1
|
Sampat C, Ramachandran R. Optimizing Energy Efficiency of a Twin-Screw Granulation Process in Real-Time Using a Long Short-Term Memory (LSTM) Network. ACS ENGINEERING AU 2024; 4:278-289. [PMID: 38646515 PMCID: PMC11027094 DOI: 10.1021/acsengineeringau.3c00038] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/07/2023] [Revised: 12/07/2023] [Accepted: 12/08/2023] [Indexed: 04/23/2024]
Abstract
Traditional pharmaceutical manufacturing processes for solid oral dosage forms can be inefficient and have been known to produce a large amount of undesired product. With the progressing trend of achieving carbon neutrality, there is an impetus to increase the energy efficiency of these manufacturing processes while maintaining the critical quality attributes of the product. One of the important steps in downstream pharmaceutical manufacturing is wet granulation, and within that, twin screw granulation (TSG) is a popular continuous manufacturing technique. In this study, the energy efficiency of the TSG process was maximized by combining a long-term memory (LSTM) model with an optimization algorithm. The LSTM model was trained on time-series process data obtained from the TSG experimental runs. The optimization process, with the objective of maximizing energy efficiency, was performed using a stochastic optimization algorithm, and constraints were enforced on the process parameter design space. Experimental runs at the optimal process parameters were conducted on the TSG equipment with updates occurring at predefined intervals depending on the optimization scenarios. The purpose of these experimental runs was to validate the capability of increasing the overall process energy efficiency when operating at the optimized process parameters. A maximum increase of 27% was obtained between two tested optimization scenarios while maintaining the yield of the granules at the end of the twin-screw granulation process.
Collapse
Affiliation(s)
| | - Rohit Ramachandran
- Rutgers—The State
University of New Jersey, 98 Brett Road, Piscataway, New Jersey 08854, United States
| |
Collapse
|
2
|
Zhao J, Tian G, Qu H. Application of I-Optimal Design for Modeling and Optimizing the Operational Parameters of Ibuprofen Granules in Continuous Twin-Screw Wet Granulation. Biomedicines 2023; 11:2030. [PMID: 37509668 PMCID: PMC10377492 DOI: 10.3390/biomedicines11072030] [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] [Received: 06/08/2023] [Revised: 07/06/2023] [Accepted: 07/14/2023] [Indexed: 07/30/2023] Open
Abstract
The continuous twin-screw wet granulation (TSWG) process was investigated and optimized with prediction-oriented I-optimal designs. The I-optimal designs can not only obtain a precise estimation of the parameters that describe the effect of five input process parameters, including the screw speed, liquid-to-solid (L/S) ratio, TSWG feed rate, and numbers of the 30° and 60° mixing elements, on the granule quality in a TSWG process, but it can also provide a prediction of the response to determine the optimum operating conditions. Based on the constraints of the desired granule properties, a design space for the TSWG was determined, and the ranges of the operating parameters were defined. An acceptable degree of prediction was confirmed through validation experiments, demonstrating the reliability and effectiveness of using the I-optimal design method to study the TSWG process. The I-optimal design method can accelerate the screening and optimization of the TSWG process.
Collapse
Affiliation(s)
- Jie Zhao
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| | - Geng Tian
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| | - Haibin Qu
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| |
Collapse
|
3
|
Zhao J, Tian G, Qu H. Pharmaceutical Application of Process Understanding and Optimization Techniques: A Review on the Continuous Twin-Screw Wet Granulation. Biomedicines 2023; 11:1923. [PMID: 37509561 PMCID: PMC10377609 DOI: 10.3390/biomedicines11071923] [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] [Received: 05/31/2023] [Revised: 06/15/2023] [Accepted: 07/05/2023] [Indexed: 07/30/2023] Open
Abstract
Twin-screw wet granulation (TSWG) is a method of continuous pharmaceutical manufacturing and a potential alternative method to batch granulation processes. It has attracted more and more interest nowadays due to its high efficiency, robustness, and applications. To improve both the product quality and process efficiency, the process understanding is critical. This article reviews the recent work in process understanding and optimization for TSWG. Various aspects of the progress in TSWG like process model construction, process monitoring method development, and the strategy of process control for TSWG have been thoroughly analyzed and discussed. The process modeling technique including the empirical model, the mechanistic model, and the hybrid model in the TSWG process are presented to increase the knowledge of the granulation process, and the influence of process parameters involved in granulation process on granule properties by experimental study are highlighted. The study analyzed several process monitoring tools and the associated technologies used to monitor granule attributes. In addition, control strategies based on process analytical technology (PAT) are presented as a reference to enhance product quality and ensure the applicability and capability of continuous manufacturing (CM) processes. Furthermore, this article aims to review the current research progress in an effort to make recommendations for further research in process understanding and development of TSWG.
