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Simões A, Veiga F, Vitorino C. Question-based review for pharmaceutical development: An enhanced quality approach. Eur J Pharm Biopharm 2024; 195:114174. [PMID: 38160986 DOI: 10.1016/j.ejpb.2023.114174] [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: 11/22/2023] [Revised: 12/21/2023] [Accepted: 12/26/2023] [Indexed: 01/03/2024]
Abstract
Over the last years, the pharmaceutical industry has faced real challenges regarding quality assurance. In this context, the establishment of more holistic approaches to the pharmaceutical development has been encouraged. The emergence of the Quality by Design (QbD) paradigm as systematic, scientific and risk-based methodology introduced a new concept of pharmaceutical quality. In essence, QbD can be interpreted as a strategy to maximize time and cost savings. An in-depth understanding of the formulation and manufacturing process is demanded to optimize the safety, efficacy and quality of a drug product at all stages of development. This innovative approach streamlines the pharmaceutical Research and Development (R&D) process, provides greater manufacturing flexibility and reduces regulatory burden. To assist in QbD implementation, International Conference on Harmonisation (ICH), U.S. Food and Drug Administration (FDA) and European Medicines Agency (EMA) organized and launched QbD principles in their guidance for industry, identifying key concepts and tools to design and develop a high-quality drug product. Despite the undeniable advantages of the QbD approach, and the widespread information on QbD regulatory expectations, its full implementation in the pharmaceutical field is still limited. The present review aims to establish a crosswise overview on the current application status of QbD within the framework of the ICH guidelines (ICH Q8(R2) - Q14 and ICH Q2(R2)). Moreover, it outlines the way information gathered from the QbD methodology is being harmonized in Marketing Authorization Applications (MAAs) for European market approval. This work also highlights the challenges that hinder the deployment of the QbD strategy as a standard practice.
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Affiliation(s)
- Ana Simões
- Faculty of Pharmacy, University of Coimbra, 3000-548 Coimbra, Portugal; Associated Laboratory for Green Chemistry of the Network of Chemistry and Technology (LAQV/REQUIMTE), Group of Pharmaceutical Technology, Faculty of Pharmacy, University of Coimbra, 3000-548 Coimbra, Portugal
| | - Francisco Veiga
- Faculty of Pharmacy, University of Coimbra, 3000-548 Coimbra, Portugal; Associated Laboratory for Green Chemistry of the Network of Chemistry and Technology (LAQV/REQUIMTE), Group of Pharmaceutical Technology, Faculty of Pharmacy, University of Coimbra, 3000-548 Coimbra, Portugal
| | - Carla Vitorino
- Faculty of Pharmacy, University of Coimbra, 3000-548 Coimbra, Portugal; Coimbra Chemistry Centre, Institute of Molecular Sciences - IMS, Department of Chemistry, University of Coimbra 3004-535 Coimbra, Portugal.
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2
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Teng K, Fu H, Wu G, Gong P, Xie Y, Zhou P, Gong X, Qu H. QbD-Guided Traditional Chinese Medicine Manufacturing Process: Development and Optimization of Fluid-Bed Granulation and Drying Processes for Xiaochaihu Capsules. AAPS PharmSciTech 2023; 24:210. [PMID: 37821749 DOI: 10.1208/s12249-023-02663-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/28/2023] [Accepted: 09/19/2023] [Indexed: 10/13/2023] Open
Abstract
Traditional methods of producing Xiaochaihu (XCH) capsules, a traditional Chinese medicine, are time-consuming, costly, and labor-intensive, which is not conductive to modernizing TCM. To address the challenges, new fluid-bed granulation and drying processes with water as the binder were developed and optimized guided by the principles of Quality by Design (QbD) in this study. Ishikawa diagram was applied to conduct a preliminary risk assessment, followed by 6-factor definitive screening design (DSD) serving as a QbD statistical tool to develop and optimize the new processes. Multiple potential factors and interactions were studied with a small number of experiments using the DSD. This study identified critical process parameters (CPPs), established quadratic regression models to reveal CPP-critical quality attributes (CQAs) connections within the DSD framework, and defined a dependable design space. Processes conducted by parameter combinations in the design space produced qualified granules with production yield and raw material utilization higher than 90% and moisture content lower than 4%. Furthermore, quantitative analysis of baicalin of all the granules ensured qualified contents of active pharmaceutical ingredient. The newly developed processes for XCH capsules, with advantages of shorter time, environmental friendliness, and decreased cost, exemplify the effective application of QbD and design of experiments (DoE) methodologies in the modernization of TCM manufacturing processes.
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Affiliation(s)
- Kaixuan Teng
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou, 310058, China
- Innovation Institute for Artificial Intelligence in Medicine of Zhejiang University, Hangzhou, 310018, China
| | - Hao Fu
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou, 310058, China
- Innovation Institute for Artificial Intelligence in Medicine of Zhejiang University, Hangzhou, 310018, China
| | - Gelin Wu
- Zhejiang Pralife Pharmaceutical Co., Ltd., Taizhou, 318000, China
| | - Ping Gong
- Zhejiang Pralife Pharmaceutical Co., Ltd., Taizhou, 318000, China
| | - Yongjian Xie
- Zhejiang Pralife Pharmaceutical Co., Ltd., Taizhou, 318000, China
| | - Peng Zhou
- Zhejiang Pralife Pharmaceutical Co., Ltd., Taizhou, 318000, China
| | - Xingchu Gong
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou, 310058, China
- Innovation Institute for Artificial Intelligence in Medicine of Zhejiang University, Hangzhou, 310018, China
| | - Haibin Qu
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou, 310058, China.
- Innovation Institute for Artificial Intelligence in Medicine of Zhejiang University, Hangzhou, 310018, China.
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Barriga R, Romero M, Hassan H, Nettleton DF. Energy Consumption Optimization of a Fluid Bed Dryer in Pharmaceutical Manufacturing Using EDA (Exploratory Data Analysis). SENSORS (BASEL, SWITZERLAND) 2023; 23:3994. [PMID: 37112342 PMCID: PMC10144200 DOI: 10.3390/s23083994] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 02/06/2023] [Revised: 03/11/2023] [Accepted: 03/30/2023] [Indexed: 06/19/2023]
Abstract
In this paper, a data preprocessing methodology, EDA (Exploratory Data Analysis), is used for performing an exploration of the data captured from the sensors of a fluid bed dryer to reduce the energy consumption during the preheating phase. The objective of this process is the extraction of liquids such as water through the injection of dry and hot air. The time taken to dry a pharmaceutical product is typically uniform, independent of the product weight (Kg) or the type of product. However, the time it takes to heat up the equipment before drying can vary depending on different factors, such as the skill level of the person operating the machine. EDA (Exploratory Data Analysis) is a method of evaluating or comprehending sensor data to derive insights and key characteristics. EDA is a critical component of any data science or machine learning process. The exploration and analysis of the sensor data from experimental trials has facilitated the identification of an optimal configuration, with an average reduction in preheating time of one hour. For each processed batch of 150 kg in the fluid bed dryer, this translates into an energy saving of around 18.5 kWh, giving an annual energy saving of over 3.700 kWh.
