1
|
Górecki J, Berdychowski M, Wałęsa K, Kostov B. Analysis of Density Distribution in a Cylindrical Specimen under Compaction Using the Example of Dry Ice. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2658. [PMID: 38893921 PMCID: PMC11173460 DOI: 10.3390/ma17112658] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/30/2024] [Revised: 05/28/2024] [Accepted: 05/29/2024] [Indexed: 06/21/2024]
Abstract
When dealing with processes involving the compaction of bulk materials, very often the quality of the product is determined based on density measurements. Methods used in the industry do not produce compacted materials with high degrees of homogeneity. As a result, the quality of the resulting product, interpreted as its density, varies over the cross-section of the product. In this article, the authors present the results of a numerical study involving the analysis of the density distribution of compacted dry ice during the reciprocating process. The Drucker-Prager/cap model was used in this study, which allowed the change in mechanical properties of the compacted material to be taken into account during the simulation of the process. The diameter, height and density of the cylindrical specimens used in the numerical tests were taken as the variable parameters. Thus, as a result of the testing, the authors could formulate conclusions relating to their impact on the homogeneity of the material.
Collapse
Affiliation(s)
- Jan Górecki
- Faculty of Mechanical Engineering, Institute of Machine Design, Poznan University of Technology, 60-965 Poznan, Poland (K.W.)
| | - Maciej Berdychowski
- Faculty of Mechanical Engineering, Institute of Machine Design, Poznan University of Technology, 60-965 Poznan, Poland (K.W.)
| | - Krzysztof Wałęsa
- Faculty of Mechanical Engineering, Institute of Machine Design, Poznan University of Technology, 60-965 Poznan, Poland (K.W.)
| | - Boris Kostov
- Department of Thermodynamics, Hydraulic and Ecology, University of Ruse, Studentska 8, 7017 Ruse, Bulgaria
| |
Collapse
|
2
|
Matsunami K, Vandeputte T, Barrera Jiménez AA, Peeters M, Ghijs M, Van Hauwermeiren D, Stauffer F, Dos Santos Schultz E, Nopens I, De Beer T. Validation of model-based design of experiments for continuous wet granulation and drying. Int J Pharm 2023; 646:123493. [PMID: 37813175 DOI: 10.1016/j.ijpharm.2023.123493] [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: 07/07/2023] [Revised: 09/27/2023] [Accepted: 10/05/2023] [Indexed: 10/11/2023]
Abstract
This paper presents an application case of model-based design of experiments for the continuous twin-screw wet granulation and fluid-bed drying sequence. The proposed framework consists of three previously developed models. Here, we are testing the applicability of previously published unit operation models in this specific part of the production line to a new active pharmaceutical ingredient. Firstly, a T-shaped partial least squares regression model predicts d-values of granules after wet granulation with different process settings. Then, a high-resolution full granule size distribution is computed by a hybrid population balance and partial least squares regression model. Lastly, a mechanistic model of fluid-bed drying simulates drying time and energy efficiency, using the outputs of the first two models as a part of the inputs. In the application case, good operating conditions were calculated based on material and formulation properties as well as the developed process models. The framework was validated by comparing the simulation results with three experimental results. Overall, the proposed framework enables a process designer to find appropriate process settings with a less experimental workload. The framework combined with process knowledge reduced 73.2% of material consumption and 72.3% of time, especially in the early process development phase.
Collapse
Affiliation(s)
- Kensaku Matsunami
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium.
| | - Tuur Vandeputte
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Ana Alejandra Barrera Jiménez
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Michiel Peeters
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Michael Ghijs
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Daan Van Hauwermeiren
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Fanny Stauffer
- Product Design & Performance, UCB, Braine l'Alleud, 1420, Belgium
| | | | - Ingmar Nopens
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium
| |
Collapse
|
3
|
Matsunami K, Meyer J, Rowland M, Dawson N, De Beer T, Van Hauwermeiren D. T-shaped partial least squares for high-dosed new active pharmaceutical ingredients in continuous twin-screw wet granulation: Granule size prediction with limited material information. Int J Pharm 2023; 646:123481. [PMID: 37805145 DOI: 10.1016/j.ijpharm.2023.123481] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/23/2023] [Revised: 10/02/2023] [Accepted: 10/03/2023] [Indexed: 10/09/2023]
Abstract
This work presents a granule size prediction approach applicable to diverse formulations containing new active pharmaceutical ingredients (APIs) in continuous twin-screw wet granulation. The approach consists of a surrogate selection method to identify similar materials with new APIs and a T-shaped partial least squares (T-PLS) model for granule size prediction across varying formulations and process conditions. We devised a surrogate material selection method, employing a combination of linear pre-processing and nonlinear classification algorithms, which effectively identified suitable surrogates for new materials. Using only material properties obtained through four characterization methods, our approach demonstrated its predictive prowess. The selected surrogate methods were seamlessly integrated with our developed T-PLS model, which was meticulously validated for high-dose formulations involving three new APIs. When surrogating new APIs based on Gaussian process classification, we achieved the lowest prediction errors, signifying the method's robustness. The predicted d-values were within the range of uncertainty bounds for all cases, except for d90 of API C. Notably, the approach offers a direct and efficient solution for early-phase formulation and process development, considerably reducing the need for extensive experimental work. By relying on just four material characterization methods, it streamlines the research process while maintaining a high degree of accuracy.
