1
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Peeters M, Barrera Jiménez AA, Matsunami K, Ghijs M, Dos Santos Schultz E, Roudgar M, Vigh T, Stauffer F, Nopens I, De Beer T. Analysis of the effect of formulation properties and process parameters on granule formation in twin-screw wet granulation. Int J Pharm 2024; 650:123671. [PMID: 38065345 DOI: 10.1016/j.ijpharm.2023.123671] [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: 06/14/2023] [Revised: 12/01/2023] [Accepted: 12/02/2023] [Indexed: 01/08/2024]
Abstract
In the last few years, twin-screw wet granulation (TSWG) has become one of the key continuous pharmaceutical unit operations. Despite the many studies that have been performed, only little is known about the effect of the starting material properties on the stepwise granule formation along the length of the twin-screw granulator (TSG) barrel. Hence, this study obtained a detailed understanding of the effect of formulation properties (i.e., Active Pharmaceutical Ingredient (API) properties, formulation blend particle size distribution and formulation drug load) and process settings on granule formation in TSWG. An experimental set-up was used allowing the collection of granules at the different TSG compartments. Granules were characterized in terms of granule size, shape, binder liquid and API distributions. Liquid-to-solid (L/S) ratio was the only TSG process parameter impacting the granule size and shape evolution. Particle size and flow properties (e.g., flow rate index) had an important effect on the granule size and shape changes whereas water-related properties (e.g., water binding capacity and solubility) became influential at the last TSG compartments. The API solubility and L/S ratio were found to have a major impact on the distribution of binder liquid over the different granule size fractions. In the first TSG compartment (i.e., wetting compartment), the distribution of the API in the granules was influenced by its solubility in the granulation liquid.
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Affiliation(s)
- Michiel Peeters
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Ana Alejandra Barrera Jiménez
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Kensaku Matsunami
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent 9000, Oost-Vlaanderen, Belgium.
| | - Michael Ghijs
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | | | - Mina Roudgar
- Discovery, Product Development & Supply, Janssen R&D, Beerse B-2340, Belgium
| | - Tamas Vigh
- Discovery, Product Development & Supply, Janssen R&D, Beerse B-2340, Belgium
| | - Fanny Stauffer
- Product Design & Performance, UCB, Braine l'Alleud 1420, Belgium
| | - Ingmar Nopens
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium
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2
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Technological advances and challenges for exploring attribute transmission in tablet development by high shear wet granulation. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118402] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/08/2023]
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3
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Chen FC, Liu WJ, Zhu WF, Yang LY, Zhang JW, Feng Y, Ming LS, Li Z. Surface Modifiers on Composite Particles for Direct Compaction. Pharmaceutics 2022; 14:pharmaceutics14102217. [PMID: 36297653 PMCID: PMC9612340 DOI: 10.3390/pharmaceutics14102217] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/16/2022] [Revised: 10/13/2022] [Accepted: 10/13/2022] [Indexed: 11/16/2022] Open
Abstract
Direct compaction (DC) is considered to be the most effective method of tablet production. However, only a small number of the active pharmaceutical ingredients (APIs) can be successfully manufactured into tablets using DC since most APIs lack adequate functional properties to meet DC requirements. The use of suitable modifiers and appropriate co-processing technologies can provide a promising approach for the preparation of composite particles with high functional properties. The purpose of this review is to provide an overview and classification of different modifiers and their multiple combinations that may improve API tableting properties or prepare composite excipients with appropriate co-processed technology, as well as discuss the corresponding modification mechanism. Moreover, it provides solutions for selecting appropriate modifiers and co-processing technologies to prepare composite particles with improved properties.
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Affiliation(s)
- Fu-Cai Chen
- Key Laboratory of Preparation of Modern TCM, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
| | - Wen-Jun Liu
- Jiangzhong Pharmaceutical Co., Ltd., Nanchang 330049, China
| | - Wei-Feng Zhu
- Key Laboratory of Preparation of Modern TCM, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
| | - Ling-Yu Yang
- Jiangzhong Pharmaceutical Co., Ltd., Nanchang 330049, China
| | - Ji-Wen Zhang
- Key Laboratory of Preparation of Modern TCM, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
- Shanghai Institute of Materia Medica, Chinese Academy of Sciences, Shanghai 201203, China
| | - Yi Feng
- Key Laboratory of Preparation of Modern TCM, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
- Engineering Research Center of Modern Preparation Technology of TCM of Ministry of Education, Shanghai University of Traditional Chinese Medicine, Shanghai 201203, China
| | - Liang-Shan Ming
- Key Laboratory of Preparation of Modern TCM, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
- Correspondence: (L.-S.M.); (Z.L.); Tel.: +86-791-8711-9027 (L.-S.M. & Z.L.)
| | - Zhe Li
- Key Laboratory of Preparation of Modern TCM, Ministry of Education, Jiangxi University of Chinese Medicine, Nanchang 330004, China
- Correspondence: (L.-S.M.); (Z.L.); Tel.: +86-791-8711-9027 (L.-S.M. & Z.L.)