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Affiliation(s)
- Roberto Barriga
- Industrias Farmacéuticas Almirall, Ctra. N-II, Km. 593, 08740 Sant Andreu de la Barca, Spain
| | - Miquel Romero
- Industrias Farmacéuticas Almirall, Ctra. N-II, Km. 593, 08740 Sant Andreu de la Barca, Spain
| | - Houcine Hassan
- Departamento de Informática de Sistemas y Computadores, Universitat Politècnica de València, Camino de Vera, No. 14, 46022 Valencia, Spain
| | - David F. Nettleton
- IRIS Technology Solutions, Ctra. d’Esplugues, 39, 08940 Cornella de Llobregat, Spain
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Timoumi A, Nguyen TC, Le T, Kraiem H, Cescut J, Anne-Archard D, Gorret N, Molina-Jouve C, To KA, Fillaudeau L. Comparison of methods to explore the morphology and granulometry of biological particles with complex shapes: Interpretation and limitations. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.118067] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
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Zhang K, Wang H, Zhong L, Liu L, Huang R, Zhang H, Xu D, Yin W, Li L, Zang H. Evaluation and Monitoring of the API Content of a Portable Near Infrared Instrument Combined with Chemometrics Based on Fluidized Bed Mixing Process. J Pharm Innov 2021. [DOI: 10.1007/s12247-021-09581-2] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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Furukawa R, Singh R, Ierapetritou M. Experimental investigation and modelling of tensile strength of pharmaceutical tablets based on shear force applied by feed frame paddles. Int J Pharm 2021; 606:120908. [PMID: 34298106 DOI: 10.1016/j.ijpharm.2021.120908] [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: 05/09/2021] [Revised: 07/13/2021] [Accepted: 07/18/2021] [Indexed: 02/02/2023]
Abstract
The feed frame is an essential device used in a rotary tablet press and it improves the performance of the powder filling process into dies. However, the feed frame affects critical quality attributes such as a tensile strength and a dissolution negatively due to a shear applied to powders from feed frame paddles, leading to over-lubrication. This effects may be significant for shear sensitive materials. The work focuses on the effect of tablet press parameters (die disk speed and feed frame speed) and mixture composition (amount of magnesium stearate) on the tensile strength and the prediction of the tensile strength by considering the extent of shear. It is found that within the investigated range of tablet press parameters and the amount of magnesium stearate, the feed frame speed and the amount of magnesium stearate have an impact on the tensile strength. Furthermore, a lubrication model based on the extent of shear is presented to predict the decreasing trend of the tensile strength of tablets during tableting process and the results demonstrate that the prediction of tensile strength is in good agreement with experimental measurements.
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Affiliation(s)
- Ryoichi Furukawa
- Pharmaceutical Research Department, Mitsubishi Tanabe Pharma Corporation, 3-16-89, Kashima, Yodogawa-ku, Osaka 532-8505, Japan
| | - Ravendra Singh
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), 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, 150 Academy St, Newark, DE 19716, USA.
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Kim B, Byun Y, Lee EH. DoE-Based Design of a Simple but Efficient Preparation Method for a Non-Effervescent Gastro-Retentive Floating Tablet Containing Metformin HCl. Pharmaceutics 2021; 13:1225. [PMID: 34452186 PMCID: PMC8399106 DOI: 10.3390/pharmaceutics13081225] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/23/2021] [Revised: 08/05/2021] [Accepted: 08/06/2021] [Indexed: 11/21/2022] Open
Abstract
A sustained-release non-effervescent floating matrix tablet was prepared using a simple and efficient direct compression of spray-dried granules containing metformin hydrochloride and cetyl alcohol with hydroxypropyl methylcellulose K15M (HPMC K15M). The design of experiments was employed to explore the optimal composition of the tablet. The similarity factor was employed to evaluate the equivalence in dissolution profiles between the test tablets and Glucophage XR as a reference. Bootstrap analysis was used to eliminate the formulations for which the dissolution profile was potentially inequivalent to that of the reference. The optimized tablet consisting of 150 mg of cetyl alcohol and 17% HPMC K15M showed a dissolution profile comparable with that of the reference with a similarity factor of 52.41, exhibited a floating lag time of less than 3 s in buffer media, remained floating for 24 h, and reduced the tablet weight by about 20% compared to that of the reference. The current study sheds light on the potential use of non-effervescent gastro-retentive extended-release tablets for high-dose drugs using a simple and efficient direct compression method, and as a potential alternative treatment for Glucophage XR. This study also highlights the importance of a systematic approach to formulation optimization and the evaluation of the dissolution profile.
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Affiliation(s)
| | | | - Eun Hee Lee
- College of Pharmacy, Korea University, 2511 Sejong-ro, Sejong 339700, Korea; (B.K.); (Y.B.)
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Kim EJ, Kim JH, Kim MS, Jeong SH, Choi DH. Process Analytical Technology Tools for Monitoring Pharmaceutical Unit Operations: A Control Strategy for Continuous Process Verification. Pharmaceutics 2021; 13:919. [PMID: 34205797 PMCID: PMC8234957 DOI: 10.3390/pharmaceutics13060919] [Citation(s) in RCA: 29] [Impact Index Per Article: 9.7] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 05/31/2021] [Accepted: 06/16/2021] [Indexed: 11/16/2022] Open
Abstract
Various frameworks and methods, such as quality by design (QbD), real time release test (RTRT), and continuous process verification (CPV), have been introduced to improve drug product quality in the pharmaceutical industry. The methods recognize that an appropriate combination of process controls and predefined material attributes and intermediate quality attributes (IQAs) during processing may provide greater assurance of product quality than end-product testing. The efficient analysis method to monitor the relationship between process and quality should be used. Process analytical technology (PAT) was introduced to analyze IQAs during the process of establishing regulatory specifications and facilitating continuous manufacturing improvement. Although PAT was introduced in the pharmaceutical industry in the early 21st century, new PAT tools have been introduced during the last 20 years. In this review, we present the recent pharmaceutical PAT tools and their application in pharmaceutical unit operations. Based on unit operations, the significant IQAs monitored by PAT are presented to establish a control strategy for CPV and real time release testing (RTRT). In addition, the equipment type used in unit operation, PAT tools, multivariate statistical tools, and mathematical preprocessing are introduced, along with relevant literature. This review suggests that various PAT tools are rapidly advancing, and various IQAs are efficiently and precisely monitored in the pharmaceutical industry. Therefore, PAT could be a fundamental tool for the present QbD and CPV to improve drug product quality.
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Affiliation(s)
- Eun Ji Kim
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si, Gyeongnam 621-749, Korea; (E.J.K.); (J.H.K.)
| | - Ji Hyeon Kim
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si, Gyeongnam 621-749, Korea; (E.J.K.); (J.H.K.)
| | - Min-Soo Kim
- College of Pharmacy, Pusan National University, Busandaehak-ro 63 heon-gil, Geumjeong-gu, Busan 46241, Korea;
| | - Seong Hoon Jeong
- College of Pharmacy, Dongguk University-Seoul, Dongguk-ro-32, Ilsan-Donggu, Goyang 10326, Korea;
| | - Du Hyung Choi
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si, Gyeongnam 621-749, Korea; (E.J.K.); (J.H.K.)
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Nandi U, Trivedi V, Ross SA, Douroumis D. Advances in Twin-Screw Granulation Processing. Pharmaceutics 2021; 13:pharmaceutics13050624. [PMID: 33925577 PMCID: PMC8146340 DOI: 10.3390/pharmaceutics13050624] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/25/2021] [Revised: 03/31/2021] [Accepted: 04/07/2021] [Indexed: 11/23/2022] Open
Abstract
Twin-screw granulation (TSG) is a pharmaceutical process that has gained increased interest from the pharmaceutical industry for its potential for the development of oral dosage forms. The technology has evolved rapidly due to the flexibility of the equipment design, the selection of the process variables and the wide range of processed materials. Most importantly, TSG offers the benefits of both batch and continuous manufacturing for pharmaceutical products, accompanied by excellent process control, high product quality which can be achieved through the implementation of Quality by Design (QbD) approaches and the integration of Process Analytical Tools (PAT). Here, we present basic concepts of the various twin-screw granulation techniques and present in detail their advantages and disadvantages. In addition, we discuss the detail of the instrumentation used for TSG and how the critical processing paraments (CPP) affect the critical quality attributes (CQA) of the produced granules. Finally, we present recent advances in TSG continuous manufacturing including the paradigms of modelling of continuous granulation process, QbD approaches coupled with PAT monitoring for granule optimization and process understanding.
