1
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Pradhan A, Phillips B, Yang F, Karan K, Durig T, Haight B, Martin C, Zhang F. Optimizing twin-screw melt granulation: The role of overflight clearance on granulation behavior. Int J Pharm 2024; 653:123900. [PMID: 38360288 DOI: 10.1016/j.ijpharm.2024.123900] [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: 11/20/2023] [Revised: 02/07/2024] [Accepted: 02/08/2024] [Indexed: 02/17/2024]
Abstract
Twin-screw melt granulation (TSMG) relies on the dispersive and distributive mixing at the kneading zone for granule growth to happen highlighting the critical role played by the kneading elements in TSMG. Despite extensive research conducted on the impact of screw geometry in melt compounding, there is not enough literature for TSMG. Disc width for the kneading elements was 2 mm, contrary to the standard 5 mm. The objective of this study was to evaluate if varying overflight clearance (OC) can alter the paradigm for TSMG. The new elements reduce the peak shear at kneading zone however a higher barrel temperature and degree of fill (DoF) is required to compensate to attain similar granule attributes. The change in DoF was achieved through a combination of modified screw configuration to pre-densify powders before kneading and processing at a lower screw speed. Despite the higher barrel temperature, process optimization of thermally unstable gabapentin was carried out. Using the new elements, compressible granules (Tensile strength > 2 MPa) with low % GABA-L content were manufactured despite increasing OC to 0.4 mm. Granule stability at 40 °C, ambient humidity for 6 months indicated gabapentin was stable (% GABA-L ≪0.4 %) despite a high barrel temperature of 120 °C.
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Affiliation(s)
- Adwait Pradhan
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, University of Texas at Austin, Austin, TX, United States
| | - Brian Phillips
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE, United States
| | - Fengyuan Yang
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE, United States
| | - Kapish Karan
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE, United States
| | - Thomas Durig
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE, United States
| | - Brian Haight
- Leistritz Extrusion Technology, Somerville, NJ, United States
| | - Charlie Martin
- Leistritz Extrusion Technology, Somerville, NJ, United States
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, University of Texas at Austin, Austin, TX, United States.
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2
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Van de Steene S, Van Renterghem J, Vanhoorne V, Vervaet C, Kumar A, De Beer T. Visualization of the granule temperature using thermal imaging to improve understanding of the granulation mechanism in continuous twin-screw melt granulation. Int J Pharm 2023; 645:123423. [PMID: 37722494 DOI: 10.1016/j.ijpharm.2023.123423] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/26/2023] [Revised: 09/12/2023] [Accepted: 09/15/2023] [Indexed: 09/20/2023]
Abstract
The aim of this study is to increase process understanding of the granulation mechanism in twin-screw melt granulation by evaluating the influence of different screw configurations on granule formation and granule temperature via thermal imaging. The study used a Design of Experiments (DoE) to process a miscible and immiscible formulation (85% API/binder w/w) using a twin-screw extruder with varying screw configurations. The barrel temperature (°C), screw speed (rpm), throughput (kg/h), and kneading zone (direction and stagger angle) were varied. Granule and process properties were evaluated for samples collected at four different locations along the length of the granulation barrel to visualize the granule formation, and granule temperature was monitored by an infrared camera to measure heat transfer on the granules. The resulting temperature was linked to the granule properties and the granule formation along the length of the barrel. The most influencing factors on the granule temperature are the direction of the kneading zone and the set barrel temperature. It was observed that granule formation mainly occurred in the zones that apply more kneading on the granules. The highest temperature increase was observed when the smallest stagger angle in reverse configuration was used, and could be linked to better granule quality attributes.
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Affiliation(s)
- S Van de Steene
- Laboratory of Pharmaceutical Process Analytical Technology, Faculty of Pharmaceutical Sciences Ghent University, Ghent, Belgium
| | - J Van Renterghem
- Laboratory of Pharmaceutical Process Analytical Technology, Faculty of Pharmaceutical Sciences Ghent University, Ghent, Belgium
| | - V Vanhoorne
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences Ghent University, Ghent, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences Ghent University, Ghent, Belgium
| | - A Kumar
- Pharmaceutical Engineering Research Group, Faculty of Pharmaceutical Sciences, Ghent University, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Faculty of Pharmaceutical Sciences Ghent University, Ghent, Belgium.