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4
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Guo S, Yu C, Feng S, Wei J, Tong L, Li K, Gao Y, Zhao P, Li T, Chen M, Han D, Gong J. Enabling the drug combination of celecoxib through a spherical co-agglomeration strategy with controllable and stable drug content and good powder properties. Int J Pharm 2022; 626:122180. [PMID: 36087627 DOI: 10.1016/j.ijpharm.2022.122180] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/22/2022] [Revised: 08/26/2022] [Accepted: 09/02/2022] [Indexed: 02/05/2023]
Abstract
Combining celecoxib with other chemopreventive drugs is a promising method of chemoprevention for cancer, especially for colorectal cancer. However, the traditional drug combination approaches are restricted with high-cost apparatus, complex and numerous unit operations. This work aims to develop an efficient spherical co-agglomeration strategy for celecoxib in combination with lovastatin, which can achieve drug combination in a single crystallization unit. The ternary solvent system was determined based on molecular simulation, and then a stable spherical agglomeration process was developed through the design of molar fraction of anti-solvent (MFA) and stirring rate to produce spherical agglomerates with high sphericity (84.2-89.9 %) and narrow size distribution. On this basis, celecoxib-benzoic acid spherical co-agglomerates were designed to form a complete spherical co-agglomeration strategy, which includes solvent system selection, spherical agglomeration and spherical co-agglomeration. Finally, celecoxib-lovastatin spherical co-agglomerates with synergistic efficacy were successfully produced by this strategy, with controllable and stable drug content (fluctuation < 2.7 %), good powder properties, and improved tabletability.
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Affiliation(s)
- Shilin Guo
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China
| | - Changyou Yu
- Institute of Shaoxing, Tianjin University, Zhejiang 312300, China
| | - Shanshan Feng
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China
| | - Jiahao Wei
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China
| | - Li Tong
- Institute of Shaoxing, Tianjin University, Zhejiang 312300, China
| | - Kangli Li
- Institute of Shaoxing, Tianjin University, Zhejiang 312300, China
| | - Ye Gao
- Institute of Shaoxing, Tianjin University, Zhejiang 312300, China
| | - Pengwei Zhao
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China
| | - Tao Li
- Institute of Shaoxing, Tianjin University, Zhejiang 312300, China
| | - Mingyang Chen
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China; Institute of Shaoxing, Tianjin University, Zhejiang 312300, China.
| | - Dandan Han
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China.
| | - Junbo Gong
- State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, China; Haihe Laboratory of Sustainable Chemical Transformations, Tianjin 300192, China; Chemistry and Chemical Engineering Guangdong Laboratory, Shantou 515031, China; Institute of Shaoxing, Tianjin University, Zhejiang 312300, China
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5
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Asgarpour Khansary M, Shirazian S, Walker G. A molecularly enhanced proof of concept for targeting cocrystals at molecular scale in continuous pharmaceuticals cocrystallization. Proc Natl Acad Sci U S A 2022; 119:e2114277119. [PMID: 35594395 PMCID: PMC9173768 DOI: 10.1073/pnas.2114277119] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/05/2021] [Accepted: 12/09/2021] [Indexed: 11/18/2022] Open
Abstract
It is impossible to optimize a process for a target drug product with the desired profile without a proper understanding of the interplay among the material attributes, the process parameters, and the attributes of the drug product. There is a particular need to bridge the micro- and mesoscale events that occur during this process. Here, we propose а molecular engineering methodology for the continuous cocrystallization process, based on Raman spectra measured experimentally with a probe and from quantum mechanical calculations. Using molecular dynamics simulations, the theoretical Raman spectra were calculated from first principles for local mixture structures under an external shear force at various temperatures. A proof of concept is developed to build the process design space from the computed data. We show that the determined process design space provides valuable insight for optimizing the cocrystallization process at the nanoscale, where experimental measurements are difficult and/or inapplicable. The results suggest that our method may be used to target cocrystallization processes at the molecular scale for improved pharmaceutical synthesis.
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Affiliation(s)
| | - Saeed Shirazian
- Department of Chemical Science, Bernal Institute, University of Limerick, Limerick, V94 T9PX Ireland
| | - Gavin Walker
- Synthesis and Solid State Pharmaceutical Centre, Bernal Institute, University of Limerick, Limerick, V94 T9PX Ireland
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6
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Singh M, Shirazian S, Ranade V, Walker GM, Kumar A. Challenges and opportunities in modelling wet granulation in pharmaceutical industry – A critical review. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117380] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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7
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A critical review on granulation of pharmaceuticals and excipients: Principle, analysis and typical applications. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117329] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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8
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Koide T, Hiyama Y. Analysis of Over-Granulated Particles using Near-Infrared Chemical Imaging and Attenuated Total Reflectance-Infrared Techniques. Int J Pharm 2022. [PMID: 35202724 DOI: 10.1016/j.ijpharm.2022.121607] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
Abstract
To elucidate the previously described mechanism of segregation caused by over-granulation, we analyzed over-granulated particles using the techniques of near-infrared chemical imaging (NIR-CI) and attenuated total reflectance infrared (ATR-IR). The same area of over-granulated particles was measured using both techniques. The distributions of the active ingredient, ethenzamide, and other additives in the over-granulated particles were compared. As ATR-IR chemical imaging easily identifies components and has higher spatial resolution than NIR-CI, it permitted a clearer observation of the distribution of ingredients, particularly in fine cornstarch particles. Using both techniques, segregation of components were observed as previously reported. Although lactose was barely observed in the ethenzamide-enriched regions, ethenzamide and cornstarch were observed in lactose-enriched regions. This suggests that only lactose aggregated and segregated from the other compounds during the process of granulation. Hydrophilic lactose aggregation is supposedly caused by the behavior of water during granulation. In conclusion, ATR-IR chemical imaging is an excellent analytical technique for obtaining the detailed distribution of components. Furthermore, fusion of ATR-IR chemical imaging and NIR-CI is a useful tool for understanding drug manufacturing processes and may be applicable to pharmaceutical manufacturing and quality control.
