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Aroniada M, Bano G, Vueva Y, Christodoulou C, Li F, Litster JD. A novel mixing rule model to predict the flowability of directly compressed pharmaceutical blends. Int J Pharm 2023; 647:123475. [PMID: 37832706 DOI: 10.1016/j.ijpharm.2023.123475] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/03/2023] [Revised: 08/29/2023] [Accepted: 09/30/2023] [Indexed: 10/15/2023]
Abstract
In the pharmaceutical industry, powder flowability is an essential manufacturability attribute to consider when selecting the suitable manufacturing route and formulation. The selection of the formulation is usually based on the physical and chemical properties of the Active Pharmaceutical Ingredient (API) under consideration. Current industrial practice heavily relies on experimental work, which often results in significant labor and API consumption that results in higher costs. In this study we describe the development of a mixing rule to predict powder blend flowability from the flow properties of the individual components for industrial formulations manufactured via Direct Compression (DC). The mixing rule assumes that the granular solids' interactions are dominated by cohesive forces but are pragmatic to calibrate from the perspective of the typical data collated in an industrial environment. The proposed model was validated using a range of different APIs and the results show that the model can effectively predict the flowability properties of any formulation across the space of DC-relevant formulation compositions. Finally, a connection between the model and APIs properties (shape and size) was investigated via a linear correlation between the API particle properties and interparticle forces.
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Affiliation(s)
| | - Gabriele Bano
- GlaxoSmithKline (GSK), 1250 S Collegeville Rd., Collegeville, PA 19426, United States
| | - Yuliya Vueva
- GlaxoSmithKline (GSK), Park Road, Ware SG12 0DP, United Kingdom
| | | | - Feng Li
- Department of Chemical & Biological Engineering, University of Sheffield, Sheffield S10 2TN, United Kingdom; School of Environmental Science and Engineering, Suzhou University of Science and Technology, Suzhou 215009, PR China
| | - James D Litster
- Department of Chemical & Biological Engineering, University of Sheffield, Sheffield S10 2TN, United Kingdom
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Jin C, Zhao L, Feng Y, Hong Y, Shen L, Lin X. Simultaneous modeling prediction of three key quality attributes of tablets by powder physical properties. Int J Pharm 2022; 628:122344. [DOI: 10.1016/j.ijpharm.2022.122344] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2022] [Revised: 10/11/2022] [Accepted: 10/22/2022] [Indexed: 11/06/2022]
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3
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Wünsch I, Henrik Finke J, John E, Juhnke M, Kwade A. Influence of the drug deformation behaviour on the predictability of compressibility and compactibility of binary mixtures. Int J Pharm 2022; 626:122117. [PMID: 35985527 DOI: 10.1016/j.ijpharm.2022.122117] [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: 04/16/2022] [Revised: 08/06/2022] [Accepted: 08/11/2022] [Indexed: 10/15/2022]
Abstract
Various studies investigate the predictability of the compressibility and compactibility of tablet formulations based on the behaviour of the pure materials. However, these studies are limited to a few materials so far probably because of the complexity of the powder compaction process. One approach preventing the excessive increase in complexity is the extension of the investigations from pure materials to binary powder mixtures. The focus of this study is on the predictability of the compressibility and compactibility of binary mixtures consisting of an active pharmaceutical ingredient (API) and the excipient microcrystalline cellulose. Three APIs with markedly different deformation behaviour were used. The API concentration and type are systematically varied. For all three material combinations it is found that the in-die compressibility of the binary mixtures can be precisely predicted based on the characteristic compression parameters of the raw materials using the extended in-die compression function in combination with a volume-based linear mixing rule. Since the tablet porosity (out-of-die) also follows a linear mixing rule, the predictability can be further extended using the method of Katz et al. In contrast, the influence of the API concentration on compactibility or rather on tablet tensile strength is non-linear and strongly dependent on the deformation behaviour of the API, making the predictability more difficult. Neither the approach of Reynolds et al. nor this of Kuentz and Leuenberger are able to predict the compactibility when clear deviations from a linear mixing rule appear.
