1
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Futran M, Muzzio F, Chatterjee B. Accelerating Process Development and Product Formulation. Pharm Res 2024; 41:833-837. [PMID: 38698195 DOI: 10.1007/s11095-024-03708-z] [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: 01/30/2024] [Accepted: 04/21/2024] [Indexed: 05/05/2024]
Abstract
Currently, the lengthy time needed to bring new drugs to market or to implement postapproval changes causes multiple problems, such as delaying patients access to new lifesaving or life-enhancing medications and slowing the response to emergencies that require new treatments. However, new technologies are available that can help solve these problems. The January 2023 NIPTE pathfinding workshop on accelerating drug product development and approval included a session in which participants considered the current state of product formulation and process development, barriers to acceleration of the development timeline, and opportunities for overcoming these barriers using new technologies. The authors participated in this workshop, and in this article have shared their perspective of some of the ways forward, including advanced manufacturing techniques and adaptive development. In addition, there is a need for paradigm shifts in regulatory processes, increased pre-competitive collaboration, and a shared strategy among regulators, industry, and academia.
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Affiliation(s)
- Mauricio Futran
- Pharmaceutical Engineering Solutions, LLC, Westfield, NJ, USA.
| | - Fernando Muzzio
- Chemical and Biochemical Engineering, Rutgers University, Piscataway, NJ, USA
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2
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Hur I, Casas-Orozco D, Laky D, Destro F, Nagy ZK. Digital design of an integrated purification system for continuous pharmaceutical manufacturing. Chem Eng Sci 2024; 285:119534. [PMID: 38975615 PMCID: PMC11225065 DOI: 10.1016/j.ces.2023.119534] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 07/09/2024]
Abstract
In this work dynamic models of the continuous crystallization, filtration, deliquoring, washing, and drying steps are introduced, which are developed in the open-source pharmaceutical modeling tool PharmaPy. These models enable the simulation and digital design of an integrated continuous two-stage crystallization and filtration-drying carousel system. The carousel offers an intensified process that can manufacture products with tailored properties through optimal design and control. Results show that improved crystallization design enhances overall process efficiency by improving critical material attributes of the crystal slurry for downstream filtration and drying operations. The digital design of the integrated process achieves enhanced productivity while satisfying multiple design and product quality constraints. Additionally, the impact of model uncertainty on the optimal operating conditions is investigated. The findings demonstrate the systematic process development potential of PharmaPy, providing improved process understanding, design space identification, and optimized robust operation.
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Affiliation(s)
- Inyoung Hur
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
| | - Daniel Casas-Orozco
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
| | - Daniel Laky
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
| | - Francesco Destro
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
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3
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C Dias R, Korhonen O, Ketolainen J, A Lopes J, Ervasti T. Flowsheet modelling of a powder continuous feeder-mixer system. Int J Pharm 2023; 639:122969. [PMID: 37084833 DOI: 10.1016/j.ijpharm.2023.122969] [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: 09/23/2022] [Revised: 03/28/2023] [Accepted: 04/15/2023] [Indexed: 04/23/2023]
Abstract
In this study, an integrated flowsheet model of the continuous feeder-mixer system was calibrated, simulated and compared against experimental data. The feeding process was first investigated using two major components (ibuprofen and microcrystalline cellulose (MCC)), in a formulation comprised of: 30 wt% of ibuprofen, 67.5 wt% MCC, 2 wt% of sodium starch glycolate and 0.5 wt% of magnesium stearate. The impact of a refill on feeder performance was experimentally evaluated for different operating conditions. Results showed that it had no influence on feeder performance. While simulations with the feeder model fairly reproduced the material behaviour observed in the feeder, unintended disturbances were underpredicted due to the model's low complexity. Experimentally, mixer's efficiency was assessed based on ibuprofen residence time distribution. Mean residence time pointed to a higher mixer's efficiency at lower flow rates. Blend homogeneity results showed that for the entire set of experiments, ibuprofen RSD <5%, irrespective of process variables. A feeder-mixer flowsheet model was calibrated, after regressing the axial model coefficients. The regression curves exhibited a R2 above 0.96, whereas the RMSE varied from 1.58x10-4 to 1.06x10-3 s-1 across all fitted curves. Simulations confirmed that flowsheet model captured the powder dynamics inside the mixer and qualitatively predicted the mixer's filtering ability against feeding composition fluctuations, as well as ibuprofen RSD in blend, in line with real experiments.
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Affiliation(s)
- Rute C Dias
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland; iMed.ULisboa, Faculty of Pharmacy, University of Lisbon, 1649-003 Lisbon, Portugal.
| | - Ossi Korhonen
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
| | - Jarkko Ketolainen
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
| | - João A Lopes
- iMed.ULisboa, Faculty of Pharmacy, University of Lisbon, 1649-003 Lisbon, Portugal
| | - Tuomas Ervasti
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
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4
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Casas-Orozco D, Laky D, Wang V, Abdi M, Feng X, Wood E, Reklaitis GV, Nagy ZK. Techno-economic analysis of dynamic, end-to-end optimal pharmaceutical campaign manufacturing using PharmaPy. AIChE J 2023; 69:e18142. [PMID: 38179085 PMCID: PMC10765457 DOI: 10.1002/aic.18142] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/28/2022] [Accepted: 04/16/2023] [Indexed: 01/06/2024]
Abstract
Increased interest in the pharmaceutical industry to transition from batch to continuouos manufacturing motivates the use of digital frameworks that allow systematic comparison of candidate process configurations. This paper evaluates the technical and economic feasibility of different end-to-end optimal process configurations, viz. batch, hybrid and continuous, for small-scale manufacturing of an active pharmaceutical ingredient. Production campaigns were analyzed for those configurations containing continuous equipment, where significant start-up effects are expected given the relatively short campaign times considered. Hybrid operating mode was found to be the most attractive process configuration at intermediate and large annual production targets, which stems from combining continuous reactors and semi-batch vaporization equipment. Continuous operation was found to be more costly, due to long stabilization times of continuous crystallization, and thermodynamic limitations of flash vaporization. Our work reveals the benefits of systematic digital evaluation of process configurations that operate under feasible conditions and compliant product quality attributes.
