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Celikovic S, Poms J, Khinast J, Horn M, Rehrl J. Development and Application of Control Concepts for Twin-Screw Wet Granulation in the ConsiGma TM-25: Part 1 Granule Composition. Int J Pharm 2024; 657:124124. [PMID: 38636678 DOI: 10.1016/j.ijpharm.2024.124124] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/23/2024] [Revised: 04/09/2024] [Accepted: 04/12/2024] [Indexed: 04/20/2024]
Abstract
Continuous manufacturing of pharmaceuticals offers several benefits, such as increased production efficiency, enhanced product quality control, and lower environmental footprint. To fully exploit these benefits, standard operation mode (production processes with no or minimal disturbance mitigation measures) should be supported by adopting novel quality-by-control (QbC) methodologies. The paper at hand is the first part of a study focused on developing QbC algorithms for optimizing twin-screw wet granulation in the industrial manufacturing line ConsiGmaTM-25, specifically addressing granule composition. This work relies on previously established process-analytical-technology (PAT) equipment for real-time monitoring of the granule composition, i.e., the active pharmaceutical ingredient (API) and liquid content in wet granules. The developed control platform integrates model-based process control algorithms that aim to keep the API- and liquid content at target values through real-time adjustments of the process parameters. Furthermore, the platform integrates a digital operator assistant, which aims to detect and classify granulation disturbances and provides messages and instructions for the plant operator. The present manuscript systematically outlines all design steps from the development phase in the simulation environment to the final real system application and validation. The control platform's performance is demonstrated through selected test scenarios on the ConsiGmaTM-25 manufacturing line. The obtained results indicate improved disturbance robustness and an increase in intermediate/final product quality (compared to conventional operating modes): The process control algorithms successfully maintained the API- and liquid content at target values despite process disturbances. Furthermore, realistic disturbances (feeder, pump, and material) were accurately detected and classified by the digital assistant algorithm. The information was provided through a user interface, offering real-time support for plant personnel.
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Affiliation(s)
- Selma Celikovic
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria; Institute of Automation and Control, Graz University of Technology, Inffeldgasse 21b, 8010 Graz, Austria
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria; Institute of Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
| | - Martin Horn
- Institute of Automation and Control, Graz University of Technology, Inffeldgasse 21b, 8010 Graz, Austria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria.
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2
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Bhalode P, Razavi SM, Tian H, Roman-Ospino A, Scicolone J, Callegari G, Dubey A, Koolivand A, Krull S, O'Connor T, Muzzio FJ, Ierapetritou MG. Statistical data treatment for residence time distribution studies in pharmaceutical manufacturing. Int J Pharm 2024; 657:124133. [PMID: 38642620 DOI: 10.1016/j.ijpharm.2024.124133] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/18/2024] [Revised: 04/13/2024] [Accepted: 04/15/2024] [Indexed: 04/22/2024]
Abstract
Residence time distribution (RTD) method has been widely used in the pharmaceutical manufacturing for understanding powder dynamics within unit operations and continuous integrated manufacturing lines. The dynamics thus captured is then used to develop predictive models for unit operations and important RTD-based applications ensuring product quality assurance. Despite thorough efforts in tracer selection, data acquisition, and calibration model development to obtain tracer concentration profiles for RTD studies, there can exist significant noise in these profiles. This noise can make it challenging to identify the underlying signal and get a representative RTD of the system under study. Such concerns have previously indicated the importance of noise handling for RTD measurements in literature. However, the literature does not provide sufficient information on noise handling or data treatment strategies for RTD studies. To this end, we investigate the impact of varying levels of noise using different tracers on measurement of RTD profile and its applications. We quantify the impact of different denoising methods (time and frequency averaging methods). Through this investigation, we see that Savitsky Golay filtering turns out to a good method for denoising RTD profiles despite varying noise levels. The investigation is performed such that the key features of the RTD profile (which are important for RTD based applications) are preserved. Subsequently, we also investigate the impact of denoising on RTD-based applications such as out-of-specification (OOS) analysis and RTD modeling. The results show that the degree of noise levels considered in this work do not significantly impact the RTD-based applications.
