1
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Pohl S, Frey K, Kleinebudde P. Towards the prediction of barrel fill level in twin-screw wet granulation. Eur J Pharm Biopharm 2024; 203:114428. [PMID: 39074596 DOI: 10.1016/j.ejpb.2024.114428] [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: 03/06/2024] [Revised: 07/02/2024] [Accepted: 07/26/2024] [Indexed: 07/31/2024]
Abstract
The barrel fill level is defined as the fraction of the free available volume for a given screw configuration that is occupied by the wet material and is an interplay of the material throughput, screw speed, screw setup, barrel length of the twin-screw granulator used and the properties of the starting material. The fill level has a major impact on mixing and densification of the wetted mass and thus on the granules produced. It influences the twin-screw granulation process accordingly. In the current study, a model has been developed which is predictive in terms of material hold-ups in the barrel at various process settings by considering the geometries of the different screw elements in a configuration and the conveying velocity of the wet mass through the barrel. The model was checked on two granulators of different dimensions with various screw configurations, different materials and at different process settings. The model represents a step forward in predicting the barrel fill level but further research with a broader spectrum of materials, screw configurations and process settings is still needed and additional twin-screw granulators of other dimensions must be investigated.
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Affiliation(s)
- Sebastian Pohl
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstrasse 1, Building 26.22, 40225 Düsseldorf, Germany; INVITE GmbH, Drug Delivery Innovation Center, Chempark, Buildung, W32, 51368 Leverkusen, Germany.
| | - Katrina Frey
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstrasse 1, Building 26.22, 40225 Düsseldorf, Germany.
| | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstrasse 1, Building 26.22, 40225 Düsseldorf, Germany.
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2
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Franke M, Riedel T, Meier R, Schmidt C, Kleinebudde P. Scale-up in twin-screw wet granulation: impact of formulation properties. Pharm Dev Technol 2023; 28:948-961. [PMID: 37889884 DOI: 10.1080/10837450.2023.2276791] [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: 08/24/2023] [Accepted: 10/25/2023] [Indexed: 10/29/2023]
Abstract
The focus of this study was to investigate the sensitivity of different drug formulations to differences in process parameters based on previously developed scale-up strategies. Three different formulations were used for scale-up experiments from a QbCon® 1 with a screw diameter of 16 mm and a throughput of 2 kg/h to a QbCon® 25 line with a screw diameter of 25 mm and a throughput of 25 kg/h. Two of those formulations were similar in their composition of excipients but had a different API added to the blend to investigate the effect of solubility of the API during twin-screw wet granulation, while the third formulation was based on a controlled release formulation with different excipients and a high fraction of HPMC. The L/S-ratio had to be set specifically for each formulation as depending on the binder and the overall composition the blends varied significantly in their response to water addition and their overall granulation behavior. Before milling there were large differences in granule size distributions based on scale (Earth Mover's Distance 140-1100 µm, higher values indicating low similarity) for all formulations. However, no major differences in granule properties (e.g. Earth Mover's Distance for GSDs: 23-88 µm) or tablet tensile strength (> 1.8 MPa at a compaction pressure of 200 MPa for all formulations with a coefficient of variation < 0.1, indicating high robustness for all formulations) were observed after milling, which allowed for a successful scale-up independent of the selected formulations.
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Affiliation(s)
- Marcel Franke
- Department of Pharmaceutical Technologies, Merck Healthcare KGaA, Darmstadt, Germany
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Düsseldorf, Germany
| | - Thomas Riedel
- Department of Pharmaceutical Technologies, Merck Healthcare KGaA, Darmstadt, Germany
| | - Robin Meier
- L.B. Bohle Maschinen und Verfahren GmbH, Ennigerloh, Germany
| | - Carsten Schmidt
- Department of Pharmaceutical Technologies, Merck Healthcare KGaA, Darmstadt, Germany
| | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Düsseldorf, Germany
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3
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Xu H, Wu L, Xue Y, Yang T, Xiong T, Wang C, He S, Sun H, Cao Z, Liu J, Wang S, Li Z, Naeem A, Yin X, Zhang J. Advances in Structure Pharmaceutics from Discovery to Evaluation and Design. Mol Pharm 2023; 20:4404-4429. [PMID: 37552597 DOI: 10.1021/acs.molpharmaceut.3c00514] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 08/10/2023]
Abstract
Drug delivery systems (DDSs) play an important role in delivering active pharmaceutical ingredients (APIs) to targeted sites with a predesigned release pattern. The chemical and biological properties of APIs and excipients have been extensively studied for their contribution to DDS quality and effectiveness; however, the structural characteristics of DDSs have not been adequately explored. Structure pharmaceutics involves the study of the structure of DDSs, especially the three-dimensional (3D) structures, and its interaction with the physiological and pathological structure of organisms, possibly influencing their release kinetics and targeting abilities. A systematic overview of the structures of a variety of dosage forms, such as tablets, granules, pellets, microspheres, powders, and nanoparticles, is presented. Moreover, the influence of structures on the release and targeting capability of DDSs has also been discussed, especially the in vitro and in vivo release correlation and the structure-based organ- and tumor-targeting capabilities of particles with different structures. Additionally, an in-depth discussion is provided regarding the application of structural strategies in the DDSs design and evaluation. Furthermore, some of the most frequently used characterization techniques in structure pharmaceutics are briefly described along with their potential future applications.
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Affiliation(s)
- Huipeng Xu
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- University of Chinese Academy of Sciences, Beijing 100049, China
| | - Li Wu
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- Key Laboratory of Molecular Pharmacology and Drug Evaluation, School of Pharmacy, Ministry of Education, Yantai University, Yantai 264005, China
- Key Laboratory of Modern Preparation of Traditional Chinese Medicine, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
| | - Yanling Xue
- Shanghai Synchrotron Radiation Facility, Shanghai Advanced Research Institute, Chinese Academy of Sciences, Shanghai 201204, China
| | - Ting Yang
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
| | - Ting Xiong
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
| | - Caifen Wang
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
| | - Siyu He
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- University of Chinese Academy of Sciences, Beijing 100049, China
| | - Hongyu Sun
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
| | - Zeying Cao
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- University of Chinese Academy of Sciences, Beijing 100049, China
| | - Jun Liu
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
| | - Siwen Wang
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- University of Chinese Academy of Sciences, Beijing 100049, China
| | - Zhe Li
- Key Laboratory of Modern Preparation of Traditional Chinese Medicine, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
| | - Abid Naeem
- Key Laboratory of Modern Preparation of Traditional Chinese Medicine, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
| | - Xianzhen Yin
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- Lingang Laboratory, Shanghai 201602, China
| | - Jiwen Zhang
- Center for Drug Delivery Systems, Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
- University of Chinese Academy of Sciences, Beijing 100049, China
- Key Laboratory of Modern Preparation of Traditional Chinese Medicine, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
- NMPA Key Laboratory for Quality Research and Evaluation of Pharmaceutical Excipients, National Institutes for Food and Drug Control, No.2 Tiantan Xili, Beijing 100050, China
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4
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Franke M, Riedel T, Meier R, Schmidt C, Kleinebudde P. Comparison of scale-up strategies in twin-screw wet granulation. Int J Pharm 2023; 641:123052. [PMID: 37196882 DOI: 10.1016/j.ijpharm.2023.123052] [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: 02/24/2023] [Revised: 05/09/2023] [Accepted: 05/11/2023] [Indexed: 05/19/2023]
Abstract
The aim of this study was to compare different scale-up strategies in twin-screw wet granulation and investigate the impact of the selected strategy on granule and tablet properties for a defined formulation. For the scale-up, a granulation process was transferred from a QbCon® 1 with a screw diameter of 16mm to a QbCon® 25 line with a screw diameter of 25mm. Three different scale-up strategies were introduced based on differences in process parameters and their resulting effects on various aspects. such as the powder feed number as a surrogate for the barrel fill level or the circumferential speed. Both are highly dependent on screw diameter and screw speed (SS), while the barrel fill level also depends on the overall throughput. Granules produced on the larger scale were significantly larger due to the larger gap size in the granulator, however, these differences were eliminated after milling. Despite major differences in powder feed number, circumferential speed, overall throughput and SS, product properties for both tablets and granules were strikingly similar after milling on both scales and with all applied strategies. For the selected formulation the effect of varying liquid to solid ratio at the same scale was much higher than the differences between scale-up strategies. The results of this study are promising for future process scale-up from lab scale to production scale in twin-screw wet granulation, as they are indicating towards a robust granulation process leading to similar tablet properties afterwards.