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3
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Kaba K, Purnell B, Liu Y, Royall PG, Alhnan MA. Computer numerical control (CNC) carving as an on-demand point-of-care manufacturing of solid dosage form: A digital alternative method for 3D printing. Int J Pharm 2023; 645:123390. [PMID: 37683980 DOI: 10.1016/j.ijpharm.2023.123390] [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: 05/24/2023] [Revised: 09/03/2023] [Accepted: 09/05/2023] [Indexed: 09/10/2023]
Abstract
Computer numerical control (CNC) carving is a widely used method of industrial subtractive manufacturing of wood, plastics, and metal products. However, there have been no previous reports of applying this approach to manufacture medicines. In this work, the novel method of tablet production using CNC carving is introduced for the first time. This report provides a proof-of-concept for applying subtractive manufacturing as an alternative to formative (powder compression) and additive (3D printing) manufacturing for the on-demand production of solid dosage forms. This exemplar manufacturing approach was employed to produce patient-specific hydrocortisone (HC) tablets for the treatment of children with congenital adrenal hyperplasia. A specially made drug-polymer cast based on polyethene glycol (PEG 6,000) and hydroxypropyl cellulose was produced using thermal casting. The cast was used as a workpiece and digitally carved using a small-scale 3-dimensional (3D) CNC carving. To establish the ability of this new approach to provide an accurate dose of HC, four different sizes of CNC carved tablet were manufactured to achieve HC doses of 2.5, 5, 7.5 and 10 mg with a relative standard deviation of the tablet weight in the range of 3.69-4.79%. In addition, batches of 2.5 and 5 mg HC tablets met the British Pharmacopeia standards for weight uniformity. Thermal analysis and X-ray powder diffraction indicated that the model drug was in amorphous form. In addition, HPLC analysis indicated a level of purity of 96.5 ± 1.1% of HC. In addition, the process yielded mechanically strong cylindrical tablets with tensile strength ranging from 0.49 to 1.6 MPa and friability values of <1%, whilst maintaining an aesthetic look. In vitro, HC release from the CNC-carved tablets was slower with larger tablet sizes and higher binder contents. This is the first report on applying CNC carving in the pharmaceutical context of producing solid dosage forms. The work showed the potential of this technology as an alternative method for the on-demand manufacturing of patient-specific dosage forms.
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Affiliation(s)
- Kazim Kaba
- Centre for Pharmaceutical Medicine Research, Institute of Pharmaceutical Science, King's College London, London SE1 9NH, United Kingdom
| | - Bryn Purnell
- Centre for Pharmaceutical Medicine Research, Institute of Pharmaceutical Science, King's College London, London SE1 9NH, United Kingdom
| | - Yujing Liu
- Centre for Pharmaceutical Medicine Research, Institute of Pharmaceutical Science, King's College London, London SE1 9NH, United Kingdom
| | - Paul G Royall
- Centre for Pharmaceutical Medicine Research, Institute of Pharmaceutical Science, King's College London, London SE1 9NH, United Kingdom
| | - Mohamed A Alhnan
- Centre for Pharmaceutical Medicine Research, Institute of Pharmaceutical Science, King's College London, London SE1 9NH, United Kingdom.
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4
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Ren A, Koleng JJ, Costello M, Spahn JE, Smyth HDC, Zhang F. Twin-Screw Continuous Mixing Can Produce Dry Powder Inhalation Mixtures for Pulmonary Delivery. J Pharm Sci 2023; 112:272-281. [PMID: 36228755 DOI: 10.1016/j.xphs.2022.10.007] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/09/2022] [Revised: 10/05/2022] [Accepted: 10/05/2022] [Indexed: 12/23/2022]
Abstract
The feasibility of twin-screw corotating extruder as a continuous process mixer to prepare dry powder inhalation (DPI) powders was investigated. Interactive mixtures of 1% micronized budesonide, 0.3% magnesium stearate and 98.7% alpha-lactose monohydrate were manufactured using a Leistritz Nano-16 extruder at various processing conditions. One set of GFM (grooved mixing) elements were included in the screw profile to provide distributive mixing of conveyed powders with the goal of resulting in a homogeneous mixture. Residence time in the twin-screw mixer was modelled to quantify mixing efficiency. Comparative powders were also prepared using either low or high-shear batch mixing to compare the effect of mixing methods on the properties of the budesonide dry powder inhalation formulation. Twin screw mixing results in homogeneous mixtures with aerosol performance comparable to that of high-shear batch mixing. Scanning electron microscopy confirmed that twin screw mixing produces particles with morphology like that of low and high-shear batch mixing. X-ray diffraction (XRD) analysis verified that there was no form change of the drug due to twin-screw processing. Statistical regression was used to probe the relationship between twin screw mixing process parameters such as screw speed and feed rate and aerosol performance. The twin screw mixing process was found to be robust, as no significant differences in aerosol performance were found for various processing parameters.