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Affiliation(s)
- Uttom Nandi
- Faculty of Engineering and Science, School of Science, University of Greenwich, Chatham Maritime, Chatham, Kent ME4 4TB, UK;
- CIPER Centre for Innovation and Process Engineering Research, Kent ME4 4TB, UK;
| | - Vivek Trivedi
- Medway School of Pharmacy, Medway Campus, University of Kent, Central Avenue, Chatham Maritime, Chatham, Kent ME4 4TB, UK;
| | - Steven A. Ross
- CIPER Centre for Innovation and Process Engineering Research, Kent ME4 4TB, UK;
- Cubi-Tech Extrusion: 3, Sextant Park, Neptune Cl, Rochester ME2 4LU, UK
| | - Dennis Douroumis
- Faculty of Engineering and Science, School of Science, University of Greenwich, Chatham Maritime, Chatham, Kent ME4 4TB, UK;
- CIPER Centre for Innovation and Process Engineering Research, Kent ME4 4TB, UK;
- Correspondence: ; Tel.: +44-2083318440
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KUANG TK, KANG YB, SEGARRA I, KANWAL U, AHSAN M, BUKHARI NI. Microwave-assisted Preparation of Cross-linked Gelatin-Paracetamol Matrices: Optimization Using the D-optimal Design. Turk J Pharm Sci 2021; 18:167-175. [PMID: 33902255 PMCID: PMC8100778 DOI: 10.4274/tjps.galenos.2020.48902] [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: 10/25/2019] [Accepted: 04/01/2020] [Indexed: 12/01/2022]
Abstract
Objectives This study was conducted to assess the effect of microwave heating on the preparation of paracetamol cross-linked gelatin matrices by using the design of experiment (DoE) approach and explore the influence of the duration of microwave irradiation, the concentrations of crosslinker, and the amount of sodium bicarbonate (salt) on paracetamol release. These parameters were also compared with those of the matrices prepared via conventional heating. Materials and Methods Twenty gel matrices were prepared with different durations of microwave irradiation, amounts of maize, and concentrations of sodium bicarbonate as suggested by Design Expert (DX®). The percentage drug release, the coefficient of variance (CV) in release, and the mean dissolution time (MDT) were the properties explored in the designed experimentation. Results Target responses were dependent on microwave irradiation time, cross-linker amount, and salt concentration. Classical and microwave heating did not demonstrate statistically significant difference in modifying the percentage of drug released from the matrices. However, the CVs of microwave-assisted formulations were lower than those of the gel matrices prepared via classical heating. Thus, microwave heating produced lesser variations in drug release. The optimized gel matrices demonstrated that the observed percentage of drug release, CV, and MDT were within the prediction interval generated by DX®. The release mechanism of the matrix formulations followed the Peppas-Korsmeyer anomalous transport model. Conclusion The DoE-supported microwave-assisted approach could be applied to optimize the critical factors of drug release with less variation.
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Affiliation(s)
- Tan Kian KUANG
- International Medical University School of Pharmacy, Department of Pharmaceutical Technology, Kuala Lumpur, Malaysia
| | - Yew-Beng KANG
- International Medical University School of Pharmacy, Department of Pharmaceutical Chemistry, Kuala Lumpur, Malaysia
| | - Ignacio SEGARRA
- International Medical University School of Pharmacy, Department of Pharmaceutical Technology, Kuala Lumpur, Malaysia
- Department of Pharmacy, School of Health Sciences and Pharmacy, Catholic University of Murcia, Murcia, Spain
| | - Ummarah KANWAL
- Punjab University College of Pharmacy, University of the Punjab, Lahore, Pakistan
| | - Muhammad AHSAN
- Punjab University College of Pharmacy, University of the Punjab, Lahore, Pakistan
| | - Nadeem Irfan BUKHARI
- International Medical University School of Pharmacy, Department of Pharmaceutical Technology, Kuala Lumpur, Malaysia
- Punjab University College of Pharmacy, University of the Punjab, Lahore, Pakistan
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Model-Based Scale-Up Methodologies for Pharmaceutical Granulation. Pharmaceutics 2020; 12:pharmaceutics12050453. [PMID: 32423051 PMCID: PMC7284585 DOI: 10.3390/pharmaceutics12050453] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2020] [Revised: 05/09/2020] [Accepted: 05/11/2020] [Indexed: 12/13/2022] Open
Abstract
In the pharmaceutical industry, it is a major challenge to maintain consistent quality of drug products when the batch scale of a process is changed from a laboratory scale to a pilot or commercial scale. Generally, a pharmaceutical manufacturing process involves various unit operations, such as blending, granulation, milling, tableting and coating and the process parameters of a unit operation have significant effects on the quality of the drug product. Depending on the change in batch scale, various process parameters should be strategically controlled to ensure consistent quality attributes of a drug product. In particular, the granulation may be significantly influenced by scale variation as a result of changes in various process parameters and equipment geometry. In this study, model-based scale-up methodologies for pharmaceutical granulation are presented, along with data from various related reports. The first is an engineering-based modeling method that uses dimensionless numbers based on process similarity. The second is a process analytical technology-based modeling method that maintains the desired quality attributes through flexible adjustment of process parameters by monitoring the quality attributes of process products in real time. The third is a physics-based modeling method that involves a process simulation that understands and predicts drug quality through calculation of the behavior of the process using physics related to the process. The applications of these three scale-up methods are summarized according to granulation mechanisms, such as wet granulation and dry granulation. This review shows that these model-based scale-up methodologies provide a systematic process strategy that can ensure the quality of drug products in the pharmaceutical industry.
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Grangeia HB, Silva C, Simões SP, Reis MS. Quality by design in pharmaceutical manufacturing: A systematic review of current status, challenges and future perspectives. Eur J Pharm Biopharm 2020; 147:19-37. [DOI: 10.1016/j.ejpb.2019.12.007] [Citation(s) in RCA: 55] [Impact Index Per Article: 13.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2019] [Revised: 12/03/2019] [Accepted: 12/11/2019] [Indexed: 12/17/2022]
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Singh BN. Product Development, Manufacturing, and Packaging of Solid Dosage Forms Under QbD and PAT Paradigm: DOE Case Studies for Industrial Applications. AAPS PharmSciTech 2019; 20:313. [PMID: 31529232 DOI: 10.1208/s12249-019-1515-8] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/17/2019] [Accepted: 08/18/2019] [Indexed: 11/30/2022] Open
Abstract
An integrated approach based on QbD and PAT provides a systematic and innovative framework for product development, manufacturing, and quality risk management. In this context, the significance of the outcome of design of experiments (DOEs) to the selection of the product design, robust commercial manufacturing process, design space, and overall control strategy remains vital for the success of a drug product throughout its life cycle. This paper aims at discussing selected recent DOE case studies conducted during QbD-based and integrated QbD/PAT-based development of solid oral formulations and process improvement studies. The main focus of this paper is to highlight the rationales and importance of design selection during development and applications of mathematical models and statistical tools in analyzing DOE and PAT data for developing a design space, control strategy, and improved process monitoring. A total of 25 case studies (includes 9 PAT application studies) have been discussed in this paper which cover 11 manufacturing processes commonly utilized for solid dosage forms. Two case studies relevant to selection of packaging design for solid dosage forms are also briefly discussed to complete the scope. Overall, for a successful modern QbD approach, it is highly important that DOEs are conducted and analyzed in a logical sequence which involves designs that are phase-appropriate and quality-driven and facilitate both statistical and chemometric thinking at each development stage. This approach can result into higher regulatory flexibility along with lower economic burden during life cycle of a product, irrespective of regulatory path used (NDA or ANDA).
