Is the adjustment of the impeller speed a reliable attempt to influence granule size in continuous dry granulation?

Implementing Feedback Granule Size Control in a Continuous Dry Granulation Line Using Controlled Impeller Speed of the Granulation Unit, Compaction Force and Gap Width

Purpose

In continuous manufacturing of pharmaceuticals, dry granulation is of interest because of its large throughput capacity and energy efficiency. In order to manufacture solid oral dosage forms continuously, valid control strategies for critical quality attributes should be established. To this date, there are no published control strategies for granule size distribution in continuous dry granulation.

Methods

In-line laser diffraction was used to determine the size of granules in a continuous roll compaction/dry granulation line (QbCon® dry). Different process parameters were evaluated regarding their influences on granule size. The identified critical process parameters were then incorporated into control strategies. The uncontrolled and the controlled processes were compared based on the resulting granule size. In both processes, a process parameter was changed to induce a shift in median particle size and the controller had to counteract this shift.

Results

In principle, all process parameters that affect the median particle size could also be used to control the particle size in a dry granulation process. The sieve impeller speed was found to be well suited to control the median particle size as it reacts fast and can be controlled independently of the throughput or material.

Conclusion

The median particle size in continuous roll compaction can be controlled by adjusting process parameters depending on real-time granule size measurements. The method has to be validated and explored further to identify critical requirements to the material and environmental conditions.

Towards better understanding of the influence of process parameters in roll compaction/dry granulation on throughput, ribbon microhardness and granule failure load

A key quality attribute for solid oral dosage forms is their hardness and ability to withstand breaking or grinding. If the product is to be manufactured continuously, it can be of interest to monitor the hardness of the material at different stages of manufacturing. Using the controlled process parameters of roll compaction/dry granulation specific compaction force, roll speed and gap width, hardness of the resulting ribbons and granules can be predicted. For the first time, in this study two yield variables (corrected torque of the granulation unit and throughput of material) are used to predict the granules failure load. The increase in granule hardness was monitored in-line when the specific compaction force was increased during the compaction process. This opens the way for in-line control of material hardness, and its use for feedback and feedforward control loops for future continuous manufacturing processes.

Implementation of real-time and in-line feedback control for a fluid bed granulation process

The application of process analytical technologies (PAT) to monitor critical quality attributes (CQAs) provides an important approach to enhance process understanding and improve the reliability of pharmaceutical production processes. The present study focuses on the first PAT based feedback control system for a fluid bed granulation batch process. Real-time particle size measurement by in-line spatial filtering technique (SFT) using a modified time-based buffer system was applied to define a target particle size after spraying a specific amount of binder solution. After identifying an appropriate control variable, a suitable strategy for feedback control was established, followed by tuning of the control loop to obtain best performance of the integrated system. By adapting the final target particle size within a specified range good functionality of the system could be demonstrated. Investigations of the robustness further showed that the implemented system enables the production of a predefined target particle size also by varying process and formulation parameters. The effect of increasing spray rates and binder concentrations on the particle size could be compensated in a given range by feedback control ensuring a predefined product quality. The study provides an advanced approach for quality assurance of fluid bed granulation.

Laser based thermo-conductometry as an approach to determine ribbon solid fraction off-line and in-line

Ribbon solid fraction is one of the most important quality attributes during roll compaction/dry granulation. Accurate and precise determination is challenging and no in-line measurement tool has been generally accepted, yet. In this study, a new analytical tool with potential off-line as well as in-line applicability is described. It is based on the thermo-conductivity of the compacted material, which is known to depend on the solid fraction. A laser diode was used to punctually heat the ribbon and the heat propagation monitored by infrared thermography. After performing a Gaussian fit of the transverse ribbon profile, the scale parameter σ showed correlation to ribbon solid fraction in off-line as well as in-line studies. Accurate predictions of the solid fraction were possible for a relevant range of process settings. Drug stability was not affected, as could be demonstrated for the model drug nifedipine. The application of this technique was limited when using certain fillers and working at higher roll speeds. This study showed the potentials of this new technique and is a starting point for additional work that has to be done to overcome these challenges.