Collapse
Affiliation(s)
- Jie Zhao
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| | - Geng Tian
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| | - Haibin Qu
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| |
Collapse
|
4
|
Glace M, Armstrong C, Puryear N, Bailey C, Moazeni-Pourasil RS, Scott D, Abdelwahed S, Roper TD. An Automated Continuous Synthesis and Isolation for the Scalable Production of Aryl Sulfonyl Chlorides. Molecules 2023; 28:molecules28104213. [PMID: 37241953 DOI: 10.3390/molecules28104213] [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] [Received: 04/24/2023] [Revised: 05/16/2023] [Accepted: 05/17/2023] [Indexed: 05/28/2023] Open
Abstract
In this work, a continuous system to produce multi-hundred-gram quantities of aryl sulfonyl chlorides is described. The scheme employs multiple continuous stirred-tank reactors (CSTRs) and a continuous filtration system and incorporates an automated process control scheme. The experimental process outlined is intended to safely produce the desired sulfonyl chloride at laboratory scale. Suitable reaction conditions were first determined using a batch-chemistry design of experiments (DOE) and several isolation methods. The hazards and incompatibilities of the heated chlorosulfonic acid reaction mixture were addressed by careful equipment selection, process monitoring, and automation. The approximations of the CSTR fill levels and pumping performance were measured by real-time data from gravimetric balances, ultimately leading to the incorporation of feedback controllers. The introduction of process automation demonstrated in this work resulted in significant improvements in process setpoint consistency, reliability, and spacetime yield, as demonstrated in medium- and large-scale continuous manufacturing runs.
Collapse
Affiliation(s)
- Matthew Glace
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Cameron Armstrong
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Nathan Puryear
- Department of Electrical and Computer Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Colin Bailey
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | | | - Drew Scott
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Sherif Abdelwahed
- Department of Electrical and Computer Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Thomas D Roper
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| |
Collapse
|
5
|
Monaco D, Reynolds GK, Tajarobi P, Litster JD, Salman AD. Modelling the effect of L/S ratio and granule moisture content on the compaction properties in continuous manufacturing. Int J Pharm 2023; 633:122624. [PMID: 36690126 DOI: 10.1016/j.ijpharm.2023.122624] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/12/2022] [Revised: 01/05/2023] [Accepted: 01/16/2023] [Indexed: 01/22/2023]
Abstract
The pharmaceutical field is currently moving towards continuous manufacturing pursuing reduced waste, consistency, and automation. During continuous manufacturing, it is important to understand how both operating conditions and material properties throughout the process affect the final properties of the product to optimise and control production. In this study of a continuous wet granulation line, the liquid to solid ratio (L/S) and drying times were varied to investigate the effect of the final granule moisture content and the liquid to solid ratio on the properties of the granules during tabletting and the final tensile strength of the tablets. Both variables (L/S and granule moisture) affected the tablet tensile strength with the moisture content having a larger impact. Further analysis using a compaction model, showed that the compactability of the granules was largely unaffected by both L/S and moisture content while the compressibility was influenced by these variables, leading to a difference in the final tablet strength and porosity. The granule porosity was linked to the L/S ratio and used instead for the model fitting. The effect of moisture content and granule porosity was added to the model using a 3d plane relationship between the compressibility constant, the moisture content and porosity of the granules. The tablet tensile strength model, considering the effect of moisture and granule porosity, performed well averaging a root mean squared error across the different conditions of 0.17 MPa.