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Affiliation(s)
- Marcel Franke
- Merck Healthcare KGaA, Department of Pharmaceutical Technologies, Darmstadt, Germany; Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitätsstr. 1, Building 26.22, Düsseldorf, Germany
| | - Thomas Riedel
- Merck Healthcare KGaA, Department of Pharmaceutical Technologies, Darmstadt, Germany
| | - Robin Meier
- L.B. Bohle Maschinen und Verfahren GmbH, Ennigerloh, Germany
| | - Carsten Schmidt
- Merck Healthcare KGaA, Department of Pharmaceutical Technologies, Darmstadt, Germany
| | - Peter Kleinebudde
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitätsstr. 1, Building 26.22, Düsseldorf, Germany.
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5
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Peeters M, Alejandra Barrera Jimenez A, Matsunami K, Stauffer F, Nopens I, De Beer T. Evaluation of the influence of material properties and process parameters on granule porosity in twin-screw wet granulation. Int J Pharm 2023; 641:123010. [PMID: 37169104 DOI: 10.1016/j.ijpharm.2023.123010] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/08/2023] [Revised: 04/26/2023] [Accepted: 04/27/2023] [Indexed: 05/13/2023]
Abstract
In recent years, continuous twin-screw wet granulation (TSWG) is gaining increasing interest from the pharmaceutical industry. Despite the many publications on TSWG, only a limited number of studies focused on granule porosity, which was found to be an important granule property affecting the final tablet quality attributes, e.g. dissolution. In current study, the granule porosity along the length of the twin-screw granulator (TSG) barrel was evaluated. An experimental set-up was used allowing the collection of granules at the different TSG compartments. The effect of active pharmaceutical ingredient (API) properties on granule porosity was evaluated by using six formulations with a fixed composition but containing APIs with different physical-chemical properties. Furthermore, the importance of TSWG process parameters liquid-to-solid (L/S) ratio, mass feed rate and screw speed for the granule porosity was evaluated. Several water-related properties as well as particle size, density and flow properties of the API were found to have an important effect on granule porosity. While the L/S ratio was confirmed to be the dictating TSWG process parameter, granulator screw speed was also found to be an important process variable affecting granule porosity. This study obtained crucial information on the effect of material properties and process parameters on granule porosity (and granule formation) which can be used to accelerate TSWG process and formulation development.
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Affiliation(s)
- Michiel Peeters
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Ana Alejandra Barrera Jimenez
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure Links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Kensaku Matsunami
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure Links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Fanny Stauffer
- Product Design & Performance, UCB, Ottergemsesteenweg 460, Braine l'Alleud 1420, Belgium
| | - Ingmar Nopens
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure Links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium.
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6
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Köster C, Kleinebudde P. Evaluation of binders in twin-screw wet granulation - Optimal combination of binder and disintegrant. Eur J Pharm Biopharm 2023; 186:55-64. [PMID: 36913991 DOI: 10.1016/j.ejpb.2023.03.003] [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: 11/29/2022] [Revised: 02/24/2023] [Accepted: 03/08/2023] [Indexed: 03/15/2023]
Abstract
The influence of localization (intragranular, split or extragranular) of three superdisintegrants (croscarmellose sodium, crospovidone, sodium starch glycolate) on granules and tablets after twin-screw granulation was studied. The aim was to find a suitable disintegrant type and disintegrant localization for lactose tablets manufactured with different hydroxypropyl cellulose (HPC) types. The disintegrants were found to decrease the particle size in granulation, where sodium starch glycolate had the lowest influence. The tablet tensile strength was not influenced strongly by the disintegrant type or localization. By contrast, the disintegration was dependent on the disintegrant type as well as the localization, where sodium starch glycolate performed worst. Intragranular croscarmellose sodium and extragranular crospovidone were identified as beneficial for chosen conditions because a satisfying tensile strength in combination with the fastest disintegration was found. These findings were achieved for one HPC type and the suitability of the best disintegrant-localization-combinations were confirmed for another two HPC types.
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Affiliation(s)
- Claudia Köster
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstr. 1, 40225 Düsseldorf, Germany
| | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstr. 1, 40225 Düsseldorf, Germany.
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7
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Effect of fill level in continuous twin-screw granulator: A combined experimental and simulation study. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103822] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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8
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Li T, Meng W, Wang Y, Valia A, Jamsandekar R, Kumar R, Muzzio FJ, Glasser BJ. Effect of liquid addition on the bulk and flow properties of cohesive powders. PARTICULATE SCIENCE AND TECHNOLOGY 2022. [DOI: 10.1080/02726351.2021.1924328] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
Affiliation(s)
- Tianyi Li
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Wei Meng
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Yifan Wang
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Anand Valia
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Rhea Jamsandekar
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Ravish Kumar
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Fernando J. Muzzio
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
| | - Benjamin J. Glasser
- Department of Chemical and Biochemical Engineering, Rutgers, the State University of New Jersey, Piscataway, New Jersey, USA
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9
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Rao RR, Pandey A, Hegde AR, Kulkarni VI, Chincholi C, Rao V, Bhushan I, Mutalik S. Metamorphosis of Twin Screw Extruder-Based Granulation Technology: Applications Focusing on Its Impact on Conventional Granulation Technology. AAPS PharmSciTech 2021; 23:24. [PMID: 34907508 PMCID: PMC8816530 DOI: 10.1208/s12249-021-02173-w] [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: 07/22/2021] [Accepted: 10/29/2021] [Indexed: 11/30/2022] Open
Abstract
In order to be at pace with the market requirements of solid dosage forms and regulatory standards, a transformation towards systematic processing using continuous manufacturing (CM) and automated model-based control is being thought through for its fundamental advantages over conventional batch manufacturing. CM eliminates the key gaps through the integration of various processes while preserving quality attributes via the use of process analytical technology (PAT). The twin screw extruder (TSE) is one such equipment adopted by the pharmaceutical industry as a substitute for the traditional batch granulation process. Various types of granulation techniques using twin screw extrusion technology have been explored in the article. Furthermore, individual components of a TSE and their conjugation with PAT tools and the advancements and applications in the field of nutraceuticals and nanotechnology have also been discussed. Thus, the future of granulation lies on the shoulders of continuous TSE, where it can be coupled with computational mathematical studies to mitigate its complications.
