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Zheng C, Li L, Nitert BJ, Govender N, Chamberlain T, Zhang L, Wu CY. Investigation of granular dynamics in a continuous blender using the GPU-enhanced discrete element method. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117968] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/31/2022]
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2
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Destro F, Barolo M. A review on the modernization of pharmaceutical development and manufacturing - Trends, perspectives, and the role of mathematical modeling. Int J Pharm 2022; 620:121715. [PMID: 35367580 DOI: 10.1016/j.ijpharm.2022.121715] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2022] [Revised: 03/23/2022] [Accepted: 03/29/2022] [Indexed: 01/20/2023]
Abstract
Recently, the pharmaceutical industry has been facing several challenges associated to the use of outdated development and manufacturing technologies. The return on investment on research and development has been shrinking, and, at the same time, an alarming number of shortages and recalls for quality concerns has been registered. The pharmaceutical industry has been responding to these issues through a technological modernization of development and manufacturing, under the support of initiatives and activities such as quality-by-design (QbD), process analytical technology, and pharmaceutical emerging technology. In this review, we analyze this modernization trend, with emphasis on the role that mathematical modeling plays within it. We begin by outlining the main socio-economic trends of the pharmaceutical industry, and by highlighting the life-cycle stages of a pharmaceutical product in which technological modernization can help both achieve consistently high product quality and increase return on investment. Then, we review the historical evolution of the pharmaceutical regulatory framework, and we discuss the current state of implementation and future trends of QbD. The pharmaceutical emerging technology is reviewed afterwards, and a discussion on the evolution of QbD into the more effective quality-by-control (QbC) paradigm is presented. Further, we illustrate how mathematical modeling can support the implementation of QbD and QbC across all stages of the pharmaceutical life-cycle. In this respect, we review academic and industrial applications demonstrating the impact of mathematical modeling on three key activities within pharmaceutical development and manufacturing, namely design space description, process monitoring, and active process control. Finally, we discuss some future research opportunities on the use of mathematical modeling in industrial pharmaceutical environments.
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Affiliation(s)
- Francesco Destro
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy
| | - Massimiliano Barolo
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy.
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3
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Conceição EL. Measurement Bias Invariant Moving Horizon Estimation in the Presence of Outliers for Data Reconciliation of Nonlinear Dynamic Systems. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.117578] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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4
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A robust moving horizon estimation under unknown distributions of process or measurement noises. Comput Chem Eng 2022. [DOI: 10.1016/j.compchemeng.2021.107620] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
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5
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Huang YS, Sheriff MZ, Bachawala S, Gonzalez M, Nagy ZK, Reklaitis GV. Evaluation of a Combined MHE-NMPC Approach to Handle Plant-Model Mismatch in a Rotary Tablet Press. Processes (Basel) 2021; 9:10.3390/pr9091612. [PMID: 36776491 PMCID: PMC9912115 DOI: 10.3390/pr9091612] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
The transition from batch to continuous processes in the pharmaceutical industry has been driven by the potential improvement in process controllability, product quality homogeneity, and reduction of material inventory. A quality-by-control (QbC) approach has been implemented in a variety of pharmaceutical product manufacturing modalities to increase product quality through a three-level hierarchical control structure. In the implementation of the QbC approach it is common practice to simplify control algorithms by utilizing linearized models with constant model parameters. Nonlinear model predictive control (NMPC) can effectively deliver control functionality for highly sensitive variations and nonlinear multiple-input-multiple-output (MIMO) systems, which is essential for the highly regulated pharmaceutical manufacturing industry. This work focuses on developing and implementing NMPC in continuous manufacturing of solid dosage forms. To mitigate control degradation caused by plant-model mismatch, careful monitoring and continuous improvement strategies are studied. When moving horizon estimation (MHE) is integrated with NMPC, historical data in the past time window together with real-time data from the sensor network enable state estimation and accurate tracking of the highly sensitive model parameters. The adaptive model used in the NMPC strategy can compensate for process uncertainties, further reducing plant-model mismatch effects. The nonlinear mechanistic model used in both MHE and NMPC can predict the essential but complex powder properties and provide physical interpretation of abnormal events. The adaptive NMPC implementation and its real-time control performance analysis and practical applicability are demonstrated through a series of illustrative examples that highlight the effectiveness of the proposed approach for different scenarios of plant-model mismatch, while also incorporating glidant effects.
