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Brands R, Tebart N, Thommes M, Bartsch J. UV/Vis spectroscopy as an in-line monitoring tool for tablet content uniformity. J Pharm Biomed Anal 2023; 236:115721. [PMID: 37769525 DOI: 10.1016/j.jpba.2023.115721] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/02/2023] [Revised: 08/28/2023] [Accepted: 09/12/2023] [Indexed: 10/03/2023]
Abstract
Continuous manufacturing provides advantages compared to batch manufacturing and is increasingly gaining importance in the pharmaceutical industry. In particular, the implementation of tablet processes in continuous plants is an important part of current research. For this, in-line real-time monitoring of product quality through process analytical technology (PAT) tools is crucial. This study focuses on an in-line UV/Vis spectroscopy method for monitoring the active pharmaceutical ingredient (API) content in tablets. UV/Vis spectroscopy is particularly advantageous here, because it allows univariate data analysis without complex data processing. Experiments were conducted on a rotary tablet press. The tablets consisted of 7- 13 wt% theophylline monohydrate as API, lactose monohydrate and magnesium stearate. Two tablet production rates were investigated, 7200 and 20000 tablets per hour. The UV/Vis probe was mounted at the ejection position and measurements were taken on the tablet sidewall. Validation was according to ICH Q2 with respect to specificity, linearity, precision, accuracy and range. The specificity for this formulation was proven and linearity was sufficient with coefficients of determination of 0.9891 for the low throughput and 0.9936 for the high throughput. Repeatability and intermediate precision were investigated. Both were sufficient, indicated by coefficients of variations with a maximum of 6.46% and 6.34%, respectively. The accuracy was evaluated by mean percent recovery. This showed a higher accuracy at 20000 tablets per hour than 7200 tablets per hour. However, both throughputs demonstrate sufficient accuracy. Finally, UV/Vis spectroscopy is a promising alternative to the common NIR and Raman Spectroscopy.
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Affiliation(s)
- René Brands
- Laboratory of Solids Process Engineering, TU Dortmund University, Emil-Figge-Straße 68, Dortmund 44227, DE, Germany
| | - Noah Tebart
- Laboratory of Solids Process Engineering, TU Dortmund University, Emil-Figge-Straße 68, Dortmund 44227, DE, Germany
| | - Markus Thommes
- Laboratory of Solids Process Engineering, TU Dortmund University, Emil-Figge-Straße 68, Dortmund 44227, DE, Germany
| | - Jens Bartsch
- Laboratory of Solids Process Engineering, TU Dortmund University, Emil-Figge-Straße 68, Dortmund 44227, DE, Germany.
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2
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C Dias R, Korhonen O, Ketolainen J, A Lopes J, Ervasti T. Flowsheet modelling of a powder continuous feeder-mixer system. Int J Pharm 2023; 639:122969. [PMID: 37084833 DOI: 10.1016/j.ijpharm.2023.122969] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/23/2022] [Revised: 03/28/2023] [Accepted: 04/15/2023] [Indexed: 04/23/2023]
Abstract
In this study, an integrated flowsheet model of the continuous feeder-mixer system was calibrated, simulated and compared against experimental data. The feeding process was first investigated using two major components (ibuprofen and microcrystalline cellulose (MCC)), in a formulation comprised of: 30 wt% of ibuprofen, 67.5 wt% MCC, 2 wt% of sodium starch glycolate and 0.5 wt% of magnesium stearate. The impact of a refill on feeder performance was experimentally evaluated for different operating conditions. Results showed that it had no influence on feeder performance. While simulations with the feeder model fairly reproduced the material behaviour observed in the feeder, unintended disturbances were underpredicted due to the model's low complexity. Experimentally, mixer's efficiency was assessed based on ibuprofen residence time distribution. Mean residence time pointed to a higher mixer's efficiency at lower flow rates. Blend homogeneity results showed that for the entire set of experiments, ibuprofen RSD <5%, irrespective of process variables. A feeder-mixer flowsheet model was calibrated, after regressing the axial model coefficients. The regression curves exhibited a R2 above 0.96, whereas the RMSE varied from 1.58x10-4 to 1.06x10-3 s-1 across all fitted curves. Simulations confirmed that flowsheet model captured the powder dynamics inside the mixer and qualitatively predicted the mixer's filtering ability against feeding composition fluctuations, as well as ibuprofen RSD in blend, in line with real experiments.
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Affiliation(s)
- Rute C Dias
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland; iMed.ULisboa, Faculty of Pharmacy, University of Lisbon, 1649-003 Lisbon, Portugal.