Collapse
Affiliation(s)
- Daniele Monaco
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, UK.
| | - Gavin K Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, AstraZeneca, Macclesfield, UK
| | - Pirjo Tajarobi
- Early Product Development and Manufacture, Pharmaceutical Sciences, AstraZeneca, Gothenburg, Sweden
| | - James D Litster
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, UK
| | - Agba D Salman
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, UK
| |
Collapse
|
6
|
Model development and calibration of two-dimensional population balance model for twin-screw wet granulation based on particle size distribution and porosity. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118334] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/11/2023]
|
7
|
The Role of Process Systems Engineering in Applying Quality by Design (QbD) in Mesenchymal Stem Cell Production. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2023.108144] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/22/2023]
|
8
|
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.
Collapse
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
| |
Collapse
|
9
|
Fayed MH, Alalaiwe A, Almalki ZS, Helal DA. Design Space Approach for the Optimization of Green Fluidized Bed Granulation Process in the Granulation of a Poorly Water-Soluble Fenofibrate Using Design of Experiment. Pharmaceutics 2022; 14:pharmaceutics14071471. [PMID: 35890366 PMCID: PMC9316798 DOI: 10.3390/pharmaceutics14071471] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/01/2022] [Revised: 07/07/2022] [Accepted: 07/13/2022] [Indexed: 01/09/2023] Open
Abstract
In the pharmaceutical industry, the systematic optimization of process variables using a quality-by-design (QbD) approach is highly precise, economic and ensures product quality. The current research presents the implementation of a design-of-experiment (DoE) driven QbD approach for the optimization of key process variables of the green fluidized bed granulation (GFBG) process. A 32 full-factorial design was performed to explore the effect of water amount (X1; 1–6% w/w) and spray rate (X2; 2–8 g/min) as key process variables on critical quality attributes (CQAs) of granules and tablets. Regression analysis have demonstrated that changing the levels of X1 and X2 significantly affect (p ≤ 0.05) the CQAs of granules and tablets. Particularly, X1 was found to have the pronounced effect on the CQAs. The GFBG process was optimized, and a design space (DS) was built using numerical optimization. It was found that X1 and X2 at high (5.69% w/w) and low (2 g/min) levels, respectively, demonstrated the optimum operating conditions. By optimizing X1 and X2, GFBG could enhance the disintegration and dissolution of tablets containing a poorly water-soluble drug. The prediction error values of dependent responses were less than 5% that confirm validity, robustness and accuracy of the generated DS in optimization of GFBG.
Collapse
Affiliation(s)
- Mohamed H. Fayed
- Department of Pharmaceutics, Faculty of Pharmacy, Fayoum University, Fayoum 63514, Egypt;
- Correspondence:
| | - Ahmed Alalaiwe
- Department of Pharmaceutics, College of Pharmacy, Prince Sattam Bin Abdulaziz University, Al-Kharj 11942, Saudi Arabia;
| | - Ziyad S. Almalki
- Department of Clinical Pharmacy, College of Pharmacy, Prince Sattam Bin Abdulaziz University, Al-Kharj 11942, Saudi Arabia;
| | - Doaa A. Helal
- Department of Pharmaceutics, Faculty of Pharmacy, Fayoum University, Fayoum 63514, Egypt;
| |
Collapse
|
10
|
Fisher AC, Liu W, Schick A, Ramanadham M, Chatterjee S, Brykman R, Lee SL, Kozlowski S, Boam AB, Tsinontides S, Kopcha M. An Audit of Pharmaceutical Continuous Manufacturing Regulatory Submissions and Outcomes in the US. Int J Pharm 2022; 622:121778. [DOI: 10.1016/j.ijpharm.2022.121778] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/14/2022] [Revised: 04/20/2022] [Accepted: 04/24/2022] [Indexed: 10/18/2022]
|
11
|
Rao RR, Pandey A, Hegde AR, Kulkarni VI, Chincholi C, Rao V, Bhushan I, Mutalik S. Metamorphosis of Twin Screw Extruder-Based Granulation Technology: Applications Focusing on Its Impact on Conventional Granulation Technology. AAPS PharmSciTech 2021; 23:24. [PMID: 34907508 PMCID: PMC8816530 DOI: 10.1208/s12249-021-02173-w] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/22/2021] [Accepted: 10/29/2021] [Indexed: 11/30/2022] Open
Abstract
In order to be at pace with the market requirements of solid dosage forms and regulatory standards, a transformation towards systematic processing using continuous manufacturing (CM) and automated model-based control is being thought through for its fundamental advantages over conventional batch manufacturing. CM eliminates the key gaps through the integration of various processes while preserving quality attributes via the use of process analytical technology (PAT). The twin screw extruder (TSE) is one such equipment adopted by the pharmaceutical industry as a substitute for the traditional batch granulation process. Various types of granulation techniques using twin screw extrusion technology have been explored in the article. Furthermore, individual components of a TSE and their conjugation with PAT tools and the advancements and applications in the field of nutraceuticals and nanotechnology have also been discussed. Thus, the future of granulation lies on the shoulders of continuous TSE, where it can be coupled with computational mathematical studies to mitigate its complications.