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Affiliation(s)
- Angela Ren
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - John J Koleng
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Mark Costello
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Jamie E Spahn
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Hugh D C Smyth
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA.
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5
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Suk Kim J, ud Din F, Jin Choi Y, Ran Woo M, Cheon S, Hun Ji S, Park S, Oh Kim J, Seok Youn Y, Lim SJ, Giu Jin S, Choi HG. Hydroxypropyl-β-cyclodextrin-based solid dispersed granules: A prospective alternative to conventional solid dispersion. Int J Pharm 2022; 628:122286. [DOI: 10.1016/j.ijpharm.2022.122286] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/24/2022] [Revised: 09/20/2022] [Accepted: 10/07/2022] [Indexed: 10/31/2022]
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6
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Liu T, Kaur N, Chen B, Phillips B, Chang SY, Yang F, Bi V, Durig T, Zhang F. Physicochemical Changes and Chemical Degradation of Gliclazide during Twin-Screw Melt Granulation. Int J Pharm 2022; 619:121702. [PMID: 35341908 DOI: 10.1016/j.ijpharm.2022.121702] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/10/2022] [Revised: 03/20/2022] [Accepted: 03/22/2022] [Indexed: 10/18/2022]
Abstract
Using a miscible model formulation consisting of 80% gliclazide (GLZ) and 20% hydroxypropyl cellulose, we investigate how the twin-screw melt granulation process affects the chemical stability and process-induced physicochemical changes of the drug. No degradation was observed in the conveying section that leads to kneading element. Approximately 1/3 of the GLZ degradant was generated at the kneading section, while the remaining 2/3 was generated in the conveying section post-kneading and during cooling outside the barrel. A strong correlation was observed between the overall degradation and the temperature of the granules at the barrel exit. In the kneading section, the degradant content correlates best with the specific mechanical energy. With higher specific mechanical energies, the size of the GLZ crystals was reduced further, resulting in more surface defects. In the section post-kneading element, GLZ degradation correlates best with the granule temperature measured at the kneading section. This knowledge of drug degradation during twin-screw melt granulation can be used to develop processing strategies to maintain drug stability during and post processing.
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Affiliation(s)
- Tongzhou Liu
- Division of Molecular Pharmaceutics and Drug Delivery, the University of Texas at Austin, Austin, TX
| | - Navpreet Kaur
- Department of Pharmaceutics, University of Minnesota, Minneapolis, MN
| | - Beibei Chen
- Division of Molecular Pharmaceutics and Drug Delivery, the University of Texas at Austin, Austin, TX
| | - Brian Phillips
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Shao-Yu Chang
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Fengyuan Yang
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Vivian Bi
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Thomas Durig
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, the University of Texas at Austin, Austin, TX.
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7
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A critical review on granulation of pharmaceuticals and excipients: Principle, analysis and typical applications. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117329] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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8
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Binder-free twin-screw melt granulation: An effective approach to manufacture high-dose API formulations. Int J Pharm 2021; 606:120886. [PMID: 34298107 DOI: 10.1016/j.ijpharm.2021.120886] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/09/2021] [Revised: 06/28/2021] [Accepted: 07/11/2021] [Indexed: 11/23/2022]
Abstract
This study investigates the use of twin-screw binder-free melt granulation (BFMG) in the development of high-dose solid dose formulations for low melting point thermally stable drugs. Both ibuprofen and guaifenesin are examined. By granulating pure API powder, it is shown that BFMG can successfully be used to produce granules that contain 100% API. A design of experiments (DoE) response surface methodology was used to establish the design space for the end-product. The effects of the most relevant process variables (barrel operating temperature, powder feed rate, screw speed and screw configuration) on granule properties (outlet temperature, size distribution, morphology, flowability, compressibility, porosity) and tablet attributes (tensile strength and in-vitro dissolution) were thoroughly studied. Barrel temperature (alone or in interactions with the other variables) represented the most significant variable for both drugs since it governs the formation of granules by partial melting and subsequent agglomeration of the fed powder. Interestingly, the shear action originated by screw speed and screw configuration resulted in various significant responses depending on the drug substance, indicating that it can also be affected by the nature of the processed molecule. Flow properties were improved (i.e., lower Hausner ratio) for both drugs after formation of granules. Tabletability was also tested by preparing 600 mg tablets for all samples. Surprisingly, the resulting granules were highly compactible, requiring only 1% lubricant to form strong tablets containing 96% API and 3% disintegrant. The results also showed that tablets become harder as the granule size increased, especially for guaifenesin. As expected, in-vitro dissolution results indicated that tablets and capsules showed slightly slower dissolution rates than the granules.