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Affiliation(s)
- Yan-Shu Huang
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - M Ziyan Sheriff
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Sunidhi Bachawala
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
- Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
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6
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Szabó E, Záhonyi P, Gyürkés M, Nagy B, Galata DL, Madarász L, Hirsch E, Farkas A, Andersen SK, Vígh T, Verreck G, Csontos I, Marosi G, Nagy ZK. Continuous downstream processing of milled electrospun fibers to tablets monitored by near-infrared and Raman spectroscopy. Eur J Pharm Sci 2021; 164:105907. [PMID: 34118411 DOI: 10.1016/j.ejps.2021.105907] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/27/2021] [Revised: 04/30/2021] [Accepted: 06/07/2021] [Indexed: 10/21/2022]
Abstract
Electrospinning is a technology for manufacture of nano- and micro-sized fibers, which can enhance the dissolution properties of poorly water-soluble drugs. Tableting of electrospun fibers have been demonstrated in several studies, however, continuous manufacturing of tablets have not been realized yet. This research presents the first integrated continuous processing of milled drug-loaded electrospun materials to tablet form supplemented by process analytical tools for monitoring the active pharmaceutical ingredient (API) content. Electrospun fibers of an amorphous solid dispersion (ASD) of itraconazole and poly(vinylpyrrolidone-co-vinyl acetate) were produced using high speed electrospinning and afterwards milled. The milled fibers with an average fiber diameter of 1.6 ± 0.9 µm were continuously fed with a vibratory feeder into a twin-screw blender, which was integrated with a tableting machine to prepare tablets with ~ 10 kN compression force. The blend of fibers and excipients leaving the continuous blender was characterized with a bulk density of 0.43 g/cm3 and proved to be suitable for direct tablet compression. The ASD content, and thus the API content was determined in-line before tableting and at-line after tableting using near-infrared and Raman spectroscopy. The prepared tablets fulfilled the USP <905> content uniformity requirement based on the API content of ten randomly selected tablets. This work highlights that combining the advantages of electrospinning (e.g. less solvent, fast and gentle drying, low energy consumption, and amorphous products with high specific surface area) and the continuous technologies opens a new and effective way in the field of manufacturing of the poorly water-soluble APIs.
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Affiliation(s)
- Edina Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Petra Záhonyi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Martin Gyürkés
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Dorián L Galata
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Edit Hirsch
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Sune K Andersen
- Oral Solids Development, Janssen R&D, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - Tamás Vígh
- Oral Solids Development, Janssen R&D, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - Geert Verreck
- Oral Solids Development, Janssen R&D, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - István Csontos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Zsombor K Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary.
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7
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Powder composition monitoring in continuous pharmaceutical solid-dosage form manufacturing using state estimation - Proof of concept. Int J Pharm 2021; 605:120808. [PMID: 34144142 DOI: 10.1016/j.ijpharm.2021.120808] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/08/2021] [Revised: 05/25/2021] [Accepted: 06/13/2021] [Indexed: 12/18/2022]
Abstract
In continuous solid-dosage form manufacturing, the powder feeding system is responsible for supplying downstream the correct formulation of the drug product ingredients. The composition of the powder delivered by the feeding system is inferred from the measurements of powder mass flow from the system feeders. The mass flows are, in turn, inferred from the loss in weight measured in the feeder hoppers. Most loss-in-weight feeders post-process the mass flow signal to deliver a smoothed value to the user. However, such estimated mass flows can exhibit a low signal-to-noise ratio. As the feeders are critical elements of the control strategy of the manufacturing line, better instantaneous estimates of mass flow are desirable for improving the quality assurance. In this study, we propose a model-based approach for monitoring the composition of the powder fed to a continuous solid-dosage line. The monitoring system is based on a moving-horizon state estimator, which carries out model-based reconciliation of the feeder mass measurements, thus enabling accurate composition estimation of the powder mixture. Experimental datasets from a direct compression line are used to validate the methodology. Results demonstrate improvement with respect to current industrial solutions.