Collapse
|
12
|
Morrissey JP, Hanley KJ, Ooi JY. Conceptualisation of an Efficient Particle-Based Simulation of a Twin-Screw Granulator. Pharmaceutics 2021; 13:pharmaceutics13122136. [PMID: 34959417 PMCID: PMC8704810 DOI: 10.3390/pharmaceutics13122136] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/29/2021] [Revised: 11/29/2021] [Accepted: 12/06/2021] [Indexed: 11/29/2022] Open
Abstract
Discrete Element Method (DEM) simulations have the potential to provide particle-scale understanding of twin-screw granulators. This is difficult to obtain experimentally because of the closed, tightly confined geometry. An essential prerequisite for successful DEM modelling of a twin-screw granulator is making the simulations tractable, i.e., reducing the significant computational cost while retaining the key physics. Four methods are evaluated in this paper to achieve this goal: (i) develop reduced-scale periodic simulations to reduce the number of particles; (ii) further reduce this number by scaling particle sizes appropriately; (iii) adopt an adhesive, elasto-plastic contact model to capture the effect of the liquid binder rather than fluid coupling; (iv) identify the subset of model parameters that are influential for calibration. All DEM simulations considered a GEA ConsiGma™ 1 twin-screw granulator with a 60° rearward configuration for kneading elements. Periodic simulations yielded similar results to a full-scale simulation at significantly reduced computational cost. If the level of cohesion in the contact model is calibrated using laboratory testing, valid results can be obtained without fluid coupling. Friction between granules and the internal surfaces of the granulator is a very influential parameter because the response of this system is dominated by interactions with the geometry.
Collapse
|
13
|
Analysis of the Effects of Process Parameters on Start-Up Operation in Continuous Wet Granulation. Processes (Basel) 2021. [DOI: 10.3390/pr9091502] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Toward further implementation of continuous tablet manufacturing, one key issue is the time needed for start-up operation because it could lead to lower product yield and reduced economic performance. The behavior of the start-up operation is not well understood; moreover, the definition of the start-up time is still unclear. This work investigates the effects of process parameters on the start-up operation in continuous wet granulation, which is a critical unit operation in solid drug manufacturing. The profiles of torque and granule size distribution were monitored and measured for the first hour of operation, including the start-up phase. We analyzed the impact of process parameters based on design of experiments and performed an economic assessment to see the effects of the start-up operation. The torque profiles indicated that liquid-to-solid ratio and screw speed would affect the start-up operation, whereas different start-up behavior resulted in different granule size. Depending on the indicator used to define the start-up operation, the economic optimal point was significantly different. The results of this study stress that the start-up time differs according to the process parameters and used definition, e.g., indicators and criteria. This aspect should be considered for the further study and regulation of continuous manufacturing.
