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Zou W, Liu W, Hu C. Characterization of enteric-coated erythromycin tablets by Raman mapping and its pharmaceutical evaluation. Front Chem 2023; 11:1270737. [PMID: 37920414 PMCID: PMC10619665 DOI: 10.3389/fchem.2023.1270737] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/01/2023] [Accepted: 10/09/2023] [Indexed: 11/04/2023] Open
Abstract
Enteric tablet coating thickness is a critical quality attribute of the coating process that can affect dissolution behavior in vitro as well as release in vivo. Raman mapping offers unique advantages in analyzing the distribution of active pharmaceutical ingredients and excipients in formulations. In this study, Raman mapping was used to characterize the coating of enteric-coated erythromycin tablets coated by two different processes and compare the differences in their coating formulation, thickness, and uniformity. Furthermore, we aimed to select the appropriate pH of the dissolution medium at which the coating slowly cracks to release the drug and determine the dissolution profile. The differences in the coating thickness and uniformity of the two products resulted in differences in dissolution behavior. Although there are differences in the coating processes for the two types of enteric-coated erythromycin tablets, the thickness of the outer coating on the side is a critical quality attribute in both processes. The outer coating of product A is relatively thick, and the thickness of the outer coating on the side affects the dissolution amount. The outer coating of product B is relatively thin, resulting in a short cracking time and large variation and a significant difference in the initial dissolution amounts between tablets. Raman mapping can be used to analyze the differences in coating formulations and for process evaluation.
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Affiliation(s)
- Wenbo Zou
- Key Laboratory of Molecular Pharmacology and Drug Evaluation (Yantai University), School of Pharmacy, Ministry of Education, Collaborative Innovation Center of Advanced Drug Delivery System and Biotech Drugs in Universities of Shandong, Yantai University, Yantai, China
- National Institutes for Food and Drug Control, Beijing, China
| | - Wanhui Liu
- Key Laboratory of Molecular Pharmacology and Drug Evaluation (Yantai University), School of Pharmacy, Ministry of Education, Collaborative Innovation Center of Advanced Drug Delivery System and Biotech Drugs in Universities of Shandong, Yantai University, Yantai, China
| | - Changqin Hu
- National Institutes for Food and Drug Control, Beijing, China
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2
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Sun Z, Zhang K, Lin B, Huang R, Yang X, Li S, Liang M, Nie L, Yin W, Wang H, Zhang H, Li L, Wu A, Zang H. Real-time in-line prediction of drug loading and release rate in the coating process of diclofenac sodium spheres based on near infrared spectroscopy. SPECTROCHIMICA ACTA. PART A, MOLECULAR AND BIOMOLECULAR SPECTROSCOPY 2023; 301:122952. [PMID: 37270976 DOI: 10.1016/j.saa.2023.122952] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/28/2022] [Revised: 05/09/2023] [Accepted: 05/29/2023] [Indexed: 06/06/2023]
Abstract
The preparation of diclofenac sodium spheres by fluidized bed is a common production mode for the pharmaceutical preparations at present, but the critical material attributes in the production process is mostly analyzed off-line, which is time-consuming and laborious, and the analysis results lag behind. In this paper, the real-time in-line prediction of drug loading of diclofenac sodium and the release rate during the coating process was realized by using near infrared spectroscopy. For the best near infrared spectroscopy (NIRS) model of drug loading, R2cv, R2p, RMSECV, RMSEP were 0.9874, 0.9973, 0.002549 mg/g, 0.001515 mg/g respectively. For the best NIRS model of three release time points, the R2cv, R2p, RMSECV and RMSEP were 0.9755, 0.9823, 3.233%, 4.500%; 0.9358, 0.9965, 2.598%, 0.7939% and 0.9867, 0.9927, 0.4085%, 0.4726% respectively. And the analytical ability of these model was verified. The organic combination of these two parts of work constituted an important basis for ensuring the safety and effectiveness of diclofenac sodium spheres from the perspective of production process.
