Electrostatics in pharmaceutical solids

Electrostatic interactions between rough dielectric particles

From colloid suspension to particle aggregation in protoplanetary formation, electrostatic attraction and repulsion between particles is a key mechanism behind the aggregation and clustering of particles. Although most studies have focused on canonical spherical particles, it remains unclear how nonspherical and rough dielectric particles interact and whether the complicated interplay between roughness and charge distribution affects their force couplings. Here a boundary-element method model was leveraged to study electrostatic interactions between charged dielectric particles with modular, axisymmetric surface features. Charge accumulation at convex surface asperities decreases the strength of electrostatic interactions between particles, and the sensitivity of the electrostatic force to the particle surface roughness and orientation is especially apparent at small particle separations. Surface interactions between the particle near-contact regions were isolated to determine the degree that near-contact interactions dictate the relationship between the net electrostatic force and the particle roughness and orientation. A correction factor ΔF is introduced to recover higher order dielectric effects from a low order analytical model. Finally, implications of surface charge asymmetries produced for different particle orientations and surface roughnesses on the long-standing problem of triboelectrification are discussed.

Mitigation of Tribocharging in Pharmaceutical Powders using Surface Modified V-Blenders

INTRODUCTION

The pharmaceutical industry involves handling of powders on a large scale for manufacturing of solid dosage forms such as tablets and capsules constituting about 85% of the dosage forms. During this manufacturing process, powders get electrostatically charged due to numerous particle-particle and particle-equipment wall collisions. Most of the pharmaceutical powders are insulators in nature and they accumulate charge for longer durations making it difficult to dissipate the generated charge. In this study, a surface modified blender has been used to analyze tribocharging in pharmaceutical powders.

METHODS

The surface modified blender has been fabricated using two types of materials, an insulator, and a conductor. The conductor or the metal arm induces charge of opposite polarity to that of the charge induced by the insulator arm and the overall charge on the powder decreases during the tumbling motion of the blender. Ibuprofen was used as the model drug and processed in aluminum, polyvinyl chloride (PVC), stainless steel, surface modified aluminum-PVC (Al-PVC) and surface modified stainless steel- PVC (SS-PVC) blender at 20% RH for different blending times such as 2, 10, 20, 30 and 40 min. To better understand the tribocharging phenomenon in surface modified V blenders, an experimentally validated computational model was developed using Discrete Element Method (DEM) modeling.

RESULTS

Significant reduction (> 50%) in electrostatic charge was observed for Ibuprofen using surface modified blenders in comparison to metal only and insulator only V blenders. Additionally, an identical charging trend was observed between the simulation and experimental data.  CONCLUSION: It was established that careful selection of equipment materials could significantly reduce the electrostatic charging of pharmaceutical powders and DEM model could be a really useful tool in assessing the applicability of the modified V blenders.

Prediction of the Effective Work Function of Aspirin and Paracetamol Crystals by Density Functional Theory-A First-Principles Study

Crystals of active pharmaceutical ingredients (API) are prone to triboelectric charging due to their dielectric nature. This characteristic, coupled with their typically low density and often large aspect ratio, poses significant challenges in the manufacturing process. The pharmaceutical industry frequently encounters issues during the secondary processing of APIs, such as particle adhesion to walls, clump formation, unreliable flow, and the need for careful handling to mitigate the risk of fire and explosions. These challenges are further intensified by the limited availability of powder quantities for testing, particularly in the early stages of drug development. Therefore, it is highly desirable to develop predictive tools that can assess the triboelectric propensity of APIs. In this study, Density Functional Theory calculations are employed to predict the effective work function of different facets of aspirin and paracetamol crystals, both in a vacuum and in the presence of water molecules on their surfaces. The calculations reveal significant variations in the work function across different facets and materials. Moreover, the adsorption of water molecules induces a shift in the work function. These findings underscore the considerable impact of distinct surface terminations and the presence of molecular water on the calculated effective work function of pharmaceuticals. Consequently, this approach offers a valuable predictive tool for determining the triboelectric propensity of APIs.