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9
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Forster SP, Lebo DB. Continuous Melt Granulation for Taste-Masking of Ibuprofen. Pharmaceutics 2021; 13:pharmaceutics13060863. [PMID: 34208288 PMCID: PMC8230814 DOI: 10.3390/pharmaceutics13060863] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2021] [Revised: 06/07/2021] [Accepted: 06/08/2021] [Indexed: 11/16/2022] Open
Abstract
Taste-masking of drugs, particularly to produce formulations for pediatric patients, can be challenging and require complex manufacturing approaches. The objective of this study was to produce taste-masked ibuprofen granules using a novel process, twin-screw melt granulation (TSMG). TSMG is an emerging, high-productivity, continuous process. Granules of ibuprofen embedded in a lipid matrix were produced across a range of process conditions, resulting in a range of output granule particle sizes. The ibuprofen appeared to be miscible with the lipid binder though it recrystallized after processing. The ibuprofen melt granules were tested in simulated saliva using a novel, small-volume dissolution technique with continuous acquisition of the ibuprofen concentration. The ibuprofen release from the granules was slower than the neat API and physical blend, beyond the expected residence time of the granules in the mouth. The ibuprofen release was inversely related to the granule size. A Noyes–Whitney dissolution model was used and the resulting dissolution rate constants correlated well with the granule size.
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Affiliation(s)
- Seth P. Forster
- Pharmaceutical Commercialization Technology, MMD, Merck & Co., Inc., Kenilworth, NJ 07033, USA
- Department of Pharmaceutical Sciences, School of Pharmacy, Temple University, Philadelphia, PA 19140, USA;
- Correspondence:
| | - David B. Lebo
- Department of Pharmaceutical Sciences, School of Pharmacy, Temple University, Philadelphia, PA 19140, USA;
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10
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11
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Batra A, Thongsukmak A, Desai D, Serajuddin ATM. The Effect of Process Variables and Binder Concentration on Tabletability of Metformin Hydrochloride and Acetaminophen Granules Produced by Twin Screw Melt Granulation with Different Polymeric Binders. AAPS PharmSciTech 2021; 22:154. [PMID: 33983536 DOI: 10.1208/s12249-021-02018-6] [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: 12/15/2020] [Accepted: 04/14/2021] [Indexed: 11/30/2022] Open
Abstract
In twin screw melt granulation, granules are produced by passing mixtures of drug substances and polymeric binders through twin screw extruder such that temperatures are maintained below melting point of drugs but above glass transition of polymers used, whereby the polymers coat surfaces of drug particles and cause their agglomeration into granules. Since various formulation factors, such as binder type and concentration, and processing variables like extrusion temperature, screw configuration, and screw speed, can influence the granulation process, the present investigation was undertaken to study their effects on tabletability of granules produced. Three different types of polymeric binders, Klucel® EXF (hydroxypropyl cellulose), Eudragit® EPO (polyacrylate binder), and Soluplus® (polyvinyl caprolactam-co-vinyl acetate-ethylene glycol graft polymer), were used at 2, 5, and 10% concentrations. Metformin hydrochloride (HCl) (mp: 222°C) and acetaminophen (mp: 169°C) were used as model drugs, and drug-polymer mixtures with metformin HCl were extruded at 180, 160, and 130°C, while those with acetaminophen were extruded at 130 and 110°C. Other process variables included screw configurations: low, medium, and high shear for metformin HCl, and low and medium shear for acetaminophen; feed rates: 20 and 60 g/min; and screw speed of 100 and 300 RPM. Formulation and process variables had significant impact on tabletability. The target tensile strength of ≥2 MPa could be obtained with all polymers and at all processing temperatures when metformin HCl was granulated at 180°C and acetaminophen at 130°C. At other temperatures, the target tensile strength could be achieved at certain specific sets of processing conditions.
