Tablet strength, porosity, elasticity and solid state structure of tablets compressed at high loads

Calorimetric investigation on heat release during the disintegration process of pharmaceutical tablets

The compendial USP〈701〉 disintegration test method offers a crucial pass/fail assessment for immediate release tablet disintegration. However, its single end-point approach provides limited insight into underlying mechanisms. This study introduces a novel calorimetric approach, aimed at providing comprehensive process profiles beyond binary outcomes. We developed a novel disintegration reaction calorimeter to monitor the heat release throughout the disintegration process and successfully obtained enthalpy change profiles of placebo tablets with various porosities. The formulation comprised microcrystalline cellulose (MCC), anhydrous lactose, croscarmellose sodium (CCS), and magnesium stearate (MgSt). An abrupt temperature rise was observed after introducing the disintegration medium to tablets, and the relationship between the heat rise time and the tablet's porosity was investigated. The calorimeter's sensitivity was sufficient to discern distinct heat changes among individual tablets, and the analysis revealed a direct correlation between the two. Higher porosity corresponded to shorter heat rise time, indicating faster disintegration rates. Additionally, the analysis identified a concurrent endothermic process alongside the anticipated exothermic phenomenon, potentially associated with the dissolution of anhydrous lactose. Since lactose is the only soluble excipient within the blend composition, the endothermic process can be attributed to the absorption of heat as lactose molecules dissolve in water. The findings from this study underscore the potential of utilising calorimetric methods to quantify the wettability of complex compounds and, ultimately, optimise tablet formulations.

Dynamic compaction of cohesive granular materials: scaling behavior and bonding structures

The compaction of cohesive granular materials is a common operation in powder-based manufacture of many products. However, the influence of particle-scale parameters such as bond strength on the packing structure and the general scaling of the compaction process are still poorly understood. We use particle dynamics simulations to analyze jammed configurations obtained by dynamic compaction of sticky particles under a fixed compressive pressure for a broad range of system parameter values. We show that relative porosity, representing the relative importance of porosity with respect to its minimum and maximum values, is a unique function of a modified cohesion number that combines adhesion force, confining pressure, and particle size, as well as contact stiffness, which is often assumed to be ineffective but is shown here to play an essential role in compaction. An asymmetric sigmoidal form based on two power laws provides an excellent fit to the data. The statistical properties of the bond network reveal self-balanced force structures and an exponential fall-off of the number of both tensile and compressive forces. Remarkably, the properties of the bond network depend on the cohesion number rather than the modified cohesion number, implying that similar bond network characteristics are compatible with a broad range of porosities mainly due to the effect of contact stiffness. We also discuss the origins of data points escaping the general scaling of porosity and show that they reflect either finite system size or rigid confining walls.

The Influence of Wet Granulation Parameters on the Compaction Behavior and Tablet Strength of a Hydralazine Powder Mixture

The aim of this paper was to describe the influence of high-shear wet granulation process parameters on tablet tensile strength and compaction behavior of a powder mixture and granules containing hydralazine. The hydralazine powder mixture and eight types of granules were compacted into tablets and evaluated using the Heckel, Kawakita and Adams analyses. The granules were created using two types of granulation liquid (distilled water and aqueous solution of polyvinylpyrrolidone), at different impeller speeds (500 and 700 rpm) and with different wet massing times (without wet massing and for 2 min). Granulation resulted in improved compressibility, reduced dustiness and narrower particle-size distribution. A significant influence of wet massing time on parameters from the Kawakita and Adams analysis was found. Wet massing time had an equally significant effect on tablet tensile strength, regardless of the granulation liquid used. Granules formed with the same wet massing time showed the same trends in tabletability graphs. Tablets created using a single-tablet press (batch compaction) and an eccentric tablet press showed opposite values of tensile strength. Tablets from granules with a higher bulk density showed lower strength during batch compaction and, conversely, higher strength during eccentric tableting.

