Comprehensive study of dynamic curing effect on tablet coating structure

Advances in Structure Pharmaceutics from Discovery to Evaluation and Design

Drug delivery systems (DDSs) play an important role in delivering active pharmaceutical ingredients (APIs) to targeted sites with a predesigned release pattern. The chemical and biological properties of APIs and excipients have been extensively studied for their contribution to DDS quality and effectiveness; however, the structural characteristics of DDSs have not been adequately explored. Structure pharmaceutics involves the study of the structure of DDSs, especially the three-dimensional (3D) structures, and its interaction with the physiological and pathological structure of organisms, possibly influencing their release kinetics and targeting abilities. A systematic overview of the structures of a variety of dosage forms, such as tablets, granules, pellets, microspheres, powders, and nanoparticles, is presented. Moreover, the influence of structures on the release and targeting capability of DDSs has also been discussed, especially the in vitro and in vivo release correlation and the structure-based organ- and tumor-targeting capabilities of particles with different structures. Additionally, an in-depth discussion is provided regarding the application of structural strategies in the DDSs design and evaluation. Furthermore, some of the most frequently used characterization techniques in structure pharmaceutics are briefly described along with their potential future applications.

Studying the dissolution of immediate release film coating using terahertz pulsed imaging

Coated tablets introduce complexity to the dissolution process, even with readily soluble immediate release coating layers. Therefore, a more detailed understanding of the physical steps involved in the dissolution process can improve the efficiency of formulation and process design. The current study uses terahertz pulsed imaging to visualise the hydration process of microcrystalline cellulose (MCC) tablet cores that were film coated with an immediate release coating formulation upon exposure to the dissolution medium. Film coated tablets that were prepared from three levels of core porosity (10%, 20% and 30%) and with coating thickness in the range of 30μm to 250μm were investigated. It was possible to resolve and quantify the distinct stages of wetting of the coating layer, swelling of the MCC particles at the core surface, and dissolution of the coating layer followed by the ingress of dissolution media into the tablet core. The liquid transport process through the coating layer was highly consistent and scalable. The penetration rate through the coating layer and the tablet core both strongly depended on coating thickness and core porosity.

Investigation of a Low-Toxicity Energetic Binder for a Solid Propellant: Curing, Microstructures, and Performance

In this work, a promising propellant binder using the energetic branched glycidyl azide polymer (B-GAP) as a matrix and the low-toxic dimer acid diisocyanate (DDI) as a curing agent was prepared, under the catalysis of dibutyl tin dilaurate. The curing kinetics considering the thermal diffusion effect and the reaction endpoint of B-GAP/DDI were investigated by the thermal analysis method and a newly proposed variance method, respectively. Moreover, the buildup of microstructures during curing and the tensile and dynamic mechanical performance of this binder were respectively explored. Results show that there exists an obvious induction period in the beginning of the curing reaction, and the autocatalytic model shows that thermal diffusion can effectively describe the curing process. Shore A hardness of sample stabilizes around 40.78 in the end of curing, and the reaction endpoint of B-GAP/DDI is in the time range of 156-168 h. There exist cross-linking, suspension, and free chains during the whole curing process, and the cross-linking density of the binder reaches approximately 4.0 × 10^-4 mol·cm^-3 when the curing completes. Hydrogen bonding (H-bond) is found to be a strong binder: 53.3% of the carbonyls participates in forming the H-bond. Furthermore, this binder has better mechanical performance and lower glass-transition temperature than the GAP/N100 binder.

Pharmaceutical Application of Tablet Film Coating

Tablet film coating is a common but critical process providing various functionalities to tablets, thereby meeting diverse clinical needs and increasing the value of oral solid dosage forms. Tablet film coating is a technology-driven process and the evolution of coated dosage forms relies on advancements in coating technology, equipment, analytical techniques, and coating materials. Although multiple coating techniques are developed for solvent-based or solvent-free coating processes, each method has advantages and disadvantages that may require continuous technical refinement. In the film coating process, intra- and inter-batch coating uniformity of tablets is critical to ensure the quality of the final product, especially for active film coating containing active pharmaceutical ingredients in the coating layer. In addition to experimental evaluation, computational modeling is also actively pursued to predict the influence of operation parameters on the quality of the final product and optimize process variables of tablet film coating. The concerted efforts of experiments and computational modeling can save time and cost in optimizing the tablet coating process. This review provides a brief overview of tablet film coating technology and modeling approaches with a focus on recent advancements in pharmaceutical applications.

Application of Process Analytical Technology for Pharmaceutical Coating: Challenges, Pitfalls, and Trends

Coating process is a critical unit operation for manufacturing solid oral dosage forms. For a long time, the coating weight gain has been discerned as the most important, if not only, characteristic describing the coating quality. As the introduction of quality by design (QbD) and advancement of process analytical technology (PAT), nowadays more techniques are available to analyze other quality attributes which have been overlooked but have substantial impacts on the performance of coated products. The techniques that permit rapid and non-destructive measurements are of particular importance to improve process operation and product quality. This article reviews the analytical techniques that have been and potentially could be used as PAT tools for characterizing the quality of pharmaceutical coating product. By identifying the challenges and pitfalls encountered during PAT application, the review aims at fostering the adoption of PAT for paving the way to enhanced quality and efficiency of the coating processes.