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Affiliation(s)
- Tatsuo Koide
- Division of Drugs, National Institute of Health Sciences, Tonomachi, Kawasaki-ku, Kawasaki, 210-9501, Japan.
| | - Yukio Hiyama
- Division of Drugs, National Institute of Health Sciences, Tonomachi, Kawasaki-ku, Kawasaki, 210-9501, Japan
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9
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Chen P, Ansari MJ, Bokov D, Suksatan W, Rahman ML, Sarjadi MS. A review on key aspects of wet granulation process for continuous pharmaceutical manufacturing of solid dosage oral formulations. ARAB J CHEM 2022. [DOI: 10.1016/j.arabjc.2021.103598] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022] Open
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10
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Kristó K, Csík E, Sebők D, Kukovecz Á, Sovány T, Regdon G, Csóka I, Penke B, Pintye-Hódi K. Effects of the controlled temperature in the production of high-shear granulated protein-containing granules. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.10.003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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11
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Bellinghausen S, Gavi E, Jerke L, Barrasso D, Salman AD, Litster JD. Model-driven design using population balance modelling for high-shear wet granulation. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.10.028] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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12
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Sacher S, Poms J, Rehrl J, Khinast JG. PAT implementation for advanced process control in solid dosage manufacturing - A practical guide. Int J Pharm 2021; 613:121408. [PMID: 34952147 DOI: 10.1016/j.ijpharm.2021.121408] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2021] [Revised: 12/10/2021] [Accepted: 12/16/2021] [Indexed: 01/14/2023]
Abstract
The implementation of continuous pharmaceutical manufacturing requires advanced control strategies rather than traditional end product testing or an operation within a small range of controlled parameters. A high level of automation based on process models and hierarchical control concepts is desired. The relevant tools that have been developed and successfully tested in academic and industrial environments in recent years are now ready for utilization on the commercial scale. To date, the focus in Process Analytical Technology (PAT) has mainly been on achieving process understanding and quality control with the ultimate goal of real-time release testing (RTRT). This work describes the workflow for the development of an in-line monitoring strategy to support PAT-based real-time control actions and its integration into solid dosage manufacturing. All stages are discussed in this paper, from process analysis and definition of the monitoring task to technology assessment and selection, its process integration and the development of data acquisition.
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Affiliation(s)
- Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria.
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Johannes G Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
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13
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Liu B, Wang J, Zhou Q, Zhao L, Wang Y, Shen L, Feng Y, Du R. High shear wet granulation: Improved understanding of the effects of process variables on granule and tablet properties of a high-dose, high-hydrophobicity API based on quality by design and multivariate analysis approaches. ADV POWDER TECHNOL 2021. [DOI: 10.1016/j.apt.2021.11.021] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/01/2022]
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14
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Investigation the iron ore fine granulation effects and particle adhesion behavior in a horizontal high-shear granulator. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.08.047] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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15
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Sansare S, Aziz H, Sen K, Patel S, Chaudhuri B. Computational Modeling of Fluidized Beds with a Focus on Pharmaceutical Applications: A Review. J Pharm Sci 2021; 111:1110-1125. [PMID: 34555391 DOI: 10.1016/j.xphs.2021.09.020] [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: 04/16/2021] [Revised: 09/10/2021] [Accepted: 09/10/2021] [Indexed: 11/29/2022]
Abstract
The fluidized bed is an essential and standard equipment in the field of process development. It has a wide application in various areas and has been extensively studied. This review paper aims to discuss computational modeling of a fluidized bed with a focus on pharmaceutical applications. Eulerian, Lagrangian, and combined Eulerian-Lagrangian models have been studied for fluid bed applications with the rise of modeling capabilities. Such models assist in optimizing the process parameters and expedite the process development cycle. This paper discusses the background of modeling and then summarizes research papers relevant to pharmaceutical unit operations.
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Affiliation(s)
- Sameera Sansare
- Department of Pharmaceutical Sciences, University of Connecticut, Storrs, CT 06269, USA
| | - Hossain Aziz
- Department of Physiology and Neurobiology, University of Connecticut, Storrs, CT 06269, USA
| | - Koyel Sen
- Department of Pharmaceutical Sciences, University of Connecticut, Storrs, CT 06269, USA
| | - Shivangi Patel
- Department of Physiology and Neurobiology, University of Connecticut, Storrs, CT 06269, USA
| | - Bodhisattwa Chaudhuri
- Department of Pharmaceutical Sciences, University of Connecticut, Storrs, CT 06269, USA; Institute of Material Sciences, University of Connecticut, Storrs, CT 06269, USA; Department of Chemical and Biomolecular Engineering, University of Connecticut, Storrs, CT 06269, USA.
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16
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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.
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17
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Kumar A, Radl S, Gernaey KV, De Beer T, Nopens I. Particle-Scale Modeling to Understand Liquid Distribution in Twin-Screw Wet Granulation. Pharmaceutics 2021; 13:pharmaceutics13070928. [PMID: 34206609 PMCID: PMC8308998 DOI: 10.3390/pharmaceutics13070928] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/10/2021] [Revised: 06/10/2021] [Accepted: 06/15/2021] [Indexed: 11/24/2022] Open
Abstract
Experimental characterization of solid-liquid mixing for a high shear wet granulation process in a twin-screw granulator (TSG) is very challenging. This is due to the opacity of the multiphase system and high-speed processing. In this study, discrete element method (DEM) based simulations are performed for a short quasi-two-dimensional simulation domain, incorporating models for liquid bridge formation, rupture, and the effect of the bridges on inter-particular forces. Based on the knowledge gained from these simulations, the kneading section of a twin-screw wet granulation process was simulated. The time evolution of particle flow and liquid distribution between particles, leading to the formation of agglomerates, was analyzed. The study showed that agglomeration is a rather delayed process that takes place once the free liquid on the particle surface is well distributed.