Synthesis and Structural and Strength Properties of xLi2ZrO3-(1-x)MgO Ceramics-Materials for Blankets

The article considers the effect of doping with magnesium oxide (MgO) on changes in the properties of lithium-containing ceramics based on lithium metazirconate (Li₂ZrO₃). There is interest in this type of ceramics on account of their prospects for application in tritium production in thermonuclear power engineering, as well as several other applications related to alternative energy sources. During the investigations undertaken, it was found that variation in the MgO dopant concentration above 0.10-0.15 mol resulted in the formation of impurity inclusions in the ceramic structure in the form of a MgLi₂ZrO₄ phase, the presence of which resulted in a rise in the density of the ceramics, along with elevation in resistance to external influences. Moreover, during experimental work on the study of the thermal stability of the ceramics to external influences, it was found that the formation of two-phase ceramics resulted in growth in the preservation of stable strength properties during high-temperature cyclic tests. The decrease in strength characteristics was observed to be less than 1%.

Multivariate data analysis to evaluate commonly used compression descriptors

Numerous studies elucidated material behavior based on compression analyses. Especially compressibility, compactibility and tabletability were in the focus of these investigations. In the present study, a comprehensive multivariate data analysis was performed using principal component analysis method. Twelve pharmaceutically used excipients were selected for direct compression tableting and subsequent evaluation of several compression analyses. Material properties, tablet properties, tableting parameters and parameters from compression analyses were used as input variables. The materials could successfully be grouped using principal component analysis. Of the tableting parameters, the compression pressure showed the greatest influence on the results. The tabletability was found to be the most important compression analysis in the material characterization. Compressibility and compactibility only played a minor role in the evaluation. Some important insights have been gained for a deeper understanding of the tableting process using the multivariate approach to evaluate the variety of compression data.

Breaking patterns of press-coated tablets during the diametral compression test: Influence of the product, geometry and process parameters

Press-coated tablets are a high-interest technology in chronopharmaceutics, for modified release applications. As for any kind of tablet, the test of the mechanical resistance is of primary importance at the industrial level during both the development and production steps. For this purpose, the diametral compression test is commonly used in the industry for press-coated tablets. Nevertheless, the result of this test can be much more complex compared to the case of single layer tablets. This work aims to study the applicability of this test to press-coated tablets. Diametral compression tests were performed on press-coated tablets obtained with different products (shell/core), shell sizes and compaction pressures. Four types of breaking profiles were found: total diametral, shell diametral, around the core and laminated depending on the process parameters/products used to obtain the tablet. Digital image correlation was used in order to understand the breaking patterns especially in terms of failure initiation and propagation. The kind of breaking pattern obtained is dependent on the final structure of the tablet in terms of density distribution and thus of elastic properties. To confirm the findings, numerical simulations by the finite element method was used to visualize the stress distribution inside the tablet and confirm the influence of the process parameters. The multiple failure profiles obtained imply that the output value of the diametral compression test applied to press-coated tablets should be taken with caution.

Evaluation of a Combined MHE-NMPC Approach to Handle Plant-Model Mismatch in a Rotary Tablet Press

The transition from batch to continuous processes in the pharmaceutical industry has been driven by the potential improvement in process controllability, product quality homogeneity, and reduction of material inventory. A quality-by-control (QbC) approach has been implemented in a variety of pharmaceutical product manufacturing modalities to increase product quality through a three-level hierarchical control structure. In the implementation of the QbC approach it is common practice to simplify control algorithms by utilizing linearized models with constant model parameters. Nonlinear model predictive control (NMPC) can effectively deliver control functionality for highly sensitive variations and nonlinear multiple-input-multiple-output (MIMO) systems, which is essential for the highly regulated pharmaceutical manufacturing industry. This work focuses on developing and implementing NMPC in continuous manufacturing of solid dosage forms. To mitigate control degradation caused by plant-model mismatch, careful monitoring and continuous improvement strategies are studied. When moving horizon estimation (MHE) is integrated with NMPC, historical data in the past time window together with real-time data from the sensor network enable state estimation and accurate tracking of the highly sensitive model parameters. The adaptive model used in the NMPC strategy can compensate for process uncertainties, further reducing plant-model mismatch effects. The nonlinear mechanistic model used in both MHE and NMPC can predict the essential but complex powder properties and provide physical interpretation of abnormal events. The adaptive NMPC implementation and its real-time control performance analysis and practical applicability are demonstrated through a series of illustrative examples that highlight the effectiveness of the proposed approach for different scenarios of plant-model mismatch, while also incorporating glidant effects.