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10
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Morrissey JP, Hanley KJ, Ooi JY. Conceptualisation of an Efficient Particle-Based Simulation of a Twin-Screw Granulator. Pharmaceutics 2021; 13:pharmaceutics13122136. [PMID: 34959417 PMCID: PMC8704810 DOI: 10.3390/pharmaceutics13122136] [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: 10/29/2021] [Revised: 11/29/2021] [Accepted: 12/06/2021] [Indexed: 11/29/2022] Open
Abstract
Discrete Element Method (DEM) simulations have the potential to provide particle-scale understanding of twin-screw granulators. This is difficult to obtain experimentally because of the closed, tightly confined geometry. An essential prerequisite for successful DEM modelling of a twin-screw granulator is making the simulations tractable, i.e., reducing the significant computational cost while retaining the key physics. Four methods are evaluated in this paper to achieve this goal: (i) develop reduced-scale periodic simulations to reduce the number of particles; (ii) further reduce this number by scaling particle sizes appropriately; (iii) adopt an adhesive, elasto-plastic contact model to capture the effect of the liquid binder rather than fluid coupling; (iv) identify the subset of model parameters that are influential for calibration. All DEM simulations considered a GEA ConsiGma™ 1 twin-screw granulator with a 60° rearward configuration for kneading elements. Periodic simulations yielded similar results to a full-scale simulation at significantly reduced computational cost. If the level of cohesion in the contact model is calibrated using laboratory testing, valid results can be obtained without fluid coupling. Friction between granules and the internal surfaces of the granulator is a very influential parameter because the response of this system is dominated by interactions with the geometry.
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11
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Monaco D, Omar C, Reynolds GK, Tajarobi P, Litster JD, Salman AD. Drying in a continuous wet granulation line: Investigation of different end of drying control methods. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.07.004] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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12
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Wang LG, Morrissey JP, Barrasso D, Slade D, Clifford S, Reynolds G, Ooi JY, Litster JD. Model driven design for twin screw granulation using mechanistic-based population balance model. Int J Pharm 2021; 607:120939. [PMID: 34310953 DOI: 10.1016/j.ijpharm.2021.120939] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/26/2021] [Revised: 07/20/2021] [Accepted: 07/21/2021] [Indexed: 11/30/2022]
Abstract
This paper presents a generic framework of Model Driven Design (MDD) with its application for a twin screw granulation process using a mechanistic-based population balance model (PBM). The process kernels including nucleation, breakage, layering and consolidation are defined in the PBM. A recently developed breakage kernel is used with key physics incorporated in the model formulation. Prior to granulation experiments, sensitivity analysis of PBM parameters is performed to investigate the variation of model outputs given the input parameter variance. The significance of liquid to solid ratio (L/S ratio), nucleation and breakage parameters is identified by sensitivity analysis. The sensitivity analysis dramatically reduces the number of fitting parameters in PBM and only nine granulation experiments are required for model calibration and validation. A model validation flowchart is proposed to elucidate the evolution of kinetic rate parameters associated with L/S ratio and screw element geometry. The presented MDD framework for sensitivity analysis, parameter estimation, model verification and validation can be generalized and applied for any particulate process.
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Affiliation(s)
- Li Ge Wang
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | | | | | | | - Sean Clifford
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
| | - Gavin Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
| | - Jin Y Ooi
- School of Engineering, University of Edinburgh, UK
| | - James D Litster
- Department of Chemical and Biological Engineering, University of Sheffield, UK.
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13
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Kim EJ, Kim JH, Kim MS, Jeong SH, Choi DH. Process Analytical Technology Tools for Monitoring Pharmaceutical Unit Operations: A Control Strategy for Continuous Process Verification. Pharmaceutics 2021; 13:919. [PMID: 34205797 PMCID: PMC8234957 DOI: 10.3390/pharmaceutics13060919] [Citation(s) in RCA: 29] [Impact Index Per Article: 9.7] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 05/31/2021] [Accepted: 06/16/2021] [Indexed: 11/16/2022] Open
Abstract
Various frameworks and methods, such as quality by design (QbD), real time release test (RTRT), and continuous process verification (CPV), have been introduced to improve drug product quality in the pharmaceutical industry. The methods recognize that an appropriate combination of process controls and predefined material attributes and intermediate quality attributes (IQAs) during processing may provide greater assurance of product quality than end-product testing. The efficient analysis method to monitor the relationship between process and quality should be used. Process analytical technology (PAT) was introduced to analyze IQAs during the process of establishing regulatory specifications and facilitating continuous manufacturing improvement. Although PAT was introduced in the pharmaceutical industry in the early 21st century, new PAT tools have been introduced during the last 20 years. In this review, we present the recent pharmaceutical PAT tools and their application in pharmaceutical unit operations. Based on unit operations, the significant IQAs monitored by PAT are presented to establish a control strategy for CPV and real time release testing (RTRT). In addition, the equipment type used in unit operation, PAT tools, multivariate statistical tools, and mathematical preprocessing are introduced, along with relevant literature. This review suggests that various PAT tools are rapidly advancing, and various IQAs are efficiently and precisely monitored in the pharmaceutical industry. Therefore, PAT could be a fundamental tool for the present QbD and CPV to improve drug product quality.
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Affiliation(s)
- Eun Ji Kim
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si, Gyeongnam 621-749, Korea; (E.J.K.); (J.H.K.)
| | - Ji Hyeon Kim
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si, Gyeongnam 621-749, Korea; (E.J.K.); (J.H.K.)
| | - Min-Soo Kim
- College of Pharmacy, Pusan National University, Busandaehak-ro 63 heon-gil, Geumjeong-gu, Busan 46241, Korea;
| | - Seong Hoon Jeong
- College of Pharmacy, Dongguk University-Seoul, Dongguk-ro-32, Ilsan-Donggu, Goyang 10326, Korea;
| | - Du Hyung Choi
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si, Gyeongnam 621-749, Korea; (E.J.K.); (J.H.K.)
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14
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Ryckaert A, Van Hauwermeiren D, Dhondt J, De Man A, Funke A, Djuric D, Vervaet C, Nopens I, De Beer T. TPLS as predictive platform for twin-screw wet granulation process and formulation development. Int J Pharm 2021; 605:120785. [PMID: 34111548 DOI: 10.1016/j.ijpharm.2021.120785] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/04/2021] [Revised: 06/03/2021] [Accepted: 06/04/2021] [Indexed: 11/25/2022]
Abstract
In recent years, the interest in continuous manufacturing techniques, such as twin-screw wet granulation, has increased. However, the understanding of the influence of the combination of raw material properties and process settings upon the granule quality attributes is still limited. In this study, a T-shaped partial least squares (TPLS) model was developed to link raw material properties, the ratios in which these raw materials were combined and the applied process parameters for the twin-screw wet granulation process with the granule quality attributes. In addition, the predictive ability of the TPLS model was used to find a suitable combination of formulation composition and twin-screw granulation process settings for a new API leading to desired granule quality attributes. Overall, this study helped to better understand the link between raw material properties, formulation composition and process settings on granule quality attributes. Moreover, as TPLS can provide a reasonable starting point for formulation and process development for new APIs, it can reduce the experimental development efforts and consequently the consumption of expensive (and often limited available) new API.