| | - Ossi Korhonen
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
| | - Jarkko Ketolainen
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
| | - João A Lopes
- iMed.ULisboa, Faculty of Pharmacy, University of Lisbon, 1649-003 Lisbon, Portugal
| | - Tuomas Ervasti
- PromisLab, School of Pharmacy, University of Eastern Finland, 70211 Kuopio, Finland
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3
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Effects of particle size, shape and loading rate on the normal compaction of an advanced granular ceramic. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118243] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/15/2023]
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4
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Matsunami K, Miura T, Yaginuma K, Tanabe S, Badr S, Sugiyama H. Surrogate modeling of dissolution behavior toward efficient design of tablet manufacturing processes. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2023.108141] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/18/2023]
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5
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Karimi-Jafari M, Ziaee A, O’Reilly E, Croker D, Walker G. Formation of Ciprofloxacin–Isonicotinic Acid Cocrystal Using Mechanochemical Synthesis Routes—An Investigation into Critical Process Parameters. Pharmaceutics 2022; 14:pharmaceutics14030634. [PMID: 35336009 PMCID: PMC8949855 DOI: 10.3390/pharmaceutics14030634] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/12/2022] [Revised: 03/04/2022] [Accepted: 03/10/2022] [Indexed: 12/10/2022] Open
Abstract
The mechanochemical synthesis of cocrystals has been introduced as a promising approach of formulating poorly water-soluble active pharmaceutical ingredients (APIs). In this study, hot-melt extrusion (HME) as a continuous process and grinding and ball milling as batch processes were employed to explore the feasibility of cocrystallization. Ciprofloxacin (CIP) and isonicotinic acid (INCA) were selected as the model API and coformer. CIP–INCA cocrystal was produced in all techniques. It was revealed that higher cocrystal content could be achieved at longer durations of grinding and ball milling. However, milling for more than 10 min led to increased co-amorphous content instead of cocrystal. A design of experiment (DoE) approach was used for deciphering the complex correlation of screw configuration, screw speed, and temperature as HME process parameters and their respective effect on final relative cocrystal yield. Statistical analysis showed that screw configuration, temperature, and their interaction were the most critical factors affecting cocrystallization. Interestingly, screw speed had minimal impact on the relative cocrystallization yield. Cocrystallization led to increased dissolution rate of CIP in phosphate buffer up to 2.5-fold. Overall, this study shed a light on the potential of mechanochemical synthesis techniques with special focus on HME as a continuous process for producing cocrystals.
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6
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Yang W, Qian W, Yuan Z, Chen B. Perspectives on the flexibility analysis for continuous pharmaceutical manufacturing processes. Chin J Chem Eng 2022; 41:29-41. [PMID: 36644479 PMCID: PMC9828886 DOI: 10.1016/j.cjche.2021.12.005] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/04/2021] [Revised: 12/08/2021] [Accepted: 12/10/2021] [Indexed: 01/18/2023]
Abstract
Pharmaceutical continuous manufacturing, especially under the context of COVID-19 pandemic, is regarded as an emerging technology that can guarantee the adequate quality assurance and mitigate process risk while guaranteeing the desirable economic performance. Flexibility analysis is one approach to quantitively assess the capability of chemical process to guarantee feasible operation in face of variations on uncertain parameters. The aim of this paper is to provide the perspectives on the flexibility analysis for continuous pharmaceutical manufacturing processes. State-of-the-art and progress in the flexibility analysis for chemical processes including concept evolution, mathematical model formulations, solution strategies, and applications are systematically overviewed. Recent achievements on the flexibility/feasibility analysis of the downstream dosage form manufacturing process are also touched upon. Further challenges and developments in the field of flexibility analysis for novel continuous manufacturing processes of active pharmaceutical ingredients along with the integrated continuous manufacturing processes are identified.
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Affiliation(s)
- Wenhui Yang
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Wuxi Qian
- Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Zhihong Yuan
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Bingzhen Chen
- Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
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7
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Moritz P, Simon B, Meier R, Gerhard S. Tracking raw material flow through a continuous direct compression line. Part II of II: Predicting dynamic changes in quality attributes of tablets due to disturbances in raw material properties using an independent residence time distribution model. Int J Pharm 2022; 615:121528. [DOI: 10.1016/j.ijpharm.2022.121528] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/05/2021] [Revised: 01/23/2022] [Accepted: 01/26/2022] [Indexed: 10/19/2022]
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8
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Soft sensor for real-time estimation of tablet potency in continuous direct compression manufacturing operation. Int J Pharm 2021; 602:120624. [PMID: 33892055 DOI: 10.1016/j.ijpharm.2021.120624] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2020] [Revised: 04/13/2021] [Accepted: 04/17/2021] [Indexed: 11/20/2022]
Abstract
One of the critical quality attributes of the solid oral dosage forms produced in continuous direct compression operations is the tablet potency. A novel soft sensor comprising of a combination of first principle-based and empirical models has been developed to enable real-time monitoring of blend and tablet potency, and concentrations of other excipients at various stream levels along the direct compression line. The soft sensor model has only three adjustable parameters, primarily associated with the equipment design and operation, so the model is product agnostic which is key to enable flexible manufacturing. The estimation accuracy of the soft sensor is demonstrated through a series of real time experiments which include steady state and dynamic transitions of potency during the runs, compared with offline analytically tested tablet cores. The results indicate that the proposed soft sensor can be utilized as a robust tool for real-time monitoring of potency, suggesting an extension of its utilization to higher levels of control. Two potential applications of the soft sensor are: 1. An element of a control strategy for product diversion; 2. A predictive model for advanced process control strategy to minimize the variability in tablet composition.
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9
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Nandi U, Trivedi V, Ross SA, Douroumis D. Advances in Twin-Screw Granulation Processing. Pharmaceutics 2021; 13:pharmaceutics13050624. [PMID: 33925577 PMCID: PMC8146340 DOI: 10.3390/pharmaceutics13050624] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/25/2021] [Revised: 03/31/2021] [Accepted: 04/07/2021] [Indexed: 11/23/2022] Open
Abstract
Twin-screw granulation (TSG) is a pharmaceutical process that has gained increased interest from the pharmaceutical industry for its potential for the development of oral dosage forms. The technology has evolved rapidly due to the flexibility of the equipment design, the selection of the process variables and the wide range of processed materials. Most importantly, TSG offers the benefits of both batch and continuous manufacturing for pharmaceutical products, accompanied by excellent process control, high product quality which can be achieved through the implementation of Quality by Design (QbD) approaches and the integration of Process Analytical Tools (PAT). Here, we present basic concepts of the various twin-screw granulation techniques and present in detail their advantages and disadvantages. In addition, we discuss the detail of the instrumentation used for TSG and how the critical processing paraments (CPP) affect the critical quality attributes (CQA) of the produced granules. Finally, we present recent advances in TSG continuous manufacturing including the paradigms of modelling of continuous granulation process, QbD approaches coupled with PAT monitoring for granule optimization and process understanding.