Investigation of critical factors affecting mechanical characteristics of press-coated tablets using a compaction simulator

Press-coated tablets have become an indispensable dosage form in chronotherapeutic drug delivery. Drug release from press-coated tablets has been extensively studied, yet there is little knowledge about their mechanical characteristics. This study aimed to systematically investigate the effects of critical factors on the structure, layer adhesion, and delamination tendency of the tablets. Material elasticity was found to play an important role in determining tablet structure in that excessive elastic mismatch between core and shell materials caused tablet defects during decompression and ejection. Unlike bilayer tablets, the overall strength of press-coated tablets was more affected by binding capacity of coating materials than by the core properties. Shell/core ratio was another factor affecting tablet integrity against external stresses. To mitigate the risk of delamination, poor layer adhesion must be compensated by increasing the coating thickness or enhanced by optimizing the formulation and process (e.g., core plasticity/brittleness, initial core solid fraction, and compression speed). X-ray micro-computed tomography revealed the presence of a shell-core gap and inhomogeneous density distribution within the tablet where the side coat appeared as the least dense and weakest region. These findings will enable the improvement of tablet quality and widen the application of press coating in industrial manufacturing.

A novel approach to avoid capping and/or lamination by application of external lower punch vibration

Capping as well as lamination are two common problems, which affect the resulting product quality of the tablet. Usually, capping and lamination occur during or after tablet manufacturing, and may therefore influence follow-up processes such as the coating. In this context, there is an urgent need for approaches to overcome the occurrences of capping and lamination. In the present study, a novel lower punch vibration technique was used to decrease the capping or lamination tendency of different powder formulations. Different microcrystalline cellulose types, as well as an API (acetaminophen), were selected as model powders. The powders were investigated regarding their powder flow, density, particle morphology, and surface area. Moreover, the manufactured tablets were characterized regarding their tablet weight, tensile strength, and capping or lamination indices. It was shown that the capping or lamination tendency was strongly affected by the physical powder properties, the formulation composition, and the adjusted turret speed. In addition, the application of externally applied lower punch vibration led to a pronounced decrease of the capping or lamination tendency and improved mechanical stability of the manufactured tablets.

Atypical compaction behaviour of disordered lactose explained by a shift in type of compact fracture pattern

The objective was to investigate tabletability and compactibility for compacts of a series of α-lactose monohydrate powders with different degree of disorder. Regarding the tabletability, the powders of high degree of disorder displayed similar behaviour that deviated markedly from the behaviour of the crystalline powders and the milled powder of modest degree of disorder. The Ryshkewitch-Duckworth equation, describing compactibility, was nearly linear for the crystalline powders, while for the disordered powders the model failed to describe the relationships, i.e. the disordered powders were characterised by a plateau in the Ryshkewitch-Duckworth plots over a relatively wide range of compact porosities. It was concluded that the difference in compaction behaviour of the milled particles compared to the crystalline powders was primarily explained by the increased particle plasticity of the disordered particles. The plateau in the Ryshkewitch-Duckworth plots obtained for the disordered powders was explained by a change in the fracture behaviour of the compacts, from an around grain to an across grain fracture pattern. This implied that the disordered particles can be described as a type of core-shell particles with an amorphous shell and a defective crystalline core.

