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Charoo NA, Akanji O, Rahman Z, Khan AA, Badshah A. Risk-Based Approach for Defining Retest Dates for Active Pharmaceutical Ingredients and Excipients. Pharmaceuticals (Basel) 2024; 17:903. [PMID: 39065753 PMCID: PMC11280389 DOI: 10.3390/ph17070903] [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: 05/14/2024] [Revised: 05/22/2024] [Accepted: 06/20/2024] [Indexed: 07/28/2024] Open
Abstract
Drug substances and excipients must be stored in recommended storage conditions and should comply with their specifications during the retest period for their use in the manufacture of drug products. The ICH (International Council for Harmonization of Technical Requirements for Pharmaceuticals for Human Use) and WHO (World Health Organization) regulatory guidelines mandate that after the retest period, the drug substances must be retested for compliance with the specification and then used immediately in the manufacture of the finished product. Although these substances can be retested multiple times, an emphasis is placed on immediate use following a retest and compliance with standards. The phrase "used immediately" is ambiguous and is left for interpretation. In this article, we will look at the various processes that must be completed to determine the retest date. In addition, we present a risk-based method for establishing retest dates and the time during which material can be used.
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Affiliation(s)
- Naseem A. Charoo
- Aramed, 216, Laboratory Complex, Dubai Science Park, Dubai P.O. Box 478861, United Arab Emirates;
| | - Omotayo Akanji
- Katchey Laboratories, 26, Adeniyi, Adeniyi Jones Ave, Ogba, Ikeja 101233, Nigeria;
| | - Ziyaur Rahman
- Irma Lerma Rangel College of Pharmacy, Texas A&M Health Science Center, Texas A&M University, College Station, TX 77843, USA
| | - Aqeel A. Khan
- Adcan Pharma LLC, ICAD, Abu Dhabi P.O. Box 9824, United Arab Emirates; (A.A.K.); (A.B.)
| | - Aqal Badshah
- Adcan Pharma LLC, ICAD, Abu Dhabi P.O. Box 9824, United Arab Emirates; (A.A.K.); (A.B.)
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Hebbink GA, Janssen PHM, Kok JH, Menarini L, Giatti F, Funaro C, Consoli SF, Dickhoff BHJ. Lubricant Sensitivity of Direct Compression Grades of Lactose in Continuous and Batch Tableting Process. Pharmaceutics 2023; 15:2575. [PMID: 38004554 PMCID: PMC10674241 DOI: 10.3390/pharmaceutics15112575] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/11/2023] [Revised: 10/30/2023] [Accepted: 11/01/2023] [Indexed: 11/26/2023] Open
Abstract
Modern pharmaceutical manufacturing based on Quality by Design and digitalisation is revolutionising the pharmaceutical industry. Continuous processes are promoted as they increase efficiency and improve quality control. Compared to batch blending, continuous blending is easier to scale and provides advantages for achieving blend homogeneity. One potential challenge of continuous blending is the risk of over-lubrication. In this study, blending homogeneity and lubricant sensitivity are investigated for both batch and continuous processes. Given their distinct chemical structures and morphologies, anhydrous lactose and granulated lactose are expected to exhibit varying sensitivities to changes in process settings across both technologies. The findings suggest that both lactose grades provide highly stable blends that can be safely utilised in both batch and continuous modes. Optimisation should focus on process variables, such as the quality of loss-in-weight feeders used for dosing low doses of ingredients. The most significant process parameter for lubricant sensitivity was the type of lactose used. Anhydrous lactose produced harder tablets than the more porous granulated lactose but was more sensitive to lubrication at the same settings. The magnesium stearate content and its interaction with the type of lactose are also critical factors, with magnesium stearate having a counterproductive impact on tabletability.
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Affiliation(s)
| | - Pauline H. M. Janssen
- DFE Pharma GmbH & Co. KG, 47574 Goch, Germany (B.H.J.D.)
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, 9713 AV Groningen, The Netherlands
| | - Jurjen H. Kok
- DFE Pharma GmbH & Co. KG, 47574 Goch, Germany (B.H.J.D.)
| | - Lorenzo Menarini
- IMA S.p.A. Active Division, 40064 Ozzano dell’Emilia Bologna, Italy; (L.M.)
| | - Federica Giatti
- IMA S.p.A. Active Division, 40064 Ozzano dell’Emilia Bologna, Italy; (L.M.)
| | - Caterina Funaro
- IMA S.p.A. Active Division, 40064 Ozzano dell’Emilia Bologna, Italy; (L.M.)