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Affiliation(s)
- Uttom Nandi
- Faculty of Engineering and Science, School of Science, University of Greenwich, Chatham Maritime, Chatham, Kent ME4 4TB, UK;
- CIPER Centre for Innovation and Process Engineering Research, Kent ME4 4TB, UK;
| | - Vivek Trivedi
- Medway School of Pharmacy, Medway Campus, University of Kent, Central Avenue, Chatham Maritime, Chatham, Kent ME4 4TB, UK;
| | - Steven A. Ross
- CIPER Centre for Innovation and Process Engineering Research, Kent ME4 4TB, UK;
- Cubi-Tech Extrusion: 3, Sextant Park, Neptune Cl, Rochester ME2 4LU, UK
| | - Dennis Douroumis
- Faculty of Engineering and Science, School of Science, University of Greenwich, Chatham Maritime, Chatham, Kent ME4 4TB, UK;
- CIPER Centre for Innovation and Process Engineering Research, Kent ME4 4TB, UK;
- Correspondence: ; Tel.: +44-2083318440
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10
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Implementing Feedback Granule Size Control in a Continuous Dry Granulation Line Using Controlled Impeller Speed of the Granulation Unit, Compaction Force and Gap Width. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09524-3] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
Abstract
Abstract
Purpose
In continuous manufacturing of pharmaceuticals, dry granulation is of interest because of its large throughput capacity and energy efficiency. In order to manufacture solid oral dosage forms continuously, valid control strategies for critical quality attributes should be established. To this date, there are no published control strategies for granule size distribution in continuous dry granulation.
Methods
In-line laser diffraction was used to determine the size of granules in a continuous roll compaction/dry granulation line (QbCon® dry). Different process parameters were evaluated regarding their influences on granule size. The identified critical process parameters were then incorporated into control strategies. The uncontrolled and the controlled processes were compared based on the resulting granule size. In both processes, a process parameter was changed to induce a shift in median particle size and the controller had to counteract this shift.
Results
In principle, all process parameters that affect the median particle size could also be used to control the particle size in a dry granulation process. The sieve impeller speed was found to be well suited to control the median particle size as it reacts fast and can be controlled independently of the throughput or material.
Conclusion
The median particle size in continuous roll compaction can be controlled by adjusting process parameters depending on real-time granule size measurements. The method has to be validated and explored further to identify critical requirements to the material and environmental conditions.
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11
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Huang Z, Galbraith SC, Cha B, Liu H, Park S, Flamm MH, Metzger M, Tantuccio A, Yoon S. Effects of process parameters on tablet critical quality attributes in continuous direct compression: a case study of integrating data-driven statistical models and mechanistic compaction models. Pharm Dev Technol 2020; 25:1204-1215. [PMID: 32808839 DOI: 10.1080/10837450.2020.1805760] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
Abstract
Continuous manufacturing of oral-dosage drug products is increasing the need for rigorous process understanding both from a process design and control perspective. The purpose of this study is to develop a methodology that analyzes the effects of upstream process parameters on continuous tablet compaction and then correlates associated upstream variables to the final tablet attributes (e.g. relative density and hardness). The impact of three process parameters (system throughput, blender speed, and compaction force) on tablet attributes is investigated using a full factorial experimental design. As expected, the compaction force was found to be the most significant process parameter. However, importantly, throughput was discovered to have a non-negligible impact which was previously unaccounted for. This impact is proposed to be related to differing levels of powder pre-compression. An empirical model for this relationship is regressed and incorporated into a flowsheet model. The flowsheet model is then used to develop an in silico design space which is compared favorably to that built from experiments. Moreover, in the future, the in silico design space based on the validated flowsheet model can provide better manufacturing flexibility and make control strategy development simpler.
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Affiliation(s)
- Zhuangrong Huang
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Shaun C Galbraith
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Bumjoon Cha
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Huolong Liu
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Seoyoung Park
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
| | - Matthew H Flamm
- Applied Mathematics and Modeling, Scientific Modeling Platforms, Merck & Co., Inc, Kenilworth, NJ, USA
| | - Matt Metzger
- Pharmaceutical Commercialization Technology, Merck & Co., Inc, Kenilworth, NJ, USA
| | - Anthony Tantuccio
- Pharmaceutical Commercialization Technology, Merck & Co., Inc, Kenilworth, NJ, USA
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts Lowell, Lowell, MA, USA
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12
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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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13
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Development and Evaluation of an In-line and On-line Monitoring System for Granule Size Distributions in Continuous Roll Compaction/Dry Granulation Based on Laser Diffraction. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09443-3] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
Abstract
Abstract
Purpose
Roll compaction/dry granulation is established in manufacturing of solid oral dosage forms and, within the context of continuous manufacturing, it has sparked interest as material is fed, processed, and ejected continuously while also providing large possible throughputs. However, this amount of material has to be adequately controlled in real time to assure quality.