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Affiliation(s)
- Ashish Kumar
- Pharmaceutical Engineering Research Group (PharmaEng), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg, B-9000 Ghent, Belgium
- Correspondence: ; Tel.: +32-(0)-9-264-80-91
| | - Stefan Radl
- Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria;
| | - Krist V. Gernaey
- Process and Systems Engineering Center (PROSYS), Department of Chemical and Biochemical Engineering, Technical University of Denmark, 2800 Kongens Lyngby, Denmark;
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg, B-9000 Ghent, Belgium;
| | - Ingmar Nopens
- BIOMATH, Department of Mathematical Modelling, Statistics and Bioinformatics, Faculty of Bioscience Engineering, Ghent University, Coupure Links 653, B-9000 Ghent, Belgium;
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18
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19
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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.
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Affiliation(s)
| | | | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium; (C.P.); (C.V.)
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20
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Liu B, Wang J, Zeng J, Zhao L, Wang Y, Feng Y, Du R. A review of high shear wet granulation for better process understanding, control and product development. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.11.051] [Citation(s) in RCA: 16] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022]
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21
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Shi G, Lin L, Liu Y, Chen G, Luo Y, Wu Y, Li H. Pharmaceutical application of multivariate modelling techniques: a review on the manufacturing of tablets. RSC Adv 2021; 11:8323-8345. [PMID: 35423324 PMCID: PMC8695199 DOI: 10.1039/d0ra08030f] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/20/2020] [Accepted: 01/26/2021] [Indexed: 11/21/2022] Open
Abstract
The tablet manufacturing process is a complex system, especially in continuous manufacturing (CM). It includes multiple unit operations, such as mixing, granulation, and tableting. In tablet manufacturing, critical quality attributes are influenced by multiple factorial relationships between material properties, process variables, and interactions. Moreover, the variation in raw material attributes and manufacturing processes is an inherent characteristic and seriously affects the quality of pharmaceutical products. To deepen our understanding of the tablet manufacturing process, multivariable modeling techniques can replace univariate analysis to investigate tablet manufacturing. In this review, the roles of the most prominent multivariate modeling techniques in the tablet manufacturing process are discussed. The review mainly focuses on applying multivariate modeling techniques to process understanding, optimization, process monitoring, and process control within multiple unit operations. To minimize the errors in the process of modeling, good modeling practice (GMoP) was introduced into the pharmaceutical process. Furthermore, current progress in the continuous manufacturing of tablets and the role of multivariate modeling techniques in continuous manufacturing are introduced. In this review, information is provided to both researchers and manufacturers to improve tablet quality.
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Affiliation(s)
- Guolin Shi
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Longfei Lin
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Yuling Liu
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Gongsen Chen
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Yuting Luo
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Yanqiu Wu
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Hui Li
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
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22
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Baba T, Nakamura H, Takimoto H, Ohsaki S, Watano S, Takehara K, Higuchi T, Hirosawa T, Yamamoto T. DEM–PBM coupling method for the layering granulation of iron ore. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.09.059] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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23
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Mathe R, Casian T, Tomuţă I. Multivariate feed forward process control and optimization of an industrial, granulation based tablet manufacturing line using historical data. Int J Pharm 2020; 591:119988. [PMID: 33080308 DOI: 10.1016/j.ijpharm.2020.119988] [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: 06/15/2020] [Revised: 10/10/2020] [Accepted: 10/12/2020] [Indexed: 10/23/2022]
Abstract
The purpose of this work was to understand the variability in disintegration time and tableting yield of high drug load (>60%) tablets prepared by batch-wise high shear wet granulation. The novelty of the study is the use of multivariate methods (Batch Evolution Models - BEMs and Batch Level Models - BLMs) to enhance process control, with a feed forward component, using prediction models built from a historical dataset acquired for 95 industrial scale batches. Time dependent process variables and significant influences on investigated parameters were identified. Prediction of output from input was tested with Partial Least Squares (PLS) and Artificial Neural Network (ANN) modeling. A reliable prediction ability was achieved for granulation water amount (±2 kg in a 16-31 kg range), tableting speed (±5000 tablets/h in a 23,000-72,500 tabl./h range) and disintegration time of cores (±100 s; in a 250-900 s range). Offsets from the optimal process evolution and certain raw material properties were correlated with differences observed in the output variables. Improvement options were identified for 80% of the batches with high disintegration time. Hence, the trained models can be applied for systematic process improvement, enabling feed forward control.
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Affiliation(s)
- Rita Mathe
- Department of Pharmaceutical Technology and Biopharmacy, "Iuliu Hatieganu" University of Medicine and Pharmacy, 400012 Cluj-Napoca, Romania
| | - Tibor Casian
- Department of Pharmaceutical Technology and Biopharmacy, "Iuliu Hatieganu" University of Medicine and Pharmacy, 400012 Cluj-Napoca, Romania.
| | - Ioan Tomuţă
- Department of Pharmaceutical Technology and Biopharmacy, "Iuliu Hatieganu" University of Medicine and Pharmacy, 400012 Cluj-Napoca, Romania
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24
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Singh M, Kumar A, Shirazian S, Ranade V, Walker G. Characterization of Simultaneous Evolution of Size and Composition Distributions Using Generalized Aggregation Population Balance Equation. Pharmaceutics 2020; 12:pharmaceutics12121152. [PMID: 33260899 PMCID: PMC7760032 DOI: 10.3390/pharmaceutics12121152] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/19/2020] [Revised: 11/19/2020] [Accepted: 11/24/2020] [Indexed: 11/16/2022] Open
Abstract
The application of multi-dimensional population balance equations (PBEs) for the simulation of granulation processes is recommended due to the multi-component system. Irrespective of the application area, numerical scheme selection for solving multi-dimensional PBEs is driven by the accuracy in (size) number density prediction alone. However, mixing the components, i.e., the particles (excipients and API) and the binding liquid, plays a crucial role in predicting the granule compositional distribution during the pharmaceutical granulation. A numerical scheme should, therefore, be able to predict this accurately. Here, we compare the cell average technique (CAT) and finite volume scheme (FVS) in terms of their accuracy and applicability in predicting the mixing state. To quantify the degree of mixing in the system, the sum-square χ2 parameter is studied to observe the deviation in the amount binder from its average. It has been illustrated that the accurate prediction of integral moments computed by the FVS leads to an inaccurate prediction of the χ2 parameter for a bicomponent population balance equation. Moreover, the cell average technique (CAT) predicts the moments with moderate accuracy; however, it computes the mixing of components χ2 parameter with higher precision than the finite volume scheme. The numerical testing is performed for some benchmarking kernels corresponding to which the analytical solutions are available in the literature. It will be also shown that both numerical methods equally well predict the average size of the particles formed in the system; however, the finite volume scheme takes less time to compute these results.