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Affiliation(s)
- Pooja Bhalode
- Center of Plastics Innovation, University of Delaware, DE, USA
| | - Sonia M Razavi
- Department of Chemical and Biochemical Engineering, Rutgers University, NJ, USA
| | - Huayu Tian
- Department of Chemical and Biomolecular Engineering, University of Delaware, DE, USA
| | - Andres Roman-Ospino
- Department of Chemical and Biochemical Engineering, Rutgers University, NJ, USA
| | - James Scicolone
- Department of Chemical and Biochemical Engineering, Rutgers University, NJ, USA
| | - Gerardo Callegari
- Department of Chemical and Biochemical Engineering, Rutgers University, NJ, USA
| | - Atul Dubey
- Pharmaceutical Continuous Manufacturing (PCM), United States Pharmacopeia, 12601 Twinbrook Parkway, Rockville, MD, USA
| | - Abdollah Koolivand
- Office of Pharmaceutical Quality, Center for Drug Evaluation Research, Food and Drug Administration, 10903 New Hampshire Ave, Silver Springs, MD 20993, USA
| | - Scott Krull
- Office of Pharmaceutical Quality, Center for Drug Evaluation Research, Food and Drug Administration, 10903 New Hampshire Ave, Silver Springs, MD 20993, USA
| | - Thomas O'Connor
- Office of Pharmaceutical Quality, Center for Drug Evaluation Research, Food and Drug Administration, 10903 New Hampshire Ave, Silver Springs, MD 20993, USA
| | - Fernando J Muzzio
- Department of Chemical and Biochemical Engineering, Rutgers University, NJ, USA
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3
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Toson P, Khinast JG. A DEM Model to Evaluate Refill Strategies of a Twin-Screw Feeder. Int J Pharm 2023; 641:122915. [PMID: 37015295 DOI: 10.1016/j.ijpharm.2023.122915] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/10/2023] [Revised: 03/28/2023] [Accepted: 03/29/2023] [Indexed: 04/04/2023]
Abstract
Residence time distribution (RTD) modeling has proven to be a valuable tool for material tracking in continuous pharmaceutical processes. Refilling is thoroughly studied in the literature, but the main focus lies on the feed rate disturbances. The impact of the feeders themselves on intermixing of different material batches is often overlooked. Since the experimental methods to measure the RTD feeder discharging processes feeder are complex and material intensive, there is only limited experimental RTD data available in the literature. A DEM (discrete element method) simulation of a discharge of a twin-screw feeder shows that a large fraction of material that is moved and intermixed by the agitator. In addition to the intermixing, there is a tendency to discharge material located above the agitator early. In order to predict the behavior during multiple refill events, three models in order of increasing complexity are presented: (1) A simple exponential RTD assuming perfect intermixing of material batches; (2) a RTD model based on DEM results; (3) particle-level material tracking by extrapolation of the DEM results. All three of these models are able to predict the survival function of old material for late refills at low fill levels, however, earlier refills at high fill levels require more complex models to accurately represent the dynamics inside the hopper of the feeder.
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4
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Tian H, Bhalode P, Razavi SM, Koolivand A, Muzzio FJ, Ierapetritou MG. Characterization and propagation of RTD uncertainty for continuous powder blending processes. Int J Pharm 2022; 628:122326. [DOI: 10.1016/j.ijpharm.2022.122326] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/15/2022] [Revised: 09/18/2022] [Accepted: 10/16/2022] [Indexed: 10/31/2022]
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5
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An extended 3-compartment model for describing step change experiments in pharmaceutical twin-screw feeders at different refill regimes. Int J Pharm 2022; 627:122154. [DOI: 10.1016/j.ijpharm.2022.122154] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/25/2022] [Revised: 08/24/2022] [Accepted: 08/26/2022] [Indexed: 11/18/2022]
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Gyürkés M, Madarász L, Záhonyi P, Köte Á, Nagy B, Pataki H, Nagy ZK, Domokos A, Farkas A. Soft sensor for content prediction in an integrated continuous pharmaceutical formulation line based on the residence time distribution of unit operations. Int J Pharm 2022; 624:121950. [PMID: 35753540 DOI: 10.1016/j.ijpharm.2022.121950] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/31/2022] [Revised: 06/14/2022] [Accepted: 06/20/2022] [Indexed: 12/01/2022]
Abstract
In this study, a concentration predicting soft sensor was achieved based on the Residence Time Distribution (RTD) of an integrated, three-step pharmaceutical formulation line. The RTD was investigated with color-based tracer experiments using image analysis. Twin-screw wet granulation (TSWG) was directly coupled with a horizontal fluid bed dryer and an oscillating mill. Based on integrated measurement, we proved that it is also possible to couple the unit operations in silico. Three surrogate tracers were produced with a coloring agent to investigate the separated unit operations and the solid and liquid inputs of the TSWG. The soft sensor's prediction was compared to validating experiments of a 0.05 mg/g (15% of the nominal) concentration change with High-Performance Liquid Chromatography (HPLC) reference measurements of the active ingredient proving the adequacy of the soft sensor (RMSE < 4%).