Reducing Burst Release Effect of Freely Water-Soluble Drug Incorporated into Gastro-Floating Formulation Below HPMC Threshold Concentration Through Interpolymer Complex

Undesired-burst release effect is observed in a freely water-soluble drug formulated into a gastro-floating formulation with effervescent (GFFE) delivery system. In order to address this limitation, interpolymer complex (IPC) of two swellable and non-soluble polymers, poly-ammonium methacrylate and poly-vinyl acetate, was incorporated into hydroxypropyl methyl cellulose (HPMC)-based matrix GFFE. This research studied the effect and interaction of the IPC-HPMC blending on the drug release of GFFE using a freely water-soluble drug, metformin HCl, under different threshold concentration levels and curing effect. The interaction between the IPC and HPMC was characterized using vibrational spectroscopy and thermal analyses under curing and swelling conditions. Anti-solvent followed by lyophilization had better physicochemical and physicomechanic properties than spray dying technique. The interaction was observed by a specific shifting of the vibrational peaks and alteration of the thermal behavior pattern. These effects altered the drug release behavior. Thereafter, the IPC reduced burst release effects in the initial time and during testing, and the IPC improved the HPMC matrix robustness under mechanical stress testing below threshold concentration of HPMC matrix formulated in the GFFE.

Smart polymers in drug delivery: a biological perspective

Key to the widespread application of smart polymers in drug delivery is understanding the mechanistic interplay, as well as consequence, of the presence of these macromolecules within living systems.

Applicability of near-infrared spectroscopy in the monitoring of film coating and curing process of the prolonged release coated pellets

Although process analytical technology (PAT) guidance has been introduced to the pharmaceutical industry just a decade ago, this innovative approach has already become an important part of efficient pharmaceutical development, manufacturing, and quality assurance. PAT tools are especially important in technologically complex operations which require strict control of critical process parameters and have significant effect on final product quality. Manufacturing of prolonged release film coated pellets is definitely one of such processes. The aim of the present work was to study the applicability of the at-line near-infrared spectroscopy (NIR) approach in the monitoring of pellet film coating and curing steps. Film coated pellets were manufactured by coating the active ingredient containing pellets with film coating based on polymethacrylate polymers (Eudragit® RS/RL). The NIR proved as a useful tool for the monitoring of the curing process since it was able to determine the extent of the curing and hence predict drug release rate by using partial least square (PLS) model. However, such approach also showed a number of limitations, such as low reliability and high susceptibility to pellet moisture content, and was thus not able to predict drug release from pellets with high moisture content. On the other hand, the at-line NIR was capable to predict the thickness of Eudragit® RS/RL film coating in a wide range (up to 40μm) with good accuracy even in the pellets with high moisture content. To sum up, high applicability of the at-line NIR in the monitoring of the prolonged release pellets production was demonstrated in the present study. The present findings may contribute to more efficient and reliable PAT solutions in the manufacturing of prolonged release dosage forms.

Improvement of mechanical properties of pellet containing tablets by thermal treatment

Batches of partially spray-dried lactose tablets with three different initial tensile strength (∼20N, ∼35N, ∼50N) were made. Changes along a 24h long thermal treatment at 100°C in tensile strength, friability, individual mass, water content, disintegration time, average free volume and wetting properties were evaluated. Caffeine containing gastroresistant pellets were gained by drug layering and filmcoating of inert microcrystalline cellulose pellet cores in fluid bed equipment. Shape, size, mechanical properties, drug content and dissolution profile of the coated pellets were determined. Batches of pellet containing tablets with three different pellet-filler ratios were compressed where partially spray-dried lactose was used as a filler-binder material.Characteristics of pellet containing tablets were evaluated before and after a 24h long thermal treatment at 100°C. Results shown that the poor initial mechanical properties (friability, tensile strength) were improved by thermal exposure while there were no remarkable alterations in drug release profiles.

Terahertz pulsed imaging and magnetic resonance imaging as tools to probe formulation stability

Dissolution stability over the entire shelf life duration is of critical importance to ensure the quality of solid dosage forms. Changes in the drug release profile during storage may affect the bioavailability of drug products. This study investigated the stability of a commercial tablet (Lescol^® XL) when stored under accelerated conditions (40 °C/75% r.h.). Terahertz pulsed imaging (TPI) was used to investigate the structure of the tablet coating before and after the accelerated aging process. The results indicate that the coating was reduced in thickness and exhibited a higher density after being stored under accelerated conditions for four weeks. In situ magnetic resonance imaging (MRI) of the water penetration processes during tablet dissolution in a USP-IV dissolution cell equipped with an in-line UV-vis analyzer was carried out to study local differences in water uptake into the tablet matrix between the stressed and unstressed state. The drug release profiles of the Lescol^® XL tablet before and after the accelerated storage stability testing were compared using a “difference” factor f₁ and a “similarity” factor f₂. The results reveal that even though the physical properties of the coating layers changed significantly during the stress testing, the coating protected the tablet matrix and the densification of the coating polymer had no adverse effect on the drug release performance.