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Affiliation(s)
- Mehakpreet Singh
- Department of Chemical Sciences, Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland; (S.S.); (V.R.); (G.W.)
- Correspondence:
| | - Ashish Kumar
- Pharmaceutical Engineering, Faculty of Pharmaceutical Sciences, Ghent University, 9000 Gent, Belgium;
| | - Saeed Shirazian
- Department of Chemical Sciences, Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland; (S.S.); (V.R.); (G.W.)
- Laboratory of Computational Modeling of Drugs, South Ural State University, 76 Lenin Prospekt, 454080 Chelyabinsk, Russia
| | - Vivek Ranade
- Department of Chemical Sciences, Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland; (S.S.); (V.R.); (G.W.)
| | - Gavin Walker
- Department of Chemical Sciences, Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland; (S.S.); (V.R.); (G.W.)
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25
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Converting a batch based high-shear granulation process to a continuous dry granulation process; a demonstration with ketoprofen tablets. Eur J Pharm Sci 2020; 151:105381. [PMID: 32464174 DOI: 10.1016/j.ejps.2020.105381] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/23/2019] [Revised: 04/29/2020] [Accepted: 05/13/2020] [Indexed: 11/22/2022]
Abstract
When one wishes to convert a batch based manufacturing process of an existing tablet product to a continuous process, there are several available strategies which can be adopted. Theoretically, the most straightforward way would be to proceed with the corresponding processing principles, for example to change a wet granulation (WG) batch process into its continuous WG counterpart. However, in some cases, the choice of roller compaction (RC) could be very attractive due to the notably simpler and inherently continuous nature of the RC manufacturing principle. The aim of this study was to examine a process conversion from batch based high-shear wet granulation (HSWG) to continuous RC manufacturing, without any significant formulation changes. An optimization of the formulation is often needed during the process conversion. However, our primary goal was to demonstrate the possibilities to perform this kind of process adaptation with minimal formulation changes. Furthermore, the effect of three different locations of lubrication feeding with two production rate levels was studied. An additional target was to identify possible over-lubrication with these manufacturing configurations, and to clarify which of these three possibilities steps produced a final product that conformed to the same quality requirements as HSWG tablets. Previously, the effects of lubrication only on compacted ribbons (Miguelez-Moran A.M, 2008) and final product with CDC (continuous direct compression) (Taipale-Kovalainen, et al., 2017; 2019) have been investigated. Here, the effect of lubrication on both ribbon and on final product was examined. No signs of over-lubrication were observed, but there was a clear effect of the feeding location of lubricant on the final product. On the basis of these results, it is concluded that in the future, if a good product/process understanding of the alternative manufacturing process with different techniques can be obtained, it will be possible to devise more flexible and effective ways to allow the pharmaceutical industry to switch from batch manufacturing towards CM.
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26
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Chromatography bioseparation technologies and in-silico modelings for continuous production of biotherapeutics. J Chromatogr A 2020; 1627:461376. [PMID: 32823091 DOI: 10.1016/j.chroma.2020.461376] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/06/2020] [Revised: 06/22/2020] [Accepted: 06/28/2020] [Indexed: 12/23/2022]
Abstract
The potential of continuous bioprocessing is hindered by the bottlenecks of chromatography processing, which continues to be executed in batch mode. Highlighting the critical drawbacks of batch chromatography, this review underscores the transition that the industry has made by implementing continuous upstream process without devising a working model for downstream chromatography operations. Even though multitude of process development initiatives have commenced, the review emphasizes the first principle models of chromatography on which these initiatives are built. Various models of continuous chromatography, which are essential, but not limited to multi-column systems, employed to congeal a unified process are reviewed. Advancements made by several mechanistic models and simulations to maximize productivity and performance are described, in an attempt to provide the integral tools. The modeling tools can be used for development of a strong model based control strategy and can be embedded into the continuous chromatography framework. The review addresses the limitations and challenges of the current modeling methods for development of robust mechanistic modeling and efficient unit operation platform in continuous chromatography.