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Affiliation(s)
- Martin Gyürkés
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Petra Záhonyi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Ákos Köte
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Zsombor Kristóf Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - András Domokos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
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7
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Peterwitz M, Jodwirschat J, Loll R, Schembecker G. Tracking raw material flow through a continuous direct compression line Part I of II: Residence time distribution modeling and sensitivity analysis enabling increased process yield. Int J Pharm 2022; 614:121467. [PMID: 35032576 DOI: 10.1016/j.ijpharm.2022.121467] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/05/2021] [Revised: 12/30/2021] [Accepted: 01/08/2022] [Indexed: 11/30/2022]
Abstract
Continuous manufacturing (CM) offers advantages in quality and space-time yield compared to common batch manufacturing. However, higher yield losses due to the start-up procedure make a broad application uneconomical. This work discusses the possibility of reducing yield losses by adjusting the degree of back-mixing. Back-mixing of nonconforming material from disturbances or start-up will result in the contamination of subsequent material. Therefore, higher degrees of back-mixing cause the discharge of additional material. Choosing an advantageous setting of operational parameters may be a simple way to change the degree of back-mixing. Based on direct compression, this work demonstrates the identification of promising parameters. Therefore, step-change experiments using color-marked material in the feeder, blender, and tablet press quantify the impact of three operational parameters per device. Models for the devices and the entire process result from those measurements. Subsequently, a global variance-based sensitivity analysis identifies the most influential parameters. As a result, adjusting the minimal filling level of the feeder and the rotational feed frame speed of the tablet press reduces back-mixing by more than 30%. At high costs of the raw materials, the resulting savings can significantly improve the economic performance of CM compared to batch manufacturing.
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Affiliation(s)
- Moritz Peterwitz
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany; Invite GmbH, Otto-Bayer-Straße 32, D-51061 Cologne, Germany
| | - Janis Jodwirschat
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
| | - Rouven Loll
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
| | - Gerhard Schembecker
- Laboratory of Plant and Process Design, Faculty of Biochemical and Chemical Engineering, TU Dortmund University, Emil-Figge-Straße 70, D-44227 Dortmund, Germany
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8
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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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9
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Bhalode P, Tian H, Gupta S, Razavi SM, Roman-Ospino A, Talebian S, Singh R, Scicolone JV, Muzzio FJ, Ierapetritou M. Using residence time distribution in pharmaceutical solid dose manufacturing - A critical review. Int J Pharm 2021; 610:121248. [PMID: 34748808 DOI: 10.1016/j.ijpharm.2021.121248] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/20/2021] [Revised: 10/04/2021] [Accepted: 10/27/2021] [Indexed: 11/18/2022]
Abstract
While continuous manufacturing (CM) of pharmaceutical solid-based drug products has been shown to be advantageous for improving the product quality and process efficiency in alignment with FDA's support of the quality-by-design paradigm (Lee, 2015; Ierapetritou et al., 2016; Plumb, 2005; Schaber, 2011), it is critical to enable full utilization of CM technology for robust production and commercialization (Schaber, 2011; Byrn, 2015). To do so, an important prerequisite is to obtain a detailed understanding of overall process characteristics to develop cost-effective and accurate predictive models for unit operations and process flowsheets. These models are utilized to predict product quality and maintain desired manufacturing efficiency (Ierapetritou et al., 2016). Residence time distribution (RTD) has been a widely used tool to characterize the extent of mixing in pharmaceutical unit operations (Vanhoorne, 2020; Rogers and Ierapetritou, 2015; Teżyk et al., 2015) and manufacturing lines and develop computationally cheap predictive models. These models developed using RTD have been demonstrated to be crucial for various flowsheet applications (Kruisz, 2017; Martinetz, 2018; Tian, 2021). Though extensively used in the literature (Gao et al., 2012), the implementation, execution, evaluation, and assessment of RTD studies has not been standardized by regulatory agencies and can thus lead to ambiguity regarding their accurate implementation. To address this issue and subsequently prevent unforeseen errors in RTD implementation, the presented article aims to aid in developing standardized guidelines through a detailed review and critical discussion of RTD studies in the pharmaceutical manufacturing literature. The review article is divided into two main sections - 1) determination of RTD including different steps for RTD evaluation including experimental approach, data acquisition and pre-treatment, RTD modeling, and RTD metrics and, 2) applications of RTD for solid dose manufacturing. Critical considerations, pertaining to the limitations of RTDs for solid dose manufacturing, are also examined along with a perspective discussion of future avenues of improvement.
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Affiliation(s)
- Pooja Bhalode
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Huayu Tian
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, USA
| | - Shashwat Gupta
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Sonia M Razavi
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Andres Roman-Ospino
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Shahrzad Talebian
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Ravendra Singh
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - James V Scicolone
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Fernando J Muzzio
- Department of Chemical and Biochemical Engineering, Rutgers - The State University of New Jersey, Piscataway, NJ 08854, USA
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, USA.
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10
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Single-crystal Drying: Development of a Continuous Drying Prototype to Optimize Particle Flow and Residence Time Distribution. J Pharm Innov 2021. [DOI: 10.1007/s12247-021-09573-2] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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11
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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: 29] [Impact Index Per Article: 9.7] [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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12
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Matić J, Alva C, Eder S, Reusch K, Paudel A, Khinast J. Towards predicting the product quality in hot-melt extrusion: Pilot plant scale extrusion. INTERNATIONAL JOURNAL OF PHARMACEUTICS-X 2021; 3:100084. [PMID: 34159312 PMCID: PMC8193368 DOI: 10.1016/j.ijpx.2021.100084] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/16/2021] [Accepted: 05/17/2021] [Indexed: 11/25/2022]
Abstract
Following our study on the impact of hot melt extrusion (HME) process conditions on the product quality, we expanded our investigation to assessing the effect of scale-up on the product quality. To this end, we studied the influence of process settings and different scale-up variants on the active pharmaceutical ingredient (API) degradation in a pilot plant scale extruder. Six scale-up variants were investigated and none of them could replicate the product quality from the original process setup on a lab-scale extruder. By analyzing several process-dependent and -independent variables and cross referencing them to the experiments in the lab-scale extruder, we identified certain patterns. The results of the reduced order mechanistic 1D HME simulation of various process states made it possible to establish a correlation between the achieved API degradation and the local melt temperature and the exposure time in specific zones along the screw configuration. Since the same melt temperature and exposure time correlations were also valid for the lab scale-extruder, such an approach could be used in the future to predict the product quality as a function of processing conditions fully in silico prior to the first extrusion trials.
