Effect of resonant acoustic mixing on pharmaceutical powder blends and tablets

The effects of resonance acoustic mixing modulation on the structural and emulsifying properties of pea protein isolate

The effects of resonant acoustic mixing (RAM) with different treatment times (0, 5, 10, 15, 20 and 30 min) on the structural and emulsifying properties of pea protein isolate (PPI) were investigated for the first time. Increasing the RAM treatment time from 0 to 20 min decreased the α-helix/β-sheet ratio and particle size of the PPI samples by 37.84 % and 46.44 %, respectively, accompanied by an increase in solubility from 54.79 % to 71.80 % (P < 0.05). Consequently, the emulsifying activity index of PPI (from 10.45 m2/g to 14.2 m2/g) and the physical stability of RAM-PPI emulsions were effectively enhanced, which was confirmed by the small and uniformly distributed oil droplets in the micrographs of the emulsions. However, excessive RAM treatment (30 min) diminished the effectiveness of the aforementioned improvements. Therefore, obviously enhanced solubility and emulsifying properties of PPI can be attained through proper RAM treatment (15-20 min).

Use of Resonant Acoustic Mixing Technology for Ultra-Low-Dose Blending in a Single-Step Mixing Process

PURPOSE

To evaluate the use of resonant acoustic mixing (RAM) technology for homogenous blending of a morphologically challenging model API in low-dose concentrations (<0.1% w/w), and assess the potential for blend uniformity (BU) optimization.

METHODS

Caffeine (CAF) mixing was carried out using a LabRAM I benchtop mixer. Uniformity was assessed under a range of mixing conditions and sample preparation procedures in order to optimize system performance. The capacity for microscale mixing was evaluated from final parameters for 0.05% and 0.0125% CAF blends.

RESULTS

Upon optimization, RAM was able to accurately prepare homogeneous mixtures of <0.1% CAF in dilutions of up to 1 part per 8,000. Results from a 0.05% blend targeting 125 μg CAF dosage amounts revealed an AV score of 8.8 while a 0.0125% w/w blend accurately prepared 25 μg of CAF with 99.3% accuracy (98.7% label claim) and AV of 10.1. Microscale mixing in the 0.05% w/w blend was confirmed from plots of BU data against sample size demonstrating a slope of 0.05 within the range of 250-10 mg sample (125-5 μg CAF). L1 BU criteria only failed at the level of 2 μg CAF, despite target precision to 26 nanograms (98.7% label claim).

CONCLUSIONS

This study presents the first instance of a homogenously mixed <0.1% (w/w) blend using RAM technology and demonstrate the suitability for reproducible dosing of single-digit microgram drug amounts. Uniformity is documented for API amounts 60x smaller than a recent report has shown and 10,000x smaller than achieved previously with CAF.

Impact of Silica Dry Coprocessing with API and Blend Mixing Time on Blend Flowability and Drug Content Uniformity

This paper considers two fine-sized (d50 ∼10 µm) model drugs, acetaminophen (mAPAP) and ibuprofen (Ibu), to examine the effect of API dry coprocessing on their multi-component medium DL (30 wt%) blends with fine excipients. The impact of blend mixing time on the bulk properties such as flowability, bulk density, and agglomeration was studied. The hypothesis tested is that blends with fine APIs at medium DL require good blend flowability to have good blend uniformity (BU). Moreover, the good flowability could be achieved through dry coating with hydrophobic (R972P) silica, which reduces agglomeration of not only fine API, but also of its blends while using fine excipients. For uncoated APIs, the blend flowability was poor, i.e. cohesive regime at all mixing times, and the blends failed to achieve acceptable BU. In contrast, for dry coated APIs, their blend flowability improved to easy-flow regime or better, improving with mixing time, and as hypothesized, all blends consequently achieved desired BU. All dry coated API blends exhibited improved bulk density and reduced agglomeration, attributed to mixing induced synergistic property enhancements, likely due to silica transfer. Despite coating with hydrophobic silica, tablet dissolution was improved, attributed to the reduced agglomeration of fine API.