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27
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Park MS, Choi DH. Application of mechanism-based modeling to predict drug quality during the pharmaceutical unit operations of granulation and compression: a review. JOURNAL OF PHARMACEUTICAL INVESTIGATION 2020. [DOI: 10.1007/s40005-020-00489-6] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/21/2023]
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28
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High shear seeded granulation: Its preparation mechanism, formulation, process, evaluation, and mathematical simulation. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.03.020] [Citation(s) in RCA: 12] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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29
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Portier C, Vigh T, Di Pretoro G, De Beer T, Vervaet C, Vanhoorne V. Continuous twin screw granulation: Impact of binder addition method and surfactants on granulation of a high-dosed, poorly soluble API. Int J Pharm 2020; 577:119068. [DOI: 10.1016/j.ijpharm.2020.119068] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/16/2019] [Revised: 01/14/2020] [Accepted: 01/17/2020] [Indexed: 10/25/2022]
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30
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Compartmental approach for modelling twin-screw granulation using population balances. Int J Pharm 2020; 576:118737. [DOI: 10.1016/j.ijpharm.2019.118737] [Citation(s) in RCA: 26] [Impact Index Per Article: 6.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/08/2019] [Revised: 09/20/2019] [Accepted: 09/25/2019] [Indexed: 11/22/2022]
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31
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Continuous twin screw granulation: A complex interplay between formulation properties, process settings and screw design. Int J Pharm 2020; 576:119004. [DOI: 10.1016/j.ijpharm.2019.119004] [Citation(s) in RCA: 32] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/02/2019] [Revised: 12/23/2019] [Accepted: 12/26/2019] [Indexed: 11/19/2022]
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32
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Continuous twin screw granulation: Influence of process and formulation variables on granule quality attributes of model formulations. Int J Pharm 2020; 576:118981. [PMID: 31935472 DOI: 10.1016/j.ijpharm.2019.118981] [Citation(s) in RCA: 25] [Impact Index Per Article: 6.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/25/2019] [Revised: 12/17/2019] [Accepted: 12/17/2019] [Indexed: 11/21/2022]
Abstract
In recent years, continuous manufacturing techniques, such as twin screw wet granulation, have gained significant momentum. Due to the large diversity of the (model) formulations and equipment, it is often difficult to generalize conclusions about the importance of process settings. As only limited knowledge is available on the importance of formulation variables, this study focused on the systematic quantification of both process as formulation effects on critical quality attributes of granules from several model formulations. Apart from conventional process and formulation variables, also non-conventional process factors such as nozzle diameter, nozzle orientation and inclusion of a new type of size control elements were evaluated using a Plackett-Burman screening design. Although effects were often formulation-dependent, liquid-to-solid ratio proved the most influential variable for all formulations. Furthermore, binder concentration had a clear effect on granule characteristics, whereas barrel fill level and barrel temperature were less influential. The novel type of size control elements improved granule size distribution and density. The impact of nozzle diameter and wet binder addition proved negligible towards granule properties. Overall it was apparent that lactose/MCC-based formulations correlated better than lactose-based formulations, indicating the possible process robustness of the first filler combination to accommodate API and excipient variability and to handle APIs with different characteristics.
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33
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Tanaka R, Duggirala NK, Hattori Y, Otsuka M, Suryanarayanan R. Formation of Indomethacin-Saccharin Cocrystals during Wet Granulation: Role of Polymeric Excipients. Mol Pharm 2019; 17:274-283. [PMID: 31756100 DOI: 10.1021/acs.molpharmaceut.9b01004] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/08/2023]
Abstract
Formulation of a cocrystal into a solid pharmaceutical dosage form entails numerous processing steps during which there is risk of dissociation. In an effort to reduce the number of unit operations, we have attempted the in situ formation of an indomethacin-saccharin (INDSAC) cocrystal during high-shear wet granulation (HSWG). HSWG of IND (poorly water-soluble drug) and SAC (coformer), with polymers (granulating agents), was carried out using ethanol as the granulation liquid and yielded INDSAC cocrystal granules. Therefore, cocrystal formation and granulation were simultaneously accomplished. Our objectives were to (i) evaluate the influence of polymers on cocrystal formation kinetics during wet granulation and (ii) mechanistically understand the role of polymers in facilitating the cocrystal formation. Polyvinylpyrrolidone (PVP), hydroxypropyl cellulose (HPC), and polyethylene oxide (PEO) were chosen to investigate the influence of soluble polymers. The cocrystal formation kinetics was influenced by the polymer (PVP < HPC < PEO) and its concentration. The interaction of the polymer with cocrystal components inhibited the cocrystal formation. Complete cocrystal formation was observed in the presence of PEO, a polymer which does not interact with IND and SAC.
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Affiliation(s)
- Ryoma Tanaka
- Department of Pharmaceutics, College of Pharmacy , University of Minnesota , Minneapolis , Minnesota 55455 , United States
| | - Naga Kiran Duggirala
- Department of Pharmaceutics, College of Pharmacy , University of Minnesota , Minneapolis , Minnesota 55455 , United States
| | | | | | - Raj Suryanarayanan
- Department of Pharmaceutics, College of Pharmacy , University of Minnesota , Minneapolis , Minnesota 55455 , United States
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34
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35
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Stauffer F, Ryckaert A, Van Hauwermeiren D, Funke A, Djuric D, Nopens I, De Beer T. Heat Transfer Evaluation During Twin-Screw Wet Granulation in View of Detailed Process Understanding. AAPS PharmSciTech 2019; 20:291. [PMID: 31428889 DOI: 10.1208/s12249-019-1483-z] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/12/2019] [Accepted: 07/16/2019] [Indexed: 11/30/2022] Open
Abstract
During the last decade, the pharmaceutical industry has shown a growing interest in continuous twin-screw granulation (TSG). Despite flourishing literature on TSG, limited studies focused on fundamental process understanding on its mechanisms. In current study, granule quality attributes along the length of the TSG barrel were evaluated together with heat transfer in order to achieve a more fundamental understanding of the granulation process. An experimental setup was developed allowing the collection of granules at the different TSG compartments. In addition to the determination of typical granule attributes, mechanical energy, barrel and granule temperature (measured using an in-line implemented infra-red camera) were measured to evaluate heat transfer occurring at the different compartments and to relate them to granulation mechanisms. Collected data identified wetting enthalpy and friction forces as the main sources of heat along the granulator length. Wetting occurred in the wetting zone and generated temperature increase depending on liquid-to-solid ratio and powder wettability. In the kneading zones, granule temperature increase was proportional to mechanical energy. While it is usually admitted that granule consolidation and reshaping are the consequence of the high shear experienced by the granules, it was highlighted that most of the mechanical energy is converted into thermal energy with no correlation between mechanical energy and granule size distribution. Combined mass and energy balance of the granulation process are therefore necessary to capture the interaction between granule properties and physico-chemical and mechanical phenomena occurring in each compartment.