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Affiliation(s)
- Josip Matić
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Carolina Alva
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Simone Eder
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Kathrin Reusch
- Leistritz Pharma Extrusion, Markgrafenstraße. 29-39 1, 90459 Nürnberg, Germany
| | - Amrit Paudel
- 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
| | - 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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13
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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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14
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Applications of machine vision in pharmaceutical technology: A review. Eur J Pharm Sci 2021; 159:105717. [DOI: 10.1016/j.ejps.2021.105717] [Citation(s) in RCA: 21] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/20/2020] [Revised: 01/08/2021] [Accepted: 01/11/2021] [Indexed: 02/07/2023]
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15
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Galata DL, Mészáros LA, Ficzere M, Vass P, Nagy B, Szabó E, Domokos A, Farkas A, Csontos I, Marosi G, Nagy ZK. Continuous blending monitored and feedback controlled by machine vision-based PAT tool. J Pharm Biomed Anal 2021; 196:113902. [PMID: 33486449 DOI: 10.1016/j.jpba.2021.113902] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/10/2020] [Revised: 01/11/2021] [Accepted: 01/12/2021] [Indexed: 12/20/2022]
Abstract
In a continuous powder blending process machine vision is utilized as a Process Analytical Technology (PAT) tool. While near-infrared (NIR) and Raman spectroscopy are reliable methods in this field, measurements become challenging when concentrations below 2 w/w% are quantified. However, an active pharmaceutical ingredient (API) with an intense color might be quantified in even lower quantities by images recorded with a digital camera. Riboflavin (RI) was used as a model API with orange color, its Limit of Detection was found to be 0.015 w/w% and the Limit of Quantification was 0.046 w/w% using a calibration based on the pixel value of images. A calibration for in-line measurement of RI concentration was prepared in the range of 0.2-0.45 w/w%, validation with UV/VIS spectrometry showed great accuracy with a relative error of 2.53 %. The developed method was then utilized for a residence time distribution (RTD) measurement in order to characterize the dynamics of the blending process. Lastly, the technique was applied in real-time feedback control of a continuous powder blending process. Machine vision based direct or indirect API concentration determination is a promising and fast method with a great potential for monitoring and control of continuous pharmaceutical processes.
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Affiliation(s)
- Dorián László Galata
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Lilla Alexandra Mészáros
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Máté Ficzere
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Panna Vass
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Edina Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - András Domokos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - István Csontos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Zsombor Kristóf Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111, Budapest, Műegyetem rakpart 3, Hungary.
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16
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Fluid dynamic analysis and residence time distribution determination for rectangular based spouted beds. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.10.064] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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17
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Shibayama S, Funatsu K. Investigation of Preprocessing and Validation Methodologies for PAT: Case Study of the Granulation and Coating Steps for the Manufacturing of Ethenzamide Tablets. AAPS PharmSciTech 2021; 22:41. [PMID: 33420526 DOI: 10.1208/s12249-020-01911-w] [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: 09/14/2020] [Accepted: 12/18/2020] [Indexed: 11/30/2022] Open
Abstract
After the Food and Drug Association in the USA published guidelines on the enhanced use of process analytical technology (PAT) and continuous manufacturing, many studies regarding PAT and continuous manufacturing have been published. This paper describes a case study involving granulation and coating steps with ethenzamide to investigate interference for PAT model construction and model management. We investigated what factors should be considered and addressed when PAT is implemented for continuous manufacturing and how predictive models should be constructed. The product qualities that were monitored were moisture content and particle size in the granulation step and tablet weight and moisture content in the coating step. We have constructed models for the granulation step and validated the predictive capability of the models against an external dataset. A partial least squares (PLS) model with manual wavelength selection had the best predictive accuracy for loss on drying against the external validation set. We found that the prediction of loss on drying was accurate, but the prediction of particle size was not sufficiently accurate. In the coating step, because of the small amount of data, we performed three-fold cross-validation and y-scrambling 10 times, to select the optimal hyper-parameters and to check if the models were fitted to chance correlations. We confirmed that the coating agent weights, tablet weights, and water content could be accurately predicted based on the mean of the R2 score for cross-validation. Addition of other variables, as well as the absorbance, slightly improved the predictive accuracy.