Collapse
|
14
|
Portier C, Vervaet C, Vanhoorne V. Continuous Twin Screw Granulation: A Review of Recent Progress and Opportunities in Formulation and Equipment Design. Pharmaceutics 2021; 13:668. [PMID: 34066921 PMCID: PMC8148523 DOI: 10.3390/pharmaceutics13050668] [Citation(s) in RCA: 23] [Impact Index Per Article: 7.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 04/30/2021] [Accepted: 05/02/2021] [Indexed: 11/16/2022] Open
Abstract
Continuous twin screw wet granulation is one of the key continuous manufacturing technologies that have gained significant interest in the pharmaceutical industry as well as in academia over the last ten years. Given its considerable advantages compared to wet granulation techniques operated in batch mode such as high shear granulation and fluid bed granulation, several equipment manufacturers have designed their own manufacturing setup. This has led to a steep increase in the research output in this field. However, most studies still focused on a single (often placebo) formulation, hence making it difficult to assess the general validity of the obtained results. Therefore, current review provides an overview of recent progress in the field of continuous twin screw wet granulation, with special focus on the importance of the formulation aspect and raw material properties. It gives practical guidance for novel and more experienced users of this technique and highlights some of the unmet needs that require further research.
Collapse
Affiliation(s)
| | | | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium; (C.P.); (C.V.)
| |
Collapse
|
15
|
Plath T, Korte C, Sivanesapillai R, Weinhart T. Parametric Study of Residence Time Distributions and Granulation Kinetics as a Basis for Process Modeling of Twin-Screw Wet Granulation. Pharmaceutics 2021; 13:pharmaceutics13050645. [PMID: 34062801 PMCID: PMC8147328 DOI: 10.3390/pharmaceutics13050645] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/31/2021] [Revised: 04/23/2021] [Accepted: 04/25/2021] [Indexed: 11/17/2022] Open
Abstract
Twin-screw wet granulation is a crucial unit operation in shifting from pharmaceutical batch to continuous processes, but granulation kinetics as well as residence times are yet poorly understood. Experimental findings are highly dependent on screw configuration as well as formulation, and thus have limited universal validity. In this study, an experimental design with a repetitive screw setup was conducted to measure the effect of specific feed load (SFL), liquid-to-solid ratio (L/S), and inclusion of a distributive feed screw on particle size distribution (PSD) and shape as well as residence time distribution of a hydrophilic lactose/microcrystalline cellulose based formulation. An intermediate sampling point was obtained by changing inlet ports along the screw axis. Camera-based particle size analysis (QICPIC) indicated no significant change of PSD between the first and second kneading section, except for low L/S and low SFL where fines increase. Mean residence time was approximated as a bilinear fit of L/S and SFL. Moreover, large mass flow pulsations were observed by continuous camera measurements of residence time distribution and correlated to hold-up of the twin-screw granulator. These findings indicate fast granulation kinetics and process instabilities for high mean residence times, questioning current standards of two kneading compartments for wet granulation. The present study further underlines the necessity of developing a multiscale simulation approach including particle dynamics in the future.
Collapse
Affiliation(s)
- Timo Plath
- Multi-Scale Mechanics, TFE, ET, MESA+, University of Twente, P.O. Box 217, 7500 AE Enschede, The Netherlands;
- Correspondence: ; Tel.: +31-53-489-3997
| | - Carolin Korte
- Process Technology Development, Engineering & Technology, Bayer AG, 51368 Leverkusen, Germany; (C.K.); (R.S.)
| | - Rakulan Sivanesapillai
- Process Technology Development, Engineering & Technology, Bayer AG, 51368 Leverkusen, Germany; (C.K.); (R.S.)
| | - Thomas Weinhart
- Multi-Scale Mechanics, TFE, ET, MESA+, University of Twente, P.O. Box 217, 7500 AE Enschede, The Netherlands;
| |
Collapse
|
16
|
Ishimoto H, Kano M, Sugiyama H, Takeuchi H, Terada K, Aoyama A, Shoda T, Demizu Y, Shimamura J, Yokoyama R, Miyamoto Y, Hasegawa K, Serizawa M, Unosawa K, Osaki K, Asai N, Matsuda Y. Approach to Establishment of Control Strategy for Oral Solid Dosage Forms Using Continuous Manufacturing. Chem Pharm Bull (Tokyo) 2021; 69:211-217. [PMID: 33298636 DOI: 10.1248/cpb.c20-00824] [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] [Indexed: 11/22/2022]
Abstract
As a result of the research activities of the Japan Agency for Medical Research and Development (AMED), this document aims to show an approach to establishing control strategy for continuous manufacturing of oral solid dosage forms. The methods of drug development, technology transfer, process control, and quality control used in the current commercial batch manufacturing would be effective also in continuous manufacturing, while there are differences in the process development using continuous manufacturing and batch manufacturing. This document introduces an example of the way of thinking for establishing a control strategy for continuous manufacturing processes.