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36
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Yeom SB, Ha ES, Kim MS, Jeong SH, Hwang SJ, Choi DH. Application of the Discrete Element Method for Manufacturing Process Simulation in the Pharmaceutical Industry. Pharmaceutics 2019; 11:E414. [PMID: 31443327 PMCID: PMC6723742 DOI: 10.3390/pharmaceutics11080414] [Citation(s) in RCA: 35] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/08/2019] [Revised: 08/10/2019] [Accepted: 08/12/2019] [Indexed: 12/15/2022] Open
Abstract
Process simulation using mathematical modeling tools is becoming more common in the pharmaceutical industry. A mechanistic model is a mathematical modeling tool that can enhance process understanding, reduce experimentation cost and improve product quality. A commonly used mechanistic modeling approach for powder is the discrete element method (DEM). Most pharmaceutical materials have powder or granular material. Therefore, DEM might be widely applied in the pharmaceutical industry. This review focused on the basic elements of DEM and its implementations in pharmaceutical manufacturing simulation. Contact models and input parameters are essential elements in DEM simulation. Contact models computed contact forces acting on the particle-particle and particle-geometry interactions. Input parameters were divided into two types-material properties and interaction parameters. Various calibration methods were presented to define the interaction parameters of pharmaceutical materials. Several applications of DEM simulation in pharmaceutical manufacturing processes, such as milling, blending, granulation and coating, were categorized and summarized. Based on this review, DEM simulation might provide a systematic process understanding and process control to ensure the quality of a drug product.
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Affiliation(s)
- Su Bin Yeom
- Department of Pharmaceutical Engineering, Inje University, Gyeongnam 621-749, Korea
| | - Eun-Sol Ha
- College of Pharmacy, Pusan National University, Busandaehak-ro 63 beon-gil, Geumjeong-gu, Busan 46241, Korea
| | - Min-Soo Kim
- College of Pharmacy, Pusan National University, Busandaehak-ro 63 beon-gil, Geumjeong-gu, Busan 46241, Korea.
| | | | - Sung-Joo Hwang
- College of Pharmacy, Yonsei University, 85 Songdogwahak-ro, Yeonsu-gu, Incheon 21983, Korea
| | - Du Hyung Choi
- Department of Pharmaceutical Engineering, Inje University, Gyeongnam 621-749, Korea.
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37
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Analysing the effect of screw configuration using a stochastic twin-screw granulation model. Chem Eng Sci 2019. [DOI: 10.1016/j.ces.2019.03.078] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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38
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Dahlgren G, Tajarobi P, Simone E, Ricart B, Melnick J, Puri V, Stanton C, Bajwa G. Continuous Twin Screw Wet Granulation and Drying-Control Strategy for Drug Product Manufacturing. J Pharm Sci 2019; 108:3502-3514. [PMID: 31276686 DOI: 10.1016/j.xphs.2019.06.023] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/03/2018] [Revised: 06/16/2019] [Accepted: 06/26/2019] [Indexed: 01/28/2023]
Abstract
The use of continuous manufacturing has been increasing within the pharmaceutical industry over the last few years. Continuous direct compression has been the focus of publications on the topic to date. The use of wet granulation can improve segregation resistance, uniformity, enhance density, and flow properties for improved tabletability, or improve stability of products that cannot be manufactured by using a direction compression process. This article focuses on development of appropriate control strategies for continuous wet granulation (especially twin screw wet granulation) through equipment design, material properties and manufacturing process along with areas where additional understanding is required. The article also discusses the use of process analytical technologies as part of the control and automation approach to ensure a higher assurance of product quality. Increased understanding of continuous wet granulation should result in increased utilization of the technique, thereby allowing for an increase in diversity of products manufactured by continuous manufacturing and the benefits that comes with a more complex process such as wet granulation compared with direct compression process.
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Affiliation(s)
| | | | - Eric Simone
- Agios Pharmaceuticals Inc., Cambridge, Massachusetts 02139
| | | | | | - Vibha Puri
- Genentech, Inc., San Francisco, California 94080
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39
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Han JK, Shin BS, Choi DH. Comprehensive Study of Intermediate and Critical Quality Attributes for Process Control of High-Shear Wet Granulation Using Multivariate Analysis and The Quality by Design Approach. Pharmaceutics 2019; 11:E252. [PMID: 31159393 PMCID: PMC6630614 DOI: 10.3390/pharmaceutics11060252] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/22/2019] [Revised: 05/19/2019] [Accepted: 05/30/2019] [Indexed: 12/26/2022] Open
Abstract
A robust manufacturing process and the relationship between intermediate quality attributes (IQAs), critical quality attributes (CQAs), and critical process parameters (CPPs) for high-shear wet granulation was determined in this study. Based on quality by the design (QbD) approach, IQAs, CQAs, and CPPs of a telmisartan tablet prepared by high-shear wet granulation were determined and then analyzed with multivariate analysis (MVA) to evaluate mutual interactions between IQAs, CQAs, and CPPs. The effects of the CPPs on the IQAs and CQAs were quantitatively predicted with empirical models of best fit. The models were used to define operating space, and an evaluation of the risk of uncertainty in model prediction was performed using Monte Carlo simulation. MVA showed that granule size and granule hardness were significantly related to % dissolution. In addition, granule FE (Flow Energy) and Carr's index had effects on tablet tensile strength. Using the manufacture of a clinical batch and robustness testing, a scale-up from lab to pilot scale was performed using geometric similarity, agitator torque profile, and agitator tip speed. The absolute biases and relative bias percentages of the IQAs and CQAs generated by the lab and pilot scale process exhibited small differences. Therefore, the results suggest that a risk reduction in the manufacturing process can be obtained with integrated process parameters as a result of the QbD approach, and the relationship between IQAs, CQAs, and CPPs can be used to predict CQAs for a control strategy and SUPAC (Scale-Up and Post-Approval Guidance).