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18
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Tian G, Koolivand A, Gu Z, Orella M, Shaw R, O’Connor TF. Development of an RTD-Based Flowsheet Modeling Framework for the Assessment of In-Process Control Strategies. AAPS PharmSciTech 2021; 22:25. [PMID: 33400033 DOI: 10.1208/s12249-020-01913-8] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/27/2020] [Accepted: 12/21/2020] [Indexed: 11/30/2022] Open
Abstract
Continuous manufacturing (CM) is an emerging technology which can improve pharmaceutical manufacturing and reduce drug product quality issues. One challenge that needs to be addressed when adopting CM technology is material traceability through the entire continuous process, which constitutes one key aspect of control strategy. Residence time distribution (RTD) plays an important role in material traceability as it characterizes the material spreading through the process. The propagation of upstream disturbances could be predictively tracked through the entire process by convolution of the disturbance and the RTD. The present study sets up the RTD-based modeling framework in a commonly used process modeling environment, gPROMS, and integrates it with existing modules and built-in tools (e.g., parameter estimation). Concentration calculations based on the convolution integral requires access to historical stream property information, which is not readily available in flowsheet modeling platforms. Thus, a novel approach is taken whereby a partial differential equation is used to propagate and store historical data as the simulation marches forward in time. Other stream properties not modeled by an RTD are determined in auxiliary modules. To illustrate the application of the framework, an integrated RTD-auxiliary model for a continuous direct compression manufacturing line was developed. An excellent agreement was found between the model predictions and experiments. The validated model was subsequently used to assess in-process control strategies for feeder and material traceability through the process. Our simulation results show that the employed modeling approach facilitates risk-based assessment of the continuous line by promoting our understanding on the process.
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19
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Matić J, Alva C, Witschnigg A, Eder S, Reusch K, Paudel A, Khinast J. Towards predicting the product quality in hot-melt extrusion: Small scale extrusion. INTERNATIONAL JOURNAL OF PHARMACEUTICS-X 2020; 2:100062. [PMID: 33299982 PMCID: PMC7704403 DOI: 10.1016/j.ijpx.2020.100062] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/16/2020] [Revised: 11/06/2020] [Accepted: 11/08/2020] [Indexed: 12/02/2022]
Abstract
In product development, it is crucial to choose the appropriate drug manufacturing route accurately and timely and to ensure that the technique selected is suitable for achieving the desired product quality. Guided by the QbD principles, the pharmaceutical industry is currently transitioning from batch to continuous manufacturing. In this context, process understanding and prediction are becoming even more important. With regard to hot melt extrusion, the process setup, optimization and scale-up in early stages of product development are particularly challenging due to poor process understanding, complex product-process relationship and a small amount of premix available for extensive experimental studies. Hence, automated, quick and reliable process setup and scale-up requires simulation tools that are accurate enough to capture the process and determine the product-process relationships. To this end, the effect of process settings on the degradation of the active pharmaceutical ingredient (API) in a lab-scale Leistritz ZSE12 extruder was investigated. As part of the presented study, the limitations of traditional process analysis using integral process values were investigated, together with the potential that simulations may have in predicting the process performance and the product quality. The results of our investigation indicate that the average melt temperatures and the exposure times in specific zones along the screw configuration correlate well with the API degradation values and can be used as potent process design criteria to simplify the process development.
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Affiliation(s)
- Josip Matić
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Carolina Alva
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Andreas Witschnigg
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Simone Eder
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Kathrin Reusch
- Leistritz Pharma Extrusion, Markgrafenstraße, 29-39 1, 90459 Nürnberg, Germany
| | - Amrit Paudel
- 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
| | - 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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20
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Pedersen T, Karttunen AP, Korhonen O, Wu JX, Naelapää K, Skibsted E, Rantanen J. Determination of Residence Time Distribution in a Continuous Powder Mixing Process With Supervised and Unsupervised Modeling of In-line Near Infrared (NIR) Spectroscopic Data. J Pharm Sci 2020; 110:1259-1269. [PMID: 33217424 DOI: 10.1016/j.xphs.2020.10.067] [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: 08/20/2020] [Revised: 10/12/2020] [Accepted: 10/30/2020] [Indexed: 11/25/2022]
Abstract
Successful implementation of continuous manufacturing processes requires robust methods to assess and control product quality in a real-time mode. In this study, the residence time distribution of a continuous powder mixing process was investigated via pulse tracer experiments using near infrared spectroscopy for tracer detection in an in-line mode. The residence time distribution was modeled by applying the continuous stirred tank reactor in series model for achieving the tracer (paracetamol) concentration profiles. Partial least squares discriminant analysis and principal component analysis of the near infrared spectroscopy data were applied to investigate both supervised and unsupervised chemometric modeling approaches. Additionally, the mean residence time for three powder systems was measured with different process settings. It was found that a significant change in the mean residence time occurred when comparing powder systems with different flowability and mixing process settings. This study also confirmed that the partial least squares discriminant analysis applied as a supervised chemometric model enabled an efficient and fast estimate of the mean residence time based on pulse tracer experiments.