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Affiliation(s)
- Daniel Casas-Orozco
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Daniel Laky
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Vivian Wang
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Mesfin Abdi
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - X Feng
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - E Wood
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
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5
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Askr H, Elgeldawi E, Aboul Ella H, Elshaier YAMM, Gomaa MM, Hassanien AE. Deep learning in drug discovery: an integrative review and future challenges. Artif Intell Rev 2022; 56:5975-6037. [PMID: 36415536 PMCID: PMC9669545 DOI: 10.1007/s10462-022-10306-1] [Citation(s) in RCA: 30] [Impact Index Per Article: 15.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Accepted: 10/24/2022] [Indexed: 11/18/2022]
Abstract
Recently, using artificial intelligence (AI) in drug discovery has received much attention since it significantly shortens the time and cost of developing new drugs. Deep learning (DL)-based approaches are increasingly being used in all stages of drug development as DL technology advances, and drug-related data grows. Therefore, this paper presents a systematic Literature review (SLR) that integrates the recent DL technologies and applications in drug discovery Including, drug-target interactions (DTIs), drug-drug similarity interactions (DDIs), drug sensitivity and responsiveness, and drug-side effect predictions. We present a review of more than 300 articles between 2000 and 2022. The benchmark data sets, the databases, and the evaluation measures are also presented. In addition, this paper provides an overview of how explainable AI (XAI) supports drug discovery problems. The drug dosing optimization and success stories are discussed as well. Finally, digital twining (DT) and open issues are suggested as future research challenges for drug discovery problems. Challenges to be addressed, future research directions are identified, and an extensive bibliography is also included.
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Affiliation(s)
- Heba Askr
- Faculty of Computers and Artificial Intelligence, University of Sadat City, Sadat City, Egypt
| | - Enas Elgeldawi
- Computer Science Department, Faculty of Science, Minia University, Minia, Egypt
| | - Heba Aboul Ella
- Faculty of Pharmacy and Drug Technology, Chinese University in Egypt (CUE), Cairo, Egypt
| | | | - Mamdouh M. Gomaa
- Computer Science Department, Faculty of Science, Minia University, Minia, Egypt
| | - Aboul Ella Hassanien
- Faculty of Computers and Artificial Intelligence, Cairo University, Cairo, Egypt
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6
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Digital twin of a continuous direct compression line for drug product and process design using a hybrid flowsheet modelling approach. Int J Pharm 2022; 628:122336. [DOI: 10.1016/j.ijpharm.2022.122336] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/13/2022] [Revised: 10/19/2022] [Accepted: 10/20/2022] [Indexed: 11/06/2022]
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7
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Laky D, Casas-Orozco D, Laird CD, Reklaitis GV, Nagy ZK. Simulation-optimization framework for the digital design of pharmaceutical processes using Pyomo and PharmaPy. Ind Eng Chem Res 2022; 61:16128-16140. [PMID: 38179037 PMCID: PMC10765421 DOI: 10.1021/acs.iecr.2c01636] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2024]
Abstract
The problem of performing model-based process design and optimization in the pharmaceutical industry is an important and challenging one both computationally and in choice of solution implementation. In this work, a framework is presented to directly utilize a process simulator via callbacks during derivative-based optimization. The framework allows users with little experience in translating mechanistic ODEs and PDEs to robust, fully discretized algebraic formulations, required for executing simultaneous equation-oriented optimization, to obtain mathematically guaranteed optima at a competitive solution time when compared with existing derivative-free and derivative-based frameworks. The effectiveness of the framework in accuracy of optimal solution as well as computational efficiency is analyzed on on two case studies: (i) an integrated 2-unit reaction synthesis train used for the synthesis of an anti-cancer active pharmaceutical ingredient, and (ii) a more complex flowsheet representing a common synthesis-purification-isolation train of a pharmaceutical manufacturing processes.
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Affiliation(s)
- Daniel Laky
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Daniel Casas-Orozco
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Carl D. Laird
- Chemical Engineering Department, Carnegie Mellon University, Pittsburgh, PA 15213, USA
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
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8
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Ge Wang L, Omar C, Litster J, Slade D, Li J, Salman A, Bellinghausen S, Barrasso D, Mitchell N. Model Driven Design for Integrated Twin Screw Granulator and Fluid Bed Dryer via Flowsheet Modelling. Int J Pharm 2022; 628:122186. [PMID: 36130681 DOI: 10.1016/j.ijpharm.2022.122186] [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: 04/07/2022] [Revised: 09/02/2022] [Accepted: 09/03/2022] [Indexed: 11/27/2022]
Abstract
This paper presents a flowsheet modelling of an integrated twin screw granulation (TSG) and fluid bed dryer (FBD) process using a Model Driven Design (MDD) approach. The MDD approach is featured by appropriate process models and efficient model calibration workflow to ensure the product quality. The design space exploration is driven by the physics of the process instead of extensive experimental trials. By means of MDD, the mechanistic-based process kernels are first defined for the TSG and FBD processes. With the awareness of the underlying physics, the complementary experiments are carried out with relevance to the kinetic parameters in the defined models. As a result, the experiments are specifically purposeful for model calibration and validation. The L/S ratio (liquid to solid ratio) and inlet air temperature are selected as the Critical Process Parameters (CPPs) in TSG and FBD for model validation, respectively. Global System Analysis (GSA) is further performed to assess the uncertainty of CPPs imposed on the Critical Quality Attributes (CQAs), which provides significant insights to the exploration of the design space considering both TSG and FBD process parameters.