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Affiliation(s)
- Zhongyu Sun
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Kefan Zhang
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Boran Lin
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Ruiqi Huang
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Xiangchun Yang
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Shuangshuang Li
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Mengying Liang
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Lei Nie
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Wenping Yin
- Shandong SMA Pharmatech Co., Ltd, Zibo, 255000, Shandong, China
| | - Hui Wang
- Shandong SMA Pharmatech Co., Ltd, Zibo, 255000, Shandong, China
| | - Hui Zhang
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Lian Li
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China; Key Laboratory of Chemical Biology (Ministry of Education), Shandong University, Jinan, 250012, Shandong, China
| | - Aoli Wu
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China
| | - Hengchang Zang
- NMPA Key Laboratory for Technology Research and Evaluation of Drug Products, Institute of Biochemical and Biotechnological Drug, School of Pharmaceutical Sciences, Cheeloo College of Medicine, Shandong University, Jinan, 250012, Shandong, China; Key Laboratory of Chemical Biology (Ministry of Education), Shandong University, Jinan, 250012, Shandong, China; National Glycoengineering Research Center, Shandong University, Jinan, 250012, Shandong, China.
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3
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Yamaguchi S, Hosaka S, Sugaya K, Tokunaga Y, Yokota S. Monitoring and Predicting the Size of Fine Particles Prepared in a Fluidized-Bed Granulator Using a Handheld-Type Raman Spectrometer. Chem Pharm Bull (Tokyo) 2022; 70:362-368. [DOI: 10.1248/cpb.c21-00958] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Affiliation(s)
- Shingo Yamaguchi
- Research and Development Division, Sawai Pharmaceutical Co., Ltd
| | - Shouichi Hosaka
- Research and Development Division, Sawai Pharmaceutical Co., Ltd
| | - Kayo Sugaya
- Research and Development Division, Sawai Pharmaceutical Co., Ltd
| | - Yuji Tokunaga
- Research and Development Division, Sawai Pharmaceutical Co., Ltd
| | - Shouji Yokota
- Research and Development Division, Sawai Pharmaceutical Co., Ltd
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4
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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: 26] [Impact Index Per Article: 8.7] [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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5
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Farkas D, Madarász L, Nagy ZK, Antal I, Kállai-Szabó N. Image Analysis: A Versatile Tool in the Manufacturing and Quality Control of Pharmaceutical Dosage Forms. Pharmaceutics 2021; 13:pharmaceutics13050685. [PMID: 34068724 PMCID: PMC8151645 DOI: 10.3390/pharmaceutics13050685] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/16/2021] [Revised: 04/28/2021] [Accepted: 05/04/2021] [Indexed: 11/16/2022] Open
Abstract
In pharmaceutical sciences, visual inspection is one of the oldest methods used for description in pharmacopeias and is still an important part of the characterization and qualification of active ingredients, excipients, and dosage forms. With the development of technology, it is now also possible to take images of various pharmaceutical dosage forms with different imaging methods in a size range that is hardly visible or completely invisible to the human eye. By analyzing high-quality designs, physicochemical processes can be understood, and the results can be used even in the optimization of the composition of the dosage form and in the development of its production. The present study aims to show some of the countless ways image analysis can be used in the manufacturing and quality assessment of different dosage forms. This summary also includes measurements and an evaluation of, amongst others, a less studied dosage form, medicated foams.
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Affiliation(s)
- Dóra Farkas
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (D.F.); (I.A.)
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rakpart 3, H-1111 Budapest, Hungary; (L.M.); (Z.K.N.)
| | - Zsombor K. Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rakpart 3, H-1111 Budapest, Hungary; (L.M.); (Z.K.N.)
| | - István Antal
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (D.F.); (I.A.)
| | - Nikolett Kállai-Szabó
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (D.F.); (I.A.)
- Correspondence:
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6
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Zhong L, Gao L, Li L, Zang H. Trends-process analytical technology in solid oral dosage manufacturing. Eur J Pharm Biopharm 2020; 153:187-199. [DOI: 10.1016/j.ejpb.2020.06.008] [Citation(s) in RCA: 12] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/26/2020] [Revised: 06/11/2020] [Accepted: 06/14/2020] [Indexed: 10/24/2022]
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7
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Feng H, Mohan S. Application of Process Analytical Technology for Pharmaceutical Coating: Challenges, Pitfalls, and Trends. AAPS PharmSciTech 2020; 21:179. [PMID: 32596747 DOI: 10.1208/s12249-020-01727-8] [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: 02/28/2020] [Accepted: 06/08/2020] [Indexed: 12/31/2022] Open
Abstract
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.