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Affiliation(s)
- A Ryckaert
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - D Van Hauwermeiren
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; BIOMATH, Department of Mathematical Modelling, Statistics and Bio-informatics, Ghent University, Coupure Links 653, 9000 Ghent, Belgium.
| | - J Dhondt
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - A De Man
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - A Funke
- Chemical & Pharmaceutical Development, Pharma R&D, Bayer AG, Friedrich-Ebert-Straße 475, 42369 Wuppertal, Germany.
| | - D Djuric
- Chemical & Pharmaceutical Development, Pharma R&D, Bayer AG, Friedrich-Ebert-Straße 475, 42369 Wuppertal, Germany.
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics Ghent University, Ottergemsesteenweg 460, Ghent, Belgium.
| | - I Nopens
- BIOMATH, Department of Mathematical Modelling, Statistics and Bio-informatics, Ghent University, Coupure Links 653, 9000 Ghent, Belgium.
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
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15
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Portier C, Vervaet C, Vanhoorne V. Continuous Twin Screw Granulation: A Review of Recent Progress and Opportunities in Formulation and Equipment Design. Pharmaceutics 2021; 13:668. [PMID: 34066921 PMCID: PMC8148523 DOI: 10.3390/pharmaceutics13050668] [Citation(s) in RCA: 23] [Impact Index Per Article: 7.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 04/30/2021] [Accepted: 05/02/2021] [Indexed: 11/16/2022] Open
Abstract
Continuous twin screw wet granulation is one of the key continuous manufacturing technologies that have gained significant interest in the pharmaceutical industry as well as in academia over the last ten years. Given its considerable advantages compared to wet granulation techniques operated in batch mode such as high shear granulation and fluid bed granulation, several equipment manufacturers have designed their own manufacturing setup. This has led to a steep increase in the research output in this field. However, most studies still focused on a single (often placebo) formulation, hence making it difficult to assess the general validity of the obtained results. Therefore, current review provides an overview of recent progress in the field of continuous twin screw wet granulation, with special focus on the importance of the formulation aspect and raw material properties. It gives practical guidance for novel and more experienced users of this technique and highlights some of the unmet needs that require further research.
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Affiliation(s)
| | | | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium; (C.P.); (C.V.)
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16
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A Semi-Mechanistic Prediction of Residence Time Metrics in Twin Screw Granulation. Pharmaceutics 2021; 13:pharmaceutics13030393. [PMID: 33809652 PMCID: PMC8002318 DOI: 10.3390/pharmaceutics13030393] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/25/2021] [Revised: 03/03/2021] [Accepted: 03/08/2021] [Indexed: 11/29/2022] Open
Abstract
This work is concerned with the semi-mechanistic prediction of residence time metrics using historical data from mono-component twin screw wet granulation processes. From the data, several key parameters such as powder throughput rate, shafts rotation speed, liquid binder feed ratio, number of kneading elements in the shafts and the stagger angle between the kneading elements were identified and physical factors were developed to translate those varying parameters into expressions affecting the key intermediate phenomena in the equipment, holdup, flow and mixing. The developed relations were then tested across datasets to evaluate the performance of the model, applying a k-fold optimization technique. The semi-mechanistic predictions were evaluated both qualitatively through the main effects plots and quantitatively through the parity plots and correlations between the tuning constants across datasets. The root mean square error (RMSE) was used as a metric to compare the degree of goodness of fit for different datasets using the developed semi-mechanistic relations. In summary this paper presents a new approach at estimating both the residence time metrics in twin screw wet granulation, mean residence time (MRT) and variance through semi-mechanistic relations, the validity of which have been tested for different datasets.
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17
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Ryckaert A, Ghijs M, Portier C, Djuric D, Funke A, Vervaet C, De Beer T. The Influence of Equipment Design and Process Parameters on Granule Breakage in a Semi-Continuous Fluid Bed Dryer after Continuous Twin-Screw Wet Granulation. Pharmaceutics 2021; 13:pharmaceutics13020293. [PMID: 33672389 PMCID: PMC7926462 DOI: 10.3390/pharmaceutics13020293] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/22/2021] [Revised: 02/18/2021] [Accepted: 02/19/2021] [Indexed: 12/02/2022] Open
Abstract
The drying unit of a continuous from-powder-to-tablet manufacturing line based on twin-screw granulation (TSG) is a crucial intermediate process step to achieve the desired tablet quality. Understanding the size reduction of pharmaceutical granules before, during, and after the fluid bed drying process is, however, still lacking. A first major goal was to investigate the breakage and attrition phenomena during transport of wet and dry granules, the filling phase, and drying phase on a ConsiGma-25 system (C25). Pneumatic transport of the wet granules after TSG towards the dryer induced extensive breakage, whereas the turbulent filling and drying phase of the drying cells caused rather moderate breakage and attrition. Subsequently, the dry transfer line was responsible for additional extensive breakage and attrition. The second major goal was to compare the influence of drying air temperature and drying time on granule size and moisture content for granules processed with a commercial-scale ConsiGma-25 system and with the R&D-scale ConsiGma-1 (C1) system. Generally, the granule quality obtained after drying with C1 was not predictive for the C25, making it challenging during process development with the C1 to obtain representative granules for the C25.
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Affiliation(s)
- Alexander Ryckaert
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium;
| | - Michael Ghijs
- BIOMATH, Department of Mathematical Modelling, Statistics and Bio-informatics, Ghent University, Coupure Links 653, 9000 Ghent, Belgium;
| | - Christoph Portier
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (C.P.); (C.V.)
| | - Dejan Djuric
- Chemical & Pharmaceutical Development, Pharma R&D, Bayer AG, Friedrich-Ebert-Straße 475, 42117 Wuppertal, Germany; (D.D.); (A.F.)
| | - Adrian Funke
- Chemical & Pharmaceutical Development, Pharma R&D, Bayer AG, Friedrich-Ebert-Straße 475, 42117 Wuppertal, Germany; (D.D.); (A.F.)
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (C.P.); (C.V.)
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium;
- Correspondence: ; Tel.: +32-9-264-80-97
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18
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Köster C, Pohl S, Kleinebudde P. Evaluation of Binders in Twin-Screw Wet Granulation. Pharmaceutics 2021; 13:pharmaceutics13020241. [PMID: 33572394 PMCID: PMC7916237 DOI: 10.3390/pharmaceutics13020241] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/20/2021] [Revised: 02/05/2021] [Accepted: 02/05/2021] [Indexed: 11/16/2022] Open
Abstract
The binders povidone (Kollidon 30), copovidone (Kollidon VA64), hypromellose (Pharmacoat 606), and three types of hyprolose (HPC SSL‑SFP, HPC SSL, and HPC SL‑FP) were evaluated regarding their suitability in twin-screw wet granulation. Six mixtures of lactose and binder as well as lactose without binder were twin-screw granulated with demineralized water at different barrel fill levels and subsequently tableted. A screening run with HPC SSL determined the amount of water as an influential parameter for oversized agglomerates. Subsequent examination of different binders, especially Kollidon 30 and Kollidon VA64 resulted in large granules. All binders, except Pharmacoat 606, led to a reduction of fines compared to granulation without a binder. The molecular weight of applied hyproloses did not appear as influential. Tableting required an upstream sieving step to remove overlarge granules. Tableting was possible for all formulations at sufficient compression pressure. Most binders resulted in comparable tensile strengths, while Pharmacoat 606 led to lower and lactose without a binder to the lowest tensile strength. Tablets without a binder disintegrated easily, whereas binder containing tablets of sufficient tensile strength often nearly failed or failed the disintegration test. Especially tablets containing Pharmacoat 606 and HPC SL‑FP disintegrated too slowly.