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Liu J, Klinzing GR, Nie H. Effect of Material Properties and Variability of Mannitol on Tablet Formulation Development. Pharm Res 2023; 40:2071-2085. [PMID: 37552385 DOI: 10.1007/s11095-023-03577-y] [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: 05/06/2023] [Accepted: 07/21/2023] [Indexed: 08/09/2023]
Abstract
PURPOSE Using a high level of mannitol as a diluent in oral formulations can potentially result in tablet defects (e.g., chipping, cracking) during compression. This work aims to scrutinize the linkage between the mechanical properties and material attributes of mannitol and also uncover how variations between vendors and lots can lead to significant changes in the compaction performance of tablet formulations containing mannitol. METHODS The mechanical properties (Poisson's ratio, fracture energy) and mechanical performance (ejection force, pressure transmission ratio, residual radial die-wall stress, and tensile strength) of mannitol compacts were assessed on a compaction simulator for four lots of mannitol from two different vendors. The variation of material attributes of each lot, including particle size distribution (PSD), crystal form, primary crystal size and morphology, specific surface area (SSA), powder flow, and moisture absorption were investigated. RESULTS The variability of material attributes in mannitol lots, especially primary crystal size and SSA, can result in significant changes in mechanical properties and mechanical performance such as ejection force and residual radial die-wall stresses, which potentially led to chipping during compression. CONCLUSION The study elucidated the linkage between fundamental material attributes and mechanical properties of mannitol, highlighting their impact on tablet defects and compaction performance in compression. A comprehensive understanding of the variability in mannitol properties between vendors and lots is crucial for successful formulation development, particularly when high percentages of mannitol are included as a brittle excipient.
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Affiliation(s)
- Jiaying Liu
- Pharmaceutical Sciences, Merck & Co., Inc, 126 E. Lincoln Ave, Rahway, NJ, 07065, USA
| | - Gerard R Klinzing
- Pharmaceutical Sciences, Merck & Co., Inc, 126 E. Lincoln Ave, Rahway, NJ, 07065, USA
| | - Haichen Nie
- Pharmaceutical Sciences, Merck & Co., Inc, 126 E. Lincoln Ave, Rahway, NJ, 07065, USA.
- Center for Materials Science and Engineering, Merck & Co., Inc., 770 Sumneytown Pike, West Point, PA, 19486, USA.
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Zupančič O, Doğan A, Martins Fraga R, Demiri V, Paudel A, Khinast J, Spoerk M, Sacher S. On the influence of raw material attributes on process behaviour and product quality in a continuous WET granulation tableting line. Int J Pharm 2023; 642:123097. [PMID: 37268028 DOI: 10.1016/j.ijpharm.2023.123097] [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: 03/09/2023] [Revised: 05/27/2023] [Accepted: 05/29/2023] [Indexed: 06/04/2023]
Abstract
Continuous manufacturing of oral solids is a complex process in which critical material attributes (CMAs), formulation and critical process parameters (CPPs) play a fundamental role. However, assessing their effect on the intermediate and final product's critical quality attributes (CQAs) remains challenging. The aim of this study was to tackle this shortcoming by evaluating the influence of raw material properties and formulation composition on the processability and quality of granules and tablets on a continuous manufacturing line. Powder-to-tablet manufacturing was performed using four formulations in various process settings. Pre-blends of different drug loadings (2.5 % w/w and 25% w/w) and two BCS classes (Class I and II) were continuously processed on an integrated process line ConsiGmaTM 25, including twin screw wet granulation, fluid bed drying, milling, sieving, in-line lubrication and tableting. The liquid-to-solid ratio and the granule drying time were varied to process granules under nominal, dry and wet conditions. It was shown that the BCS class and the drug dosage influenced the processability. Intermediate quality attributes, such as the loss on drying and the particle size distribution, directly correlated with the raw material's properties and process parameters. Process settings had a profound impact on the tablet's hardness, disintegration time, wettability and porosity.
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Affiliation(s)
- Ožbej Zupančič
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Aygün Doğan
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Rúben Martins Fraga
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Valjon Demiri
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Amrit Paudel
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria; Institute of Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria; Institute of Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13, 8010 Graz, Austria
| | - Martin Spoerk
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.