Methods
This research aimed at monitoring the critical quality attribute granule size distribution in continuous roll compaction/dry granulation (QbCon®; L.B. Bohle, Ennigerloh, Germany) using in-line and on-line laser diffraction. The influence of varying process parameters and excipient formulations was studied and evaluated with the prospect of using this technique to develop control loops. For this purpose, residence time parameters were assessed. In- and on-line data was compared with off-line laser diffraction and dynamic image analysis data.
Results
The system successfully monitored the granule size distribution in a variety of process parameters and throughputs (up to 27.5 kg/h). It was sensitive to changes in process parameters and changes in material blends, which could pose a potential threat to the final drug products’ quality. Average event propagation time from the compaction zone to the laser diffraction system of 17.7 s demonstrates the systems’ fast reaction time.
Conclusion
Results highlight laser diffraction as a valuable method of in- and on-line size determination and allow for the development of a control strategy using this principle.
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14
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Combination of a rotating tube sample divider and dynamic image analysis for continuous on-line determination of granule size distribution. INTERNATIONAL JOURNAL OF PHARMACEUTICS-X 2019; 1:100029. [PMID: 31517294 PMCID: PMC6733292 DOI: 10.1016/j.ijpx.2019.100029] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/11/2019] [Revised: 08/08/2019] [Accepted: 08/09/2019] [Indexed: 11/20/2022]
Abstract
The granule size distribution is a critical quality attribute of granules. It has a great impact on further packaging or processing. Due to increasing interest in continuous manufacturing techniques, it is of high interest to develop an in-line or on-line tool to monitor the granule size distribution. However, development of an in-line measurement tool for granule size distribution was challenging since large throughput and inhomogeneous product stream are limiting factors for current particle size analyzers. In this study, continuous sampling was tested in conjunction to a continuous on-line method of size determination using dynamic image analysis. A rotating tube sample divider was used to split previously compacted material in representative samples at different ratios and the sample was directly conveyed to the particle size analyzer where the granule size distribution was determined. The method was tested for different granule sizes to determine limits of detection and its ability to detect these changes immediately, as this enables real-time monitoring of the process. This research is the base for development of control tools concerning the granule size distributions for continuous granulation processes.
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Key Words
- CM, continuous manufacturing
- CQA, critical quality attributes
- Continuous manufacturing
- DIA, dynamic image analysis
- Dynamic image analysis
- FDA, U.S. Food and Drug Administration
- GSD, granule size distribution
- Granule size distribution
- PAT, process analytical technologies
- Process analytical technologies
- Process monitoring
- Q3, volume-based cumulative undersized curve
- RCDG, roll compaction/dry granulation
- Representative sampling
- SY, symmetry factor
- TSG, Twin Screw granulation
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15
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Toson P, Lopes DG, Paus R, Kumar A, Geens J, Stibale S, Quodbach J, Kleinebudde P, Hsiao WK, Khinast J. Model-based approach to the design of pharmaceutical roller-compaction processes. INTERNATIONAL JOURNAL OF PHARMACEUTICS-X 2019; 1:100005. [PMID: 31517270 PMCID: PMC6733294 DOI: 10.1016/j.ijpx.2019.100005] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/02/2018] [Revised: 12/18/2018] [Accepted: 12/29/2018] [Indexed: 11/29/2022]
Abstract
This work presents a new model based approach to process design and scale-up within the same equipment of a roller compaction process. The prediction of the operating space is not performed fully in-silico, but uses low-throughput experiments as input. This low-throughput data is utilized in an iterative calibration routine to describe the behavior of the powder in the roller compactor and improves the predictive quality of the mechanistic models at low and high-throughput. The model has been validated with an experimental design of experiments of two ibuprofen formulations. The predicted sweet spots in the operating space are in good agreement with the experimental results.
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Affiliation(s)
- Peter Toson
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Diogo G Lopes
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Raphael Paus
- Discovery, Product Development and Supply, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Ashish Kumar
- Discovery, Product Development and Supply, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Jeroen Geens
- Discovery, Product Development and Supply, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Sandy Stibale
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstraße 1, 40225 Düsseldorf, Germany
| | - Julian Quodbach
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstraße 1, 40225 Düsseldorf, Germany
| | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstraße 1, 40225 Düsseldorf, Germany
| | - Wen-Kai Hsiao
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.,Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13, 8010 Graz, Austria
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16
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Integrated modeling of a continuous direct compression tablet manufacturing process: A production scale case study. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.05.078] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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17
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Khan A. Optimization of the process variables of roller compaction, on the basis of granules characteristics (flow, mechanical strength, and disintegration behavior): an application of SeDeM-ODT expert system. Drug Dev Ind Pharm 2019; 45:1537-1546. [PMID: 31210544 DOI: 10.1080/03639045.2019.1634094] [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: 10/26/2022]
Abstract
The objective of the study was application of SeDeM-ODT expert system for optimization of process variables for roller compaction and for the preparation of granules with better flow, compressibility, and disintegration behavior. In the present study, granules were prepared at pre-determined (on the basis of factorial design) process variables and characterized using SeDeM-ODT expert system. Compatibility of ribavirin with excipients (microcrystalline cellulose, tablettose-80, cross carmellose sodium, and magnesium stearate) was evaluated by binary mixture approach, using FTIR. According to the SeDeM-ODT expert system, granules were characterized for various parameters related to flow, compressibility and disintegration behavior and Index of Good Compressibility and Buccodispersibility (IGCB) was calculated. The process variables resulting in highest IGCB value were considered as optimum. Ribavirin was found compatible with all the excipients used in the study and characteristics peaks were present in FTIR spectra after subjecting to stress conditions (75% relative humidity at 45 ± 5 °C) for 30 days. Both Ribavirin powder and Ribavirin containing powder blend had poor flow and compressibility while disintegration behavior was good due to higher water solubility. Screw speed of 35 rpm and roller speed at 12 rpm resulted in granules with acceptable characteristics. The IGCB value (5.63) of the granules was highest of all, indicating its better characteristics. SeDeM-ODT expert system presents a more practical picture of the granules and also predicts the mechanical strength and disintegration behavior of the tablets prepared from the granules. By proper optimization of screw and roller speed, efficiency of the process can be improved.