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Affiliation(s)
- Troels Pedersen
- University of Copenhagen, Copenhagen, Denmark; Novo Nordisk A/S, Måløv, Denmark
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21
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Tanimura S, Singh R, Román-Ospino AD, Ierapetritou M. Residence time distribution modelling and in line monitoring of drug concentration in a tablet press feed frame containing dead zones. Int J Pharm 2020; 592:120048. [PMID: 33161037 DOI: 10.1016/j.ijpharm.2020.120048] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/17/2020] [Revised: 10/15/2020] [Accepted: 11/01/2020] [Indexed: 01/08/2023]
Abstract
The presence of a 'significant dead zone' in any continuous manufacturing equipment may affect the product quality and need to be investigated systematically. Dead zone will affect the residence time distribution (RTD) of continuous manufacturing and thus the mixing and product quality. Tablet press (feed frame) is one of unit operations that directly influence the critical quality attributes (CQA's). However, currently no systematic methods and tools are available to characterize and model the feed frame dead zone. In this manuscript, the RTD of the tablet press feed frame containing dead zone is investigated. Step-change experiments revealed that the feed frame could be expressed as a traditional continuous stirred tank model. The volume fractions of the dead zones are determined experimentally as well as using RTD model. In addition, an in-line NIR method for drug concentration monitoring inside the feed frame is also developed. The developed NIR calibration model enables to monitor the drug concentration precisely and detect the variation immediately with the probe positioned right above the left paddle. It is also found that the feed frame paddle speed slightly affects the predictive accuracy of NIR, while the die disc speed has no significant effect.
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Affiliation(s)
- Shinji Tanimura
- CMC R&D Center, Kyowa Kirin Co., Ltd., 1188 Shimotogari, Nagaizumi-cho, Sunto-gun, Shizuoka 411-8731 Japan
| | - 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.
| | - Andrés D Román-Ospino
- 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 Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, DE 19716, USA.
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22
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Model-Based Scale-Up Methodologies for Pharmaceutical Granulation. Pharmaceutics 2020; 12:pharmaceutics12050453. [PMID: 32423051 PMCID: PMC7284585 DOI: 10.3390/pharmaceutics12050453] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2020] [Revised: 05/09/2020] [Accepted: 05/11/2020] [Indexed: 12/13/2022] Open
Abstract
In the pharmaceutical industry, it is a major challenge to maintain consistent quality of drug products when the batch scale of a process is changed from a laboratory scale to a pilot or commercial scale. Generally, a pharmaceutical manufacturing process involves various unit operations, such as blending, granulation, milling, tableting and coating and the process parameters of a unit operation have significant effects on the quality of the drug product. Depending on the change in batch scale, various process parameters should be strategically controlled to ensure consistent quality attributes of a drug product. In particular, the granulation may be significantly influenced by scale variation as a result of changes in various process parameters and equipment geometry. In this study, model-based scale-up methodologies for pharmaceutical granulation are presented, along with data from various related reports. The first is an engineering-based modeling method that uses dimensionless numbers based on process similarity. The second is a process analytical technology-based modeling method that maintains the desired quality attributes through flexible adjustment of process parameters by monitoring the quality attributes of process products in real time. The third is a physics-based modeling method that involves a process simulation that understands and predicts drug quality through calculation of the behavior of the process using physics related to the process. The applications of these three scale-up methods are summarized according to granulation mechanisms, such as wet granulation and dry granulation. This review shows that these model-based scale-up methodologies provide a systematic process strategy that can ensure the quality of drug products in the pharmaceutical industry.
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23
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Scheibelhofer O, Kruisz J, Rehrl J, Faulhammer E, Witschnigg A, Khinast JG. LIF or dye: Comparison of different tracing methods for granular solids. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.03.033] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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24
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Towards a novel continuous HME-Tableting line: Process development and control concept. Eur J Pharm Sci 2020; 142:105097. [PMID: 31648048 DOI: 10.1016/j.ejps.2019.105097] [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: 07/31/2019] [Revised: 09/25/2019] [Accepted: 09/30/2019] [Indexed: 11/23/2022]
Abstract
The objective of this study was to develop a novel closed-loop controlled continuous tablet manufacturing line, which first uses hot melt extrusion (HME) to produce pellets based on API and a polymer matrix. Such systems can be used to make complex pharmaceutical formulations, e.g., amorphous solid dispersions of poorly soluble APIs. The pellets are then fed to a direct compaction (DC) line blended with an external phase and tableted continuously. Fully-automated processing requires advanced control strategies, e.g., for reacting to raw material variations and process events. While many tools have been proposed for in-line process monitoring and real-time data acquisition, establishing real-time automated feedback control based on in-process control strategies remains a challenge. Control loops were implemented to assess the quality attributes of intermediates and product and to coordinate the mass flow rate between the unit operations. Feedback control for the blend concentration, strand temperature and pellet thickness was accomplished via proportional integral derivative (PID) controllers. The tablet press hopper level was controlled using a model predictive controller. To control the mass flow rates in all unit operations, several concepts were developed, with the tablet press, the extruder or none assigned to be the master unit of the line, and compared via the simulation.