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19
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Zhang Y, Liu T, Kashani-Rahimi S, Zhang F. A review of twin screw wet granulation mechanisms in relation to granule attributes. Drug Dev Ind Pharm 2021; 47:349-360. [PMID: 33507106 DOI: 10.1080/03639045.2021.1879844] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
Abstract
Due to the trend of continuous pharmaceutical manufacturing, twin screw wet granulation (TSWG), a continuous process, has gained increased research interest as a potential substitution of traditional batch granulation processes. Despite the complex nature of TSWG, its mechanisms have been gradually unveiled with the aid of innovative research strategies. This review synthesizes these recent findings to provide a comprehensive and mechanistic understanding of TSWG. We explain the impact of screw profiles (i.e. conveying, kneading, turbine mixing, and screw mixing elements) and process conditions (i.e. screw speed, feed rate, and liquid-to-solid ratio) on TSWG mixing performance and granule growth along the barrel, both of which ultimately affect critical granule attributes such as content uniformity, size distribution, strength, and compaction properties.
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Affiliation(s)
- Yi Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
| | - Tongzhou Liu
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
| | - Shahab Kashani-Rahimi
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
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20
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21
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Experimental investigation of wet pharmaceutical granulation using in-situ synchrotron X-ray imaging. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.09.063] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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22
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Pawar P, Clancy D, Gorringe L, Barlow S, Hesketh A, Elkes R. Development and Scale-Up of Diversion Strategy for Twin Screw Granulation in Continuous Manufacturing. J Pharm Sci 2020; 109:3439-3450. [PMID: 32798502 DOI: 10.1016/j.xphs.2020.08.004] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2020] [Revised: 07/07/2020] [Accepted: 08/07/2020] [Indexed: 11/28/2022]
Abstract
Successful implementation of Continuous Manufacturing technology requires real time product quality monitoring that can result into rejection strategies for material manufactured outside process control limits. In a twin screw granulation process, parameters like water content, powder feed rate, and granulator screw speed can influence granule quality. Deviations in any of these parameters from the set-point may affect granule quality. Having a sound diversion strategy in place can help divert these implicated granules to waste. Residence time distribution experiments were conducted on a 16-mm Thermo Fisher twin screw granulator (TSG) for a range of process parameters, and the data was modelled to predict the needed diversion time as a function of process parameters. Scale-up from the 16-mm to 24-mm granulator was evaluated and data was found to scale based on mass per unit volume of granulator (channel fill), thus enabling 16-mm data to scale to 24-mm. The diversion strategy proposed is based on utilizing a wash out curve derived from residence time distribution to quantify the maximum concentration of implicated material that could be present in the next downstream unit operation(s) (e.g. a fluid bed dryer) and ensuring it is less than a suitable threshold to prevent product quality impact.
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23
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Bandari S, Nyavanandi D, Kallakunta VR, Janga KY, Sarabu S, Butreddy A, Repka MA. Continuous twin screw granulation - An advanced alternative granulation technology for use in the pharmaceutical industry. Int J Pharm 2020; 580:119215. [PMID: 32194206 PMCID: PMC7219110 DOI: 10.1016/j.ijpharm.2020.119215] [Citation(s) in RCA: 34] [Impact Index Per Article: 8.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/21/2019] [Revised: 03/04/2020] [Accepted: 03/07/2020] [Indexed: 10/24/2022]
Abstract
Hot melt extrusion has been an exciting technology in the pharmaceutical field owing to its novel applicability. Twin-screw granulation presents a great potential and offers many advantages relative to conventional granulation processes. Different twin-screw granulation techniques, such as twin-screw dry granulation, twin-screw wet granulation, and twin-screw melt granulation, are currently being developed as robust and reproducible granulation processes. The competence of twin-screw granulation as a continuous manufacturing process has contributed to its suitability as an alternative granulation option within the pharmaceutical industry. In this article, different types of twin-screw granulation techniques were discussed. In addition, the screw elements, scale-up process, continuous twin-screw granulation which involves process analytical tools, and excipients were explored. This economical, industrially scalable process can be automated for continuous manufacturing to produce granules for the development of oral solid dosage forms. However, extensive research using process analytical tools is warranted to develop processes for the continuous manufacture of granules.
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Affiliation(s)
- Suresh Bandari
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Dinesh Nyavanandi
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Venkata Raman Kallakunta
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Kartik Yadav Janga
- Formulation Development, Novel Delivery Forms, Bayer Healthcare LLC, 36 Columbia Rd, Morristown, NJ 07960, USA
| | - Sandeep Sarabu
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Arun Butreddy
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA; Pii Center for Pharmaceutical Innovation & Instruction, The University of Mississippi, University, MS 38677, USA.
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24
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Vanhoorne V, Almey R, De Beer T, Vervaet C. Delta-mannitol to enable continuous twin-screw granulation of a highly dosed, poorly compactable formulation. Int J Pharm 2020; 583:119374. [PMID: 32339631 DOI: 10.1016/j.ijpharm.2020.119374] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/03/2020] [Revised: 04/22/2020] [Accepted: 04/23/2020] [Indexed: 11/29/2022]
Abstract
In current study, it was investigated if the moisture-mediated polymorphic transition from δ- to β-mannitol during twin screw granulation (TSG) also took place in high drug loaded formulations and if the specific granule morphology associated with the polymorphic transition could enable tableting of granules comprising 75% paracetamol, a poorly compactable drug. Experiments were performed on an integrated continuous manufacturing line, including a twin screw granulator, fluid bed dryer, mill and tablet press. The polymorphic transition of δ- to β-mannitol was observed during twin screw granulation and granules exhibited the needle-shaped morphology, typical of this transition. TSG at low liquid-to-solid (L/S) ratios and use of polyvinylpyrrolidone or hydroxypropylmethylcellulose as binders inhibited the polymorphic transition, whereas screw speed, drying time, drying temperature and airflow did not affect the solid state of mannitol in the granules. Without binder and despite the high paracetamol drug load in the formulation, limited breakage and attrition was observed during drying and milling. In contrast to granules manufactured from a formulation containing paracetamol/β-mannitol which could not be tableted due to extensive capping, granules prepared from a paracetamol/δ-mannitol formulation showed good tabletability. In conclusion, δ-mannitol is a promising TSG excipient, especially for high drug-loaded formulations with poor tabletability.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - R Almey
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium.