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Gavan A, Iurian S, Casian T, Porfire A, Porav S, Voina I, Oprea A, Tomuta I. Fluidised bed granulation of two APIs: QbD approach and development of a NIR in-line monitoring method. Asian J Pharm Sci 2019; 15:506-517. [PMID: 32952673 PMCID: PMC7486511 DOI: 10.1016/j.ajps.2019.03.003] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/22/2018] [Revised: 01/28/2019] [Accepted: 03/18/2019] [Indexed: 11/18/2022] Open
Abstract
The study focused on the fluid-bed granulation process of a product with two active pharmaceutical ingredients, intended for coated tablets preparation and further transfer to industrial scale. The work aimed to prove that an accurate control of the critical granulation parameters can level the input material variability and offer a user-friendly process control strategy. Moreover, an in-line Near-Infrared monitoring method was developed, which offered a real time overview of the moisture level along the granulation process, thus a reliable supervision and control process analytical technology (PAT) tool. The experimental design's results showed that the use of apparently interchangeable active pharmaceutical ingredients (APIs) and filler sorts that comply with pharmacopoeial specifications, lead to different end-product critical attributes. By adapting critical granulation parameters (i.e. binder spray rate and atomising pressure) as a function of material characteristics, led to granules with average sizes comprised in a narrow range of 280–320 µm and low non-granulated fraction of under 5%. Therefore, the accurate control of process parameters according to the formulation particularities achieved the maintenance of product within the design space and removed material related variability. To complete the Quality by design (QbD) strategy, despite its limited spectral domain, the microNIR spectrometer was successfully used as a robust PAT monitoring tool that offered a real time overview of the moisture level and allowed the supervision and control of the granulation process.
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Affiliation(s)
- Alexandru Gavan
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | - Sonia Iurian
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
- Corresponding author. Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, 41 Victor Babes Street, Cluj-Napoca 400012, Romania. Tel.: +40 74 5629083.
| | - Tibor Casian
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | - Alina Porfire
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | - Sebastian Porav
- National Institute for Research and Development of Isotopic and Molecular Technologies, Cluj-Napoca 400293, Romania
| | - Ioana Voina
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | | | - Ioan Tomuta
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
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Thapa P, Tripathi J, Jeong SH. Recent trends and future perspective of pharmaceutical wet granulation for better process understanding and product development. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.12.080] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
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Horster L, Bernhardt A, Kiehm K, Langer K. Conversion of PLGA nanoparticle suspensions into solid dosage forms via fluid bed granulation and tableting. Eur J Pharm Biopharm 2018; 134:77-87. [PMID: 30447271 DOI: 10.1016/j.ejpb.2018.11.011] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/13/2018] [Revised: 10/07/2018] [Accepted: 11/13/2018] [Indexed: 11/16/2022]
Abstract
Incorporating poorly soluble drugs into polymeric nanoparticles is a widely investigated approach to improve their biopharmaceutical performance. Poly(DL-lactide-co-glycolide) (PLGA) nanoparticle formulations have previously been tested and recommended as drug carriers for peroral administration of poorly soluble porphyrin derivatives intended for photodynamical therapy. Based on those PLGA formulations the present study investigates conventional techniques like fluid bed granulation and tableting for conversion of such polymeric nanoparticle suspensions into solid dosage forms. Analytical methods like asymmetrical flow field-flow fractionation (AF4) and photon correlation spectroscopy (PCS) were used to assess changes of the nanoparticle properties during processing and the recovery after redispersion of the solid dosage forms. Preliminary experiments were conducted to demonstrate the feasibility of the granulation and tableting strategy. Afterwards, design of experiments (DoE) was used to determine formulation and process parameters with critical influence on several properties of the solid forms, in particular the recovery of nanoparticles during dissolution testing. Fluid bed granulation with aqueous PLGA nanoparticle suspensions and soluble carriers was shown to be a simple and high yield process for drying of the nanoparticles. The nanoparticle concentration of the granulation suspension and the ratio of the spraying rate and the atomization air pressure were critical for the physicochemical characteristics of the granules like density and particle size distribution (PSD) as well as for the redispersibility to nanoparticle suspensions of original properties. The granules were compressed to tablets without impairing the nanoparticle diameter and the recovery when an adequate level of filler and low compression forces were used.
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Affiliation(s)
- Lutz Horster
- Rottendorf Pharma GmbH, Ostenfelder Straße 51-61, 59320 Ennigerloh, Germany.
| | - Alexander Bernhardt
- Institute of Pharmaceutical Technology and Biopharmacy, University of Muenster, Corrensstraße 48, 48149 Münster, Germany.
| | - Kevin Kiehm
- Rottendorf Pharma GmbH, Ostenfelder Straße 51-61, 59320 Ennigerloh, Germany.
| | - Klaus Langer
- Institute of Pharmaceutical Technology and Biopharmacy, University of Muenster, Corrensstraße 48, 48149 Münster, Germany.
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17
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Fukuda IM, Pinto CFF, Moreira CDS, Saviano AM, Lourenço FR. Design of Experiments (DoE) applied to Pharmaceutical and Analytical Quality by Design (QbD). BRAZ J PHARM SCI 2018. [DOI: 10.1590/s2175-97902018000001006] [Citation(s) in RCA: 79] [Impact Index Per Article: 13.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/22/2022] Open
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18
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Tian G, Wei Y, Zhao J, Li W, Qu H. Application of near-infrared spectroscopy combined with design of experiments for process development of the pulsed spray fluid bed granulation process. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.08.009] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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19
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Model Development and Validation of Fluid Bed Wet Granulation with Dry Binder Addition Using a Population Balance Model Methodology. Processes (Basel) 2018. [DOI: 10.3390/pr6090154] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
Abstract
An experimental study in industry was previously carried out on a batch fluid bed granulation system by varying the inlet fluidizing air temperature, binder liquid spray atomization pressure, the binder liquid spray rate and the disintegrant composition in the formulation. A population balance model framework integrated with heat transfer and moisture balance due to liquid addition and evaporation was developed to simulate the fluid bed granulation system. The model predictions were compared with the industry data, namely, the particle size distributions (PSDs) and geometric mean diameters (GMDs) at various time-points in the granulation process. The model also predicted the trends for binder particle dissolution in the wetting liquid and the temperatures of the bed particles in the fluid bed granulator. Lastly, various process parameters were varied and extended beyond the region studied in the aforementioned experimental study to identify optimal regimes for granulation.