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Affiliation(s)
- Isabell Wünsch
- Technische Universität Braunschweig, Institute for Particle Technology, Volkmaroder Straße 5, 38104, Braunschweig, Germany; Technische Universität Braunschweig, Center of Pharmaceutical Engineering (PVZ), Franz-Liszt-Straße 35A, 38106 Braunschweig, Germany
| | - Jan Henrik Finke
- Technische Universität Braunschweig, Institute for Particle Technology, Volkmaroder Straße 5, 38104, Braunschweig, Germany; Technische Universität Braunschweig, Center of Pharmaceutical Engineering (PVZ), Franz-Liszt-Straße 35A, 38106 Braunschweig, Germany
| | | | | | - Arno Kwade
- Technische Universität Braunschweig, Institute for Particle Technology, Volkmaroder Straße 5, 38104, Braunschweig, Germany; Technische Universität Braunschweig, Center of Pharmaceutical Engineering (PVZ), Franz-Liszt-Straße 35A, 38106 Braunschweig, Germany
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Kumar A, Ramisetty KA, Bordignon S, Hodnett BK, Davern P, Hudson S. Preparation, stabilisation, isolation and tableting of valsartan nanoparticles using a semi-continuous carrier particle mediated process. Int J Pharm 2021; 597:120199. [PMID: 33486046 DOI: 10.1016/j.ijpharm.2021.120199] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/08/2020] [Revised: 11/28/2020] [Accepted: 12/20/2020] [Indexed: 01/23/2023]
Abstract
This work investigated the technical feasibility of preparing, stabilizing and isolating poorly water-soluble drug nanoparticles via a small-scale antisolvent precipitation process operating in semi-continuous mode. Specifically, a novel semi-continuous process was demonstrated for the carrier particle mediated production, stabilization and isolation of valsartan nanoparticles into a solid form using montmorillonite clay particles as the carrier. The semi-continuous process operated robustly for the full duration of the experiment (~16 min) and steady-state conditions were reached after ~5 min. Nanoparticles of valsartan (51 ± 1 nm) were successfully prepared, stabilized and isolated with the help of montmorillonite (MMT) or protamine functionalized montmorillonite (PA-MMT) into the dried form by this semi-continuous route. The dissolution profile of the isolated valsartan nanocomposite solids was similar to that of valsartan nanocomposite solids produced via the corresponding laboratory scale batch mode process, indicating that the product quality (principally the nanoscale particle size and solid-state form) is retained during the semi-continuous processing of the nanoparticles. Furthermore, tablets produced via direct compression of the isolated valsartan nanocomposite solids displayed a dissolution profile comparable with that of the powdered nanocomposite material. PXRD, DSC, SSNMR and dissolution studies indicate that the valsartan nanoparticles produced via this semi-continuous process were amorphous and exhibited shelf-life stability equivalent to > 10 months.
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Affiliation(s)
- Ajay Kumar
- Synthesis and Solid State Pharmaceutical Centre, Department of Chemical Sciences, and The Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland; SSPC the Science Foundation Ireland Research Centre for Pharmaceutics, University of Limerick, Limerick V94 T9PX, Ireland.
| | - Kiran A Ramisetty
- Synthesis and Solid State Pharmaceutical Centre, Department of Chemical Sciences, and The Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland; SSPC the Science Foundation Ireland Research Centre for Pharmaceutics, University of Limerick, Limerick V94 T9PX, Ireland.
| | - Simone Bordignon
- Synthesis and Solid State Pharmaceutical Centre, Department of Chemical Sciences, and The Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland.
| | - Benjamin K Hodnett
- Synthesis and Solid State Pharmaceutical Centre, Department of Chemical Sciences, and The Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland; SSPC the Science Foundation Ireland Research Centre for Pharmaceutics, University of Limerick, Limerick V94 T9PX, Ireland.
| | - Peter Davern
- Synthesis and Solid State Pharmaceutical Centre, Department of Chemical Sciences, and The Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland; SSPC the Science Foundation Ireland Research Centre for Pharmaceutics, University of Limerick, Limerick V94 T9PX, Ireland.
| | - Sarah Hudson
- Synthesis and Solid State Pharmaceutical Centre, Department of Chemical Sciences, and The Bernal Institute, University of Limerick, Limerick V94 T9PX, Ireland; SSPC the Science Foundation Ireland Research Centre for Pharmaceutics, University of Limerick, Limerick V94 T9PX, Ireland.
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Paul S, Wang C, Sun CC. Tabletability Flip - Role of Bonding Area and Bonding Strength Interplay. J Pharm Sci 2020; 109:3569-3573. [PMID: 32910948 DOI: 10.1016/j.xphs.2020.09.005] [Citation(s) in RCA: 12] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/07/2020] [Revised: 08/02/2020] [Accepted: 09/03/2020] [Indexed: 10/23/2022]
Abstract
Predicting tableting performance of mixtures from that of individual components is of practical importance for achieving efficient and robust tablet design. It has been commonly assumed that a solid form exhibiting better tabletability will result in better tabletability when formulated. However, we show that the rank order of tabletability between two powders can flip when mixed with another powder, a phenomenon termed tabletability flip. Using three examples, we show that the tabletability flip upon mixing with microcrystalline cellulose is activated by the switch of the dominating factor in the bonding area (BA) and bonding strength (BS) interplay that determines tablet tensile strength. A mechanistic understanding of this phenomenon can significantly improve the accuracy of predicted tableting performance of mixtures from that of individual powders.
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Affiliation(s)
- Shubhajit Paul
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, 9-127B Weaver-Densford Hall, 308 Harvard Street S.E., Minneapolis, MN 55455, USA
| | - Chenguang Wang
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, 9-127B Weaver-Densford Hall, 308 Harvard Street S.E., Minneapolis, MN 55455, USA
| | - Changquan Calvin Sun
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, 9-127B Weaver-Densford Hall, 308 Harvard Street S.E., Minneapolis, MN 55455, USA.