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12
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Forster SP, Dippold E, Chiang T. Twin-Screw Melt Granulation for Oral Solid Pharmaceutical Products. Pharmaceutics 2021; 13:pharmaceutics13050665. [PMID: 34066332 PMCID: PMC8148162 DOI: 10.3390/pharmaceutics13050665] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/01/2021] [Revised: 04/23/2021] [Accepted: 04/27/2021] [Indexed: 12/16/2022] Open
Abstract
This article highlights the advantages of pharmaceutical continuous melt granulation by twin-screw extrusion. The different melt granulation process options and excipients are described and compared, and a case is made for expanded use of twin-screw melt granulation since it is a flexible and continuous process. Methods for binder selection are profiled with a focus on rheology and physical stability impacts. For twin-screw melt granulation, the mechanism of granulation and process impact on granule properties are described. Pharmaceutical applications of melt granulation ranging from immediate release of soluble and insoluble APIs, taste-masking, and sustained release formulation are reviewed, demonstrating the range of possibilities afforded by twin-screw melt granulation.
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13
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Liu T, Kittikunakorn N, Zhang Y, Zhang F. Mechanisms of twin screw melt granulation. J Drug Deliv Sci Technol 2021. [DOI: 10.1016/j.jddst.2020.102150] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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14
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Mamidi HK, Palekar S, Nukala PK, Mishra SM, Patki M, Fu Y, Supner P, Chauhan G, Patel K. Process optimization of twin-screw melt granulation of fenofibrate using design of experiment (DoE). Int J Pharm 2020; 593:120101. [PMID: 33309834 DOI: 10.1016/j.ijpharm.2020.120101] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/02/2020] [Revised: 10/13/2020] [Accepted: 11/15/2020] [Indexed: 01/06/2023]
Abstract
The purpose of this study was to optimize the melt granulation process of fenofibrate using twin-screw granulator. Initial screening was performed to select the excipients required for melt granulation process. A 3 × 3 factorial design was used to optimize the processing conditions using the % drug loading (X1) and screw speed (X2) as the independent parameters and granule friability (Y1) % yield (Y2) as the dependent parameters. The effect of the independent parameters on the dependent parameters was determined using response surface plots and contour plots. A linear relationship was observed between % drug loading (X1) and % friability (Y1) and a quadratic relationship was observed between the independent parameters (X1 and X2) and % yield (Y2). The processing conditions for optimum granules were determined using numerical and graphical optimization and it was found that 15% drug loading at 50 rpm results in maximum % yield of 82.38% and minimum friability of 7.88%. The solid-state characterization of the optimized granules showed that the drug turned from crystalline state to amorphous state during melt granulation process. The optimized granules were compressed into tablets using Purolite® as the super disintegrating agent. The optimized formulation showed >85% drug release in 0.75% SLS solution within 60 min.
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Affiliation(s)
- Hemanth K Mamidi
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Siddhant Palekar
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Pavan Kumar Nukala
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Saurabh M Mishra
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA; SE Tylose USA Inc., Pharmaceutical Application Laboratory, 140 Commerce Way, Totowa, NJ, USA
| | - Manali Patki
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Yige Fu
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Piyush Supner
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Gautam Chauhan
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA
| | - Ketan Patel
- College of Pharmacy and Health Sciences, St. John's University, Queens, NY, USA.
