content and tablet weight for poorly flowing formulations containing the standard, cohesive, grade of API. The only formulation that performed better in the batch process was the formulation with a low API content. Thus, for this formulation, the batch process achieved lower variation in tablet content since maintaining a low feed rate for the API proved challenging in the CDC line. In addition, some of the API became stuck in the CDC line between feeding and tableting, most likely at the funnel in the mixer inlet, highlighting the need for properly designed interfaces between units. The insensitivity of the CDC line towards poor flow indicates that one could use direct compression at high drug load compositions of poorly flowing powder blends that could not be processed via batch manufacturing.
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Affiliation(s)
- Anssi-Pekka Karttunen
- University of Eastern Finland, School of Pharmacy, PROMIS-Centre, FI-70211 Kuopio, Finland
| | | | | | | | | | | | - Jarkko Ketolainen
- University of Eastern Finland, School of Pharmacy, PROMIS-Centre, FI-70211 Kuopio, Finland
| | | | - Ossi Korhonen
- University of Eastern Finland, School of Pharmacy, PROMIS-Centre, FI-70211 Kuopio, Finland.
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Bostijn N, Dhondt J, Ryckaert A, Szabó E, Dhondt W, Van Snick B, Vanhoorne V, Vervaet C, De Beer T. A multivariate approach to predict the volumetric and gravimetric feeding behavior of a low feed rate feeder based on raw material properties. Int J Pharm 2019; 557:342-353. [DOI: 10.1016/j.ijpharm.2018.12.066] [Citation(s) in RCA: 40] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/28/2018] [Revised: 12/14/2018] [Accepted: 12/15/2018] [Indexed: 12/18/2022]
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48
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Impact of material properties and process variables on the residence time distribution in twin screw feeding equipment. Int J Pharm 2019; 556:200-216. [DOI: 10.1016/j.ijpharm.2018.11.076] [Citation(s) in RCA: 35] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/23/2018] [Revised: 11/29/2018] [Accepted: 11/30/2018] [Indexed: 11/22/2022]
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49
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Stauffer F, Vanhoorne V, Pilcer G, Chavez PF, Schubert MA, Vervaet C, De Beer T. Managing active pharmaceutical ingredient raw material variability during twin-screw blend feeding. Eur J Pharm Biopharm 2018; 135:49-60. [PMID: 30582959 DOI: 10.1016/j.ejpb.2018.12.012] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/30/2018] [Revised: 10/31/2018] [Accepted: 12/20/2018] [Indexed: 10/27/2022]
Abstract
Continuous powder feeding is a critical step in continuous manufacturing of solid dosage forms, as this unit operation should ensure the mass flow consistency at the desired powder feed rate to guarantee the process throughput and final product consistency. In this study, twin-screw feeding of a pharmaceutical formulation (i.e., blend) existing of a highly dosed very poorly flowing active pharmaceutical ingredient (API) leading to insufficient feeding capacity was investigated. Furthermore, the API showed very high batch-to-batch variability in raw material properties dominating the formulation blend properties. Formulation changes were evaluated to improve the flowability of the blends and to mitigate the impact of API batch-to-batch variability on the twin-screw feeding. Herewith, feeding evaluation tests and an extensive material characterization of the reformulated blends were performed to assess the impact of the formulation changes upon continuous twin-screw feeding. The transfer of the glidant from extra-granular to intra-granular phase allowed to improve the flowability of the blends. A sufficient feeding capacity for the downstream process and a mitigation of the impact of batch-to-batch variability of the API upon twin-screw feeding of the blends could be achieved. No effect of the formulation or of the API properties on the feeding stability was observed. The material characterization of the blends allowed identifying the material attributes which were critical for continuous twin-screw feeding (i.e., bulk density, mass charge and powder cohesiveness).
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Affiliation(s)
- F Stauffer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium
| | - V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - G Pilcer
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | | | - M A Schubert
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium
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50
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Hanson J. Control of a system of loss-in-weight feeders for drug product continuous manufacturing. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.03.027] [Citation(s) in RCA: 27] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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