Collapse
Affiliation(s)
- Hayato Ishimoto
- Formulation Research, Pharmaceutical Science & Technology Core Function Unit, Medicine Development Center, Eisai Co., Ltd
| | - Manabu Kano
- Department of Systems Science, Kyoto University
| | | | - Hirofumi Takeuchi
- Advanced Pharmaceutical Process Engineering, Gifu Pharmaceutical University
| | | | - Atsushi Aoyama
- Office of New Drug III, Pharmaceuticals and Medical Devices Agency
| | - Takuji Shoda
- Division of Organic Chemistry, National Institute of Health Sciences
| | - Yosuke Demizu
- Division of Organic Chemistry, National Institute of Health Sciences
| | - Jinen Shimamura
- Pharmaceutical Research Dept. Research & Development Headquarters, TAKATA Pharmaceutical Co., Ltd
| | - Reiji Yokoyama
- CMC R&D Division, Shionogi Co., Ltd., Formulation R&D Laboratory
| | - Yuji Miyamoto
- Formulation Research & Pharmaceutical Process Group, CMC R&D Center, Kyowa Kirin Co., Ltd
| | | | | | | | | | | | | |
Collapse
|
17
|
Liu H, Meyer R, Flamm M, Wareham L, Metzger M, Tantuccio A, Yoon S. Optimization of Critical Quality Attributes in Tablet Film Coating and Design Space Determination Using Pilot-Scale Experimental Data. AAPS PharmSciTech 2021; 22:17. [PMID: 33389197 DOI: 10.1208/s12249-020-01884-w] [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] [Received: 08/10/2020] [Accepted: 11/18/2020] [Indexed: 11/30/2022] Open
Abstract
In this study, the novel high-speed tablet film coating process in the continuous manufacturing was investigated. The influence of key process variables (inlet air flow rate, inlet air temperature, and suspension spray rate) were investigated using a Box-Behnken experimental design method. Statistical regression models were developed to predict the outlet air temperature and relative humidity, the coating efficiency, the tablet moisture content, and coating uniformity. The effects of the three key process variables were comprehensively investigated based on mathematical analysis, contour plots, and interaction plots. The results indicate that all the process responses are affected by changing the inlet air flow rate, temperature, and suspension spray rate. A design space (DS) in terms of failure probability was determined based on specifications for tablet moisture content (< 3.5%) and coating uniformity (tablet weight standard deviation < 4 mg for tablet weight of 200 mg) using Monte Carlo simulations. Independent experiments were carried out and successfully validated the robustness and accuracy of the determined DS for the investigated tablet film coating process. All the data were generated using an industrial pilot-scale novel high-speed tablet coating unit from a continuous manufacturing line. The work facilitates the quality by design implementation of continuous pharmaceutical manufacturing.
Collapse
|
18
|
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.
Collapse
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
| |
Collapse
|
19
|
Kittikunakorn N, Liu T, Zhang F. Twin-screw melt granulation: Current progress and challenges. Int J Pharm 2020; 588:119670. [PMID: 32739382 DOI: 10.1016/j.ijpharm.2020.119670] [Citation(s) in RCA: 21] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/28/2020] [Revised: 07/03/2020] [Accepted: 07/15/2020] [Indexed: 02/06/2023]
Abstract
Twin-screw melt granulation (TSMG) is a new alternative method for granulation that offers several advantages over wet and dry granulation methods. TSMG has rapidly gained interest over recent years in the pharmaceutical industry. Since it is an inherently continuous process with controlled temperature and shear history, TSMG produces products with more consistent quality than the batch process. Several studies have investigated how various formulation and processing parameters influence granulation behavior and granule properties; however, there are still challenges that require a better mechanistic understanding. This review summarizes the current progress of TSMG while highlighting how various formulation and process parameters affect the physicochemical properties of granules. The challenges related to the process-induced physicochemical changes of drug substances are also discussed.