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8
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Cogoni G, Liu YA, Husain A, Alam MA, Kamyar R. A hybrid NIR-soft sensor method for real time in-process control during continuous direct compression manufacturing operations. Int J Pharm 2021; 602:120620. [PMID: 33892059 DOI: 10.1016/j.ijpharm.2021.120620] [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] [Received: 01/11/2021] [Revised: 04/07/2021] [Accepted: 04/16/2021] [Indexed: 10/21/2022]
Abstract
Near Infrared (NIR) spectroscopy is commonly utilized for continuous manufacturing as Process Analytical Technology (PAT) tool. This paper focus on a continuous direct compression manufacturing process, in which an NIR PAT probe is integrated into the tablet press feed frame and into the tablet diversion control system to ensure continuous monitoring of the potency and homogeneity of the blend within the process line. The quantification of NIR spectra is achieved through Partial Least-Squares (PLS) modeling, calibrated with offline analyzed tablet cores at different potency levels. Because the NIR measurements are often sensitive to sample physical properties caused by raw materials or process conditions, etc., adopting a data-driven approach will require a large amount of representative data throughout the method lifecycle. During the early stages of process development, whenever new uncaptured source of variability in the model space are encountered, the chemometric predictions can deviate from the offline reference, requiring frequent model updates. These deviations can be reduced by integrating process and physico-chemical knowledge in the on-line potency estimation. This paper presents a novel hybrid method combining the online NIR PLS and a potency soft sensor estimation, enabling a robust potency prediction whilst minimizing maintenance downtimes and facilitating cross-site method transfer.
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Affiliation(s)
- Giuseppe Cogoni
- Worldwide Research and Development, Pfizer Inc., Groton, CT 06340, USA
| | - Yang Angela Liu
- Worldwide Research and Development, Pfizer Inc., Groton, CT 06340, USA.
| | - Anas Husain
- Pfizer Global Supply, Pfizer Inc., Freiburg, Germany
| | - Md Anik Alam
- Worldwide Research and Development, Pfizer Inc., Groton, CT 06340, USA
| | - Reza Kamyar
- Pfizer Global Supply, Pfizer Inc., Peapack, NJ 07934, USA
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10
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Ganesh S, Su Q, Vo LBD, Pepka N, Rentz B, Vann L, Yazdanpanah N, O'Connor T, Nagy ZK, Reklaitis GV. Design of condition-based maintenance framework for process operations management in pharmaceutical continuous manufacturing. Int J Pharm 2020; 587:119621. [PMID: 32663581 PMCID: PMC9912015 DOI: 10.1016/j.ijpharm.2020.119621] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/28/2020] [Revised: 06/17/2020] [Accepted: 07/04/2020] [Indexed: 11/25/2022]
Abstract
Continuous manufacturing, an emerging technology in the pharmaceutical industry, has the potential to increase the efficiency, and agility of pharmaceutical manufacturing processes. To realize these potential benefits of continuous operations, effectively managing materials, equipment, analyzers, and data is vital. Developments for continuous pharmaceutical manufacturing have led to novel technologies and methods for processing material, designing and configuring individual equipment and process analyzers, as well as implementing strategies for active process control. However, limited work has been reported on managing abnormal conditions during operations to prevent unplanned deviations and downtime and sustain system capabilities. Moreover, although the sourcing, analysis, and management of real-time data have received growing attention, limited discussion exists on the continued verification of the infrastructure for ensuring reliable operations. Hence, this work introduces condition-based maintenance (CBM) as a general strategy for continually verifying and sustaining advanced pharmaceutical manufacturing systems, with a focus on the continuous manufacture of oral solid drug products (OSD-CM). Frameworks, such as CBM, benefit unified efforts towards continued verification and operational excellence by leveraging process knowledge and the availability of real-time data. A vital implementation consideration for manufacturing operations management applications, such as CBM, is a systems architecture and an enabling infrastructure. This work outlines the systems architecture design for CBM in OSD-CM and highlights sample fault scenarios involving equipment and process analyzers. For illustrative purposes, this work also describes the infrastructure implemented on an OSD-CM testbed, which uses commercially available automation systems and leverages enterprise architecture standards. With the increasing digitalization of manufacturing operations in the pharmaceutical industry, proactively using process data towards modernizing maintenance practices is relevant to a single unit operation as well as to a series of physically integrated unit operations.
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Affiliation(s)
- Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
| | - Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
| | - Le Bao Dan Vo
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
| | - Nolan Pepka
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
| | - Benjamin Rentz
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
| | - Lucas Vann
- Applied Global Services, Applied Materials, Inc., Santa Clara, CA, USA.
| | - Nima Yazdanpanah
- Office of Pharmaceutical Quality, Center for Drug Evaluation Research, Food and Drug Administration, Silver Spring, MD, USA.
| | - Thomas O'Connor
- Office of Pharmaceutical Quality, Center for Drug Evaluation Research, Food and Drug Administration, Silver Spring, MD, USA.
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, USA.