Isolation of Itraconazole Nanostructured Microparticles via Spray Drying with Rational Selection of Optimum Base for Successful Reconstitution and Compaction

The addition of matrix formers within a formulation provides a means for enhancing the redispersibility of nanoparticles (NPs) enabling them to retain their advantageous properties imparted onto them by their sub-micron size. In this work, NPs were isolated in the solid state via spray drying with a range of sugars. The processed powders were characterized, establishing that itraconazole (ITR) nanostructured microparticles (NMPs) spray dried in the presence of mannitol and trehalose had favorable redispersibility confirmed by dynamic light scattering and nanoparticle tracking analysis. Solid-state analysis confirmed the crystalline nature of NMPs based on mannitol and the amorphous character of trehalose-based NMPs. The NMPs powders were compacted at a range of pressures, producing tablets with high tensile strength without compromising their disintegration time. A greater amount of ITR was solubilized from trehalose NMPs compared to the mannitol-based compacts in 0.1 M HCl, showing a promise for enhanced in vivo activity. Overall, as trehalose exhibited superior carrier properties for ITR NMPs, this type of excipient included in the formulation warrants careful consideration. The structured approach to matrix former selection and tabletting studies can reduce the amount of material and time required for testing in the initial stages of product development.

Effects of granulation process variables on the physical properties of dosage forms by combination of experimental design and principal component analysis

The current study was to understand how process variables of high shear wet granulations affect physical properties of granules and tablets. The knowledge gained was intended to be used for Quality-by-Design based process design and optimization. The variables were selected based on the risk assessment as impeller speed, liquid addition rate, and wet massing time. Formulation compositions were kept constant to minimize their influence on granules properties. Multiple linear regression models were built providing understanding of the impact of each variable on granule hardness, Carr's index, tablet tensile strength, surface mean diameter of granules, and compression behavior. The experimental results showed that the impact of impeller speed was more dominant compared to wet massing time and water addition rate. The results also revealed that quality of granules and tablets could be optimized by adjusting specific process variables (impeller speed 1193 rpm, water spray rate 3.7 ml/min, and wet massing time 2.84 min). Overall desirability was 0.84 suggesting that the response values were closer to the target one. The SEM image of granules showed that spherical and smooth granules produced at higher impeller speed, whereas rough and irregular shape granules at lower speed. Moreover, multivariate data analysis demonstrated that impeller speed and massing time had strong correlation with the granule and tablet properties. In overall, the combined experimental design and principal component analysis approach allowed to better understand the correlation between process variables and granules and tablet attributes.

Effects of Formulation and Process Variables on Gastroretentive Floating Tablets with A High-Dose Soluble Drug and Experimental Design Approach

To develop sustained release gastro-retentive effervescent floating tablets (EFT), a quality-based experimental design approach was utilized during the composing of a hydrophilic matrix loaded with a high amount of a highly water-soluble model drug, metformin HCl. Effects of the amount of polyethylene oxide WSR 303 (PEO), sodium bicarbonate, and tablet compression force were used as independent variables. Various times required to release the drug, tablet tensile strength, floating lag time, tablet ejection force, and tablet porosity, were selected as the responses. Polymer screening showed that PEO had the highest gel strength among the various tested polymers. Sodium bicarbonate had the most significant effect on the release rate and floating lag time by retarding the rate from the hydrophilic matrices, whilst tablet compression force and PEO exerted the greatest influence on tablet properties (p < 0.0001). The design space was built in accordance with the drug release profiles, tensile strength, and floating lag time, following failure probability analysis using Monte Carlo simulations. The kinetic modeling revealed that the release mechanism was best described by the Korsmeyer-Peppas model. Overall, the current study provided a perspective on the systematic approach of gastro-retentive EFT, loaded with highly water-soluble drugs by applying quality by design concepts.