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Nie L, Hu M, Yan X, Guo T, Wang H, Zhang S, Qu H. Optimization of a Coupling Process for Insulin Degludec According to a Quality by Design (QbD) Paradigm. AAPS PharmSciTech 2018; 19:2185-2194. [PMID: 29725901 DOI: 10.1208/s12249-018-1032-1] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/16/2017] [Accepted: 04/21/2018] [Indexed: 11/30/2022] Open
Abstract
This case study described a successful application of the quality by design (QbD) principles to a coupling process development of insulin degludec. Failure mode effects analysis (FMEA) risk analysis was first used to recognize critical process parameters (CPPs). Five CPPs, including coupling temperature (Temp), pH of desB30 solution (pH), reaction time (Time), desB30 concentration (Conc), and molar equivalent of ester per mole of desB30 insulin (MolE), were then investigated using a fractional factorial design. The curvature effect was found significant, indicating the requirement of second-order models. Afterwards, a central composite design was built with an augmented star and center points study. Regression models were developed for the CPPs to predict the purity and yield of predegludec using above experimental data. The R2 and adjusted R2 were higher than 96 and 93% for the two models respectively. The Q2 values were more than 80% indicating a good predictive ability of models. MolE was found to be the most significant factor affecting both yield and purity of predegludec. Temp, pH, and Conc were also significant for predegludec purity, while Time appeared to remarkably influence the yield model. The multi-dimensional design space and normal operating region (NOR) with a robust setpoint were determined using a probability-based Monte-Carlo simulation method. The verified experimental results showed that the design space was reliable and effective. This study enriches the understanding of acetylation process and is instructional to other complicated operations in biopharmaceutical engineering.
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21
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Peters J, Taute W, Döscher C, Meier R, Höft M, Knöchel R, Breitkreutz J. From laboratory- to pilot-scale: moisture monitoring in fluidized bed granulation by a novel microwave sensor using multivariate calibration approaches. Drug Dev Ind Pharm 2018; 44:961-968. [DOI: 10.1080/03639045.2018.1425427] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
Affiliation(s)
- Johanna Peters
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, Düsseldorf, Germany
| | - Wolfgang Taute
- Institute of Electrical Engineering and Information Technology, Christian-Albrechts-University, Kiel, Germany
| | | | - Robin Meier
- L.B. Bohle Maschinen + Verfahren GmbH, Ennigerloh, Germany
| | - Michael Höft
- Institute of Electrical Engineering and Information Technology, Christian-Albrechts-University, Kiel, Germany
| | - Reinhard Knöchel
- Institute of Electrical Engineering and Information Technology, Christian-Albrechts-University, Kiel, Germany
| | - Jörg Breitkreutz
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, Düsseldorf, Germany
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22
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Peters J, Teske A, Taute W, Döscher C, Höft M, Knöchel R, Breitkreutz J. Real-time process monitoring in a semi-continuous fluid-bed dryer - microwave resonance technology versus near-infrared spectroscopy. Int J Pharm 2017; 537:193-201. [PMID: 29288092 DOI: 10.1016/j.ijpharm.2017.12.040] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/16/2017] [Revised: 12/20/2017] [Accepted: 12/22/2017] [Indexed: 11/28/2022]
Abstract
The trend towards continuous manufacturing in the pharmaceutical industry is associated with an increasing demand for advanced control strategies. It is a mandatory requirement to obtain reliable real-time information on critical quality attributes (CQA) during every process step as the decision on diversion of material needs to be performed fast and automatically. Where possible, production equipment should provide redundant systems for in-process control (IPC) measurements to ensure continuous process monitoring even if one of the systems is not available. In this paper, two methods for real-time monitoring of granule moisture in a semi-continuous fluid-bed drying unit are compared. While near-infrared (NIR) spectroscopy has already proven to be a suitable process analytical technology (PAT) tool for moisture measurements in fluid-bed applications, microwave resonance technology (MRT) showed difficulties to monitor moistures above 8% until recently. The results indicate, that the newly developed MRT sensor operating at four resonances is capable to compete with NIR spectroscopy. While NIR spectra were preprocessed by mean centering and first derivative before application of partial least squares (PLS) regression to build predictive models (RMSEP = 0.20%), microwave moisture values of two resonances sufficed to build a statistically close multiple linear regression (MLR) model (RMSEP = 0.07%) for moisture prediction. Thereby, it could be verified that moisture monitoring by MRT sensor systems could be a valuable alternative to NIR spectroscopy or could be used as a redundant system providing great ease of application.
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Affiliation(s)
- Johanna Peters
- Heinrich-Heine-University Düsseldorf, Institute of Pharmaceutics and Biopharmaceutics, Universitätsstr. 1, 40225 Düsseldorf, Germany.
| | - Andreas Teske
- L.B. Bohle Maschinen + Verfahren GmbH, Industriestr. 18, 59320 Ennigerloh, Germany
| | - Wolfgang Taute
- Christian-Albrechts-University Kiel, Institute of Electrical Engineering and Information Technology, Kaiserstr. 2, 24143 Kiel, Germany
| | - Claas Döscher
- Döscher Microwave Systems GmbH, Am Diebsteich 31, 22761 Hamburg, Germany
| | - Michael Höft
- Christian-Albrechts-University Kiel, Institute of Electrical Engineering and Information Technology, Kaiserstr. 2, 24143 Kiel, Germany
| | - Reinhard Knöchel
- Christian-Albrechts-University Kiel, Institute of Electrical Engineering and Information Technology, Kaiserstr. 2, 24143 Kiel, Germany
| | - Jörg Breitkreutz
- Heinrich-Heine-University Düsseldorf, Institute of Pharmaceutics and Biopharmaceutics, Universitätsstr. 1, 40225 Düsseldorf, Germany
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Peters J, Bartscher K, Döscher C, Taute W, Höft M, Knöchel R, Breitkreutz J. In-line moisture monitoring in fluidized bed granulation using a novel multi-resonance microwave sensor. Talanta 2017; 170:369-376. [DOI: 10.1016/j.talanta.2017.03.105] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/06/2017] [Revised: 03/27/2017] [Accepted: 03/31/2017] [Indexed: 10/19/2022]
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24
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Tabora JE, Domagalski N. Multivariate Analysis and Statistics in Pharmaceutical Process Research and Development. Annu Rev Chem Biomol Eng 2017; 8:403-426. [DOI: 10.1146/annurev-chembioeng-060816-101418] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
The application of statistics in pharmaceutical process research and development has evolved significantly over the past decades, motivated in part by the introduction of the Quality by Design paradigm, a landmark change in regulatory expectations for the level of scientific understanding associated with the manufacturing process. Today, statistical methods are increasingly applied to accelerate the characterization and optimization of new drugs created via numerous unit operations well known to the chemical engineering discipline. We offer here a review of the maturity in the implementation of design of experiment techniques, the increased incorporation of latent variable methods in process and material characterization, and the adoption of Bayesian methodology for process risk assessment.
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Affiliation(s)
- José E. Tabora
- Chemical & Synthetics Development, Pharmaceutical Development, Bristol-Myers Squibb Company, New Brunswick, New Jersey 08901;,
| | - Nathan Domagalski
- Chemical & Synthetics Development, Pharmaceutical Development, Bristol-Myers Squibb Company, New Brunswick, New Jersey 08901;,
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25
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Djuris J, Djuric Z. Modeling in the quality by design environment: Regulatory requirements and recommendations for design space and control strategy appointment. Int J Pharm 2017; 533:346-356. [PMID: 28579542 DOI: 10.1016/j.ijpharm.2017.05.070] [Citation(s) in RCA: 35] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/26/2017] [Revised: 05/19/2017] [Accepted: 05/29/2017] [Indexed: 12/23/2022]
Abstract
Mathematical models can be used as an integral part of the quality by design (QbD) concept throughout the product lifecycle for variety of purposes, including appointment of the design space and control strategy, continual improvement and risk assessment. Examples of different mathematical modeling techniques (mechanistic, empirical and hybrid) in the pharmaceutical development and process monitoring or control are provided in the presented review. In the QbD context, mathematical models are predominantly used to support design space and/or control strategies. Considering their impact to the final product quality, models can be divided into the following categories: high, medium and low impact models. Although there are regulatory guidelines on the topic of modeling applications, review of QbD-based submission containing modeling elements revealed concerns regarding the scale-dependency of design spaces and verification of models predictions at commercial scale of manufacturing, especially regarding real-time release (RTR) models. Authors provide critical overview on the good modeling practices and introduce concepts of multiple-unit, adaptive and dynamic design space, multivariate specifications and methods for process uncertainty analysis. RTR specification with mathematical model and different approaches to multivariate statistical process control supporting process analytical technologies are also presented.