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.

Overhead AC powerlines and rain can alter the electric charge distribution on airborne particles - Implications for aerosol dispersion and lung deposition

Corona ions from high voltage power lines (HVPL) can increase electrostatic charge on airborne pollutant particulates, possibly increasing received dose upon inhalation. To investigate the potential increased risk of childhood leukemia associated with residence near alternating current (AC) HVPL, we measured the particle charge state and atmospheric electricity parameters upwind, downwind and away from HVPL. Although we observed noticeable charge state alteration from background levels, most HVPL do not significantly increase charge magnitude. Particular HVPL types are shown to have most effect, increasing net charge to 15 times that at background. However, the magnitude of charge alteration during rainfall is comparable with the most extreme HVPL measurement. On current evidence, based on the current adult lung model, we suggest that although charge is sometimes enhanced to levels which may alter atmospheric particle dynamics, increased lung deposition is unlikely.

Atomic Layer Deposition Coating on the Surface of Active Pharmaceutical Ingredients to Reduce Surface Charge Build-Up

Active pharmaceutical ingredients (APIs) typically consist of solid therapeutic particles that may acquire electrostatic charge during milling and grinding operations. This may result in the agglomeration of particles, thereby reducing the flowability and affecting the homogeneity of the drug formulation. Electrostatic charge build-up may also lead to fire explosions. To avoid charge build-up, APIs are often coated with polymers. In this paper, atomic layer deposition (ALD) using metal oxides such as Al2O3 and TiO2 on APIs, namely, palbociclib and pazopanib HCl, has been utilized to demonstrate a uniform coating that results in a significant reduction in the surface charge of the drug particles. Kelvin probe force microscopy (KPFM) shows a 4-fold decrease in the surface contact potential of uncoated pazopanib HCl (2.3 V) to 0.52 and 0.82 V in TiO2-and Al2O3-coated APIs, respectively. Also, the ζ potential indicated a 4-fold decrease in the surface charge on coating pazopanib HCl, i.e., from -32.9 mV to -7.51 and -8.51 mV in Al2O3 and TiO2, respectively. Surface morphology, thermal stability, dissolution studies, and cytotoxicity of the drug particles after coating were also examined. Thermal analysis indicated no change in the melting temperature (Tm) after coating. ALD coating was found to be uniform and conformal as observed in images obtained from scanning electron microscopy (SEM) and scanning electron microscopy-energy-dispersive X-ray spectroscopy (SEM-EDS). The rate of dissolution was found to be delayed by the coating, and thus ALD offers slower drug release. Coating APIs with TiO2 and Al2O3 did not induce statistically significant cytotoxicity compared to the uncoated samples. The results presented in this study demonstrate that ALD coating can be used to reduce surface charge build-up and enhance the bulk properties of the drug particles without affecting their physicochemical properties.

Band Bending and Ratcheting Explain Triboelectricity in a Flexoelectric Contact Diode

Triboelectricity was recognized millennia ago, but the fundamental mechanism of charge transfer is still not understood. We have recently proposed a model where flexoelectric band bending due to local asperity contacts drives triboelectric charge transfer in non-metals. While this ab initio model is consistent with a wide range of observed phenomena, to date there have been no quantitative analyses of the proposed band bending. In this work we use a Pt_0.8Ir_0.2 conductive atomic force microscope probe to simultaneously deform a Nb-doped SrTiO₃ sample and collect current-bias data. The current that one expects based upon an analysis including the relevant flexoelectric band bending for a deformed semiconductor quantitively agrees with the experiments. The analysis indicates a general ratcheting mechanism for triboelectric transfer and strong experimental evidence that flexoelectric band bending is of fundamental importance for triboelectric contacts.