Parametric Effects on the Mixing Efficiency of Resonant Acoustic Mixing Technology for High-Viscosity Mixture: A Numerical Study

Numerical investigations were conducted on the mixing efficiency of resonant acoustic mixing (RAM) technology using a high-viscosity mixture under vertically forced vibrations. The density distribution was analyzed for a mixture of high-melting explosive (HMX) and trinitrotoluene (TNT). The effects of mixing time, amplitude, frequency, fill level, and mixing vessel geometry were evaluated to determine their influence on the blend homogeneity and the efficiency of the mixing process. The results showed that amplitude and frequency both have significant influences on the mixing efficiency of the RAM process. With higher values of amplitude and frequency, the mixing efficiency was very good, and uniform mixing was achieved in a much shorter time. At the same time, it was seen that geometric changes did not affect the mixing process; in contrast, varying the fill level did have a significant effect. This approach could potentially be used for pharmaceutical blending, cosmetics, and explosive applications, where only small quantities of active particle ingredients (APIs) can change the behavior of the mixture.

Improving the Effectiveness of the Conical Screen Mill as a Dry-Coating Process at Lab and Manufacturing Scale

The conical screen mill (comill) is investigated as a dry-coating process for flowability and bulk density enhancement of pharmaceutical powders. In this study, the effectiveness of the comill is improved by using modified screens with reduced open area. In comparison to the screens provided by the comill manufacturer, the modified screens increase mean residence time of the process and improve the extent of flowability and bulk density enhancement. The effectiveness of the comill as a dry-coating process is demonstrated using Avicel PH 105, a fine grade of microcrystalline cellulose, as a model cohesive powder. The process is evaluated thoroughly using a lab scale comill and scalability is demonstrated using a manufacturing scale model. The use of the modified screens is also compared against the so-called "multi-pass" approach in which material is passed through the comill, collected, and passed through once or several times. While the "multi-pass" approach is offered as a simple method to increase mean residence time and to improve process effectiveness, the use of the modified screens is shown to be the superior approach. Due to the ubiquitous use of the comill and the improvement in effectiveness attained in this study, dry-coating is shown to be a practical and readily implemented process for the pharmaceutical industry.

Prediction of entire tablet formulations from pure powder components' spectra via a two-step non-linear optimization methodology

Process analytical technology in the pharmaceutical industry requires the monitoring of critical quality attributes (CQA) through calibrated models. However, the development, implementation, and maintenance of these quantitative models are both resource and time-intensive. This study proposes the implementation of a non-linear iterative optimization technology (IOT) to study the magnitude of analytical errors when the calibration tablet used to extract the λ vector deviates physically and chemically from the test samples. IOT is based on mathematical optimization of excess spectral absorbance. It requires minimum calibration effort and allows simultaneous prediction of the entire formulation instead of only the active pharmaceutical ingredient (API), with just one standard and pure component spectral data. Unlike Partial Least Squares (PLS), which requires the development of standards to incorporate variations in the process, this non-destructive methodology minimizes significant calibration effort by developing a mathematical model that uses only one standard and spectral information of pure powders present in the tablet. The method described in this study allows a fast re-calculation to include factors such as change of spectroscopic instruments, variations in raw materials, environmental conditions, and methods of tablet preparation. The robustness of the proposed approach for variation in compaction (physical changes) and variation in composition (chemical changes) was evaluated for correlated and uncorrelated formulations. For uncorrelated formulation a PLS model was also constructed to compare the robustness of the proposed methodology. The RMSEP of API in target formulation predicted using non-linear IOT method was varied from 0.17 to 1.50 depends on compaction of tablet chosen to compute λ vector. On the other hand, the RMSEP of API in target formulation predicted using PLS-based model was varied from 0.13 to 0.57 depending on compaction of tablet. The additional accuracy achieved in PLS based model required significant calibration effort of preparing 84 tablets compared to just one in proposed non-linear IOT method.