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Affiliation(s)
- Jelena Djuris
- Department of Pharmaceutical Technology and Cosmetology, University of Belgrade, Faculty of Pharmacy, Vojvode Stepe 450, 11221 Belgrade, Serbia.
| | - Zorica Djuric
- Department of Pharmaceutical Technology and Cosmetology, University of Belgrade, Faculty of Pharmacy, Vojvode Stepe 450, 11221 Belgrade, Serbia
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26
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Fayed MH, Abdel-Rahman SI, Alanazi FK, Ahmed MO, Tawfeek HM, Al-Shdefat RI. New gentle-wing high-shear granulator: impact of processing variables on granules and tablets characteristics of high-drug loading formulation using design of experiment approach. Drug Dev Ind Pharm 2017; 43:1584-1600. [PMID: 28480773 DOI: 10.1080/03639045.2017.1326930] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
Abstract
The aim of this work was to study the application of design of experiment (DoE) approach in defining design space for granulation and tableting processes using a novel gentle-wing high-shear granulator. According to quality-by-design (QbD) prospective, critical attributes of granules, and tablets should be ensured by manufacturing process design. A face-centered central composite design has been employed in order to investigate the effect of water amount (X1), impeller speed (X2), wet massing time (X3), and water addition rate (X4) as independent process variables on granules and tablets characteristics. Acetaminophen was used as a model drug and granulation experiments were carried out using dry addition of povidone k30. The dried granules have been analyzed for their size distribution, density, and flow pattern. Additionally, the produced tablets have been investigated for; weight uniformity, breaking force, friability and percent capping, disintegration time, and drug dissolution. Results of regression analysis showed that water amount, impeller speed and wet massing time have significant (p < .05) effect on granules and tablets characteristics. However, the water amount had the most pronounced effect as indicated by its higher parameter estimate. On the other hand, water addition rate showed a minimal impact on granules and tablets properties. In conclusion, water amount, impeller speed, and wet massing time could be considered as critical process variables. Thus, understanding the relationship between these variables and quality attributes of granules and corresponding tablets provides the basis for adjusting granulation variables in order to optimize product performance.
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Affiliation(s)
- Mohamed H Fayed
- a Department of Pharmaceutics, College of Pharmacy , Prince Sattam Bin Abdulaziz University , Al-kharj , Saudi Arabia
| | - Sayed I Abdel-Rahman
- b Department of Industrial Pharmacy, Faculty of Pharmacy , Assiut University , Assiut , Egypt
| | - Fars K Alanazi
- c Kayyali Chair for Pharmaceutical Industries, Department of Pharmaceutics, College of Pharmacy , King Saud University , Riyadh , Saudi Arabia
| | - Mahrous O Ahmed
- b Department of Industrial Pharmacy, Faculty of Pharmacy , Assiut University , Assiut , Egypt
| | - Hesham M Tawfeek
- b Department of Industrial Pharmacy, Faculty of Pharmacy , Assiut University , Assiut , Egypt
| | - Ramadan I Al-Shdefat
- a Department of Pharmaceutics, College of Pharmacy , Prince Sattam Bin Abdulaziz University , Al-kharj , Saudi Arabia
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27
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Peters J, Taute W, Bartscher K, Döscher C, Höft M, Knöchel R, Breitkreutz J. Design, development and method validation of a novel multi-resonance microwave sensor for moisture measurement. Anal Chim Acta 2017; 961:119-127. [DOI: 10.1016/j.aca.2017.01.021] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2016] [Revised: 12/26/2016] [Accepted: 01/05/2017] [Indexed: 10/20/2022]
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28
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In-line particle size measurement and agglomeration detection of pellet fluidized bed coating by Spatial Filter Velocimetry. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.06.009] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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29
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Estimation of design space for an extrusion–spheronization process using response surface methodology and artificial neural network modelling. Eur J Pharm Biopharm 2016; 106:79-87. [DOI: 10.1016/j.ejpb.2016.05.009] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2015] [Revised: 05/11/2016] [Accepted: 05/13/2016] [Indexed: 11/18/2022]
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30
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Zhang L, Mao S. Application of quality by design in the current drug development. Asian J Pharm Sci 2016; 12:1-8. [PMID: 32104308 PMCID: PMC7032183 DOI: 10.1016/j.ajps.2016.07.006] [Citation(s) in RCA: 101] [Impact Index Per Article: 12.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2016] [Revised: 07/07/2016] [Accepted: 07/31/2016] [Indexed: 11/15/2022] Open
Abstract
Quality by Test was the only way to guarantee quality of drug products before FDA launched current Good Manufacturing Practice. To clearly understand the manufacture processes, FDA generalized Quality by Design (QbD) in the field of pharmacy, which is based on the thorough understanding of how materials and process parameters affect the quality profile of final products. The application of QbD in drug formulation and process design is based on a good understanding of the sources of variability and the manufacture process. In this paper, the basic knowledge of QbD, the elements of QbD, steps and tools for QbD implementation in pharmaceutics field, including risk assessment, design of experiment, and process analytical technology (PAT), are introduced briefly. Moreover, the concrete applications of QbD in various pharmaceutical related unit operations are summarized and presented.
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Affiliation(s)
- Lan Zhang
- Shenyang Pharmaceutical University, No.103, Wenhua Road, Shenyang 110016, China
| | - Shirui Mao
- Shenyang Pharmaceutical University, No.103, Wenhua Road, Shenyang 110016, China
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31
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Scheibelhofer O, Besenhard MO, Piller M, Khinast JG. Comparing particle size distributions of an arbitrary shape. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.02.028] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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32
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Optimization of artificial neural network by genetic algorithm for describing viral production from uniform design data. Process Biochem 2016. [DOI: 10.1016/j.procbio.2015.12.005] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Indexed: 11/19/2022]
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33
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34
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Faulhammer E, Llusa M, Wahl PR, Paudel A, Lawrence S, Biserni S, Calzolari V, Khinast JG. Development of a design space and predictive statistical model for capsule filling of low-fill-weight inhalation products. Drug Dev Ind Pharm 2015; 42:221-30. [DOI: 10.3109/03639045.2015.1040416] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
Affiliation(s)
- E. Faulhammer
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, Austria,
- Research Center Pharmaceutical Engineering, Graz, Austria,
| | - M. Llusa
- Research Center Pharmaceutical Engineering, Graz, Austria,
| | - P. R. Wahl
- Research Center Pharmaceutical Engineering, Graz, Austria,
| | - A. Paudel
- Research Center Pharmaceutical Engineering, Graz, Austria,
| | - S. Lawrence
- GlaxoSmithKline (GSK), New Frontiers Science Park, Harlow, Essex, UK, and
| | - S. Biserni
- MG2, Pian di Macina di Pianoro, Bologna, Italy
| | | | - J. G. Khinast
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, Austria,
- Research Center Pharmaceutical Engineering, Graz, Austria,
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35
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Patwardhan K, Asgarzadeh F, Dassinger T, Albers J, Repka MA. A quality by design approach to understand formulation and process variability in pharmaceutical melt extrusion processes. J Pharm Pharmacol 2015; 67:673-84. [DOI: 10.1111/jphp.12370] [Citation(s) in RCA: 21] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/14/2014] [Accepted: 10/18/2014] [Indexed: 11/27/2022]
Abstract
Abstract
Objectives
In this study, the principles of quality by design (QbD) have been uniquely applied to a pharmaceutical melt extrusion process for an immediate release formulation with a low melting model drug, ibuprofen.