Towards a better understanding of the role of stabilizers in QESD crystallizations

Quasi-emulsion solvent-diffusion crystallization (QESD) is a type of spherical crystallization which can be used as a particle design method to improve the flowability and micromeritic properties of drugs or excipients. Spherical particles are generated by dispersing a solvent phase in an antisolvent so that a transient emulsion is formed. Within the droplets the material can crystallize and agglomerate into spherical, hollow particles. Surfactants, such as surface-active polymers like hypromellose, are often required to stabilize the quasi-emulsion. To gain further understanding for the role of the stabilizer, a new screening-method was developed which compared different surface active polymers in solution at similar dynamic viscosities rather than at a set concentration. The dynamic viscosities of a low-viscosity grade hypromellose solution used in the previous publications describing the QESD crystallization of metformin hydrochloride by the authors was used as a target value. QESD crystallizations of metformin hydrochloride (MF) and celecoxib showed that the type of stabilizer and whether it is dissolved in the solvent or antisolvent has an effect on the agglomerates. For MF, the type of hypromellose used can have a significant influence on the properties of the agglomerates. More polymers could be used to stabilize the transient emulsion of celecoxib than previously found in literature. Furthermore, QESD crystallizations seem to be more robust when the stabilizer is dissolved in the antisolvent, however this can lead to a reduced drug load of the agglomerates.

Loss-in-weight feeding, powder flow and electrostatic evaluation for direct compression hydroxypropyl methylcellulose (HPMC) to support continuous manufacturing

Minimizing variability in the feeding process is important for continuous manufacturing since materials are fed individually and can impact the final product. This study demonstrates the importance of measuring powder properties and highlights the need to characterize the feeding performance both offline with multiple refills and in the intended configuration for the continuous manufacturing equipment. The standard grade hydroxypropyl methylcellulose (HPMC) had material buildup on the loss-in-weight feeder barrel from triboelectric charging and resulted in more mass flow excursions and failed refills which were not observed with the direct compression grades. The location of the electrostatic buildup changed when the feeder was connected to a hopper instead of feeding offline into a collection bucket. Overall, the direct compression HPMC exhibited better flow which resulted in more accurate loss-in-weight feeding with less excursions from the target mass flow and all refills were completed in the first attempt. The improvements with the direct compression HPMC would be beneficial when running any continuous process (wet granulation, roller compaction, or direct compression) or other processes where loss-in-weight feeding is utilized, such as melt extrusion or twin screw granulation.

A Simple μ-PTV Setup to Estimate Single-Particle Charge of Triboelectrically Charged Particles

Triboelectric separation is a useful phenomenon that can be used to separate fine powders. To design technical devices or evaluate the potential of powders to be triboelectrically separated, knowledge about the charge distribution on a single-particle level has to be obtained. To estimate the single-particle charge distribution in an application-oriented way, a simple μ-PTV system was developed. The designed setup consists of a dispersing and a charging unit using a Venturi nozzle and a tube, respectively, followed by a separation chamber. In the separation chamber, a homogenous electrical field leads to a deflection of the particles according to their individual charge. The trajectories of the particles are captured on single frames using microscope optics and a high-speed camera with a defined exposure time. The particles are illuminated using a laser beam combined with a cylindrical lens. The captured images enable simultaneous measurement of positively and negatively charged particles. The charge is calculated assuming a mean particle mass derived from the mean particle size. Initial experiments were carried out using starch of different botanical origins and protein powder. Single-component experiments with starch powders show very different charge distributions for positively and negatively charged particles, whereas protein powder shows bipolar charging. Different starch-protein mixtures show similar patterns for positive and negative charge distributions.

Controlling Surface Charge Generated by Contact Electrification: Strategies and Applications

Contact electrification is the phenomenon in which charge is generated on the surfaces of materials after they come into contact. The surface charge generated has traditionally been known to cause a vast range of undesirable consequences in our lives and in industry; on the other hand, it can also give rise to many types of useful applications. In addition, there has been a lot of interest in recent years for fabricating devices and materials based on regulating a desired amount of surface charge. It is thus important to understand the general strategies for increasing, decreasing, or controlling the surface charge generated by contact electrification. Herein, the fundamental mechanisms for influencing the amount of charge generated, the methods used for implementing these mechanisms, and some of the recent interesting applications that require regulating the amount of surface charge generated by contact electrification, are briefly summarized.