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25
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Vanhoorne V, Vervaet C. Recent progress in continuous manufacturing of oral solid dosage forms. Int J Pharm 2020; 579:119194. [PMID: 32135231 DOI: 10.1016/j.ijpharm.2020.119194] [Citation(s) in RCA: 44] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/20/2019] [Revised: 02/28/2020] [Accepted: 02/29/2020] [Indexed: 12/28/2022]
Abstract
Continuous drug product manufacturing is slowly being implemented in the pharmaceutical industry. Although the benefits related to the quality and cost of continuous manufacturing are widely recognized, several challenges hampered the widespread introduction of continuous manufacturing of drug products. Current review presents an overview of state-of-the art research, equipment, process analytical technology implementations and advanced control strategies. Additionally, guidelines and regulatory viewpoints on implementation of continuous manufacturing in the pharmaceutical industry are discussed.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University.
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26
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Wang LG, Pradhan SU, Wassgren C, Barrasso D, Slade D, Litster JD. A breakage kernel for use in population balance modelling of twin screw granulation. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.01.024] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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27
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Miyazaki Y, Lenhart V, Kleinebudde P. Switch of tablet manufacturing from high shear granulation to twin-screw granulation using quality by design approach. Int J Pharm 2020; 579:119139. [PMID: 32061724 DOI: 10.1016/j.ijpharm.2020.119139] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/30/2019] [Revised: 02/10/2020] [Accepted: 02/11/2020] [Indexed: 11/28/2022]
Abstract
This study aimed to transfer a high shear granulation (HSG) process to a twin-screw granulation (TSG) process while maintaining equivalent dissolution profiles. Ibuprofen (IBP) was used as poorly soluble model drug. Granules were obtained by HSG or TSG according to a full factorial design. The liquid-to-solid ratio and wet massing time (HSG) or powder throughput (TSG) were selected as factors. The granules were compressed to tablets with immediate release and a drug load of 50% (w/w). Quality attributes (QAs) of the granules, especially the granule strength (GS), and the resulting tablets were evaluated. The effect of process parameters on the QAs was statistically analyzed. The comparison of HSG tablets with TSG tablets revealed that TSG tablets showed higher tensile strength and lower ejection force than HSG tablets. The dissolution profiles of the tablets in different pH media were also evaluated. Equivalent dissolution profiles in all four media (e.g., f2 values ≥ 54 in pH5.5) were obtained by adjusting process parameters. It was concluded that the GS was the most important QA for dissolution.
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Affiliation(s)
- Yuta Miyazaki
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstr. 1, 40225 Duesseldorf, Germany; ONO Pharmaceutical Co., Ltd., CMC & Production HQs, Pharmaceutical Product Development & Management, Pharmaceutical Product Development, Non-Sterile Product, 15-26 Kamiji 1-Chome Higashinari-ku, 537-0003 Osaka, Japan
| | - Vincent Lenhart
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstr. 1, 40225 Duesseldorf, Germany
| | - Peter Kleinebudde
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstr. 1, 40225 Duesseldorf, Germany.
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28
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Kashani Rahimi S, Paul S, Sun CC, Zhang F. The role of the screw profile on granular structure and mixing efficiency of a high-dose hydrophobic drug formulation during twin screw wet granulation. Int J Pharm 2020; 575:118958. [DOI: 10.1016/j.ijpharm.2019.118958] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2019] [Revised: 12/10/2019] [Accepted: 12/12/2019] [Indexed: 11/24/2022]
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29
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Hwang KM, Cho CH, Yoo SD, Cha KI, Park ES. Continuous twin screw granulation: Impact of the starting material properties and various process parameters. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.08.062] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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30
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McLaughlin AM, Robertson J, Ni XW. Investigation of dissolution rate kinetics of bulk pharmaceutical feed streams within a stirred tank vessel and a twin screw extruder. Pharm Dev Technol 2019; 25:219-226. [PMID: 31651201 DOI: 10.1080/10837450.2019.1685543] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
Abstract
The introduction of continuous manufacturing of pharmaceuticals has highlighted the challenging area of continuous dissolution of solids for work ups to flow chemistry systems. In this study, the use of a 16 mm twin screw extruder (TSE) as a platform technology for solid feeds is investigated using four solid pharmaceutical ingredients (PI) in a mixture of water and IPA. In order for comparison, the same experiments were also carried out in a batch traditional stirred tank vessel (STV). The objectives of this work are to gain further scientific understanding on dissolution kinetics and to compare kinetics in both a batch and continuous system. The concentration of each PI during dissolution is monitored using an in-line UV-ATR probe, allowing the extraction of dissolution kinetics. Faster dissolution rates are achieved in the TSE than in the STV due to higher power dissipation generated by the aggressive shear mixing and thermal energy within the TSE. Complete dissolution of paracetamol is obtained within the residence time of the TSE; complete dissolution of benzoic acid and acetylsalicylic acid are achieved at higher barrel temperatures; however full dissolution of nicotinic acid is not achievable in the TSE under the experimental conditions.
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Affiliation(s)
- Arabella M McLaughlin
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh, UK
| | - John Robertson
- EPSRC Future Continuous Manufacturing and Advanced Crystallisation Research Hub, University of Strathclyde, Glasgow, UK
| | - Xiong-Wei Ni
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh, UK
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31
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Theismann EM, K Keppler J, Owen M, Schwarz K, Schlindwein W. Modelling the Effect of Process Parameters on the Wet Extrusion and Spheronisation of High-Loaded Nicotinamide Pellets Using a Quality by Design Approach. Pharmaceutics 2019; 11:E154. [PMID: 30939803 PMCID: PMC6523633 DOI: 10.3390/pharmaceutics11040154] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/18/2019] [Revised: 03/23/2019] [Accepted: 03/25/2019] [Indexed: 12/17/2022] Open
Abstract
The aim of the present study was to develop an alternative process to spray granulation in order to prepare high loaded spherical nicotinamide (NAM) pellets by wet extrusion and spheronisation. Therefore, a quality by design approach was implemented to model the effect of the process parameters of the extrusion-spheronisation process on the roundness, roughness and useable yield of the obtained pellets. The obtained results were compared to spray granulated NAM particles regarding their characteristics and their release profile in vitro after the application of an ileocolon targeted shellac coating. The wet extrusion-spheronisation process was able to form highly loaded NAM pellets (80%) with a spherical shape and a high useable yield of about 90%. However, the water content range was rather narrow between 24.7% and 21.3%. The design of experiments (DoE), showed that the spheronisation conditions speed, time and load had a greater impact on the quality attributes of the pellets than the extrusion conditions screw design, screw speed and solid feed rate (hopper speed). The best results were obtained using a low load (15 g) combined with a high rotation speed (900 m/min) and a low time (3⁻3.5 min). In comparison to spray granulated NAM pellets, the extruded NAM pellets resulted in a higher roughness and a higher useable yield (63% vs. 92%). Finally, the coating and dissolution test showed that the extruded and spheronised pellets are also suitable for a protective coating with an ileocolonic release profile. Due to its lower specific surface area, the required shellac concentration could be reduced while maintaining the release profile.
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Affiliation(s)
- Eva-Maria Theismann
- Division of Food Technology, Kiel University, Heinrich-Hecht-Platz 10, 24118 Kiel, Germany.
| | - Julia K Keppler
- Division of Food Technology, Kiel University, Heinrich-Hecht-Platz 10, 24118 Kiel, Germany.
| | - Martin Owen
- Insight by Design Ltd., Stevenage SG2 8SB, UK.
| | - Karin Schwarz
- Division of Food Technology, Kiel University, Heinrich-Hecht-Platz 10, 24118 Kiel, Germany.