Methods
Two qualitative risk assessment tools – Fishbone diagram and failure mode effect analysis – were utilized to strategically narrow down the most influential parameters. Selected variables were further assessed using a Plackett-Burman screening study, which was upgraded to a response surface design consisting of the critical factors to study the interactions between the study variables. In process torque, glass transition temperature (Tg) of the extrudates, assay, dissolution and phase change were measured as responses to evaluate the critical quality attributes (CQAs) of the extrudates. The effect of each study variable on the measured responses was analysed using multiple regression for the screening design and partial least squares for the optimization design.
Key findings
Experimental limits for formulation and process parameters to attain optimum processing have been outlined. A design space plot describing the domain of experimental variables within which the CQAs remained unchanged was developed.
Conclusions
A comprehensive approach for melt extrusion product development based on the QbD methodology has been demonstrated. Drug loading concentrations between 40- 48%w/w and extrusion temperature in the range of 90–130°C were found to be the most optimum.
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Affiliation(s)
- Ketaki Patwardhan
- Department of Pharmaceutics & Drug Delivery, The University of Mississippi, University, MS, USA
| | | | - Thomas Dassinger
- Pharma Polymers & Services, Evonik Corporation, Darmstadt, Germany
| | - Jessica Albers
- Pharma Polymers & Services, Evonik Corporation, Darmstadt, Germany
| | - Michael A Repka
- Department of Pharmaceutics & Drug Delivery, The University of Mississippi, University, MS, USA
- Pii Center for Pharmaceutical Technology, The University of Mississippi, University, MS, USA
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36
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Puñal Peces D, García-Montoya E, Manich A, Suñé-Negre JM, Pérez-Lozano P, Miñarro M, Ticó JR. Approach to design space from retrospective quality data. Pharm Dev Technol 2014; 21:26-38. [DOI: 10.3109/10837450.2014.965321] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022]
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37
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Unit operation optimization for the manufacturing of botanical injections using a design space approach: a case study of water precipitation. PLoS One 2014; 9:e104493. [PMID: 25101624 PMCID: PMC4125280 DOI: 10.1371/journal.pone.0104493] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2014] [Accepted: 07/08/2014] [Indexed: 11/25/2022] Open
Abstract
Quality by design (QbD) concept is a paradigm for the improvement of botanical injection quality control. In this work, water precipitation process for the manufacturing of Xueshuantong injection, a botanical injection made from Notoginseng Radix et Rhizoma, was optimized using a design space approach as a sample. Saponin recovery and total saponin purity (TSP) in supernatant were identified as the critical quality attributes (CQAs) of water precipitation using a risk assessment for all the processes of Xueshuantong injection. An Ishikawa diagram and experiments of fractional factorial design were applied to determine critical process parameters (CPPs). Dry matter content of concentrated extract (DMCC), amount of water added (AWA), and stirring speed (SS) were identified as CPPs. Box-Behnken designed experiments were carried out to develop models between CPPs and process CQAs. Determination coefficients were higher than 0.86 for all the models. High TSP in supernatant can be obtained when DMCC is low and SS is high. Saponin recoveries decreased as DMCC increased. Incomplete collection of supernatant was the main reason for the loss of saponins. Design space was calculated using a Monte-Carlo simulation method with acceptable probability of 0.90. Recommended normal operation region are located in DMCC of 0.38–0.41 g/g, AWA of 3.7–4.9 g/g, and SS of 280–350 rpm, with a probability more than 0.919 to attain CQA criteria. Verification experiment results showed that operating DMCC, SS, and AWA within design space can attain CQA criteria with high probability.
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38
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Ferreira AP, Tobyn M. Multivariate analysis in the pharmaceutical industry: enabling process understanding and improvement in the PAT and QbD era. Pharm Dev Technol 2014; 20:513-27. [DOI: 10.3109/10837450.2014.898656] [Citation(s) in RCA: 60] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022]
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39
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Aleksić I, Duriš J, Ilić I, Ibrić S, Parojčić J, Srčič S. In silico modeling of in situ fluidized bed melt granulation. Int J Pharm 2014; 466:21-30. [PMID: 24607215 DOI: 10.1016/j.ijpharm.2014.02.045] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2013] [Revised: 02/23/2014] [Accepted: 02/28/2014] [Indexed: 11/25/2022]
Abstract
Fluidized bed melt granulation has recently been recognized as a promising technique with numerous advantages over conventional granulation techniques. The aim of this study was to evaluate the possibility of using response surface methodology and artificial neural networks for optimizing in situ fluidized bed melt granulation and to compare them with regard to modeling ability and predictability. The experiments were organized in line with the Box-Behnken design. The influence of binder content, binder particle size, and granulation time on granule properties was evaluated. In addition to the response surface analysis, a multilayer perceptron neural network was applied for data modeling. It was found that in situ fluidized bed melt granulation can be used for production of spherical granules with good flowability. Binder particle size had the most pronounced influence on granule size and shape, suggesting the importance of this parameter in achieving desired granule properties. It was found that binder content can be a critical factor for the width of granule size distribution and yield when immersion and layering is the dominant agglomeration mechanism. The results obtained indicate that both in silico techniques can be useful tools in defining the design space and optimization of in situ fluidized bed melt granulation.
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Affiliation(s)
- Ivana Aleksić
- Department of Pharmaceutical Technology and Cosmetology, Faculty of Pharmacy, University of Belgrade, Vojvode Stepe 450, 11221 Belgrade, Serbia.
| | - Jelena Duriš
- Department of Pharmaceutical Technology and Cosmetology, Faculty of Pharmacy, University of Belgrade, Vojvode Stepe 450, 11221 Belgrade, Serbia
| | - Ilija Ilić
- Department of Pharmaceutical Technology, Faculty of Pharmacy, University of Ljubljana, Aškerčeva 7, 1000 Ljubljana, Slovenia
| | - Svetlana Ibrić
- Department of Pharmaceutical Technology and Cosmetology, Faculty of Pharmacy, University of Belgrade, Vojvode Stepe 450, 11221 Belgrade, Serbia
| | - Jelena Parojčić
- Department of Pharmaceutical Technology and Cosmetology, Faculty of Pharmacy, University of Belgrade, Vojvode Stepe 450, 11221 Belgrade, Serbia
| | - Stanko Srčič
- Department of Pharmaceutical Technology, Faculty of Pharmacy, University of Ljubljana, Aškerčeva 7, 1000 Ljubljana, Slovenia
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Yan B, Li Y, Guo Z, Qu H. Quality by design for herbal drugs: a feedforward control strategy and an approach to define the acceptable ranges of critical quality attributes. PHYTOCHEMICAL ANALYSIS : PCA 2014; 25:59-65. [PMID: 24108478 DOI: 10.1002/pca.2463] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/02/2013] [Revised: 06/10/2013] [Accepted: 06/15/2013] [Indexed: 06/02/2023]
Abstract
INTRODUCTION The concept of quality by design (QbD) has been widely accepted and applied in the pharmaceutical manufacturing industry. There are still two key issues to be addressed in the implementation of QbD for herbal drugs. The first issue is the quality variation of herbal raw materials and the second issue is the difficulty in defining the acceptable ranges of critical quality attributes (CQAs). OBJECTIVE To propose a feedforward control strategy and a method for defining the acceptable ranges of CQAs for the two issues. METHODS In the case study of the ethanol precipitation process of Danshen (Radix Salvia miltiorrhiza) injection, regression models linking input material attributes and process parameters to CQAs were built first and an optimisation model for calculating the best process parameters according to the input materials was established. Then, the feasible material space was defined and the acceptable ranges of CQAs for the previous process were determined. RESULTS In the case study, satisfactory regression models were built with cross-validated regression coefficients (Q(2) ) all above 91 %. The feedforward control strategy was applied successfully to compensate the quality variation of the input materials, which was able to control the CQAs in the 90-110 % ranges of the desired values. In addition, the feasible material space for the ethanol precipitation process was built successfully, which showed the acceptable ranges of the CQAs for the concentration process. CONCLUSION The proposed methodology can help to promote the implementation of QbD for herbal drugs.