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Quality by design approach with multivariate analysis and artificial neural network models to understand and control excipient variability. JOURNAL OF PHARMACEUTICAL INVESTIGATION 2022. [DOI: 10.1007/s40005-022-00608-5] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
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Co-processed tablet excipient composition, its preparation and use: US10071059 B2: patent spotlight. Pharm Pat Anal 2022; 12:19-25. [PMID: 36382542 DOI: 10.4155/ppa-2022-0036] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
Co-processing involves the incorporation of one excipients into the particle structure of other excipients to overcome the deficiencies of each excipients. The current patent describes the co-processing of microcrystalline cellulose and mannitol via fluid bed agglomeration with an aim to limit the use of lubricant in tablet composition. The co-processed excipients blend was compared with the physical blend of excipients and characterized for scanning electron microscopy, disintegration and hardness. The average particle size of co-processed excipients was less than 0.55 mm, characterized by large individual lactose coated particles whereas, the physical blend particles are uncoated and irregular in shape. Tablets made from both physical blend and co-processed excipients were compared. As per the hardness and disintegration studies, with increase in mixing time of excipients both hardness and disintegration time decreases.
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Recent advancements in additive manufacturing techniques employed in the pharmaceutical industry: A bird's eye view. ANNALS OF 3D PRINTED MEDICINE 2022. [DOI: 10.1016/j.stlm.2022.100081] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022] Open
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Zhao H, Zhao L, Lin X, Shen L. An update on microcrystalline cellulose in direct compression: Functionality, critical material attributes, and co-processed excipients. Carbohydr Polym 2022; 278:118968. [PMID: 34973783 DOI: 10.1016/j.carbpol.2021.118968] [Citation(s) in RCA: 16] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2021] [Revised: 11/29/2021] [Accepted: 11/29/2021] [Indexed: 11/02/2022]
Abstract
Microcrystalline cellulose (MCC) is one of the most popular cellulose derivatives in the pharmaceutical industry. Thanks to its outstanding tabletability, MCC is generally included in direct compression (DC) tablet formulations containing poor-tabletability active pharmaceutical ingredients. Nowadays, numerous grades of MCC from various brands are accessible for pharmaceutical manufacturers, leading to variability in MCC properties. Hence, it seems to be worthy and urgent to evaluate the influences of MCC variability on tablet quality and to identify critical material attributes (CMAs) based on the idea of Quality by Control. Besides, MCC-based co-processed excipients can effectively combine the functions of the filler, binder, disintegrant, lubricant, glidant, or flavor, and thus have drawn extensive interest. In this review, we focused specifically on the recent advances and development of MCC on DC tableting, including the functions in tablet formulations, potential CMAs, and MCC-based co-possessed excipients, therefore providing a reference for further studies.
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Affiliation(s)
- Haiyue Zhao
- School of Pharmacy, Shanghai University of Traditional Chinese Medicine, No.1200, Cai-lun Road, Pudong District, Shanghai 201203, PR China
| | - Lijie Zhao
- Engineering Research Center of Modern Preparation Technology of Traditional Chinese Medicine of Ministry of Education, Shanghai University of Traditional Chinese Medicine, No.1200, Cai-lun Road, Pudong District, Shanghai 201203, PR China.
| | - Xiao Lin
- School of Pharmacy, Shanghai University of Traditional Chinese Medicine, No.1200, Cai-lun Road, Pudong District, Shanghai 201203, PR China.
| | - Lan Shen
- School of Pharmacy, Shanghai University of Traditional Chinese Medicine, No.1200, Cai-lun Road, Pudong District, Shanghai 201203, PR China.