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11
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Chen Y, Ierapetritou M. A framework of hybrid model development with identification of plant‐model mismatch. AIChE J 2020. [DOI: 10.1002/aic.16996] [Citation(s) in RCA: 18] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Affiliation(s)
- Yingjie Chen
- Department of Chemical and Biomolecular Engineering University of Delaware Newark Delaware USA
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering University of Delaware Newark Delaware USA
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12
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Moreno M, Liu J, Su Q, Leach C, Giridhar A, Yazdanpanah N, O’Connor T, Nagy ZK, Reklaitis GV. Steady-State Data Reconciliation Framework for a Direct Continuous Tableting Line. J Pharm Innov 2019; 14:221-238. [PMID: 36824482 PMCID: PMC9945915 DOI: 10.1007/s12247-018-9354-9] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Abstract
Purpose Reliable process monitoring in real-time remains a challenge for the pharmaceutical industry. Dealing with random and gross errors in the process measurements in a systematic way is a potential solution. In this paper, we present a process model-based framework, which for given sensor network and measurement uncertainties will predict the most likely state of the process. Thus, real-time process decisions, whether for process control or exceptional events management, can be based on the most reliable estimate of the process state. Methods Reliable process monitoring is achieved by using data reconciliation (DR) and gross error detection (GED) to mitigate the effects of random measurement errors and non-random sensor malfunctions. Steady-state data reconciliation (SSDR) is the simplest forms of DR but offers the benefits of short computational times. We also compare and contrast the model-based DR approach (SSDR-M) to the purely data-driven approach (SSDR-D) based on the use of principal component constructions. Results We report the results of studies on a pilot plant-scale continuous direct compression-based tableting line at steady-state in two subsystems. If the process is linear or mildly nonlinear, SSDR-M and SSDR-D give comparable results for the variables estimation and GED. SSDR-M also complies with mass balances and estimate unmeasured variables. Conclusions SSDR successfully estimates the true state of the process in presence of gross errors, as long as steady state is maintained and the redundancy requirement is met. Gross errors are also detected while using SSDR-M or SSDR-D. Process monitoring is more reliable while using the SSDR framework.
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Affiliation(s)
- Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Jianfeng Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Cody Leach
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Arun Giridhar
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Nima Yazdanpanah
- Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Thomas O’Connor
- Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
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13
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Moreno M, Ganesh S, Shah YD, Su Q, Gonzalez M, Nagy ZK, Reklaitis GV. Sensor Network Robustness Using Model-Based Data Reconciliation for Continuous Tablet Manufacturing. J Pharm Sci 2019; 108:2599-2612. [PMID: 30904476 PMCID: PMC9942238 DOI: 10.1016/j.xphs.2019.03.011] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/17/2018] [Revised: 01/17/2019] [Accepted: 03/01/2019] [Indexed: 11/20/2022]
Abstract
Advances in continuous manufacturing in the pharmaceutical industry necessitate reliable process monitoring systems that are capable of handling measurement errors inherent in all sensor technologies and detecting measurement outliers to ensure operational reliability. The purpose of this work was to demonstrate data reconciliation (DR) and gross error detection methods as real-time process management tools to accomplish robust process monitoring. DR mitigates the effects of random measurement errors, while gross error detection identifies nonrandom sensor malfunctions. DR is an established methodology in other industries (i.e., oil and gas) and was recently investigated for use in drug product continuous manufacturing. This work demonstrates the development and implementation of model-based steady-state data reconciliation on 2 different end-to-end continuous tableting lines: direct compression and dry granulation. These tableting lines involve different equipment and sensor configurations, with sensor network redundancy achieved using equipment-embedded sensors and in-line process analytical technology tools for the critical process parameters and critical quality attributes. The nonlinearity of the process poses additional challenges to solve the steady-state data reconciliation optimization problem in real time. At-line and off-line measurements were used to validate the framework results.
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Affiliation(s)
- Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47906.
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47906
| | - Yash D Shah
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47906
| | - Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47906
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, Indiana 47906; Ray W. Herrick Laboratories, Purdue University, West Lafayette, Indiana 47907
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47906
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47906.