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Affiliation(s)
- Li Ge Wang
- Siemens Process Systems Engineering, Hammersmith, London, UK; Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - Chalak Omar
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - James Litster
- Department of Chemical and Biological Engineering, University of Sheffield, UK.
| | - David Slade
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Jianfeng Li
- Siemens Process Systems Engineering, Parsippany, New Jersey, USA
| | - Agba Salman
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | | | - Dana Barrasso
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Niall Mitchell
- Siemens Process Systems Engineering, Hammersmith, London, UK
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9
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Kaiser J, Babi DK, Pinelo M, Krühne U. Early-Stage In Silico Flowsheet Analysis for a Monoclonal Antibody Platform. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.04.003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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10
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Johnson BJ, Sen M, Hanson J, García-Muñoz S, Sahinidis NV. Stochastic analysis and modeling of pharmaceutical screw feeder mass flow rates. Int J Pharm 2022; 621:121776. [DOI: 10.1016/j.ijpharm.2022.121776] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/20/2021] [Revised: 04/16/2022] [Accepted: 04/24/2022] [Indexed: 11/27/2022]
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11
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Bano G, Dhenge RM, Diab S, Goodwin DJ, Gorringe L, Ahmed M, Elkes R, Zomer S. Streamlining the development of an industrial dry granulation process for an immediate release tablet with systems modelling. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2021.12.033] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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12
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Sacher S, Poms J, Rehrl J, Khinast JG. PAT implementation for advanced process control in solid dosage manufacturing - A practical guide. Int J Pharm 2021; 613:121408. [PMID: 34952147 DOI: 10.1016/j.ijpharm.2021.121408] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2021] [Revised: 12/10/2021] [Accepted: 12/16/2021] [Indexed: 01/14/2023]
Abstract
The implementation of continuous pharmaceutical manufacturing requires advanced control strategies rather than traditional end product testing or an operation within a small range of controlled parameters. A high level of automation based on process models and hierarchical control concepts is desired. The relevant tools that have been developed and successfully tested in academic and industrial environments in recent years are now ready for utilization on the commercial scale. To date, the focus in Process Analytical Technology (PAT) has mainly been on achieving process understanding and quality control with the ultimate goal of real-time release testing (RTRT). This work describes the workflow for the development of an in-line monitoring strategy to support PAT-based real-time control actions and its integration into solid dosage manufacturing. All stages are discussed in this paper, from process analysis and definition of the monitoring task to technology assessment and selection, its process integration and the development of data acquisition.
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Affiliation(s)
- Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria.
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Johannes G Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
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13
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Bhalode P, Tian H, Gupta S, Razavi SM, Roman-Ospino A, Talebian S, Singh R, Scicolone JV, Muzzio FJ, Ierapetritou M. Using residence time distribution in pharmaceutical solid dose manufacturing - A critical review. Int J Pharm 2021; 610:121248. [PMID: 34748808 DOI: 10.1016/j.ijpharm.2021.121248] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/20/2021] [Revised: 10/04/2021] [Accepted: 10/27/2021] [Indexed: 11/18/2022]
Abstract
While continuous manufacturing (CM) of pharmaceutical solid-based drug products has been shown to be advantageous for improving the product quality and process efficiency in alignment with FDA's support of the quality-by-design paradigm (Lee, 2015; Ierapetritou et al., 2016; Plumb, 2005; Schaber, 2011), it is critical to enable full utilization of CM technology for robust production and commercialization (Schaber, 2011; Byrn, 2015). To do so, an important prerequisite is to obtain a detailed understanding of overall process characteristics to develop cost-effective and accurate predictive models for unit operations and process flowsheets. These models are utilized to predict product quality and maintain desired manufacturing efficiency (Ierapetritou et al., 2016). Residence time distribution (RTD) has been a widely used tool to characterize the extent of mixing in pharmaceutical unit operations (Vanhoorne, 2020; Rogers and Ierapetritou, 2015; Teżyk et al., 2015) and manufacturing lines and develop computationally cheap predictive models. These models developed using RTD have been demonstrated to be crucial for various flowsheet applications (Kruisz, 2017; Martinetz, 2018; Tian, 2021). Though extensively used in the literature (Gao et al., 2012), the implementation, execution, evaluation, and assessment of RTD studies has not been standardized by regulatory agencies and can thus lead to ambiguity regarding their accurate implementation. To address this issue and subsequently prevent unforeseen errors in RTD implementation, the presented article aims to aid in developing standardized guidelines through a detailed review and critical discussion of RTD studies in the pharmaceutical manufacturing literature. The review article is divided into two main sections - 1) determination of RTD including different steps for RTD evaluation including experimental approach, data acquisition and pre-treatment, RTD modeling, and RTD metrics and, 2) applications of RTD for solid dose manufacturing. Critical considerations, pertaining to the limitations of RTDs for solid dose manufacturing, are also examined along with a perspective discussion of future avenues of improvement.
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Affiliation(s)
- Pooja Bhalode
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Huayu Tian
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, USA
| | - Shashwat Gupta
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Sonia M Razavi
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Andres Roman-Ospino
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Shahrzad Talebian
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Ravendra Singh
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - James V Scicolone
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Fernando J Muzzio
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, USA.