Simple, scalable mechanosynthesis of metal-organic frameworks using liquid-assisted resonant acoustic mixing (LA-RAM)

We present a rapid and readily scalable methodology for the mechanosynthesis of diverse metal-organic frameworks (MOFs) in the absence of milling media typically required for other types of mechanochemical syntheses. We demonstrate the use of liquid-assisted resonant acoustic mixing (LA-RAM) methodology for the synthesis of three- and two-dimensional MOFs based on Zn(ii), Co(ii) and Cu(ii), including a mixed ligand system. Importantly, the LA-RAM approach also allowed the synthesis of the ZIF-L framework that has never been previously obtained in a mechanochemical environment, as well as its Co(ii) analogue. Straightforward scale-up from milligrams to at least 25 grams is demonstrated using the metastable framework ZIF-L as the model.

Feed frame: The last processing step before the tablet compaction in pharmaceutical manufacturing

The feed frame is a force-feeding device used in the die filling process. The die filling process is crucial within pharmaceutical manufacturing to guarantee the critical quality attributes of the tablets. In recent years, interest in this unit has increased because it can affect the properties of the powder blend and tablets, and because of the success in real time monitoring of powder blend uniformity potential for Process Analytical Technology as described in this review. The review focuses on the recent advances in understanding the powder flow behavior inside the feed frame and how the residence time distribution of the powder within the feed frame is affected by the operating conditions and design parameters. Furthermore, this review also highlights the effect of the paddle wheel design and feed frame process parameters on the tablet weight, the principal variable for measuring die filling performance.

Assessment of blend uniformity in a continuous tablet manufacturing process

Blend uniformity was monitored throughout a continuous manufacturing (CM) process by near infrared (NIR) spectroscopic measurements of flowing blends and compared to the drug concentration in the tablets. The NIR spectra were obtained through the chute after the blender and within the feed frame, while transmission spectra were obtained for the tablets. The CM process was performed with semi-fine acetaminophen blends at 10.0% (w/w). The blender was operated at 250 RPM, for best performance, and 106 and 495 rpm where a lower mixing efficiency was expected. The variation in blender RPM increased the variation in drug concentration at the chute but not at the feed frame. Statistical results show that the drug concentration of tablets can be predicted, with great accuracy, from blends within the feed frame. This study demonstrated a mixing effect within the feed frame, which contribute to a 60% decrease in the relative standard deviation of the drug concentration, when compared to the chute. Variographic analysis showed that the minimum sampling and analytical error was five times less in the feed frame than the chute. This study demonstrates that the feed frame is an ideal location for monitoring the drug concentration of powder blends for CM processes.

Influence of Material Properties on the Effectiveness of Glidants Used to Improve the Flowability of Cohesive Pharmaceutical Powders

This study investigated the effect of material properties, primarily particle size and surface energy, on the effectiveness of glidants used for the purpose of flowability enhancement. Three pharmaceutical grade glidants (Aerosil 200, Aerosil R972, and Cab-O-Sil M5P) were evaluated and blended with various pharmaceutical actives as well as cohesive excipients common to capsule and tablet formulation. Flowability enhancement was characterized by the flow function coefficient (ff _c ). An industry-relevant mixer (Turbula mixer) and a highly efficient and effective mixer (LabRAM vibratory mixer) were used to further understand the effect of material properties on glidant effectiveness. While concepts of inter-particle cohesion and interaction strength were applied to evaluate their usefulness in understanding and predicting flowability enhancement, theoretical expectations did not fully explain the behavior of all three glidants. However, the study suggests that the low surface energy and optimal particle size of Aerosil R972 relative to the other glidants results in lower inter-particle force and consequently better flowability. Aerosil R972 was also shown to be more effectively utilized in the Turbula mixing process particularly for larger (d₅₀ > 40 μm) and less cohesive (ff _c  > 3) materials. This may be due to its lower surface energy and hydrophobic surface which allows it to disperse easily. Overall, this study provides useful insight into the material properties which influence the effectiveness of glidants used in formulation development.