Powder Compression Properties of Paracetamol, Paracetamol Hydrochloride, and Paracetamol Cocrystals and Coformers

The objective was to study the relationship between crystal structure, particle deformation properties, and tablet-forming ability for the monoclinic form of paracetamol (PRA), 2 cocrystals and a salt crystal of PRA in addition to 2 coformers (oxalic acid and 4,4'-bipyridine). Thus, the structure-property-performance relationship was investigated. Analytical powder compression was used for determination of effective plasticity, as inferred from the Heckel yield pressure and the Frenning parameter, and the elastic deformation was determined from in-die tablet elastic recovery. The plasticity could not be linked to the crystal lattice structure as crystals containing zig-zag layers displayed similar plasticity as crystals containing slip planes. In addition, crystals containing slip planes displayed both high and low plasticity. The mechanical properties could not be linked to the tablet-forming ability as the tablet tensile strength, unexpectedly, displayed a tendency to reduce with increased plasticity. Furthermore, the elastic deformation could not explain the tablet-forming ability. It was concluded that no relationship between structure-property-performance for PRA and its cocrystals and salt could be established. Thus, it was indicated that to establish such a relationship, an improved knowledge of crystallographic structure and interparticle bonding during compaction is needed.

Non-destructive Determination of Disintegration Time and Dissolution in Immediate Release Tablets by Terahertz Transmission Measurements

PURPOSE

The aim of this study was to establish the suitability of terahertz (THz) transmission measurements to accurately measure and predict the critical quality attributes of disintegration time and the amount of active pharmaceutical ingredient (API) dissolved after 15, 20 and 25 min for commercial tablets processed at production scale.

METHODS

Samples of 18 batches of biconvex tablets from a production-scale design of experiments study into exploring the design space of a commercial tablet manufacturing process were used. The tablet production involved the process steps of high-shear wet granulation, fluid-bed drying and subsequent compaction. The 18 batches were produced using a 4 factor split plot design to study the effects of process changes on the disintegration time. Non-destructive and contactless terahertz transmission measurements of the whole tablets without prior sample preparation were performed to measure the effective refractive index and absorption coefficient of 6 tablets per batch.

RESULTS

The disintegration time (R 2 = 0.86) and API dissolved after 15 min (R 2 = 0.96) linearly correlates with the effective refractive index, n eff, measured at terahertz frequencies. In contrast, no such correlation could be established from conventional hardness measurements. The magnitude of n eff represents the optical density of the sample and thus it reflects both changes in tablet porosity as well as granule density. For the absorption coefficient, α eff, we observed a better correlation with dissolution after 20 min (R 2 = 0.96) and a weaker correlation with disintegration (R 2 = 0.83) compared to n eff.

CONCLUSION

The measurements of n eff and α eff provide promising predictors for the disintegration and dissolution time of tablets. The high penetration power of terahertz radiation makes it possible to sample a significant volume proportion of a tablet without any prior sample preparation. Together with the short measurement time (seconds), the potential to measure content uniformity and the fact that the method requires no chemometric models this technology shows clear promise to be established as a process analyser to non-destructively predict critical quality attributes of tablets.

A Review of Disintegration Mechanisms and Measurement Techniques

Pharmaceutical solid dosage forms (tablets or capsules) are the predominant form to administer active pharmaceutical ingredients (APIs) to the patient. Tablets are typically powder compacts consisting of several different excipients in addition to the API. Excipients are added to a formulation in order to achieve the desired fill weight of a dosage form, to improve the processability or to affect the drug release behaviour in the body. These complex porous systems undergo different mechanisms when they come in contact with physiological fluids. The performance of a drug is primarily influenced by the disintegration and dissolution behaviour of the powder compact. The disintegration process is specifically critical for immediate-release dosage forms. Its mechanisms and the factors impacting disintegration are discussed and methods used to study the disintegration in-situ are presented. This review further summarises mathematical models used to simulate disintegration phenomena and to predict drug release kinetics.

On the role of API in determining porosity, pore structure and bulk modulus of the skeletal material in pharmaceutical tablets formed with MCC as sole excipient

The physical properties and mechanical integrity of pharmaceutical tablets are of major importance when loading with active pharmaceutical ingredient(s) (API) in order to ensure ease of processing, control of dosage and stability during transportation and handling prior to patient consumption. The interaction between API and excipient, acting as functional extender and binder, however, is little understood in this context. The API indomethacin is combined in this study with microcrystalline cellulose (MCC) at increasing loading levels. Tablets from the defined API/MCC ratios are made under conditions of controlled porosity and tablet thickness, resulting from different compression conditions, and thus compaction levels. Mercury intrusion porosimetry is used to establish the accessible pore volume, pore size distribution and, adopting the observed region of elastic intrusion-extrusion at high pressure, an elastic bulk modulus of the skeletal material is recorded. Porosity values are compared to previously published values derived from terahertz (THz) refractive index data obtained from exactly the same tablet sample sets. It is shown that the elastic bulk modulus is dependent on API wt% loading under constant tablet preparation conditions delivering equal dimensions and porosity. The findings are considered of novel value in respect to establishing consistency of tablet production and optimisation of physical properties.