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25
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Karttunen AP, Poms J, Sacher S, Sparén A, Ruiz Samblás C, Fransson M, Martin De Juan L, Remmelgas J, Wikström H, Hsiao WK, Folestad S, Korhonen O, Abrahmsén-Alami S, Tajarobi P. Robustness of a continuous direct compression line against disturbances in feeding. Int J Pharm 2020; 574:118882. [DOI: 10.1016/j.ijpharm.2019.118882] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2019] [Revised: 11/12/2019] [Accepted: 11/13/2019] [Indexed: 11/29/2022]
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26
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Explicit Residence Time Distribution of a Generalised Cascade of Continuous Stirred Tank Reactors for a Description of Short Recirculation Time (Bypassing). Processes (Basel) 2019. [DOI: 10.3390/pr7090615] [Citation(s) in RCA: 23] [Impact Index Per Article: 4.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
The tanks-in-series model (TIS) is a popular model to describe the residence time distribution (RTD) of non-ideal continuously stirred tank reactors (CSTRs) with limited back-mixing. In this work, the TIS model was generalised to a cascade of n CSTRs with non-integer non-negative n. The resulting model describes non-ideal back-mixing with n > 1. However, the most interesting feature of the n-CSTR model is the ability to describe short recirculation times (bypassing) with n < 1 without the need of complex reactor networks. The n-CSTR model is the only model that connects the three fundamental RTDs occurring in reactor modelling by variation of a single shape parameter n: The unit impulse at n→0, the exponential RTD of an ideal CSTR at n = 1, and the delayed impulse of an ideal plug flow reactor at n→∞. The n-CSTR model can be used as a stand-alone model or as part of a reactor network. The bypassing material fraction for the regime n < 1 was analysed. Finally, a Fourier analysis of the n-CSTR was performed to predict the ability of a unit operation to filter out upstream fluctuations and to model the response to upstream set point changes.
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27
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Ensuring tablet quality via model-based control of a continuous direct compaction process. Int J Pharm 2019; 567:118457. [DOI: 10.1016/j.ijpharm.2019.118457] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/01/2019] [Revised: 05/31/2019] [Accepted: 06/22/2019] [Indexed: 11/22/2022]
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28
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Sensitivity of a continuous hot-melt extrusion and strand pelletization line to control actions and composition variation. Int J Pharm 2019; 566:239-253. [DOI: 10.1016/j.ijpharm.2019.05.046] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/26/2019] [Revised: 05/14/2019] [Accepted: 05/15/2019] [Indexed: 11/20/2022]
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29
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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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30
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Karttunen AP, Hörmann TR, De Leersnyder F, Ketolainen J, De Beer T, Hsiao WK, Korhonen O. Measurement of residence time distributions and material tracking on three continuous manufacturing lines. Int J Pharm 2019; 563:184-197. [DOI: 10.1016/j.ijpharm.2019.03.058] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/11/2018] [Revised: 03/21/2019] [Accepted: 03/27/2019] [Indexed: 10/27/2022]
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31
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Taipale-Kovalainen K, Karttunen AP, Niinikoski H, Ketolainen J, Korhonen O. The effects of unintentional and intentional process disturbances on tablet quality during long continuous manufacturing runs. Eur J Pharm Sci 2019; 129:10-20. [PMID: 30550973 DOI: 10.1016/j.ejps.2018.11.030] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2018] [Revised: 11/13/2018] [Accepted: 11/26/2018] [Indexed: 11/24/2022]
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32
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Matsunami K, Nagato T, Hasegawa K, Sugiyama H. A large-scale experimental comparison of batch and continuous technologies in pharmaceutical tablet manufacturing using ethenzamide. Int J Pharm 2019; 559:210-219. [DOI: 10.1016/j.ijpharm.2019.01.028] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/02/2018] [Revised: 12/14/2018] [Accepted: 01/11/2019] [Indexed: 10/27/2022]
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33
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Impact of material properties and process variables on the residence time distribution in twin screw feeding equipment. Int J Pharm 2019; 556:200-216. [DOI: 10.1016/j.ijpharm.2018.11.076] [Citation(s) in RCA: 35] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/23/2018] [Revised: 11/29/2018] [Accepted: 11/30/2018] [Indexed: 11/22/2022]
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34
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Escotet-Espinoza MS, Moghtadernejad S, Oka S, Wang Z, Wang Y, Roman-Ospino A, Schäfer E, Cappuyns P, Van Assche I, Futran M, Muzzio F, Ierapetritou M. Effect of material properties on the residence time distribution (RTD) characterization of powder blending unit operations. Part II of II: Application of models. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.12.051] [Citation(s) in RCA: 26] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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35
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Sebastian Escotet-Espinoza M, Moghtadernejad S, Oka S, Wang Y, Roman-Ospino A, Schäfer E, Cappuyns P, Van Assche I, Futran M, Ierapetritou M, Muzzio F. Effect of tracer material properties on the residence time distribution (RTD) of continuous powder blending operations. Part I of II: Experimental evaluation. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.10.040] [Citation(s) in RCA: 41] [Impact Index Per Article: 8.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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36