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Affiliation(s)
- Binjun Yan
- Pharmaceutical Informatics Institute, Zhejiang University, Hangzhou, 310058, China
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Latent variable modeling to assist the implementation of Quality-by-Design paradigms in pharmaceutical development and manufacturing: A review. Int J Pharm 2013; 457:283-97. [DOI: 10.1016/j.ijpharm.2013.08.074] [Citation(s) in RCA: 70] [Impact Index Per Article: 6.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2013] [Revised: 08/27/2013] [Accepted: 08/28/2013] [Indexed: 11/19/2022]
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Garala KC, Patel JM, Dhingani AP, Dharamsi AT. Quality by design (QbD) approach for developing agglomerates containing racecadotril and loperamide hydrochloride by crystallo-co-agglomeration. POWDER TECHNOL 2013. [DOI: 10.1016/j.powtec.2013.07.011] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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Torkko M, Linna A, Katajavuori N, Juppo AM. Quality KPIs in Pharmaceutical and Food Industry. J Pharm Innov 2013. [DOI: 10.1007/s12247-013-9159-9] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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Hoang Thi TH, Lemdani M, Flament MP. Optimizing the taste-masked formulation of acetaminophen using sodium caseinate and lecithin by experimental design. Int J Pharm 2013; 453:408-15. [PMID: 23747505 DOI: 10.1016/j.ijpharm.2013.05.026] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/05/2013] [Revised: 05/03/2013] [Accepted: 05/04/2013] [Indexed: 11/29/2022]
Abstract
In a previous study of ours, the association of sodium caseinate and lecithin was demonstrated to be promising for masking the bitterness of acetaminophen via drug encapsulation. The encapsulating mechanisms were suggested to be based on the segregation of multicomponent droplets occurring during spray-drying. The spray-dried particles delayed the drug release within the mouth during the early time upon administration and hence masked the bitterness. Indeed, taste-masking is achieved if, within the frame of 1-2 min, drug substance is either not released or the released amount is below the human threshold for identifying its bad taste. The aim of this work was (i) to evaluate the effect of various processing and formulation parameters on the taste-masking efficiency and (ii) to determine the optimal formulation for optimal taste-masking effect. Four investigated input variables included inlet temperature (X1), spray flow (X2), sodium caseinate amount (X3) and lecithin amount (X4). The percentage of drug release amount during the first 2 min was considered as the response variable (Y). A 2(4)-full factorial design was applied and allowed screening for the most influential variables i.e. sodium caseinate amount and lecithin amount. Optimizing these two variables was therefore conducted by a simplex approach. The SEM and DSC results of spray-dried powder prepared under optimal conditions showed that drug seemed to be well encapsulated. The drug release during the first 2 min significantly decreased, 7-fold less than the unmasked drug particles. Therefore, the optimal formulation that performed the best taste-masking effect was successfully achieved.
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Affiliation(s)
- Thanh Huong Hoang Thi
- Université Lille Nord de France, College of Pharmacy, 3 rue du Professeur Laguesse, BP 83, 59006 Lille Cedex, France
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Djuris J, Medarevic D, Krstic M, Djuric Z, Ibric S. Application of Quality by Design Concepts in the Development of Fluidized Bed Granulation and Tableting Processes. J Pharm Sci 2013; 102:1869-1882. [DOI: 10.1002/jps.23530] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/19/2012] [Revised: 01/08/2013] [Accepted: 03/12/2013] [Indexed: 11/05/2022]
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Liu H, Wang K, Schlindwein W, Li M. Using the Box–Behnken experimental design to optimise operating parameters in pulsed spray fluidised bed granulation. Int J Pharm 2013; 448:329-38. [DOI: 10.1016/j.ijpharm.2013.03.057] [Citation(s) in RCA: 27] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/28/2013] [Revised: 03/21/2013] [Accepted: 03/23/2013] [Indexed: 10/27/2022]
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Gong X, Wang S, Li Y, Qu H. Separation characteristics of ethanol precipitation for the purification of the water extract of medicinal plants. Sep Purif Technol 2013. [DOI: 10.1016/j.seppur.2013.01.029] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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Tomba E, De Martin M, Facco P, Robertson J, Zomer S, Bezzo F, Barolo M. General procedure to aid the development of continuous pharmaceutical processes using multivariate statistical modeling - an industrial case study. Int J Pharm 2013; 444:25-39. [PMID: 23337630 DOI: 10.1016/j.ijpharm.2013.01.018] [Citation(s) in RCA: 17] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/12/2012] [Revised: 01/08/2013] [Accepted: 01/09/2013] [Indexed: 10/27/2022]
Abstract
Streamlining the manufacturing process has been recognized as a key issue to reduce production costs and improve safety in pharmaceutical manufacturing. Although data available from earlier developmental stages are often sparse and unstructured, they can be very useful to improve the understanding about the process under development. In this paper, a general procedure is proposed for the application of latent variable statistical methods to support the development of new continuous processes in the presence of limited experimental data. The proposed procedure is tested on an industrial case study concerning the development of a continuous line for the manufacturing of paracetamol tablets. The main driving forces acting on the process are identified and ranked according to their importance in explaining the variability in the available data. This improves the understanding about the process by elucidating how different active pharmaceutical ingredient pretreatments, different formulation modes and different settings on the processing units affect the overall operation as well as the properties of the intermediate and final products. The results can be used as a starting point to perform a comprehensive and science-based quality risk assessment that help to define a robust control strategy, possibly enhanced with the integration of a design space for the continuous process at a later stage.
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Affiliation(s)
- Emanuele Tomba
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy
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Norioka T, Hayashi Y, Onuki Y, Andou H, Tsunashima D, Yamashita K, Takayama K. A Novel Approach to Establishing the Design Space for the Oral Formulation Manufacturing Process. Chem Pharm Bull (Tokyo) 2013; 61:39-49. [DOI: 10.1248/cpb.c12-00743] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Affiliation(s)
- Tadashi Norioka
- Department of Pharmaceutics, Hoshi University
- Pharmaceutical Technology and Research Laboratories, Astellas Pharma Inc
| | | | | | - Hirotaka Andou
- Pharmaceutical Technology and Research Laboratories, Astellas Pharma Inc
| | - Daisuke Tsunashima
- Pharmaceutical Technology and Research Laboratories, Astellas Pharma Inc
| | - Kazunari Yamashita
- Pharmaceutical Technology and Research Laboratories, Astellas Pharma Inc
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