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14
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Systematic study of paracetamol powder mixtures and granules tabletability: Key role of rheological properties and dynamic image analysis. Int J Pharm 2021; 608:121110. [PMID: 34547394 DOI: 10.1016/j.ijpharm.2021.121110] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/23/2021] [Revised: 09/07/2021] [Accepted: 09/14/2021] [Indexed: 12/31/2022]
Abstract
The aim of this systematic study was to analyze the granulometric and rheological behavior of tableting mixtures in relation to tabletability by single tablet and lab-scale batch compression with an eccentric tablet machine. Three mixtures containing 33, 50, and 66% of the cohesive drug paracetamol were prepared. The high compressibility of the powder mixtures caused problems with overcompaction or lamination in the single tablet compression method; due to jamming of the material during the filling of the die, the lab-scale batch compression was impossible. Using high shear granulation, the flow properties and tabletability were adjusted. A linear relationship between the span of granules and the specific energy measured by FT4 powder rheometer was detected. In parallel, a linear relationship between conditioned bulk density and the tensile strength of the tablets at lab-scale batch tableting was noted. The combination of dynamic image analysis and powder rheometry was useful for predicting the tabletability of pharmaceutical mixtures during the single tablet (design) compression and the lab-scale batch compression.
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15
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Casas-Orozco D, Laky D, Wang V, Abdi M, Feng X, Wood E, Laird C, Reklaitis GV, Nagy ZK. PharmaPy: An object-oriented tool for the development of hybrid pharmaceutical flowsheets. Comput Chem Eng 2021; 153:107408. [PMID: 38235368 PMCID: PMC10793241 DOI: 10.1016/j.compchemeng.2021.107408] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
Abstract
Process design and optimization continue to provide computational challenges as the chemical engineering and process optimization communities seek to address more complex and larger scale applications. Software tools for digital design and flowsheet simulation are readily available for traditional chemical processing applications such as in commodity chemicals and hydrocarbon processing; however, tools for pharmaceutical manufacturing are much less well developed. This paper introduces, PharmaPy, a Python-based modelling platform for pharmaceutical manufacturing systems design and optimization. The versatility of the platform is demonstrated in simulation and optimization of both continuous and batch processes. The structure and features of a Python-based modeling platform, PharmaPy are presented. Illustrative examples are shown to highlight key features of the platform and framework.
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Affiliation(s)
- Daniel Casas-Orozco
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Daniel Laky
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Vivian Wang
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Mesfin Abdi
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - X. Feng
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - E. Wood
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Carl Laird
- Sandia National Laboratories, Albuquerque, NM 87123, USA
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
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16
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Wang LG, Omar C, Litster JD, Li J, Mitchell N, Bellinghausen S, Barrasso D, Salman A, Slade D. Tableting model assessment of porosity and tensile strength using a continuous wet granulation route. Int J Pharm 2021; 607:120934. [PMID: 34310957 DOI: 10.1016/j.ijpharm.2021.120934] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/23/2021] [Revised: 07/20/2021] [Accepted: 07/21/2021] [Indexed: 01/17/2023]
Abstract
This paper presents a comprehensive assessment of the most widely used tablet compaction models in a continuous wet granulation tableting process. The porosity models, tensile strength models and lubricant models are reviewed from the literature and classified based on their formulations i.e. empirical or theoretical and applications, i.e. batch or continuous. The majority of these models are empirical and were initially developed for batch tabletting process. To ascertain their effectiveness and serviceability in the continuous tableting process, a continuous powder processing line of Diamond Pilot Plant (DiPP) installed at The University of Sheffield was used to provide the quantitative data for tablet model assessment. Magnesium stearate (MgSt) is used as a lubricant to investigate its influence on the tensile strength. Whilst satisfactory predictions from the tablet models can be produced, a compromise between the model fidelity and model simplicity needs to be made for a suitable model selection. The Sonnergaard model outperforms amongst the porosity models whilst the Reynolds model produces the best goodness of fitting for two parameters fitting porosity models. An improved tensile strength model is proposed to consider the influence of powder size and porosity in the continuous tableting process.
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Affiliation(s)
- Li Ge Wang
- Department of Chemical and Biological Engineering, University of Sheffield, UK; Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Chalak Omar
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - James D Litster
- Department of Chemical and Biological Engineering, University of Sheffield, UK.
| | - Jianfeng Li
- Siemens Process Systems Engineering, Parsippany, NJ Office, USA
| | - Niall Mitchell
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | | | - Dana Barrasso
- Siemens Process Systems Engineering, Parsippany, NJ Office, USA
| | - Agba Salman
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - David Slade
- Siemens Process Systems Engineering, Hammersmith, London, UK
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17
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Process Modeling and Simulation of Tableting-An Agent-Based Simulation Methodology for Direct Compression. Pharmaceutics 2021; 13:pharmaceutics13070996. [PMID: 34209261 PMCID: PMC8308958 DOI: 10.3390/pharmaceutics13070996] [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: 04/23/2021] [Revised: 06/10/2021] [Accepted: 06/22/2021] [Indexed: 11/17/2022] Open
Abstract
In pharmaceutical manufacturing, the utmost aim is reliably producing high quality products. Simulation approaches allow virtual experiments of processes in the planning phase and the implementation of digital twins in operation. The industrial processing of active pharmaceutical ingredients (APIs) into tablets requires the combination of discrete and continuous sub-processes with complex interdependencies regarding the material structures and characteristics. The API and excipients are mixed, granulated if required, and subsequently tableted. Thereby, the structure as well as the properties of the intermediate and final product are influenced by the raw materials, the parametrized processes and environmental conditions, which are subject to certain fluctuations. In this study, for the first time, an agent-based simulation model is presented, which enables the prediction, tracking, and tracing of resulting structures and properties of the intermediates of an industrial tableting process. Therefore, the methodology for the identification and development of product and process agents in an agent-based simulation is shown. Implemented physical models describe the impact of process parameters on material structures. The tablet production with a pilot scale rotary press is experimentally characterized to provide calibration and validation data. Finally, the simulation results, predicting the final structures, are compared to the experimental data.