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Dülle M, Özcoban H, Leopold C. The effect of different feed frame components on the powder behavior and the residence time distribution with regard to the continuous manufacturing of tablets. Int J Pharm 2019; 555:220-227. [DOI: 10.1016/j.ijpharm.2018.11.017] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2018] [Revised: 10/30/2018] [Accepted: 11/07/2018] [Indexed: 10/27/2022]
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37
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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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38
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Material tracking in a continuous direct capsule-filling process via residence time distribution measurements. Int J Pharm 2018; 550:347-358. [PMID: 30172751 DOI: 10.1016/j.ijpharm.2018.08.056] [Citation(s) in RCA: 22] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/26/2018] [Revised: 08/23/2018] [Accepted: 08/28/2018] [Indexed: 01/13/2023]
Abstract
Continuous production of pharmaceuticals requires traceability from the raw material to the final dosage form. With that regard, understanding the residence time distribution (RTD) of the whole process and its unit operations is crucial. This work describes a structured approach to characterizing and modelling of RTDs in a continuous blender and a tamping pin capsule filling machine, including insights into data processing. The parametrized RTD models were interconnected to model a continuous direct capsule-filling process, showing the batch transition as well as the propagation of a 2 min feed disturbance throughout the process. Various control strategies were investigated in-silico, aiding in the selection of optimal material diversion point to minimize the material waste. Additionally, the RTD models can facilitate process design and optimization. In this work, adaptions to the capsule filling machine were made and their influence on the RTD was examined to achieve an optimal machine setup.
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39
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Martinetz M, Karttunen AP, Sacher S, Wahl P, Ketolainen J, Khinast J, Korhonen O. RTD-based material tracking in a fully-continuous dry granulation tableting line. Int J Pharm 2018; 547:469-479. [DOI: 10.1016/j.ijpharm.2018.06.011] [Citation(s) in RCA: 36] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2018] [Revised: 05/30/2018] [Accepted: 06/04/2018] [Indexed: 11/28/2022]
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40
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Kreimer M, Aigner I, Lepek D, Khinast J. Continuous Drying of Pharmaceutical Powders Using a Twin-Screw Extruder. Org Process Res Dev 2018. [DOI: 10.1021/acs.oprd.8b00087] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Manuel Kreimer
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | - Isabella Aigner
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | - Daniel Lepek
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
- Department of Chemical Engineering, The Cooper Union, New York, New York 10003, United States
- Institute for Process and Particle Engineering, Graz University of Technology, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
- Institute for Process and Particle Engineering, Graz University of Technology, 8010 Graz, Austria
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41
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Rehrl J, Karttunen AP, Nicolaï N, Hörmann T, Horn M, Korhonen O, Nopens I, De Beer T, Khinast JG. Control of three different continuous pharmaceutical manufacturing processes: Use of soft sensors. Int J Pharm 2018; 543:60-72. [DOI: 10.1016/j.ijpharm.2018.03.027] [Citation(s) in RCA: 49] [Impact Index Per Article: 8.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2017] [Revised: 02/26/2018] [Accepted: 03/14/2018] [Indexed: 11/30/2022]
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42
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Nicolaï N, De Leersnyder F, Copot D, Stock M, Ionescu CM, Gernaey KV, Nopens I, De Beer T. Liquid‐to‐solid ratio control as an advanced process control solution for continuous twin‐screw wet granulation. AIChE J 2018. [DOI: 10.1002/aic.16161] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/16/2023]
Affiliation(s)
- Niels Nicolaï
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
- Dept. of Data Analysis and Mathematical Modelling, BIOMATH, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Fien De Leersnyder
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
| | - Dana Copot
- Dept. of Electrical Energy, Metals, Mechanical Constructions and Systems, Research Group on Dynamical Systems and ControlGhent University, Technologiepark 914Zwijnaarde 9052 Belgium
| | - Michiel Stock
- Dept. of Data Analysis and Mathematical Modelling, KERMIT, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Clara M. Ionescu
- Dept. of Electrical Energy, Metals, Mechanical Constructions and Systems, Research Group on Dynamical Systems and ControlGhent University, Technologiepark 914Zwijnaarde 9052 Belgium
| | - Krist V. Gernaey
- Dept. of Chemical and Biochemical Engineering, CAPEC‐PROCESS Research CenterTechnical University of Denmark, Building 229Kgs. Lyngby 2800 Denmark
| | - Ingmar Nopens
- Dept. of Data Analysis and Mathematical Modelling, BIOMATH, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Thomas De Beer
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
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Industrial Scale Experiments towards the Development of Process Evaluation Models for Continuous Pharmaceutical Tablet Manufacturing. ACTA ACUST UNITED AC 2018. [DOI: 10.1016/b978-0-444-64235-6.50288-6] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register]
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