The reality of in-line tablet coating

The possibility of continuous processing in pharmaceutical tablet manufacturing is hampered by the viscoelastic recovery of tablets post-compaction. Compacted tablets are typically aged before coating to allow complete viscoelastic recovery so as to avoid subsequent coating defects. There has been little attempt to overcome tablet recovery in order to enable continuous processing and improve manufacturing efficiency. However, with the introduction of improved or newly developed types of tablet-coating equipment, there is renewed interest in the coating of tablets in-line. In-line tablet coating is defined as the coating of tablets immediately after compaction. It is a one-step highly integrated system that circumvents the delay in processing time typically given to allow viscoelastic recovery of tablets. This review aims to summarize the requirements of an in-line tablet-coating system. The possibility of carrying out in-line tablet coating in the near future will also be discussed.

Sucrose esters with various hydrophilic-lipophilic properties: novel controlled release agents for oral drug delivery matrix tablets prepared by direct compaction

Sucrose esters (SE) are esters of sucrose and fatty acids with various hydrophilic-lipophilic properties which have attracted interest from being used in pharmaceutical applications. This study aimed to gain insight into the use of SE as controlled release agents for direct compacted matrix tablets. The study focused on the effect of hydrophilic-lipophilic properties on tableting properties and drug release. Sucrose stearate with hydrophilic-lipophilic balance (HLB) values ranging from 0 to 16 was systematically tested. Tablet formulations contained SE, metoprolol tartrate as a highly soluble model drug and dibasic calcium phosphate dihydrate as a tablet formulation filler in the ratio 1:1:2. The compaction behaviour of matrix tablets was compared with the compacts of individual starting materials as reference. SE incorporation improved the plasticity, compressibility and lubricating property of powder mixtures. The hydrophilic-lipophilic properties of SE affected tableting properties, drug release rate and release mechanism. Increasing hydrophilicity corresponding to the increased monoesters in SE composition increased the relative porosity, elastic recovery and tensile strength of the tablets due to the increased hydrogen bonding between the monoesters. This also facilitated the swelling behaviour of SE, which sustained the drug release rate. A sustained release effect prevailed in tablets containing SE with HLB values of 3-16. The ability to improve the tableting properties as well as sustain the drug release rate of the highly soluble model drug via gelation of SE highlights SE as promising controlled release regulators for direct compacted matrix tablets comprising drugs with various solubilities according to the Biopharmaceutics Classification System.

Effects of drying methods on the physicochemical and compressional characteristics of Okra powder and the release properties of its metronidazole tablet formulation

A study has been made of the effects of sun and oven drying methods on the physicochemical characteristics and compressibility of Okra powder and the release properties of its metronidazole tablet formulation. Corn starch was used as the reference standard. The mechanical properties of the tablets were evaluated using crushing strength and friability, while the release properties were determined using the disintegration times and dissolution rates. The results obtained showed that sun-dried Okra powder had smaller particle size, exhibited good flow and possessed higher hydration and swelling capacities compared to the oven dried samples. The compressibility of Okra powders assessed by the indices of plasticity from Heckel (Py) and Kawakita plots (Pk) showed that sun dried Okra powders had higher Py but lower Pk values than the oven-dried Okra powder. Metronidazole tablets formulated with oven dried Okra powder formed stronger tablets than tablets containing sun dried Okra powder. Generally, tablets containing sun dried Okra powders had faster disintegration and dissolution than tablets formulated with oven-dried powder. The results suggest that the choice of drying method during the processing of pharmaceutical raw materials is critical to its physicochemical properties and the release properties of its tablet formulations.