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15
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Kittikunakorn N, Paul S, Koleng JJ, Liu T, Cook R, Yang F, Bi V, Durig T, Sun CC, Kumar A, Zhang F. How Does the Dissimilarity of Screw Geometry Impact Twin-screw Melt Granulation? Eur J Pharm Sci 2020; 157:105645. [PMID: 33207275 DOI: 10.1016/j.ejps.2020.105645] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/17/2020] [Revised: 10/19/2020] [Accepted: 11/10/2020] [Indexed: 11/19/2022]
Abstract
Using a model formulation of 80% gabapentin and 20% hydroxypropyl cellulose (KlucelTM), we investigate how differences in the geometry of mixing elements in the Leistritz Nano-16 and Micro-18 extruders affect granulation mechanisms and the properties of the resulting granules. Two extruders, Leistritz Nano-16 and Micro-18, commonly used in development and manufacturing, respectively, were used. The kneading blocks of the Nano-16 extruder are less efficient in dispersive mixing than the kneading blocks of the Micro-18 due to the thinner discs (2.5 mm wide) of the Nano-16. Therefore, our model formulation could be granulated only under a higher degree of fill (DF) by enhancing the axial compaction and heating of the barrel. In contrast, the thicker (5 mm wide) kneading blocks of the Micro-18 extruder provide efficient dispersive mixing that enables granulation without axial compaction and barrel heating. The higher specific mechanical energy (SME) achieved at higher screw speeds and lower feed rates led to more granulation. Because of the difference in granulation mechanisms between the two extruders, critical processing parameters also differed. Tabletability and degradant content of granules correlated positively with DF for the Nano-16 but with SME for the Micro-18 extruder.
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Affiliation(s)
- Nada Kittikunakorn
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, the University of Texas at Austin, 2409 University Avenue, A1920, Austin, Texas 78712, USA
| | - Shubhajit Paul
- Department of Pharmaceutics, University of Minnesota, 308 SE Harvard St, Minneapolis, MN 55455, USA
| | - John J Koleng
- Division of Chemical Engineering, School of Engineering, the University of Texas at Austin, 200 E Dean Keeton St, Austin, TX 78712, USA
| | - Tongzhou Liu
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, the University of Texas at Austin, 2409 University Avenue, A1920, Austin, Texas 78712, USA
| | - Rachel Cook
- Department of Materials Science and Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USA
| | - Fengyuan Yang
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Vivian Bi
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Thomas Durig
- Pharmaceutical Technology, Ashland Specialty Ingredients, Wilmington, DE
| | - Changquan Calvin Sun
- Department of Pharmaceutics, University of Minnesota, 308 SE Harvard St, Minneapolis, MN 55455, USA
| | - Aditya Kumar
- Department of Materials Science and Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USA
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, the University of Texas at Austin, 2409 University Avenue, A1920, Austin, Texas 78712, USA.
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16
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Spahn JE, Zhang F. Pre-plasticization of thermal binder facilitates processing and granule growth during melt granulation of gabapentin using co-rotating twin screw extruder. Drug Dev Ind Pharm 2020; 46:1971-1978. [PMID: 33016148 DOI: 10.1080/03639045.2020.1831014] [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] [Indexed: 10/23/2022]
Abstract
Plasticization, a common method of reducing the polymer melt viscosity in plastics extrusion, was investigated to improve the processability of a pharmaceutical formulation during twin-screw melt granulation. The thermolabile drug gabapentin was used as a model compound given previous work showed the benefit of preparing 80% drug loading gabapentin granules with hydroxypropyl cellulose as thermal binder. The plasticizer triethyl citrate was selected based on physicochemical compatibility with both the thermal binder and gabapentin by assessing polymer melt rheology and drug stability, respectively. Gabapentin was melt granulated at 80% drug loading with pre-plasticized binder using a co-rotating twin-screw extruder. The chemical stability and tabletability of the pre-plasticized granules were assessed to evaluate granule tabletability, drug stability, and process robustness. The granulation of gabapentin was facilitated by pre-plasticization, showing both increased granule growth and the ability to optimize processing conditions by lowering processing temperature. Pre-plasticization of thermal binder was therefore shown to be beneficial during melt granulation as a method of optimizing processing conditions while maintaining granule robustness.