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Affiliation(s)
- Hanzhou Feng
- Process analytical technology, Merck & Co., Inc., Rahway, New Jersey, USA.
| | - Shikhar Mohan
- Graduate School of Pharmaceutical Sciences, Duquesne University, 600 Forbes Avenue, Pittsburgh, Pennsylvania, USA
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8
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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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9
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How to measure coating thickness of tablets: Method comparison of optical coherence tomography, near-infrared spectroscopy and weight-, height- and diameter gain. Eur J Pharm Biopharm 2019; 142:344-352. [DOI: 10.1016/j.ejpb.2019.06.021] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2019] [Revised: 05/24/2019] [Accepted: 06/18/2019] [Indexed: 11/18/2022]
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10
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Razuc M, Grafia A, Gallo L, Ramírez-Rigo MV, Romañach RJ. Near-infrared spectroscopic applications in pharmaceutical particle technology. Drug Dev Ind Pharm 2019; 45:1565-1589. [DOI: 10.1080/03639045.2019.1641510] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
Affiliation(s)
- M. Razuc
- Instituto de Química del Sur (INQUISUR), Universidad Nacional del Sur (UNS)-CONICET, Bahía Blanca, Argentina
- Departamento de Biología, Bioquímica y Farmacia, Universidad Nacional del Sur (UNS), Bahía Blanca, Argentina
| | - A. Grafia
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur (UNS)- CONICET, Bahía Blanca, Argentina
| | - L. Gallo
- Departamento de Biología, Bioquímica y Farmacia, Universidad Nacional del Sur (UNS), Bahía Blanca, Argentina
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur (UNS)- CONICET, Bahía Blanca, Argentina
| | - M. V. Ramírez-Rigo
- Departamento de Biología, Bioquímica y Farmacia, Universidad Nacional del Sur (UNS), Bahía Blanca, Argentina
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur (UNS)- CONICET, Bahía Blanca, Argentina
| | - R. J. Romañach
- Department of Chemistry, Center for Structured Organic Particulate Systems, University of Puerto Rico – Mayagüez, Mayagüez, Puerto Rico
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11
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Vidovič S, Horvat M, Bizjak A, Planinšek O, Petek B, Burjak M, Peternel L, Parojčić J, Đuriš J, Ibrić S, Janković B. Elucidating molecular properties of kappa-carrageenan as critical material attributes contributing to drug dissolution from pellets with a multivariate approach. Int J Pharm 2019; 566:662-673. [DOI: 10.1016/j.ijpharm.2019.06.016] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/02/2019] [Revised: 05/26/2019] [Accepted: 06/06/2019] [Indexed: 11/25/2022]
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12
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Santos Silva B, Colbert MJ, Santangelo M, Bartlett JA, Lapointe-Garant PP, Simard JS, Gosselin R. Monitoring microsphere coating processes using PAT tools in a bench scale fluid bed. Eur J Pharm Sci 2019; 135:12-21. [PMID: 31067496 DOI: 10.1016/j.ejps.2019.05.003] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/21/2018] [Revised: 04/24/2019] [Accepted: 05/04/2019] [Indexed: 11/18/2022]
Abstract
Among the factors that influence adherence to medication within the pediatric population, taste/irritation has been identified as a critical barrier to patient compliance. With the goal of improving compliance, microspheres (matrix systems within which the drug is dispersed) can be coated with a reverse enteric polymer that will prevent the release of the drug in the oral cavity while maintaining an immediate release once the drug product reaches the stomach, thereby achieving a taste neutral profile. In this work, the in-line performance of three process analytical technology (PAT) tools is evaluated in order to monitor the microsphere coating process. These tools are Raman spectroscopy, near-infrared spectroscopy and focused beam reflectance measurements, together with process data and raw material attributes. The ability of these different sources of information to predict the coating's barrier performance is evaluated by using a combined-data-approach: multiblock partial least squares (MBPLS). Results show that Raman spectroscopy has a superior predictive performance and that it has the potential to monitor the coating process of the microspheres as well as to detect process discrepancies (such as spray rate changes), demonstrating its usefulness for the monitoring of fluid bed coating processes. It was also demonstrated that Raman can be used to clearly differentiate batches with significantly difference in-vitro dissolution performance. This monitoring is considered critical to ensure consistent coating performance for this thin film barrier membrane that is essential to patient compliance.
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Affiliation(s)
- Barbara Santos Silva
- Department of Chemical and Biotechnological Engineering, Université de Sherbrooke, Pfizer Industrial Research Chair, Sherbrooke, Canada.
| | - Marie-Josée Colbert
- Department of Chemical and Biotechnological Engineering, Université de Sherbrooke, Pfizer Industrial Research Chair, Sherbrooke, Canada.
| | - Matthew Santangelo
- Pharmaceutical Sciences, Drug Product Development, Pfizer Global Research and Development, Groton, USA.
| | - Jeremy A Bartlett
- Pharmaceutical Sciences, Drug Product Development, Pfizer Global Research and Development, Groton, USA.
| | | | | | - Ryan Gosselin
- Department of Chemical and Biotechnological Engineering, Université de Sherbrooke, Pfizer Industrial Research Chair, Sherbrooke, Canada.