Roll compaction/dry granulation: Effect of raw material particle size on granule and tablet properties

The influence of particle size of MCC, as a binder, and theophylline, as an active pharmaceutical ingredient on the process of roll compaction/dry granulation was investigated using a D-optimal design of experiments. Examined parameters were particle size of both starting materials, fraction of theophylline and ribbon porosity. Therefore, different binary mixtures were roll compacted, dry granulated and compressed into tablets. Flowability of powders and granules and tensile strength of tablets made from powders or granules were the focus of this study. This study showed that a decrease in particle size of MCC or theophylline resulted in an increase of tensile strength even after roll compaction/dry granulation. Comparing tensile strength of tablets made from powder using large size MCC with ones made from granules with small sized MCC revealed that the tensile strength of tablets produced from granules was equal or even higher than tensile strength from direct compressed tablets. Furthermore, using small sized MCC instead of large sized MCC led to larger granules with better flowability. It is shown that the fraction of binder can be reduced without a loss of tensile strength of the final tablets by size reduction of MCC.

Compact size and mechanical strength of pharmaceutical diluents

The effects of compact size and powder particle size on the axial compressive (sigma(C)) and diametral tensile (sigma(T)) strength were evaluated, for three compressed pharmaceutical diluents (microcrystalline cellulose, MCC, calcium hydrogen phosphate dihydrate, CHPD, and pregelatinized starch, PGS) differing in deformational behaviour during compaction and testing. Cylindrical specimens of similar aspect ratio ( approximately 1) but different diameter (13, 10 and 5mm) and total porosity (0.35-0.05) were employed and the extrapolated and interpolated strength values, at zero and 0.15 porosity (sigma(C0) or sigma(T0) and sigma(C0.15) or sigma(T0.15)), were predicted by applying an exponential relation. The ratio of sigma(C0.15)/sigma(T0.15) was correlated to the corresponding percent radial elastic recovery (%RR). It was found that the changes of compressive and tensile strength with compact size were not characteristic and general. Specimen's size affected both extrapolated and interpolated values of sigma(C) and sigma(T) most significantly in the case of MCC, for which sigma(T) increased while sigma(C) decreased, as the compact size became smaller. Less significant was the effect of compact size on the interpolated value of compressive strength (sigma(C)) and the extrapolated value of tensile strength (sigma(T)) for PGS. For CHPD, no significant and characteristic effect of compact size was observed. Particle size significantly affected the interpolated values of sigma(T) for MCC and both sigma(C) and sigma(T) for CHPD; they all increased with decreasing particle size. The sigma(C0.15)/sigma(T0.15) ratio was affected significantly by the compact size only in the case of MCC and seems to be an indication of material elasto-plasticity, since PGS has by far the highest ratio, followed by MCC and CHPD. A correlation between sigma(C0.15)/sigma(T0.15) and %RR was established as was its dependence upon deformational behaviour.

A novel approach to derive a compression parameter indicating effective particle deformability

In this article, a compression parameter is derived and its physical significance discussed. Tablets were formed from two sodium chloride powders and from two sucrose powders over a wide range of compaction pressures and the tensile strength and the porosity of the tablets were determined. From these data, the novel compression parameter and the Heckel parameter were calculated. Above a lower pressure threshold, the tablet strength increased relatively linear with compaction pressure up to 300-500 MPa and thereafter, the tablet strength leveled off. From the linear region, the compression parameter was derived. The tablet porosity data obeyed reasonably the Heckel function and from the linear region, the yield strength was calculated. For all four powders, a ratio between the compression parameter and the Heckel yield strength of about 3 was obtained. It is concluded that the suggested compression parameter represents an indication of the effective deformability of particles during compression which is suggested to correlate with the hardness of the particles.