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14
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Su Q, Ganesh S, Moreno M, Bommireddy Y, Gonzalez M, Reklaitis GV, Nagy ZK. A perspective on Quality-by-Control (QbC) in pharmaceutical continuous manufacturing. Comput Chem Eng 2019; 125:216-231. [PMID: 36845965 PMCID: PMC9948678 DOI: 10.1016/j.compchemeng.2019.03.001] [Citation(s) in RCA: 73] [Impact Index Per Article: 14.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
Abstract
The Quality-by-Design (QbD) guidance issued by the US Food and Drug Administration (FDA) has catalyzed the modernization of pharmaceutical manufacturing practices including the adoption of continuous manufacturing. Active process control was highlighted recently as a means to improve the QbD implementation. This advance has since been evolving into the concept of Quality-by-Control (QbC). In this study, the concept of QbC is discussed, including a definition of QbC, a review of the recent developments towards the QbC, and a perspective on the challenges of QbC implementation in continuous manufacturing. The QbC concept is demonstrated using a rotary tablet press, integrated into a pilot scale continuous direct compaction process. The results conclusively showed that active process control, based on product and process knowledge and advanced model-based techniques, including data reconciliation, model predictive control (MPC), and risk analysis, is indispensable to comprehensive QbC implementation, and ensures robustness and efficiency.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Yasasvi Bommireddy
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA.,Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
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15
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Su Q, Bommireddy Y, Shah Y, Ganesh S, Moreno M, Liu J, Gonzalez M, Yazdanpanah N, O’Connor T, Reklaitis GV, Nagy ZK. Data reconciliation in the Quality-by-Design (QbD) implementation of pharmaceutical continuous tablet manufacturing. Int J Pharm 2019; 563:259-272. [PMID: 30951859 PMCID: PMC9976296 DOI: 10.1016/j.ijpharm.2019.04.003] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/01/2019] [Revised: 03/25/2019] [Accepted: 04/02/2019] [Indexed: 11/25/2022]
Abstract
Data provided by in situ sensors is always affected by some level of impreciseness as well as uncertainty in the measurements due to process operation disturbance or material property variance. In-process data precision and reliability should be considered when implementing active product quality control and real-time process decision making in pharmaceutical continuous manufacturing. Data reconciliation is an important strategy to address such imperfections effectively, and to exploit the data redundancy and data correlation based on process understanding. In this study, a correlation between tablet weight and main compression force in a rotary tablet press was characterized by the classical Kawakita equation. A load cell, situated at the exit of the tablet press chute, was also designed to measure the tablet production rate as well as the tablet weight. A novel data reconciliation strategy was proposed to reconcile the tablet weight measurement subject to the correlation between tablet weight and main compression force, in such, the imperfect tablet weight measurement can be reconciled with the much more precise main compression force measurement. Special features of the Welsch robust estimator to reject the measurement gross errors and the Kawakita model parameter estimation to monitor the material property variance were also discussed. The proposed data reconciliation strategy was first evaluated with process control open-loop and closed-loop experimental data and then integrated into the process control system in a continuous tablet manufacturing line. Specifically, the real-time reconciled tablet weight measurements were independently verified with an at-line Sotax Auto Test 4 tablet weight measurements every five minutes. Promising and reliable performance of the reconciled tablet weight measurement was demonstrated in achieving process automation and quality control of tablet weight in pilot production runs.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States.
| | - Yasasvi Bommireddy
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Yash Shah
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Jianfeng Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States,Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Nima Yazdanpanah
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Thomas O’Connor
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States,Corresponding authors. (Q. Su), (Z.K. Nagy)
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Zhao L, Wang R, Wang J, Yu T, Su A. Nonlinear state estimation with delayed measurements using data fusion technique and cubature Kalman filter for chemical processes. Chem Eng Res Des 2019. [DOI: 10.1016/j.cherd.2018.11.020] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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Su Q, Moreno M, Ganesh S, Reklaitis GV, Nagy ZK. Resilience and risk analysis of fault-tolerant process control design in continuous pharmaceutical manufacturing. J Loss Prev Process Ind 2018; 55:411-422. [PMID: 36777050 PMCID: PMC9912099 DOI: 10.1016/j.jlp.2018.07.015] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Abstract
The shift from batch to continuous manufacturing, which is occurring in the pharmaceutical manufacturing industry has implications on process safety and product quality. It is now understood that fault-tolerant process control of critical process parameters (CPPs) and critical quality attributes (CQAs) is of paramount importance to the realization of safe operations and quality products. In this study, a systematic framework for fault-tolerant process control system design, analysis, and evaluation of pharmaceutical continuous oral solid dosage manufacturing is proposed. The framework encompasses system identification, controller design and analysis (controllability, stability, resilience, etc.), hierarchical three-level control structures (model predictive control, state estimation, data reconciliation, etc.), risk mapping, assessment and planning (Risk MAP) strategies, and control performance evaluation. The key idea of the proposed framework is to identify the potential risks associated with the control system design itself, the material property variations, and other process uncertainties, under which the control strategies must be evaluated. The framework is applied to a continuous direct compaction process, specifically the feeding-blending subsystem, wherein the major source of variance in the process operation and product quality arises. It is demonstrated, using simulations and experimentally, that the process operation failures and product quality variations in the feeding-blending system can be mitigated and managed through the proposed systematic fault-tolerant process control system design and risk analysis framework.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
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