Raw material variability of an active pharmaceutical ingredient and its relevance for processability in secondary continuous pharmaceutical manufacturing

Active Pharmaceutical Ingredients (API) raw material variability is not always thoroughly considered during pharmaceutical process development, mainly due to low quantities of drug substance available. However, synthesis, crystallization routes and production sites evolve during product development and product life cycle leading to changes in physical material attributes which can potentially affect their processability. Recent literature highlights the need for a global approach to understand the link between material synthesis, material variability, process and product quality. The study described in this article aims at explaining the raw material variability of an API using extensive material characterization on a restricted number of representative batches using multivariate data analysis. It is part of a larger investigation trying to link the API drug substance manufacturing process, the resulting physical API raw material attributes and the drug product continuous manufacturing process. Eight API batches produced using different synthetic routes, crystallization, drying, delumping processes and processing equipment were characterized, extensively. Seventeen properties from seven characterization techniques were retained for further analysis using Principal Component Analysis (PCA). Three principal components (PCs) were sufficient to explain 92.9% of the API raw material variability. The first PC was related to crystal length, agglomerate size and fraction, flowability and electrostatic charging. The second PC was driven by the span of the particle size distribution and the agglomerates strength. The third PC was related to surface energy. Additionally, the PCA allowed to summarize the API batch-to-batch variability in only three PCs which can be used in future drug product development studies to quantitatively evaluate the impact of the API raw material variability upon the drug product process. The approach described in this article could be applied to any other compound which is prone to batch-to-batch variability.

Surface Chemistry and Humidity in Powder Electrostatics: A Comparative Study between Tribocharging and Corona Discharge

In the present study, the correlation between surface chemical groups and the electrostatic properties of particulate materials was studied. Glass beads were modified to produce OH-, NH₂-, CN-, and F-functionalized materials. The materials were charged separately both by friction and by conventional corona charging, and the results were compared. The results obtained from both methods indicated that the electrostatic properties are directly related to the surface functional group chemistry, with hydrophobic groups accumulating greater quantities of charge than hydrophilic groups. The fluorine-rich surface accumulated 5.89 times greater charge upon tribocharging with stainless steel than the hydroxyl-rich surface. However, in contrast to the tribocharging method, the charge polarity could not be determined when corona charging was used. Moreover, discharge profiles at different humidity levels (25% RH, 50% RH, and 75% RH) were obtained for each modified surface, which showed that higher humidity facilitates faster charge decay; however, this enhancement is surface chemistry-dependent. By increasing the humidity from 25% RH to 75% RH, the charge relaxation times can be accelerated 1.6 times for fluorine and 12.2 times for the cyano group. These data confirm that surface functional groups may dictate powder electrostatic behavior and account for observed charge accumulation and discharge phenomena.

Tribo-electrification and Powder Adhesion Studies in the Development of Polymeric Hydrophilic Drug Matrices

The generation of tribo-electric charge during pharmaceutical powder processing can cause a range of complications, including segregation of components leading to content uniformity and particle surface adhesion. This phenomenon becomes problematical when excipients are introduced to a powder mixture alongside the highly charging active pharmaceutical ingredient(s) (APIs). The aim of this study was to investigate the tribo-electric charging and adhesion properties of a model drug, theophylline. Moreover, binary powder mixtures of theophylline with methylcellulose (MC) and hydroxypropyl methylcellulose (HPMC), having different polymer to drug ratios, were formed in order to study the impact of polymer concentration, particle size, substitution ratio and molecular size on the tribo-electric charging and surface adhesion properties of the drug. Furthermore, the relationship between tribo-electric charging and surface adhesion was also studied. The diversity in physicochemical properties of MC/HPMC has shown a significant impact on the tribo-electric charging and adhesion behaviour of theophylline. It was found that the magnitude of electrostatic charge and the level of surface adhesion of the API were significantly reduced with an increase in MC and HPMC concentration, substitution ratios and molecular size. In addition, the tribo-electric charge showed a linear relationship with particle surface adhesion, but the involvement of other forces cannot be neglected.