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Affiliation(s)
- Amjad Khan
- a Department of Pharmacy , Kohat University of Science and Technology , Kohat , Pakistan
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18
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Integrated continuous manufacturing in pharmaceutical industry: current evolutionary steps toward revolutionary future. Pharm Pat Anal 2019; 8:139-161. [DOI: 10.4155/ppa-2019-0011] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
Abstract
Continuous manufacturing (CM) has the potential to provide pharmaceutical products with better quality, improved yield and with reduced cost and time. Moreover, ease of scale-up, small manufacturing footprint and on-line/in-line monitoring and control of the process are other merits for CM. Regulating authorities are supporting the adoption of CM by pharmaceutical manufacturers through issuing proper guidelines. However, implementation of this technology in pharmaceutical industry is encountered by a number of challenges regarding the process development and quality assurance. This article provides a background on the implementation of CM in pharmaceutical industry, literature survey of the most recent state-of-the-art technologies and critically discussing the encountered challenges and its future prospective in pharmaceutical industry.
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19
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Su Q, Ganesh S, Moreno M, Bommireddy Y, Gonzalez M, Reklaitis GV, Nagy ZK. A perspective on Quality-by-Control (QbC) in pharmaceutical continuous manufacturing. Comput Chem Eng 2019; 125:216-231. [PMID: 36845965 PMCID: PMC9948678 DOI: 10.1016/j.compchemeng.2019.03.001] [Citation(s) in RCA: 73] [Impact Index Per Article: 14.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
Abstract
The Quality-by-Design (QbD) guidance issued by the US Food and Drug Administration (FDA) has catalyzed the modernization of pharmaceutical manufacturing practices including the adoption of continuous manufacturing. Active process control was highlighted recently as a means to improve the QbD implementation. This advance has since been evolving into the concept of Quality-by-Control (QbC). In this study, the concept of QbC is discussed, including a definition of QbC, a review of the recent developments towards the QbC, and a perspective on the challenges of QbC implementation in continuous manufacturing. The QbC concept is demonstrated using a rotary tablet press, integrated into a pilot scale continuous direct compaction process. The results conclusively showed that active process control, based on product and process knowledge and advanced model-based techniques, including data reconciliation, model predictive control (MPC), and risk analysis, is indispensable to comprehensive QbC implementation, and ensures robustness and efficiency.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Yasasvi Bommireddy
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA.,Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
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20
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Han ZY, Xing R, Zhang DH, Shen YH, Fu Q, Ding ZY, Tian CX. Vacuum pressure swing adsorption system for N2/CH4 separation under uncertainty. Chem Eng Res Des 2019. [DOI: 10.1016/j.cherd.2018.12.017] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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21
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Yeap EWQ, Ng DZL, Lai D, Ertl DJ, Sharpe S, Khan SA. Continuous Flow Droplet-Based Crystallization Platform for Producing Spherical Drug Microparticles. Org Process Res Dev 2018. [DOI: 10.1021/acs.oprd.8b00314] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
Affiliation(s)
- Eunice W. Q. Yeap
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore 117576, Singapore
| | - Denise Z. L. Ng
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore 117576, Singapore
| | - David Lai
- GlaxoSmithKline LLC, Product and Process Engineering, 709 Swedeland Road, King of Prussia, Pennsylvania 19406, United States
- GlaxoSmithKline LLC, Advanced Manufacturing Technologies, 830 Winter Street, PC2000, Waltham, Massachusetts 02451, United States
| | - Darryl J. Ertl
- GlaxoSmithKline LLC, Product and Process Engineering, 709 Swedeland Road, King of Prussia, Pennsylvania 19406, United States
| | - Sonja Sharpe
- GlaxoSmithKline LLC, Advanced Manufacturing Technologies, 830 Winter Street, PC2000, Waltham, Massachusetts 02451, United States
| | - Saif A. Khan
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore 117576, Singapore
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22
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Residence Time Distribution (RTD)-Based Control System for Continuous Pharmaceutical Manufacturing Process. J Pharm Innov 2018. [DOI: 10.1007/s12247-018-9356-7] [Citation(s) in RCA: 20] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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23
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Residence time distribution of a continuously-operated capsule filling machine: Development of a measurement technique and comparison of three volume-reducing inserts. Int J Pharm 2018; 550:180-189. [DOI: 10.1016/j.ijpharm.2018.08.017] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/30/2018] [Revised: 08/08/2018] [Accepted: 08/11/2018] [Indexed: 01/20/2023]
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24
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25
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Su Q, Moreno M, Ganesh S, Reklaitis GV, Nagy ZK. Resilience and risk analysis of fault-tolerant process control design in continuous pharmaceutical manufacturing. J Loss Prev Process Ind 2018; 55:411-422. [PMID: 36777050 PMCID: PMC9912099 DOI: 10.1016/j.jlp.2018.07.015] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Abstract