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32
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Mendez Torrecillas C, Gorringe LJ, Rajoub N, Robertson J, Elkes RG, Lamprou DA, Halbert GW. The impact of channel fill level on internal forces during continuous twin screw wet granulation. Int J Pharm 2019; 558:91-100. [PMID: 30597270 DOI: 10.1016/j.ijpharm.2018.12.052] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2018] [Revised: 12/05/2018] [Accepted: 12/15/2018] [Indexed: 11/27/2022]
Abstract
The forces experienced by the particles inside a twin screw granulator (TSG) are one of the most difficult parameters to measure quantitatively. However, it is possible to perform accurately this measurement through the use of dye containing calibrated microencapsulated sensors (CAMES) whose rupture is directly dependant on their experienced shear stress. The current study measures the extent of local stresses in the transformation from powder to granules at different channel fills during TSG processing. Channel fill has shown good potential as a design tool, however, its validity for predicting particle size distributions has yet to be demonstrated in an 11-mm TSG. The results of this study showed that the particles within the twin screw granulator experienced stresses in the range of 350-1000 kPa and this value was not linear with the specific mechanical energy applied by the granulator. It was observed that the majority of these stresses were produced by material transport processes rather than the granulation in itself. In addition it was determined that the torque required by the TSG increases exponentially after a certain channel fill a feature that requires to be considered in order to design safer, predictable and reliable granulation workspaces.
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Affiliation(s)
- Carlota Mendez Torrecillas
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom.
| | - Lee J Gorringe
- R&D Platform Technology & Science GSK, David Jack Centre for R&D, Park Road, Ware, Hertfordshire SG12 0DP, United Kingdom
| | - Nazer Rajoub
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom
| | - John Robertson
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom
| | - Richard G Elkes
- R&D Platform Technology & Science GSK, David Jack Centre for R&D, Park Road, Ware, Hertfordshire SG12 0DP, United Kingdom
| | - Dimitrios A Lamprou
- School of Pharmacy, Queen's University Belfast, 97 Lisburn Road, BT9 7BL, United Kingdom
| | - Gavin W Halbert
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom.
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Thapa P, Tripathi J, Jeong SH. Recent trends and future perspective of pharmaceutical wet granulation for better process understanding and product development. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.12.080] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
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34
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A comprehensive analysis and optimization of continuous twin-screw granulation processes via sequential experimentation strategy. Int J Pharm 2019; 556:349-362. [DOI: 10.1016/j.ijpharm.2018.12.009] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/02/2018] [Revised: 11/26/2018] [Accepted: 12/02/2018] [Indexed: 11/23/2022]
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35
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36
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Shirazian S, Zeglinski J, Darwish S, Kuhs M, Albadarin AB, Croker DM, Walker GM. Continuous twin screw wet granulation: The combined effect of process parameters on residence time, particle size, and granule morphology. J Drug Deliv Sci Technol 2018. [DOI: 10.1016/j.jddst.2018.09.016] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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37
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McGuire AD, Mosbach S, Lee KF, Reynolds G, Kraft M. A high-dimensional, stochastic model for twin-screw granulation – Part 1: Model description. Chem Eng Sci 2018. [DOI: 10.1016/j.ces.2018.04.076] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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38
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Residence time distribution of a continuously-operated capsule filling machine: Development of a measurement technique and comparison of three volume-reducing inserts. Int J Pharm 2018; 550:180-189. [DOI: 10.1016/j.ijpharm.2018.08.017] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/30/2018] [Revised: 08/08/2018] [Accepted: 08/11/2018] [Indexed: 01/20/2023]
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39
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McLaughlin AM, Robertson J, Ni XW. On the Use of a Twin Screw Extruder for Continuous Solid Feeding and Dissolution for Continuous Flow Processes. Org Process Res Dev 2018. [DOI: 10.1021/acs.oprd.8b00187] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Arabella M. McLaughlin
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh EH14 4AS, U.K
| | - John Robertson
- EPSRC Future Continuous Manufacturing and Advanced Crystallisation Research Hub, University of Strathclyde Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, U.K
| | - Xiong-Wei Ni
- EPSRC Centre for Continuous Manufacturing and Crystallisation (CMAC), Centre for Oscillatory Baffled Reactor Applications (COBRA), School of Engineering and Physical Science, Heriot-Watt University, Edinburgh EH14 4AS, U.K
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40
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Pradhan SU, Sen M, Li J, Gabbott I, Reynolds G, Litster JD, Wassgren CR. Characteristics of multi-component formulation granules formed using distributive mixing elements in twin screw granulation. Drug Dev Ind Pharm 2018; 44:1826-1837. [PMID: 30027770 DOI: 10.1080/03639045.2018.1503293] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
Affiliation(s)
- Shankali U. Pradhan
- Davidson School of Chemical Engineering, Purdue University, West Lafayette (IN), USA
| | - Maitraye Sen
- Davidson School of Chemical Engineering, Purdue University, West Lafayette (IN), USA
| | - Jiayu Li
- Davidson School of Chemical Engineering, Purdue University, West Lafayette (IN), USA
| | - Ian Gabbott
- Pharmaceutical Technology and Development, AstraZeneca, Silk Road Business Park Charter Way, Cheshire, UK
| | - Gavin Reynolds
- Pharmaceutical Technology and Development, AstraZeneca, Silk Road Business Park Charter Way, Cheshire, UK
| | - James D. Litster
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield, UK
| | - Carl R. Wassgren
- School of Mechanical Engineering, Purdue University, West Lafayette (IN), USA
- Department of Industrial and Physical Pharmacy, Purdue University, West Lafayette (IN) USA
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41
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Twin Screw Granulation: Effects of Properties of Primary Powders. Pharmaceutics 2018; 10:pharmaceutics10020068. [PMID: 29865249 PMCID: PMC6027506 DOI: 10.3390/pharmaceutics10020068] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2018] [Revised: 05/28/2018] [Accepted: 05/30/2018] [Indexed: 11/17/2022] Open
Abstract
Lactose and mannitol are some of the most commonly used powders in the pharmaceutical industry. The limited research published so far highlights the effects of process and formulation parameters on the properties of the granules and the tablets produced using these two types of powders separately. However, the comparison of the performance of these two types of powders during twin screw wet granulation has received no attention. The present research is focused on understanding the granulation mechanism of different grades of two pharmaceutical powders with varying properties (i.e., primary particle size, structure, and compressibility). Three grades each of lactose and mannitol were granulated at varying liquid to solid ratios (L/S) and screw speed. It was noticed that primary powder morphology plays an important role in determining the granule size and structure, and tablet tensile strength. It was indicated that the processed powders such as spray-dried and granulated lactose and mannitol can be used in formulation for wet granulation where flowability of active pharmaceutical ingredient (API) is poor.