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Affiliation(s)
- Jamie E Spahn
- The University of Texas at Austin College of Pharmacy, Austin, TX, USA
| | - Feng Zhang
- The University of Texas at Austin College of Pharmacy, Austin, TX, USA
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Melt granulation: A comparison of granules produced via high-shear mixing and twin-screw granulation. Int J Pharm 2020; 591:119941. [PMID: 33065223 DOI: 10.1016/j.ijpharm.2020.119941] [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: 03/22/2020] [Revised: 09/25/2020] [Accepted: 09/28/2020] [Indexed: 11/22/2022]
Abstract
Melt granules of DI-CAFOS® A12 and 15% (w/w) Kolliphor® P407 were manufactured in a twin-screw granulator (TSG) at five different conditions (screw speed and throughput varied) and compared to granules manufactured in a high-shear granulator (HSG) (rotation speed of chopper/impeller and granulation time varied). Evaluated granules characteristics were process yield, particle-size distribution (PSD), particle morphology, flowability, porosity, specific surface area (SSA), tabletability, compressibility and binder distribution. Compared to TSG, granules produced from HSG were more spherical in shape with lower porosity, smaller mean particle size and a superior flowability. Granules made by TSG showed a more elongated structure, higher porosity and larger mean particle size with smaller SSA instead. Concerning the compression process of granules, tablets made of TSG granules exhibited a higher tabletability compared to HSG granules, whereas the compressibility remained similar. In the case of the TSG granules, energy-dispersive-X-ray (EDX) measurements of the tablet surface indicated an enhanced homogenous binder distribution. Additionally, the EDX-analyses determined that more binder was available between the individual particles, resulting in a stronger bonding.
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Liu T, Paul S, Beeson BT, Alexander J, Yang F, Bi V, Durig T, Sun CC, Zhang F. Effect of Hydroxypropyl Cellulose Level on Twin-Screw Melt Granulation of Acetaminophen. AAPS PharmSciTech 2020; 21:240. [PMID: 32839891 DOI: 10.1208/s12249-020-01785-y] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/22/2020] [Accepted: 08/10/2020] [Indexed: 11/30/2022] Open
Abstract
This study investigated the effect of binder level on the physicochemical changes and tabletability of acetaminophen (APAP)-hydroxypropyl cellulose (HPC) granulated using twin-screw melt granulation. Even at 5% HPC level, the tablet tensile strength achieved up to 3.5 MPa. A minimum of 10% HPC was required for the process robustness. However, 20% HPC led to tabletability loss, attributable to the high mechanical strength of APAP granules. The over-granulated APAP granules had thick connected HPC scaffold and low porosity. Consequently, these granules were so strong that they underwent a lower degree of fracture under compression and higher elastic recovery during decompression. HPC was enriched on the surface of APAP extrudates at all HPC levels. Amorphous APAP was also observed on the extrudate surface at 20% HPC level, and it recrystallized within 24 h storage. To achieve a robust process and optimal improvement in APAP tabletability, the preferred HPC level was 10 to 15%.
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Kittikunakorn N, Liu T, Zhang F. Twin-screw melt granulation: Current progress and challenges. Int J Pharm 2020; 588:119670. [PMID: 32739382 DOI: 10.1016/j.ijpharm.2020.119670] [Citation(s) in RCA: 21] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/28/2020] [Revised: 07/03/2020] [Accepted: 07/15/2020] [Indexed: 02/06/2023]
Abstract
Twin-screw melt granulation (TSMG) is a new alternative method for granulation that offers several advantages over wet and dry granulation methods. TSMG has rapidly gained interest over recent years in the pharmaceutical industry. Since it is an inherently continuous process with controlled temperature and shear history, TSMG produces products with more consistent quality than the batch process. Several studies have investigated how various formulation and processing parameters influence granulation behavior and granule properties; however, there are still challenges that require a better mechanistic understanding. This review summarizes the current progress of TSMG while highlighting how various formulation and process parameters affect the physicochemical properties of granules. The challenges related to the process-induced physicochemical changes of drug substances are also discussed.
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Affiliation(s)
- Nada Kittikunakorn
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409, University Avenue, Austin, TX 78712, United States
| | - Tongzhou Liu
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409, University Avenue, Austin, TX 78712, United States
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409, University Avenue, Austin, TX 78712, United States.
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Roopwani R, Buckner IS. Co-Processed Particles: An Approach to Transform Poor Tableting Properties. J Pharm Sci 2019; 108:3209-3217. [DOI: 10.1016/j.xphs.2019.06.013] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/12/2019] [Revised: 05/25/2019] [Accepted: 06/04/2019] [Indexed: 10/26/2022]
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Kittikunakorn N, Sun CC, Zhang F. Effect of screw profile and processing conditions on physical transformation and chemical degradation of gabapentin during twin-screw melt granulation. Eur J Pharm Sci 2019; 131:243-253. [DOI: 10.1016/j.ejps.2019.02.024] [Citation(s) in RCA: 20] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/07/2019] [Revised: 02/12/2019] [Accepted: 02/16/2019] [Indexed: 11/26/2022]
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