The shift from batch to continuous manufacturing, which is occurring in the pharmaceutical manufacturing industry has implications on process safety and product quality. It is now understood that fault-tolerant process control of critical process parameters (CPPs) and critical quality attributes (CQAs) is of paramount importance to the realization of safe operations and quality products. In this study, a systematic framework for fault-tolerant process control system design, analysis, and evaluation of pharmaceutical continuous oral solid dosage manufacturing is proposed. The framework encompasses system identification, controller design and analysis (controllability, stability, resilience, etc.), hierarchical three-level control structures (model predictive control, state estimation, data reconciliation, etc.), risk mapping, assessment and planning (Risk MAP) strategies, and control performance evaluation. The key idea of the proposed framework is to identify the potential risks associated with the control system design itself, the material property variations, and other process uncertainties, under which the control strategies must be evaluated. The framework is applied to a continuous direct compaction process, specifically the feeding-blending subsystem, wherein the major source of variance in the process operation and product quality arises. It is demonstrated, using simulations and experimentally, that the process operation failures and product quality variations in the feeding-blending system can be mitigated and managed through the proposed systematic fault-tolerant process control system design and risk analysis framework.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, 480 Stadium Mall Drive, West Lafayette, IN, 47907, USA
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26
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Is the adjustment of the impeller speed a reliable attempt to influence granule size in continuous dry granulation? ADV POWDER TECHNOL 2018. [DOI: 10.1016/j.apt.2018.02.029] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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27
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Kappatou CD, Mhamdi A, Campano AQ, Mantalaris A, Mitsos A. Model-Based Dynamic Optimization of Monoclonal Antibodies Production in Semibatch Operation—Use of Reformulation Techniques. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.7b05357] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/28/2023]
Affiliation(s)
- Chrysoula D. Kappatou
- RWTH Aachen University, Aachener Verfahrenstechnik-Process Systems Engineering, Forckenbeckstraße 51, 52074 Aachen, Germany
| | - Adel Mhamdi
- RWTH Aachen University, Aachener Verfahrenstechnik-Process Systems Engineering, Forckenbeckstraße 51, 52074 Aachen, Germany
| | - Ana Quiroga Campano
- Department of Chemical Engineering, Centre for Process Systems Engineering (CPSE), Imperial College London SW7 2AZ, London, U.K
| | - Athanasios Mantalaris
- Department of Chemical Engineering, Centre for Process Systems Engineering (CPSE), Imperial College London SW7 2AZ, London, U.K
| | - Alexander Mitsos
- RWTH Aachen University, Aachener Verfahrenstechnik-Process Systems Engineering, Forckenbeckstraße 51, 52074 Aachen, Germany
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28
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A Systematic Framework for Data Management and Integration in a Continuous Pharmaceutical Manufacturing Processing Line. Processes (Basel) 2018. [DOI: 10.3390/pr6050053] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
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29
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Prediction of critical quality attributes and optimization of continuous dry granulation process via flowsheet modeling and experimental validation. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.02.042] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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30
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Hanson J. Control of a system of loss-in-weight feeders for drug product continuous manufacturing. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.03.027] [Citation(s) in RCA: 27] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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31
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Matsunami K, Miyano T, Arai H, Nakagawa H, Hirao M, Sugiyama H. Decision Support Method for the Choice between Batch and Continuous Technologies in Solid Drug Product Manufacturing. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.7b05230] [Citation(s) in RCA: 38] [Impact Index Per Article: 6.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Kensaku Matsunami
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Takuya Miyano
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd., 1-12-1, Shinomiya, Hiratsuka, Kanagawa 254-0014, Japan
| | - Hiroaki Arai
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd., 1-12-1, Shinomiya, Hiratsuka, Kanagawa 254-0014, Japan
| | - Hiroshi Nakagawa
- Formulation Technology Research Laboratories, Pharmaceutical Technology Division, Daiichi Sankyo Co., Ltd., 1-12-1, Shinomiya, Hiratsuka, Kanagawa 254-0014, Japan
| | - Masahiko Hirao
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
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32
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Escotet-Espinoza MS, Vadodaria S, Singh R, Muzzio FJ, Ierapetritou MG. Modeling the effects of material properties on tablet compaction: A building block for controlling both batch and continuous pharmaceutical manufacturing processes. Int J Pharm 2018; 543:274-287. [PMID: 29567195 DOI: 10.1016/j.ijpharm.2018.03.036] [Citation(s) in RCA: 21] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/05/2017] [Revised: 03/12/2018] [Accepted: 03/17/2018] [Indexed: 10/17/2022]
Abstract
As the pharmaceutical industry modernizes its manufacturing practices and incorporates more efficient processing approaches, it is important to reevaluate which process design elements affect product quality and the means to study these systems. The purpose of this work is to provide insight on a methodology to correlate the effect of raw material properties to equipment and process performance using both data-driven and semi-empirical models. In this work, lubricated blends of pharmaceutically-relevant materials were made using varying levels of magnesium stearate, ranging from 0.25 to 1.5%. Materials characterization (e.g., compressibility, permeability, density, particle size) was performed for all materials and blends. The blends were compressed using a two by three experimental design, varying tablet fill cam depth and tablet thickness, respectively. Tablet properties (e.g., weight, tensile strength, and thickness) were collected for all tablets. Using the collected tablet property results, models coefficients for the semi-empirical Kuentz and Leuenberger equation, which relates the tablet tensile strength to changes in porosity, were regressed. Empirical models were then developed to correlate the values of the Kuentz and Leuenberger equation coefficients to the blend material properties. The empirical models were then used in conjunction with the Kuentz and Leuenberger equation to evaluate the compression design and operational space, accounting for material properties. This proof of concept work aimed at developing correlations between raw material properties and unit operation models can aid process development, especially in design space characterization and robustness analysis.