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Affiliation(s)
- Jong Kwon Han
- School of Pharmacy, Sungkyunkwan University, Suwon 440-746, Korea.
| | - Beom Soo Shin
- School of Pharmacy, Sungkyunkwan University, Suwon 440-746, Korea.
| | - Du Hyung Choi
- Department of Pharmaceutical Engineering, Inje University, Gyeongnam 621-749, Korea.
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40
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Ismail HY, Singh M, Darwish S, Kuhs M, Shirazian S, Croker DM, Khraisheh M, Albadarin AB, Walker GM. Developing ANN-Kriging hybrid model based on process parameters for prediction of mean residence time distribution in twin-screw wet granulation. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.11.060] [Citation(s) in RCA: 49] [Impact Index Per Article: 9.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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41
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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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42
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Cai R, Xu L, Zheng J, Zhao Y. Modified cell-linked list method using dynamic mesh for discrete element method. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.09.034] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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43
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Schmidt A, de Waard H, Moll KP, Kleinebudde P, Krumme M. Simplified end-to-end continuous manufacturing by feeding API suspensions in twin-screw wet granulation. Eur J Pharm Biopharm 2018; 133:224-231. [PMID: 30291963 DOI: 10.1016/j.ejpb.2018.09.026] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/03/2018] [Revised: 09/25/2018] [Accepted: 09/25/2018] [Indexed: 11/26/2022]
Abstract
This study focussed on investigating the coupling of continuous manufacturing of drug substance and continuous manufacture of drug product. An important step in such an integrated end-to-end continuous manufacturing was envisioned by dosing the API as suspension into a twin-screw wet granulation process. To achieve this goal, a model drug substance (ibuprofen) was fed as a concentrated aqueous suspension (50% w/w) into a twin-screw granulator and compared against traditional solid feeding of the model drug substance to meet a target ibuprofen load of 60% w/w in the formulation. Granulation and compaction behaviour were evaluated to determine the impact of feeding API as suspension in twin-screw wet granulation on the critical quality attributes of the drug product. It was demonstrated that the ibuprofen suspension feed is comparable with the ibuprofen dry blend feed in twin-screw wet granulation. Next to enabling end-to-end continuous manufacturing, API suspension feed in twin-screw wet granulation could afford a number of additional advantages including manufacturing efficiency by removing the drying step for API, or overcoming processing issues linked to the bulk properties of the API powder (e.g. flowability).
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Affiliation(s)
- Adrian Schmidt
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, 40225 Duesseldorf, Germany; Novartis AG, Novartis Campus, 4002 Basel, Switzerland
| | - Hans de Waard
- Novartis AG, Novartis Campus, 4002 Basel, Switzerland
| | | | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, 40225 Duesseldorf, Germany
| | - Markus Krumme
- Novartis AG, Novartis Campus, 4002 Basel, Switzerland.
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44
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McGuire AD, Mosbach S, Lee KF, Reynolds G, Kraft M. A high-dimensional, stochastic model for twin-screw granulation Part 2: Numerical methodology. Chem Eng Sci 2018. [DOI: 10.1016/j.ces.2018.04.077] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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45
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Multivariate modeling to evaluate effect of fabricating process on product profile of high shear granulation. CHINESE HERBAL MEDICINES 2018. [DOI: 10.1016/j.chmed.2018.07.005] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022] Open
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46
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Multivariate monitoring for the industrialisation of a continuous wet granulation tableting process. Int J Pharm 2018; 547:506-519. [DOI: 10.1016/j.ijpharm.2018.06.034] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2018] [Revised: 06/11/2018] [Accepted: 06/12/2018] [Indexed: 11/18/2022]
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Ko SJ, Lee JH, Kang CY, Park JB. Granulation development in batch-to-batch and continuous processes from a quality by design perspective. J Drug Deliv Sci Technol 2018. [DOI: 10.1016/j.jddst.2018.04.012] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Suresh P, Surasani VK, Sreedhar I. Investigations at an industrial scale on granule and tablet attributes in high shear rapid mixer granulator. PARTICULATE SCIENCE AND TECHNOLOGY 2018. [DOI: 10.1080/02726351.2017.1363840] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
Affiliation(s)
- Pathi Suresh
- Operational Excellence, Granules India Ltd, Gagillapur, Hyderabad, India
- Department of Chemical Engineering, BITS, Pilani-Hyderabad Campus, Hyderabad, India
| | | | - Inkollu Sreedhar
- Department of Chemical Engineering, BITS, Pilani-Hyderabad Campus, Hyderabad, India
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Shirazian S, Darwish S, Kuhs M, Croker DM, Walker GM. Regime-separated approach for population balance modelling of continuous wet granulation of pharmaceutical formulations. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2017.11.047] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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50
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Kumar R, Sarkar A, Ketterhagen W, Hancock B, Curtis J, Wassgren C. Influence of normal contact force model on simulations of spherocylindrical particles. AIChE J 2018. [DOI: 10.1002/aic.16082] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Rohit Kumar
- School of Mechanical Engineering; Purdue University; West Lafayette IN 47907-2088
| | - Avik Sarkar
- Worldwide Research and Development; Pfizer Inc.; Groton CT 06340
| | | | - Bruno Hancock
- Worldwide Research and Development; Pfizer Inc.; Groton CT 06340
| | - Jennifer Curtis
- College of Engineering; University of California at Davis; Davis CA 95616-5294
| | - Carl Wassgren
- School of Mechanical Engineering; Purdue University; West Lafayette IN 47907-2088
- Dept. of Industrial and Physical Pharmacy (by courtesy); Purdue University; West Lafayette IN 47907-2091
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