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Foroughi-Dahr M, Sotudeh-Gharebagh R, Mostoufi N. Development of a PAT tool for monitoring the Wurster coater performance. Int J Pharm 2019; 561:171-186. [PMID: 30802550 DOI: 10.1016/j.ijpharm.2019.02.023] [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: 09/18/2018] [Revised: 02/12/2019] [Accepted: 02/13/2019] [Indexed: 01/02/2023]
Abstract
Real-time process analytical technology (PAT) is proposed as an effective approach for monitoring the performance of a Wurster coater. The coater was used for coating of 0.78 mm pharmaceutical pellets. The coating solution consisted of Hydroxypropyl methylcellulose/Poly ethylene glycol. During the coating process, small amounts of pellets (∼2 g) were sampled at 10 min. intervals and the pressure fluctuations were recorded at the same time. The signals were analyzed using the wavelet transform (WT) and decomposed into different sub-signals. Principal component analysis (PCA) was employed to the energies of these sub-signals, whose outliers were eliminated using the Mahalanobis distance method. The reference coating thickness data were obtained via spectrophotometry during the coating process. The partial least squares (PLS) regression was incorporated with the PCA for the development of a model for prediction of the coating thickness. The PLS regression revealed that the pressure fluctuations can be used to evaluate the thickness with a good precision. This study demonstrated the applicability of pressure fluctuations for the prediction of the coating thickness. This method can be regarded as a new robust, fast and non-intrusive PAT approach for monitoring the coating process which can be easily used by engineers and practitioners.
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Affiliation(s)
- Mohammad Foroughi-Dahr
- Multiphase Systems Research Lab, School of Chemical Engineering, College of Engineering, University of Tehran, P.O. Box 11365/4563, Tehran, Iran
| | - Rahmat Sotudeh-Gharebagh
- Multiphase Systems Research Lab, School of Chemical Engineering, College of Engineering, University of Tehran, P.O. Box 11365/4563, Tehran, Iran.
| | - Navid Mostoufi
- Multiphase Systems Research Lab, School of Chemical Engineering, College of Engineering, University of Tehran, P.O. Box 11365/4563, Tehran, Iran
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14
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Korasa K, Vrečer F. A study on the applicability of multiple process analysers in the production of coated pellets. Int J Pharm 2019; 560:261-272. [DOI: 10.1016/j.ijpharm.2019.01.069] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/26/2018] [Revised: 01/26/2019] [Accepted: 01/31/2019] [Indexed: 11/15/2022]
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15
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Korasa K, Vrečer F. Overview of PAT process analysers applicable in monitoring of film coating unit operations for manufacturing of solid oral dosage forms. Eur J Pharm Sci 2018; 111:278-292. [DOI: 10.1016/j.ejps.2017.10.010] [Citation(s) in RCA: 34] [Impact Index Per Article: 5.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/08/2017] [Revised: 09/09/2017] [Accepted: 10/07/2017] [Indexed: 10/18/2022]
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16
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Naidu VR, Deshpande RS, Syed MR, Deoghare P, Singh D, Wakte PS. PAT-Based Control of Fluid Bed Coating Process Using NIR Spectroscopy to Monitor the Cellulose Coating on Pharmaceutical Pellets. AAPS PharmSciTech 2017; 18:2045-2054. [PMID: 27995464 DOI: 10.1208/s12249-016-0680-2] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/03/2016] [Accepted: 11/20/2016] [Indexed: 11/30/2022] Open
Abstract
Current endeavor was aimed towards monitoring percent weight build-up during functional coating process on drug-layered pellets. Near-infrared (NIR) spectroscopy is an emerging process analytical technology (PAT) tool which was employed here within quality by design (QbD) framework. Samples were withdrawn after spraying every 15-Kg cellulosic coating material during Wurster coating process of drug-loaded pellets. NIR spectra of these samples were acquired using cup spinner assembly of Thermoscientific Antaris II, followed by multivariate analysis using partial least squares (PLS) calibration model. PLS model was built by selecting various absorption regions of NIR spectra for Ethyl cellulose, drug and correlating the absorption values with actual percent weight build up determined by HPLC. The spectral regions of 8971.04 to 8250.77 cm-1, 7515.24 to 7108.33 cm-1, and 5257.00 to 5098.87 cm-1 were found to be specific to cellulose, where as the spectral region of 6004.45 to 5844.14 cm-1was found to be specific to drug. The final model gave superb correlation co-efficient value of 0.9994 for calibration and 0.9984 for validation with low root mean square of error (RMSE) values of 0.147 for calibration and 0.371 for validation using 6 factors. The developed correlation between the NIR spectra and cellulose content is useful in precise at-line prediction of functional coat value and can be used for monitoring the Wurster coating process.