Compression behaviour and tablet-forming ability of spray-dried amorphous composite particles

The aim of this study was to investigate the compression behaviour and tablet-forming ability of spray-dried amorphous two- and three-component composite particles. Particles of lactose alone, two-component particles of lactose and PVP, and three-component particles of lactose, PVP and a small amount of polysorbate 80 were prepared by spray-drying. Two qualities of PVP with different molecular weights were used for the preparation of both types of particles. The particles were characterised with respect to permeametry surface area, moisture content, particle and bulk density, glass transition and crystallisation temperature, and heat of crystallisation. The tablet tensile strength of the different particles formed at a series of applied pressures was determined and compression parameters were derived from the Heckel and Kawakita equations. The presence of PVP gave particles that were less prone to deform permanently during compression while the presence of surfactant gave particles that were less able to form tablets. In conclusion, the compression behaviour and tablet-forming ability of spray-dried amorphous lactose can be modulated by the addition of stabilising polymers or surfactants to the spray feed solution.

Evaluation of Surface and Bulk Characteristics of Cellulose I Powders in Relation to Compaction Behavior and Tablet Properties

The particle properties and solid-state characteristics of two celluloses, Avicel PH101 and cellulose obtained from the alga Cladophora sp., were evaluated and related to the compaction behavior and the properties of the tablets made from them. The surface area of the celluloses was measured at different levels of penetration capacity, ranging from external surface area of particles to molecular texture with Blaine permeametry, Kr-gasadsorption, and solid-state NMR. The important cellulose fibril surface area was best reflected by solid-state NMR, although for the Cladophora cellulose, Kr-gas adsorption also resulted in a surface area of the order of what has been suggested earlier on the basis of the cellulose fibril dimensions. The difference in fibril dimension and, thereby, the fibril surface area of the two celluloses was shown to be the primary factor in determining their properties and behavior. Properties such as the crystallinity and the tablet disintegration could be related to the fibril dimensions. The Cladophora cellulose resulted in rather strong compacts that still disintegrated rapidly. The irregular surface morphology of the particles and the fragmenting behavior of Cladophora probably contributed to the strength of the tablets.

Formulation design of carbamazepine fast-release tablets prepared by melt granulation technique

This work describes a new approach to prepare a fast-release dosage form for carbamazepine (CBZ), involving the use of melt granulation process in high shear mixer for the production of tablets. In particular, the granules containing CBZ were prepared using polyethylene glycol (PEG) 4000 as a melting binder and lactose monohydrate as a hydrophilic filler. The potential of the intragranular addition of crospovidone as a dissolution enhancer and a disintegrant agent was also evaluated. After the analysis of their solid state performed by means of X-ray powder diffraction (XRD) and differential scanning calorimetry (DSC), the granules were characterised from the technological and dissolution point of view. The subsequent step encompassed the preparation and the evaluation of the tablets, including the effect of the extragranular introduction of crospovidone. Besides the remarkable enhancement of drug dissolution rate of the granulates in comparison to physical mixtures and pure drug, no significant differences were found between the dissolution profiles of the granulates containing lactose or crospovidone. However, the difficult disintegration and bad dissolution performance of the tablets not containing intragranular crospovidone highlight the necessity of this disintegrant in the granulating mixture. Moreover, the extragranular addition of a small amount of crospovidone gave rise to a further amelioration of the disintegration and dissolution performances.

Tablet surface characterisation by various imaging techniques

The aim of this study was to characterise tablet surfaces using different imaging and roughness analytical techniques including optical microscopy, scanning electron microscopy (SEM), laser profilometry and atomic force microscopy (AFM). The test materials compressed were potassium chloride (KCl) and sodium chloride (NaCl). It was found that all methods used suggested that the KCl tablets were smoother than the NaCl tablets and higher compression pressure made the tablets smoother. Imaging methods like optical microscopy and SEM can give useful information about the roughness of the sample surface, but they do not provide quantitative information about surface roughness. Laser profilometry and AFM on the other hand provide quantitative roughness data from two different scales, laser profilometer from 1 mm and atomic force microscope from 90 microm scale. AFM is a powerful technique but other imaging and roughness measuring methods like SEM, optical microscopy and laser profilometry give valuable additional information.