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42
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Twin Screw Granulation: An Investigation of the Effect of Barrel Fill Level. Pharmaceutics 2018; 10:pharmaceutics10020067. [PMID: 29857576 PMCID: PMC6027341 DOI: 10.3390/pharmaceutics10020067] [Citation(s) in RCA: 26] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2018] [Revised: 05/17/2018] [Accepted: 05/26/2018] [Indexed: 11/17/2022] Open
Abstract
This paper focuses on investigating the influence of varying barrel fill levels on the mean residence time, granule properties (median size, size distribution, and shape), and tensile strength of tablets. Specific feed load (SFL) (powder feed rate divided by screw speed) and powder feed number (PFN) (i.e., powder mass flow rate divided by the product of screw speed, screw diameter, and the material density in the denominator) were considered as surrogates for the barrel fill level. Two type of powders (lactose and microcrystalline cellulose (MCC)) were granulated separately at varying fill levels at different liquid-to-solid ratios (L/S). It was observed that by controlling the barrel fill level, the granule size, shape, and tablet tensile strength can be maintained at specific L/S. It was also noticed that the mean residence time decreased with increasing fill levels in the case of both lactose and MCC powder. However, it was only found to be related to the change in granule size in case of granulating microcrystalline cellulose at varying fill levels. At very high fill levels, granule size decreased, owing to a limited interaction between MCC powder and liquid at high throughput force and short residence time.
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43
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Verstraeten M, Van Hauwermeiren D, Lee K, Turnbull N, Wilsdon D, am Ende M, Doshi P, Vervaet C, Brouckaert D, Mortier ST, Nopens I, Beer TD. In-depth experimental analysis of pharmaceutical twin-screw wet granulation in view of detailed process understanding. Int J Pharm 2017; 529:678-693. [DOI: 10.1016/j.ijpharm.2017.07.045] [Citation(s) in RCA: 42] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/24/2017] [Revised: 07/12/2017] [Accepted: 07/14/2017] [Indexed: 11/26/2022]
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44
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Kim SH, Hwang KM, Cho CH, Nguyen TT, Seok SH, Hwang KM, Kim JY, Park CW, Rhee YS, Park ES. Application of continuous twin screw granulation for the metformin hydrochloride extended release formulation. Int J Pharm 2017; 529:410-422. [PMID: 28705620 DOI: 10.1016/j.ijpharm.2017.07.019] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2017] [Revised: 06/17/2017] [Accepted: 07/07/2017] [Indexed: 11/17/2022]
Abstract
This study focuses on evaluating the potential of transferring from a batch process to continuous process for manufacturing of the extended release formulation. Metformin hydrochloride (HCl) was used in the model formulation which was intended to contain the high amount of hydrophilic drug. The effects of barrel temperature, binder type, powder feed rate, and screw speed on granule properties (size and strength) and torque value in twin screw granulation were investigated. Due to the high content of hydrophilic model drug, the granules prepared at a higher temperature with HPMC binding solution had the narrower size distribution and greater strength than the granules prepared with distilled water as a binding solution. After continuous drying and milling steps, the granules (continuous process) satisfied the fundamental purpose of granulation with size and flowability, despite different shape compared with the granules (batch process). Furthermore, there were no significant differences between two granulation processes in tablet properties, such as tablet hardness and in vitro release. The considerations and strategies used in this study to transfer from a batch to continuous process can be applied to other existing formulations based on high shear granulation to enable rapid process transfer in the pharmaceutical industry.
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Affiliation(s)
- Su-Hyeon Kim
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Kyu-Min Hwang
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Cheol-Hee Cho
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Thi-Tram Nguyen
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Su Hyun Seok
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Kyu-Mok Hwang
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Ju-Young Kim
- College of Pharmacy, Woosuk University, Wanju-gun 55338, Republic of Korea
| | - Chun-Woong Park
- College of Pharmacy, Chungbuk National University, Cheongju 19421, Republic of Korea
| | - Yun-Seok Rhee
- College of Pharmacy and Research Institute of Pharmaceutical Sciences, Gyeongsang National University, Jinju 52828, Republic of Korea
| | - Eun-Seok Park
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea.
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45
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Affiliation(s)
- Y. Liu
- Dept. of Chemical Engineering; MMRI/ CAPPA-D, McMaster University; Hamilton Ontario Canada L8S 4L7
| | - M. R. Thompson
- Dept. of Chemical Engineering; MMRI/ CAPPA-D, McMaster University; Hamilton Ontario Canada L8S 4L7
| | - K. P. O'Donnell
- Dow food, Pharma & Medical; Larkin Laboratory, The Dow Chemical Company; Midland MI 48674
| | - S. Ali
- Pharma Solutions; BASF Corporation; 100 Park Avenue, Florham Park NJ 07932
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46
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Meier R, Moll KP, Krumme M, Kleinebudde P. Impact of fill-level in twin-screw granulation on critical quality attributes of granules and tablets. Eur J Pharm Biopharm 2017; 115:102-112. [DOI: 10.1016/j.ejpb.2017.02.010] [Citation(s) in RCA: 43] [Impact Index Per Article: 6.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/19/2016] [Indexed: 10/20/2022]
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47
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Mendez Torrecillas C, Halbert GW, Lamprou DA. A novel methodology to study polymodal particle size distributions produced during continuous wet granulation. Int J Pharm 2017; 519:230-239. [PMID: 28104406 DOI: 10.1016/j.ijpharm.2017.01.023] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/19/2016] [Revised: 01/10/2017] [Accepted: 01/11/2017] [Indexed: 11/26/2022]
Abstract
It is important during powder granulation to obtain particles of a homogeneous size especially in critical situations such as pharmaceutical manufacture. To date, homogeneity of particle size distribution has been defined by the use of the d50 combined with the span of the particle size distribution, which has been found ineffective for polymodal particle size distributions. This work focuses on demonstrating the limitations of the span parameter to quantify homogeneity and proposes a novel improved metric based on the transformation of a typical particle size distribution curve into a homogeneity factor which can vary from 0 to 100%. The potential of this method as a characterisation tool has been demonstrated through its application to the production of granules using two different materials. The workspace of an 11mm twin screw granulator was defined for two common excipients (α-lactose monohydrate and microcrystalline cellulose). Homogeneity of the obtained granules varied dramatically from 0 to 95% in the same workspace, allowing identification of critical process parameters (e.g. feed rate, liquid/solid ratio, torque velocities). In addition it defined the operational conditions required to produce the most homogeneous product within the range 5μm-2.2mm from both materials.
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Affiliation(s)
- Carlota Mendez Torrecillas
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom.
| | - Gavin W Halbert
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom
| | - Dimitrios A Lamprou
- Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom; Medway School of Pharmacy, University of Kent, Medway Campus, Anson Building, Central Avenue, Chatham Maritime, Chatham, Kent, ME4 4TB, United Kingdom.
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48
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Meng W, Kotamarthy L, Panikar S, Sen M, Pradhan S, Marc M, Litster JD, Muzzio FJ, Ramachandran R. Statistical analysis and comparison of a continuous high shear granulator with a twin screw granulator: Effect of process parameters on critical granule attributes and granulation mechanisms. Int J Pharm 2016; 513:357-375. [DOI: 10.1016/j.ijpharm.2016.09.041] [Citation(s) in RCA: 30] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/23/2016] [Revised: 08/25/2016] [Accepted: 09/10/2016] [Indexed: 10/21/2022]
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49
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Kumar A, Dhondt J, Vercruysse J, De Leersnyder F, Vanhoorne V, Vervaet C, Remon JP, Gernaey KV, De Beer T, Nopens I. Development of a process map: A step towards a regime map for steady-state high shear wet twin screw granulation. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2015.11.067] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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50
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Developing a miniaturized approach for formulation development using twin screw granulation. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.04.051] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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