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Affiliation(s)
- M Sebastian Escotet-Espinoza
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Shishir Vadodaria
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Ravendra Singh
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Fernando J Muzzio
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Marianthi G Ierapetritou
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA.
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33
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Csordas K, Wiedey R, Kleinebudde P. Impact of roll compaction design, process parameters, and material deformation behaviour on ribbon relative density. Drug Dev Ind Pharm 2018; 44:1295-1306. [PMID: 29484952 DOI: 10.1080/03639045.2018.1446444] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
Abstract
Ribbons from microcrystalline cellulose (MCC), mannitol, and their 50:50% mixture were produced using the roll compactors AlexanderWerk BT120, Hosokawa Alpine Pharmapaktor C250, L.B. Bohle BRC 25, and Gerteis Mini-Pactor in the frame of multilevel full factorial experimental plans. The specific compaction force (SCF)/hydraulic pressure (HP), gap width (GW), roll speed, and fraction of MCC were analyzed as quantitative factors, whereas the roll surface and sealing system were examined as qualitative factors. Ribbon relative density was investigated as response of the models. The SCF/HP is found to be the most significant factor in each model. A significant inverse effect of the GW is obtained in the models of AlexanderWerk BT120, Pharmapaktor C250, and BRC 25 roll compactors, using smooth rolls. The principle of the establishment of a conversion factor (cf) is introduced based on the obtained data sets of AlexanderWerk BT120 and Mini-Pactor. This can facilitate the transfer of a roll compaction process between different types of roll compactors.
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Affiliation(s)
- Kitti Csordas
- a Institute of Pharmaceutics and Biopharmaceutics , Heinrich Heine University , Duesseldorf , Germany
| | - Raphael Wiedey
- a Institute of Pharmaceutics and Biopharmaceutics , Heinrich Heine University , Duesseldorf , Germany
| | - Peter Kleinebudde
- a Institute of Pharmaceutics and Biopharmaceutics , Heinrich Heine University , Duesseldorf , Germany
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34
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Process Modification of Pharmaceutical Tablet Manufacturing Operations: An Eco-Efficiency Approach. Processes (Basel) 2018. [DOI: 10.3390/pr6020015] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
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35
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Singh R. Implementation of control system into continuous pharmaceutical manufacturing pilot plant (powder to tablet). COMPUTER AIDED CHEMICAL ENGINEERING 2018. [DOI: 10.1016/b978-0-444-63963-9.00018-x] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/13/2023]
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36
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Singh R. Model-based control system design and evaluation for continuous tablet manufacturing processes (via direct compaction, via roller compaction, via wet granulation). COMPUTER AIDED CHEMICAL ENGINEERING 2018. [DOI: 10.1016/b978-0-444-63963-9.00013-0] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
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37
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Process analysis and optimization of continuous pharmaceutical manufacturing using flowsheet models. Comput Chem Eng 2017. [DOI: 10.1016/j.compchemeng.2017.02.030] [Citation(s) in RCA: 57] [Impact Index Per Article: 8.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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38
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Development and implementation of an advanced model predictive control system into continuous pharmaceutical tablet compaction process. Int J Pharm 2017; 534:159-178. [DOI: 10.1016/j.ijpharm.2017.10.003] [Citation(s) in RCA: 27] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/28/2017] [Revised: 09/19/2017] [Accepted: 10/01/2017] [Indexed: 11/13/2022]
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39
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A Validated Model for Design and Evaluation of Control Architectures for a Continuous Tablet Compaction Process. Processes (Basel) 2017. [DOI: 10.3390/pr5040076] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
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40
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Su Q, Moreno M, Giridhar A, Reklaitis GV, Nagy ZK. A Systematic Framework for Process Control Design and Risk Analysis in Continuous Pharmaceutical Solid-Dosage Manufacturing. J Pharm Innov 2017. [DOI: 10.1007/s12247-017-9297-6] [Citation(s) in RCA: 28] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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41
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Ling J, Chadwick K. Heterogeneous Crystallization Inside Microporous Polymer Particles as a Process Intensification Technology for the Manufacture of Drug Formulations. Org Process Res Dev 2017. [DOI: 10.1021/acs.oprd.6b00380] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Jing Ling
- Department of Industrial
and Physical Pharmacy, College of Pharmacy, Purdue University, West Lafayette, Indiana 47907, United States
| | - Keith Chadwick
- Department of Industrial
and Physical Pharmacy, College of Pharmacy, Purdue University, West Lafayette, Indiana 47907, United States
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42
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Hattori Y, Otsuka M. Modeling of feed-forward control using the partial least squares regression method in the tablet compression process. Int J Pharm 2017; 524:407-413. [DOI: 10.1016/j.ijpharm.2017.04.004] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/18/2017] [Revised: 03/21/2017] [Accepted: 04/03/2017] [Indexed: 11/16/2022]
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43