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18
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Tian G, Koolivand A, Gu Z, Orella M, Shaw R, O’Connor TF. Development of an RTD-Based Flowsheet Modeling Framework for the Assessment of In-Process Control Strategies. AAPS PharmSciTech 2021; 22:25. [PMID: 33400033 DOI: 10.1208/s12249-020-01913-8] [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: 08/27/2020] [Accepted: 12/21/2020] [Indexed: 11/30/2022] Open
Abstract
Continuous manufacturing (CM) is an emerging technology which can improve pharmaceutical manufacturing and reduce drug product quality issues. One challenge that needs to be addressed when adopting CM technology is material traceability through the entire continuous process, which constitutes one key aspect of control strategy. Residence time distribution (RTD) plays an important role in material traceability as it characterizes the material spreading through the process. The propagation of upstream disturbances could be predictively tracked through the entire process by convolution of the disturbance and the RTD. The present study sets up the RTD-based modeling framework in a commonly used process modeling environment, gPROMS, and integrates it with existing modules and built-in tools (e.g., parameter estimation). Concentration calculations based on the convolution integral requires access to historical stream property information, which is not readily available in flowsheet modeling platforms. Thus, a novel approach is taken whereby a partial differential equation is used to propagate and store historical data as the simulation marches forward in time. Other stream properties not modeled by an RTD are determined in auxiliary modules. To illustrate the application of the framework, an integrated RTD-auxiliary model for a continuous direct compression manufacturing line was developed. An excellent agreement was found between the model predictions and experiments. The validated model was subsequently used to assess in-process control strategies for feeder and material traceability through the process. Our simulation results show that the employed modeling approach facilitates risk-based assessment of the continuous line by promoting our understanding on the process.
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Furukawa R, Singh R, Ierapetritou M. Effect of material properties on the residence time distribution (RTD) of a tablet press feed frame. Int J Pharm 2020; 591:119961. [DOI: 10.1016/j.ijpharm.2020.119961] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/27/2020] [Revised: 09/18/2020] [Accepted: 10/05/2020] [Indexed: 11/24/2022]
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20
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Digital Twins in Pharmaceutical and Biopharmaceutical Manufacturing: A Literature Review. Processes (Basel) 2020. [DOI: 10.3390/pr8091088] [Citation(s) in RCA: 60] [Impact Index Per Article: 15.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022] Open
Abstract
The development and application of emerging technologies of Industry 4.0 enable the realization of digital twins (DT), which facilitates the transformation of the manufacturing sector to a more agile and intelligent one. DTs are virtual constructs of physical systems that mirror the behavior and dynamics of such physical systems. A fully developed DT consists of physical components, virtual components, and information communications between the two. Integrated DTs are being applied in various processes and product industries. Although the pharmaceutical industry has evolved recently to adopt Quality-by-Design (QbD) initiatives and is undergoing a paradigm shift of digitalization to embrace Industry 4.0, there has not been a full DT application in pharmaceutical manufacturing. Therefore, there is a critical need to examine the progress of the pharmaceutical industry towards implementing DT solutions. The aim of this narrative literature review is to give an overview of the current status of DT development and its application in pharmaceutical and biopharmaceutical manufacturing. State-of-the-art Process Analytical Technology (PAT) developments, process modeling approaches, and data integration studies are reviewed. Challenges and opportunities for future research in this field are also discussed.
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21
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Huang Z, Galbraith SC, Cha B, Liu H, Park S, Flamm MH, Metzger M, Tantuccio A, Yoon S. Effects of process parameters on tablet critical quality attributes in continuous direct compression: a case study of integrating data-driven statistical models and mechanistic compaction models. Pharm Dev Technol 2020; 25:1204-1215. [PMID: 32808839 DOI: 10.1080/10837450.2020.1805760] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
Abstract
Continuous manufacturing of oral-dosage drug products is increasing the need for rigorous process understanding both from a process design and control perspective. The purpose of this study is to develop a methodology that analyzes the effects of upstream process parameters on continuous tablet compaction and then correlates associated upstream variables to the final tablet attributes (e.g. relative density and hardness). The impact of three process parameters (system throughput, blender speed, and compaction force) on tablet attributes is investigated using a full factorial experimental design. As expected, the compaction force was found to be the most significant process parameter. However, importantly, throughput was discovered to have a non-negligible impact which was previously unaccounted for. This impact is proposed to be related to differing levels of powder pre-compression. An empirical model for this relationship is regressed and incorporated into a flowsheet model. The flowsheet model is then used to develop an in silico design space which is compared favorably to that built from experiments. Moreover, in the future, the in silico design space based on the validated flowsheet model can provide better manufacturing flexibility and make control strategy development simpler.