Collapse
Affiliation(s)
- Nada Kittikunakorn
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409, University Avenue, Austin, TX 78712, United States
| | - Tongzhou Liu
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409, University Avenue, Austin, TX 78712, United States
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409, University Avenue, Austin, TX 78712, United States.
| |
Collapse
|
20
|
Liu H, Rivnay B, Avery K, Myung JH, Kozak D, Landrau N, Nivorozhkin A, Ashraf M, Yoon S. Optimization of the manufacturing process of a complex amphotericin B liposomal formulation using quality by design approach. Int J Pharm 2020; 585:119473. [PMID: 32473373 DOI: 10.1016/j.ijpharm.2020.119473] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2020] [Revised: 05/18/2020] [Accepted: 05/24/2020] [Indexed: 12/17/2022]
Abstract
In this work, the manufacturing process of a complex liposomal amphotericin B (AmB) product was optimized using quality by design (QbD) approach. A comprehensive QbD-based process understanding and design space (DS) to the critical process parameters (CPPs) is essential to the drug development and consistent quality control. The process was based on the acid-aided formation of drug-lipid complexes in a methanol-chloroform mixture (step I) followed by spray drying (step II), hydration and liposome formation by microfluidization (step III), and lyophilization (step IV). Firstly, the risk assessment was conducted to identify the critical process parameters among the four key steps. Nine CPPs and five CQAs (API Monomer identity (absorbance main peak at 321 nm), API Aggregation identity (absorbance peak ratio, OD 415 nm/321 nm), particle size, in-vitro toxicity, and the cake quality) were determined based on their severity and occurrences with their contribution to the quality target product profile (QTPP). Based on the risk assessment results, the final screening design of experiments (DoE) was developed using fractional factorial design. Secondly, the empirical equation was developed for each CQA based on experimental data. The impact of CPPs on the CQAs was analyzed using the coefficient plot and contour plot. In addition to the effect of individual formulation parameters and process parameters, the effects of the four key separate steps were also evaluated and compared. In general, the curing temperature during microfluidization has been identified as the most significant CPP. Finally, design space exploration was carried out to demonstrate how the critical process parameters can be varied to consistently produce a drug product with desired characteristics. The design space size increased at the higher value of the curing temperature, the API to phospholipid ratio (API:PL), and the lower value of the DSPG to phospholipid ratio (PG:PL) and aspirator rate.
Collapse
Affiliation(s)
- Huolong Liu
- Department of Chemical Engineering, University of Massachusetts Lowell, 1 University Ave, Lowell, MA 01854, USA
| | - Benjamin Rivnay
- Landrau Scientific Innovations, LLC, 22 Laurel Street, Leominster, MA 01453, USA
| | - Ken Avery
- Landrau Scientific Innovations, LLC, 22 Laurel Street, Leominster, MA 01453, USA
| | - Ja Hye Myung
- U.S. Food and Drug Administration, Office of Generic Drugs, 10903 New Hampshire Avenue, Silver Spring, MD 20993, USA
| | - Darby Kozak
- U.S. Food and Drug Administration, Office of Generic Drugs, 10903 New Hampshire Avenue, Silver Spring, MD 20993, USA
| | - Nelson Landrau
- Landrau Scientific Innovations, LLC, 22 Laurel Street, Leominster, MA 01453, USA
| | - Alex Nivorozhkin
- Neo-Advent Technologies, LLC, 410 Great Rd., Suite 4-2-2, Littleton, MA 01460, USA
| | - Muhammad Ashraf
- U.S. Food and Drug Administration, Office of Testing and Research, 10903 New Hampshire Avenue, Silver Spring, MD 20993, USA
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts Lowell, 1 University Ave, Lowell, MA 01854, USA.
| |
Collapse
|
21
|
Borchert D, A. Suarez-Zuluaga D, E. Thomassen Y, Herwig C. Risk assessment and integrated process modeling–an improved QbD approach for the development of the bioprocess control strategy. AIMS BIOENGINEERING 2020. [DOI: 10.3934/bioeng.2020022] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022] Open
|