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Gupte A, DeHart M, Stagner WC, Haware RV. Comparative binder efficiency modeling of dry granulation binders using roller compaction. Drug Dev Ind Pharm 2017; 43:574-583. [DOI: 10.1080/03639045.2016.1272118] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
Affiliation(s)
| | | | - William C. Stagner
- Campbell University College of Pharmacy & Health Sciences, Buies Creek, NC, USA
| | - Rahul V. Haware
- Campbell University College of Pharmacy & Health Sciences, Buies Creek, NC, USA
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44
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Sensitivity analysis of a pharmaceutical tablet production process from the control engineering perspective. Int J Pharm 2017; 517:373-382. [DOI: 10.1016/j.ijpharm.2016.11.064] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/05/2016] [Revised: 11/28/2016] [Accepted: 11/29/2016] [Indexed: 11/18/2022]
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45
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46
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Batra A, Desai D, Serajuddin ATM. Investigating the Use of Polymeric Binders in Twin Screw Melt Granulation Process for Improving Compactibility of Drugs. J Pharm Sci 2016; 106:140-150. [PMID: 27578544 DOI: 10.1016/j.xphs.2016.07.014] [Citation(s) in RCA: 46] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/30/2016] [Revised: 06/26/2016] [Accepted: 07/12/2016] [Indexed: 11/28/2022]
Abstract
Traditionally, the melt granulation for pharmaceutical products was performed at low temperature (<90°C) with high-shear granulators using low-melting waxy binders, and tablets produced using such granules were not amenable to large-scale manufacturing. The situation has changed in recent years by the use of twin screw extruder where the processing temperature could be increased to as high as 180°C and polymers with high Tg could be used as binders. In this study, different polymeric binders were screened for their suitability in improving compactibility of 2 drugs, metformin hydrochloride and acetaminophen, by twin screw melt granulation. Processing temperatures for the 2 drugs were set at 180°C and 130°C, respectively. Screw configuration, screw speed, and feed rate were optimized such that all polymeric binders used produced granules. Several hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyvinylpyrrolidone, and methacrylate-based polymers, including Klucel® EXF, Eudragit® EPO, and Soluplus®, demonstrated good tablet tensile strength (>2 MPa) when granules were produced using only 10% wt/wt polymer concentration. Certain polymers provided acceptable compactibility even at 5% wt/wt. Thus, twin screw melt granulation process may be used with different polymers at a wide range of temperature. Due to low excipient concentration, this granulation method is especially suitable for high-dose tablets.
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Affiliation(s)
- Amol Batra
- Department of Pharmaceutical Sciences, College of Pharmacy and Health Sciences, St. John's University, Queens, New York 11439
| | - Dipen Desai
- Kashiv Pharma LLC, Bridgewater, New Jersey 08807
| | - Abu T M Serajuddin
- Department of Pharmaceutical Sciences, College of Pharmacy and Health Sciences, St. John's University, Queens, New York 11439.
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47
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Zhang L, Mao S. Application of quality by design in the current drug development. Asian J Pharm Sci 2016; 12:1-8. [PMID: 32104308 PMCID: PMC7032183 DOI: 10.1016/j.ajps.2016.07.006] [Citation(s) in RCA: 101] [Impact Index Per Article: 12.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2016] [Revised: 07/07/2016] [Accepted: 07/31/2016] [Indexed: 11/15/2022] Open
Abstract
Quality by Test was the only way to guarantee quality of drug products before FDA launched current Good Manufacturing Practice. To clearly understand the manufacture processes, FDA generalized Quality by Design (QbD) in the field of pharmacy, which is based on the thorough understanding of how materials and process parameters affect the quality profile of final products. The application of QbD in drug formulation and process design is based on a good understanding of the sources of variability and the manufacture process. In this paper, the basic knowledge of QbD, the elements of QbD, steps and tools for QbD implementation in pharmaceutics field, including risk assessment, design of experiment, and process analytical technology (PAT), are introduced briefly. Moreover, the concrete applications of QbD in various pharmaceutical related unit operations are summarized and presented.
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Affiliation(s)
- Lan Zhang
- Shenyang Pharmaceutical University, No.103, Wenhua Road, Shenyang 110016, China
| | - Shirui Mao
- Shenyang Pharmaceutical University, No.103, Wenhua Road, Shenyang 110016, China
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48
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Rehrl J, Kruisz J, Sacher S, Khinast J, Horn M. Optimized continuous pharmaceutical manufacturing via model-predictive control. Int J Pharm 2016; 510:100-15. [DOI: 10.1016/j.ijpharm.2016.06.024] [Citation(s) in RCA: 29] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/29/2016] [Revised: 05/25/2016] [Accepted: 06/07/2016] [Indexed: 10/21/2022]
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49
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Ierapetritou M, Muzzio F, Reklaitis G. Perspectives on the continuous manufacturing of powder-based pharmaceutical processes. AIChE J 2016. [DOI: 10.1002/aic.15210] [Citation(s) in RCA: 106] [Impact Index Per Article: 13.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Marianthi Ierapetritou
- Dept. of Chemical and Biochemical Engineering, Rutgers; The State University of New Jersey; Piscataway NJ 08854-8058
| | - Fernando Muzzio
- Dept. of Chemical and Biochemical Engineering, Rutgers; The State University of New Jersey; Piscataway NJ 08854-8058
| | - Gintaras Reklaitis
- School of Chemical Engineering; Purdue University; 480 Stadium Mall Drive West Lafayette IN 47907-2100
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50
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