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Affiliation(s)
- Zhuangrong Huang
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Shaun C Galbraith
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Bumjoon Cha
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Huolong Liu
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Seoyoung Park
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Matthew H Flamm
- Applied Mathematics and Modeling, Scientific Modeling Platforms, Merck & Co., Inc, Kenilworth, NJ, USA
| | - Matt Metzger
- Pharmaceutical Commercialization Technology, Merck & Co., Inc, Kenilworth, NJ, USA
| | - Anthony Tantuccio
- Pharmaceutical Commercialization Technology, Merck & Co., Inc, Kenilworth, NJ, USA
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
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22
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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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23
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Wang Z, Kamyar R, Mehdizadeh H, Pendse PY. Moisture soft sensor for agitated pan dryers using a hybrid modeling approach. Int J Pharm 2020; 586:119518. [DOI: 10.1016/j.ijpharm.2020.119518] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/30/2020] [Revised: 06/01/2020] [Accepted: 06/06/2020] [Indexed: 10/24/2022]
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24
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Bhalode P, Ierapetritou M. Discrete element modeling for continuous powder feeding operation: Calibration and system analysis. Int J Pharm 2020; 585:119427. [PMID: 32473969 DOI: 10.1016/j.ijpharm.2020.119427] [Citation(s) in RCA: 16] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/17/2020] [Revised: 05/05/2020] [Accepted: 05/09/2020] [Indexed: 11/29/2022]
Abstract
Research emphases on extensive experimental studies and modeling efforts have been on the rise for the development of accurate predictive models of pharmaceutical unit operations and 'digital-twin' framework for continuous manufacturing lines. These exhaustive studies have been conducted at different process conditions to acquire comprehensive knowledge of effects of process parameters on the overall process dynamics. However, there still lacks a detailed understanding of material property effects of pharmaceutical powders on process operation. To address this issue, a discrete element modeling (DEM) approach combined with material calibration is applied for simulation of feeder unit to obtain particle-level insight into effects of material properties on feeder performance with focus on particle flow and powder mixing within the feeder unit. Bulk calibration is implemented to accurately represent powder material properties within the DEM framework. Different refill situations are simulated using DEM to observe powder mixing, measured at the outlet. Feeder DEM simulations are further applied to understand correlations of material properties on feeder operation. These studies provide a detailed physical insight and particle-scale information into the powder mechanics during powder feeding operation.
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Affiliation(s)
- Pooja Bhalode
- Department of Chemical and Biochemical Engineering, Rutgers University, Piscataway, NJ 08854, USA
| | - Marianthi Ierapetritou
- Department of Chemical and Biochemical Engineering, Rutgers University, Piscataway, NJ 08854, USA.
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25
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Park MS, Choi DH. Application of mechanism-based modeling to predict drug quality during the pharmaceutical unit operations of granulation and compression: a review. JOURNAL OF PHARMACEUTICAL INVESTIGATION 2020. [DOI: 10.1007/s40005-020-00489-6] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/21/2023]
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26
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Domokos A, Nagy B, Gyürkés M, Farkas A, Tacsi K, Pataki H, Liu YC, Balogh A, Firth P, Szilágyi B, Marosi G, Nagy ZK, Nagy ZK. End-to-end continuous manufacturing of conventional compressed tablets: From flow synthesis to tableting through integrated crystallization and filtration. Int J Pharm 2020; 581:119297. [PMID: 32243964 DOI: 10.1016/j.ijpharm.2020.119297] [Citation(s) in RCA: 23] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/02/2020] [Revised: 03/28/2020] [Accepted: 03/30/2020] [Indexed: 10/24/2022]
Abstract
An end-to-end continuous pharmaceutical manufacturing process was developed for the production of conventional direct compressed tablets on a proof-of-concept level for the first time. The output reaction mixture of the flow synthesis of acetylsalicylic acid was crystallized continuously in a mixed suspension mixed product removal crystallizer. The crystallizer was directly connected to a continuous filtration carousel device, thus the crystallization, filtration and drying of acetylsalicylic acid (ASA) was carried out in an integrated 2-step process. Steady state was reached during longer operations and the interaction of process parameters was evaluated in a series of experiments. The filtered crystals were ready for further processing in a following continuous blending and tableting experiment due to the good flowability of the material. The ASA collected during the crystallization-filtration experiments was fed into a continuous twin-screw blender along with microcrystalline cellulose as tableting excipient. After continuous blending Near-Infrared spectroscopy was applied to in-line analyze the drug content of the powder mixture. A belt conveyor carried the mixture towards an eccentric lab-scale tablet press, which continuously produced 500 mg ASA-loaded compressed tablets of 100 mg dose strength. Thus, starting from raw materials, the final drug product was obtained by continuous manufacturing steps with appropriate quality.
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Affiliation(s)
- András Domokos
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary; Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Brigitta Nagy
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary; Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Martin Gyürkés
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Attila Farkas
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Kornélia Tacsi
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Yiqing Claire Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Attila Balogh
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Paul Firth
- Alconbury Weston Ltd. (AWL), Stoke-on-Trent, Staffordshire ST4 3PE, United Kingdom
| | - Botond Szilágyi
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - György Marosi
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Zoltán K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States; Department of Chemical Engineering, Loughborough University, Loughborough, LE11 3TU, United Kingdom.
| | - Zsombor Kristóf Nagy
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary.
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27
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Escotet-Espinoza MS, Scicolone JV, Moghtadernejad S, Sanchez E, Cappuyns P, Van Assche I, Di Pretoro G, Ierapetritou M, Muzzio FJ. Improving Feedability of Highly Adhesive Active Pharmaceutical Ingredients by Silication. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09448-y] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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28
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Moroney KM, Cronin P, Adeleye OA, Schaller BE, Howard MA, Castro-Dominguez B, Ramachandran R, Walker GM. An evaluation of the Johanson model for roller compaction process development for a high dose API. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.02.058] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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29
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Ervasti T, Niinikoski H, Mäki-Lohiluoma E, Leppinen H, Ketolainen J, Korhonen O, Lakio S. The Comparison of Two Challenging Low Dose APIs in a Continuous Direct Compression Process. Pharmaceutics 2020; 12:pharmaceutics12030279. [PMID: 32244950 PMCID: PMC7151305 DOI: 10.3390/pharmaceutics12030279] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2020] [Revised: 03/13/2020] [Accepted: 03/18/2020] [Indexed: 11/18/2022] Open
Abstract
Segregation is a common problem in batch-based direct compression (BDC) processes, especially with low-dose tablet products, as is the preparation of a homogenous mixture. The scope of the current work was to explore if a continuous direct compression (CDC) process could serve as a solution for these challenges. Furthermore, the principle of a platform formulation was demonstrated for low dose tablets. The combination of filler excipients and the API in the formulation used was suitable for direct compression, but also prone to induce segregation in BDC process. The CDC process was found to be very promising; it was shown that tablets with the desired quality parameters could be manufactured successfully with both of the APIs studied. Powder analysis indicated that the APIs display some fundamental differences in their physical properties, which was also reflected in powder mixture properties and, hence, eventually in processing. However, process parameters, especially mixer impeller speed, were not found to have any significant influence on end product quality. The study suggests that a CDC process can be a viable solution to resolve the challenges described. Moreover, manufacturing by using a universal platform formulation seems to be a feasible way for producing low-dose tablets.