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Wang Z, Cao J, Li W, Wang Y, Luo G, Qiao Y, Zhang Y, Xu B. Using a material database and data fusion method to accelerate the process model development of high shear wet granulation. Sci Rep 2021; 11:16514. [PMID: 34389766 PMCID: PMC8363627 DOI: 10.1038/s41598-021-96097-x] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/10/2021] [Accepted: 08/04/2021] [Indexed: 11/09/2022] Open
Abstract
High shear wet granulation (HSWG) has been wildly used in manufacturing of oral solid dosage (OSD) forms, and process modeling is vital to understanding and controlling this complex process. In this paper, data fusion and multivariate modeling technique were applied to develop a formulation-process-quality model for HSWG process. The HSWG experimental data from both literature and the authors' laboratory were fused into a single and formatted representation. A material database and material matching method were used to compensate the incomplete physical characterization of literature formulation materials, and dimensionless parameters were utilized to reconstruct process variables at different granulator scales. The exploratory study on input materials properties by principal component analysis (PCA) revealed that the formulation data collected from different articles generated a formulation library which was full of diversity. In prediction of the median granule size, the partial least squares (PLS) regression models derived from literature data only and a combination of literature data and laboratory data were compared. The results demonstrated that incorporating a small number of laboratory data into the multivariate calibration model could help significantly reduce the prediction error, especially at low level of liquid to solid ratio. The proposed data fusion methodology was beneficial to scientific development of HSWG formulation and process, with potential advantages of saving both experimental time and cost.
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Affiliation(s)
- Zheng Wang
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China
| | - Junjie Cao
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China
| | - Wanting Li
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China
| | - Yawen Wang
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China
| | - Gan Luo
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China
| | - Yanjiang Qiao
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China.,Beijing Key Laboratory of Chinese Medicine Manufacturing Process Control and Quality Evaluation, Beijing, 100029, People's Republic of China
| | - Yanling Zhang
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China. .,Beijing Key Laboratory of Chinese Medicine Manufacturing Process Control and Quality Evaluation, Beijing, 100029, People's Republic of China.
| | - Bing Xu
- Department of Chinese Medicine Informatics, School of Chinese Materia Medica, Beijing University of Chinese Medicine, No.11, North Third Ring East Road, Beijing, 100029, People's Republic of China. .,Beijing Key Laboratory of Chinese Medicine Manufacturing Process Control and Quality Evaluation, Beijing, 100029, People's Republic of China.
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Charoo NA, Barakh Ali SF, Mohamed EM, Kuttolamadom MA, Ozkan T, Khan MA, Rahman Z. Selective laser sintering 3D printing - an overview of the technology and pharmaceutical applications. Drug Dev Ind Pharm 2020; 46:869-877. [PMID: 32364418 DOI: 10.1080/03639045.2020.1764027] [Citation(s) in RCA: 58] [Impact Index Per Article: 14.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
Abstract
Food and Drug Administration (FDA) has approved a drug product (Spritam®) and many medical devices manufactured by three-dimensional printing (3DP) processes for human use. There is immense potential to print personalized medicines using 3DP. Many 3DP methods have been reported in the literature for pharmaceutical applications. However, selective laser sintering (SLS) printing has remained least explored for pharmaceutical applications. There are many advantages and challenges in adopting a SLS method for fabrication of personalized medicines. Solvent-free nature, availability of FDA approved thermoplastic polymer/excipients (currently used in hot melt-extrusion process), minimal/no post-processing step, etc. are some of the advantages of the SLS printing process. Major challenges of the technology are requirement of at least one thermoplastic component in the formulation and thermal stability of drug and excipients. This review provides an overview of the SLS printing method, excipient requirements, process monitoring, quality defects, regulatory aspects, and potential pharmaceutical applications.
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Affiliation(s)
- Naseem A Charoo
- Zeino Pharma FZ LLC, 703-HQ Complex-North Tower, Dubai, United Arab Emirates
| | - Sogra F Barakh Ali
- Irma Lerma Rangel College of Pharmacy, Texas A&M Health Science Center, Texas A&M University, College Station, TX, USA
| | - Eman M Mohamed
- Irma Lerma Rangel College of Pharmacy, Texas A&M Health Science Center, Texas A&M University, College Station, TX, USA.,Department of Pharmaceutics, Faculty of Pharmacy, Beni-Suef University, Beni-Suef, Egypt
| | - Mathew A Kuttolamadom
- Engineering Technology & Industrial Distribution, College of Engineering, Texas A&M University, College Station, TX, USA
| | - Tanil Ozkan
- Dover Precision Components, Woodlands, TX, USA
| | - Mansoor A Khan
- Irma Lerma Rangel College of Pharmacy, Texas A&M Health Science Center, Texas A&M University, College Station, TX, USA
| | - Ziyaur Rahman
- Irma Lerma Rangel College of Pharmacy, Texas A&M Health Science Center, Texas A&M University, College Station, TX, USA
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