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Steffens KE, Wagner KG. Compression behaviour of granules produced via twin-screw melt granulation: Effect of initial particle size on granulation efficiency. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.07.037] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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Menth J, Maus M, Wagner KG. Continuous twin screw granulation and fluid bed drying: A mechanistic scaling approach focusing optimal tablet properties. Int J Pharm 2020; 586:119509. [PMID: 32561305 DOI: 10.1016/j.ijpharm.2020.119509] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/05/2020] [Revised: 06/02/2020] [Accepted: 06/03/2020] [Indexed: 11/25/2022]
Abstract
This study provides the results of investigation on scaling approaches for three differently-sized continuous granulation lines, each consisting of a twin screw wet granulation process and a continuous fluid bed drying process. To check the initial scaling approach with regard to granule and tablet properties, a process parameter Design of experiment (DoE) was performed on each of the three equipment scales. The processed formulation did not contain cellulose to allow a high overall flowrate through the directly connected granulation and drying sections. Enhanced scaling aspects showed the influence of Froude number [-] at different twin screw granulator scales and screw speeds on the overgranulated particle fraction [% (V/V] as well as on the scale-dependent drying performance of the continuous fluid bed dryers. Scale-independent, specification limits of the two granule material attributes particle fine fraction [%] and residual water content [%] could be defined, resulting in high tableting performance in terms of tabletability and compressibility. Based on these specification limits and the statistical evaluation of the process parameter DoE, a process design space for the continuous granulation and drying process for each scale was calculated. It came up, that this process design space was decreasing in range with increasing equipment scale. The applicability of the presented scaling approach in terms of granule and tablet properties could successfully be demonstrated by three control experiments performed on the different equipment scales. In sum, this work delivers a basis for a smooth transition of scales within process development on the investigated continuous twin screw granulation and drying lines.
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Affiliation(s)
- Judith Menth
- Pharmaceutical Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Straße 65, 88397 Biberach, Germany; Department of Pharmaceutical Technology, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany
| | - Martin Maus
- Pharmaceutical Development, Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Straße 65, 88397 Biberach, Germany
| | - Karl G Wagner
- Department of Pharmaceutical Technology, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany.
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Schaller BE, Moroney KM, Castro-Dominguez B, Cronin P, Belen-Girona J, Ruane P, Croker DM, Walker GM. Systematic development of a high dosage formulation to enable direct compression of a poorly flowing API: A case study. Int J Pharm 2019; 566:615-630. [PMID: 31158454 DOI: 10.1016/j.ijpharm.2019.05.073] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2019] [Revised: 05/13/2019] [Accepted: 05/30/2019] [Indexed: 10/26/2022]
Abstract
In this work, the transfer of oral solid dosage forms, currently manufactured via wet granulation, to a continuous direct compression process was considered. Two main challenges were addressed: (1) a poorly flowing API (Canagliflozin) and (2) high drug loading (51 wt%). A scientific approach was utilised for formulation development, targeting flow and compaction behaviour suitable for manufacturing scale. This was achieved through systematic screening of excipients to identify feasible formulations. Targeted design of experiments based on factors such as formulation mixture and processing parameters were utilised to investigate key responses for tablet properties, flow and compaction behaviour. Flow behaviour was primarily evaluated from percentage compressibility and shear cell testing on a powder flow rheometer (FT4). The compaction behaviour was studied using a compaction simulator (Gamlen). The relationships between tablet porosity, tensile strength and compaction pressure were used to evaluate tabletability, compactibility and compressibility to assess scale-up. The success of this design procedure is illustrated by scaling up from the compaction simulator to a Riva Piccola rotary tablet press, while maintaining critical quality attributes (CQAs). Compactibility was identified as a suitable scale-up relationship. The developed procedure should allow accelerated development of formulations for continuous direct compression.
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Affiliation(s)
- Barbara E Schaller
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland.
| | - Kevin M Moroney
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland; MACSI, Department of Mathematics and Statistics, University of Limerick, Limerick, Ireland
| | | | - Patrick Cronin
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland
| | - Jorge Belen-Girona
- Johnson & Johnson Supply Chain, Product Supply - Manufacturing Engineering and Technology, USA
| | - Patrick Ruane
- Johnson & Johnson Supply Chain, Product Supply - Manufacturing Engineering and Technology, USA
| | - Denise M Croker
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland
| | - Gavin M Walker
- Synthesis and Solid State Pharmaceutical Centre (SSPC), Bernal Institute, University of Limerick, Limerick, Ireland
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10
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Nordström J, Alderborn G, Frenning G. Compressibility and tablet forming ability of bimodal granule mixtures: Experiments and DEM simulations. Int J Pharm 2018; 540:120-131. [DOI: 10.1016/j.ijpharm.2018.02.006] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/07/2017] [Revised: 01/31/2018] [Accepted: 02/04/2018] [Indexed: 10/18/2022]
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