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Affiliation(s)
- Tuomas Ervasti
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
- Correspondence: ; Tel.: +358403553252
| | - Hannes Niinikoski
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
| | | | - Heidi Leppinen
- Orion Pharma Oyj, 02200 Espoo, Finland; (E.M.-L.); (H.L.); (S.L.)
| | - Jarkko Ketolainen
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
| | - Ossi Korhonen
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, 70210 Kuopio, Finland; (H.N.); (J.K.); (O.K.)
| | - Satu Lakio
- Orion Pharma Oyj, 02200 Espoo, Finland; (E.M.-L.); (H.L.); (S.L.)
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30
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Bascone D, Galvanin F, Shah N, Garcia-Munoz S. Hybrid Mechanistic-Empirical Approach to the Modeling of Twin Screw Feeders for Continuous Tablet Manufacturing. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c00420] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Affiliation(s)
- Davide Bascone
- Centre for Process System Engineering, Department of Chemical Engineering, Imperial College London, London SW7 2AZ, United Kingdom
| | - Federico Galvanin
- Centre for Process System Engineering, Department of Chemical Engineering, University College London (UCL), London WC1E 6BT, United Kingdom
| | - Nilay Shah
- Centre for Process System Engineering, Department of Chemical Engineering, Imperial College London, London SW7 2AZ, United Kingdom
| | - Salvador Garcia-Munoz
- Eli Lilly and Company, Lilly Research Laboratories, Indianapolis, Indiana 46285, United States
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31
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Yu I, Chen RK. A Feasibility Study of an Extrusion-Based Fabrication Process for Personalized Drugs. J Pers Med 2020; 10:jpm10010016. [PMID: 32143471 PMCID: PMC7151602 DOI: 10.3390/jpm10010016] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/09/2020] [Revised: 03/02/2020] [Accepted: 03/03/2020] [Indexed: 12/24/2022] Open
Abstract
Developing a high-efficiency manufacturing system for personalized medicine plays an important role in increasing the feasibility of personalized medication. The purpose of this study is to investigate the feasibility of a new extrusion-based fabrication process for personalized drugs with a faster production rate. This process uses two syringe pumps with a coaxial needle as an extruder, which extrudes two materials with varying ratios into a capsule. The mixture of hydrogel, polyethylene glycol (PEG), hydroxypropyl methylcellulose, poly acrylic acid and the simulated active pharmaceutical ingredient, Aspirin, was used. To validate the method, samples with different ratios of immediate release (IR) and sustained release (SR) mixtures were fabricated. The results of a dissolution test show that it is feasible to control the release profile by changing the IR and SR ratio using this fabrication setup. The fabrication time for each capsule is about 20 seconds, which is significantly faster than the current 3D printing methods. In conclusion, the proposed fabrication method shows a clear potential to step toward the feasibility of personalized medication.
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32
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Liu YC, Domokos A, Coleman S, Firth P, Nagy ZK. Development of Continuous Filtration in a Novel Continuous Filtration Carousel Integrated with Continuous Crystallization. Org Process Res Dev 2019. [DOI: 10.1021/acs.oprd.9b00342] [Citation(s) in RCA: 22] [Impact Index Per Article: 4.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/19/2023]
Affiliation(s)
- Yiqing C. Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47907, United States
| | - András Domokos
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47907, United States
| | - Simon Coleman
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47907, United States
| | - Paul Firth
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47907, United States
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47907, United States
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33
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Tian G, Koolivand A, Arden NS, Lee S, O'Connor TF. Quality risk assessment and mitigation of pharmaceutical continuous manufacturing using flowsheet modeling approach. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2019.06.033] [Citation(s) in RCA: 21] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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34
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Wang Y, O'Connor T, Li T, Ashraf M, Cruz CN. Development and applications of a material library for pharmaceutical continuous manufacturing of solid dosage forms. Int J Pharm 2019; 569:118551. [DOI: 10.1016/j.ijpharm.2019.118551] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/16/2019] [Revised: 07/08/2019] [Accepted: 07/19/2019] [Indexed: 11/29/2022]
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35
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Integrated modeling of a continuous direct compression tablet manufacturing process: A production scale case study. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.05.078] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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36
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Application of Transformation Matrices to the Solution of Population Balance Equations. Processes (Basel) 2019. [DOI: 10.3390/pr7080535] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
Abstract
The development of algorithms and methods for modelling flowsheets in the field of granular materials has a number of challenges. The difficulties are mainly related to the inhomogeneity of solid materials, requiring a description of granular materials using distributed parameters. To overcome some of these problems, an approach with transformation matrices can be used. This allows one to quantitatively describe the material transitions between different classes in a multidimensional distributed set of parameters, making it possible to properly handle dependent distributions. This contribution proposes a new method for formulating transformation matrices using population balance equations (PBE) for agglomeration and milling processes. The finite volume method for spatial discretization and the second-order Runge–Kutta method were used to obtain the complete discretized form of the PBE and to calculate the transformation matrices. The proposed method was implemented in the flowsheet modelling framework Dyssol to demonstrate and prove its applicability. Hence, it was revealed that this new approach allows the modelling of complex processes involving materials described by several interconnected distributed parameters, correctly taking into consideration their interdependency.