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17
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Naidu VR, Deshpande RS, Syed MR, Wakte PS. Real-time imaging as an emerging process analytical technology tool for monitoring of fluid bed coating process. Pharm Dev Technol 2017; 23:596-601. [PMID: 28121263 DOI: 10.1080/10837450.2017.1287730] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
Abstract
A direct imaging system (EyeconTM) was used as a Process Analytical Technology (PAT) tool to monitor fluid bed coating process. EyeconTM generated real-time onscreen images, particle size and shape information of two identically manufactured laboratory-scale batches. EyeconTM has accuracy of measuring the particle size increase of ±1 μm on particles in the size range of 50-3000 μm. EyeconTM captured data every 2 s during the entire process. The moving average of D90 particle size values recorded by EyeconTM were calculated for every 30 min to calculate the radial coating thickness of coated particles. After the completion of coating process, the radial coating thickness was found to be 11.3 and 9.11 μm, with a standard deviation of ±0.68 and 1.8 μm for Batch 1 and Batch 2, respectively. The coating thickness was also correlated with percent weight build-up by gel permeation chromatography (GPC) and dissolution. GPC indicated weight build-up of 10.6% and 9.27% for Batch 1 and Batch 2, respectively. In conclusion, weight build-up of 10% can also be correlated with 10 ± 2 μm increase in the coating thickness of pellets, indicating the potential applicability of real-time imaging as an endpoint determination tool for fluid bed coating process.
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Affiliation(s)
- Venkata Ramana Naidu
- a Pharma Research Department , Wockhardt Research Centre , Aurangabad , Maharashtra , India
| | - Rucha S Deshpande
- a Pharma Research Department , Wockhardt Research Centre , Aurangabad , Maharashtra , India
| | - Moinuddin R Syed
- a Pharma Research Department , Wockhardt Research Centre , Aurangabad , Maharashtra , India
| | - Pravin S Wakte
- b Department of Chemical Technology , Dr. Babasaheb Ambedkar Marathwada University , Aurangabad , Maharashtra , India
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Recent expansion of pharmaceutical nanotechnologies and targeting strategies in the field of phytopharmaceuticals for the delivery of herbal extracts and bioactives. J Control Release 2016; 241:110-124. [DOI: 10.1016/j.jconrel.2016.09.017] [Citation(s) in RCA: 86] [Impact Index Per Article: 10.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2016] [Revised: 09/18/2016] [Accepted: 09/19/2016] [Indexed: 12/18/2022]
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Korasa K, Hudovornik G, Vrečer F. Applicability of near-infrared spectroscopy in the monitoring of film coating and curing process of the prolonged release coated pellets. Eur J Pharm Sci 2016; 93:484-92. [PMID: 27562707 DOI: 10.1016/j.ejps.2016.08.038] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2015] [Revised: 08/07/2016] [Accepted: 08/20/2016] [Indexed: 11/29/2022]
Abstract
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.
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Affiliation(s)
- Klemen Korasa
- KRKA, d.d., Novo mesto, Šmarješka cesta 6, 8000 Novo mesto, Slovenia.
| | - Grega Hudovornik
- KRKA, d.d., Novo mesto, Šmarješka cesta 6, 8000 Novo mesto, Slovenia
| | - Franc Vrečer
- KRKA, d.d., Novo mesto, Šmarješka cesta 6, 8000 Novo mesto, Slovenia; University of Ljubljana, Faculty of Pharmacy, Aškerčeva 7, 1000 Ljubljana, Slovenia
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Hudovornik G, Korasa K, Vrečer F. A study on the applicability of in-line measurements in the monitoring of the pellet coating process. Eur J Pharm Sci 2015; 75:160-8. [DOI: 10.1016/j.ejps.2015.04.007] [Citation(s) in RCA: 27] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/21/2014] [Revised: 04/04/2015] [Accepted: 04/06/2015] [Indexed: 11/28/2022]
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