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37
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Patrascu M, Barton PI. Optimal Dynamic Continuous Manufacturing of Pharmaceuticals with Recycle. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b00646] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022]
Affiliation(s)
- Michael Patrascu
- Process Systems Engineering Laboratory, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
| | - Paul I. Barton
- Process Systems Engineering Laboratory, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, United States
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38
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Dülle M, Özcoban H, Leopold C. Influence of the feed frame design on the powder behavior and the residence time distribution. Int J Pharm 2019; 565:523-532. [DOI: 10.1016/j.ijpharm.2019.05.026] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/27/2019] [Revised: 05/08/2019] [Accepted: 05/10/2019] [Indexed: 10/26/2022]
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39
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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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Costandy JG, Edgar TF, Baldea M. Switching from Batch to Continuous Reactors Is a Trajectory Optimization Problem. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b01126] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/04/2023]
Affiliation(s)
- Joseph G. Costandy
- McKetta Department of Chemical Engineering, The University of Texas at Austin, Austin, Texas 78712, United States
| | - Thomas F. Edgar
- McKetta Department of Chemical Engineering, The University of Texas at Austin, Austin, Texas 78712, United States
- Energy Institute, The University of Texas at Austin, Austin, Texas 78712, United States
| | - Michael Baldea
- Energy Institute, The University of Texas at Austin, Austin, Texas 78712, United States
- Institute for Computational Engineering and Sciences, The University of Texas at Austin, Austin, Texas 78712, United States
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41
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42
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Casola G, Siegmund C, Mattern M, Sugiyama H. Data mining algorithm for pre-processing biopharmaceutical drug product manufacturing records. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2018.12.001] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/08/2023]
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43
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A Computationally Efficient Surrogate-Based Reduction of a Multiscale Comill Process Model. J Pharm Innov 2019. [DOI: 10.1007/s12247-019-09388-2] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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44
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Dynamic Flowsheet Model Development and Sensitivity Analysis of a Continuous Pharmaceutical Tablet Manufacturing Process Using the Wet Granulation Route. Processes (Basel) 2019. [DOI: 10.3390/pr7040234] [Citation(s) in RCA: 33] [Impact Index Per Article: 6.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
In view of growing interest and investment in continuous manufacturing, the development and utilization of mathematical model(s) of the manufacturing line is of prime importance. These models are essential for understanding the complex interplay between process-wide critical process parameters (CPPs) and critical quality attributes (CQAs) beyond the individual process operations. In this work, a flowsheet model that is an approximate representation of the ConsiGma TM -25 line for continuous tablet manufacturing, including wet granulation, is developed. The manufacturing line involves various unit operations, i.e., feeders, blenders, a twin-screw wet granulator, a fluidized bed dryer, a mill, and a tablet press. The unit operations are simulated using various modeling approaches such as data-driven models, semi-empirical models, population balance models, and mechanistic models. Intermediate feeders, blenders, and transfer lines between the units are also simulated. The continuous process is simulated using the flowsheet model thus developed and case studies are provided to demonstrate its application for dynamic simulation. Finally, the flowsheet model is used to systematically identify critical process parameters (CPPs) that affect process responses of interest using global sensitivity analysis methods. Liquid feed rate to the granulator, and air temperature and drying time in the dryer are identified as CPPs affecting the tablet properties.
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Matsunami K, Nagato T, Hasegawa K, Sugiyama H. A large-scale experimental comparison of batch and continuous technologies in pharmaceutical tablet manufacturing using ethenzamide. Int J Pharm 2019; 559:210-219. [DOI: 10.1016/j.ijpharm.2019.01.028] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/02/2018] [Revised: 12/14/2018] [Accepted: 01/11/2019] [Indexed: 10/27/2022]
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46
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Emenike VN, Xie X, Schenkendorf R, Spiess AC, Krewer U. Robust dynamic optimization of enzyme-catalyzed carboligation: A point estimate-based back-off approach. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2018.10.006] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
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47
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Escotet-Espinoza MS, Moghtadernejad S, Oka S, Wang Z, Wang Y, Roman-Ospino A, Schäfer E, Cappuyns P, Van Assche I, Futran M, Muzzio F, Ierapetritou M. Effect of material properties on the residence time distribution (RTD) characterization of powder blending unit operations. Part II of II: Application of models. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.12.051] [Citation(s) in RCA: 26] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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48
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Sebastian Escotet-Espinoza M, Moghtadernejad S, Oka S, Wang Y, Roman-Ospino A, Schäfer E, Cappuyns P, Van Assche I, Futran M, Ierapetritou M, Muzzio F. Effect of tracer material properties on the residence time distribution (RTD) of continuous powder blending operations. Part I of II: Experimental evaluation. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.10.040] [Citation(s) in RCA: 41] [Impact Index Per Article: 8.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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49
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Systematic Framework for Implementation of Material Traceability into Continuous Pharmaceutical Tablet Manufacturing Process. J Pharm Innov 2018. [DOI: 10.1007/s12247-018-9362-9] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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50
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Pereira GC, Muddu SV, Román-Ospino AD, Clancy D, Igne B, Airiau C, Muzzio FJ, Ierapetritou M, Ramachandran R, Singh R. Combined Feedforward/Feedback Control of an Integrated Continuous Granulation Process. J Pharm Innov 2018. [DOI: 10.1007/s12247-018-9347-8] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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