Collapse
Affiliation(s)
- Kensaku Matsunami
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium.
| | - Jonathan Meyer
- Worldwide Research and Development, Pfizer Inc., Sandwich, Kent, UK
| | - Martin Rowland
- Worldwide Research and Development, Pfizer Inc., Sandwich, Kent, UK
| | - Neil Dawson
- Worldwide Research and Development, Pfizer Inc., Sandwich, Kent, UK
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Daan Van Hauwermeiren
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| |
Collapse
|
4
|
Barrera Jiménez AA, Matsunami K, Van Hauwermeiren D, Peeters M, Stauffer F, Dos Santos Schultz E, Kumar A, De Beer T, Nopens I. Partial least squares regression to calculate population balance model parameters from material properties in continuous twin-screw wet granulation. Int J Pharm 2023; 640:123040. [PMID: 37172629 DOI: 10.1016/j.ijpharm.2023.123040] [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: 02/07/2023] [Revised: 05/04/2023] [Accepted: 05/06/2023] [Indexed: 05/15/2023]
Abstract
In the pharmaceutical industry, twin-screw wet granulation has become a realistic option for the continuous manufacturing of solid drug products. Towards the efficient design, population balance models (PBMs) have been recognized as a tool to compute granule size distribution and understand physical phenomena. However, the missing link between material properties and the model parameters limits the swift applicability and generalization of new active pharmaceutical ingredients (APIs). This paper proposes partial least squares (PLS) regression models to assess the impact of material properties on PBM parameters. The parameters of the compartmental one-dimensional PBMs were derived for ten formulations with varying liquid-to-solid ratios and connected with material properties and liquid-to-solid ratios by PLS models. As a result, key material properties were identified in order to calculate it with the necessary accuracy. Size- and moisture-related properties were influential in the wetting zone whereas density-related properties were more dominant in the kneading zones.
Collapse
Affiliation(s)
- Ana Alejandra Barrera Jiménez
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium; Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium.
| | - Kensaku Matsunami
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium; Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium.
| | - Daan Van Hauwermeiren
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium; Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Michiel Peeters
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Fanny Stauffer
- Product Design & Performance, UCB, Braine l'Alleud, 1420, Belgium
| | | | - Ashish Kumar
- Discovery, Product Development & Supply, Janssen R&D, Beerse, B-2340, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent, 9000, Oost-Vlaanderen, Belgium
| | - Ingmar Nopens
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure links 653, Ghent, 9000, Oost-Vlaanderen, Belgium
| |
Collapse
|
5
|
Technological advances and challenges for exploring attribute transmission in tablet development by high shear wet granulation. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118402] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/08/2023]
|
6
|
Monaco D, Reynolds GK, Tajarobi P, Litster JD, Salman AD. Modelling the effect of L/S ratio and granule moisture content on the compaction properties in continuous manufacturing. Int J Pharm 2023; 633:122624. [PMID: 36690126 DOI: 10.1016/j.ijpharm.2023.122624] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/12/2022] [Revised: 01/05/2023] [Accepted: 01/16/2023] [Indexed: 01/22/2023]
Abstract
The pharmaceutical field is currently moving towards continuous manufacturing pursuing reduced waste, consistency, and automation. During continuous manufacturing, it is important to understand how both operating conditions and material properties throughout the process affect the final properties of the product to optimise and control production. In this study of a continuous wet granulation line, the liquid to solid ratio (L/S) and drying times were varied to investigate the effect of the final granule moisture content and the liquid to solid ratio on the properties of the granules during tabletting and the final tensile strength of the tablets. Both variables (L/S and granule moisture) affected the tablet tensile strength with the moisture content having a larger impact. Further analysis using a compaction model, showed that the compactability of the granules was largely unaffected by both L/S and moisture content while the compressibility was influenced by these variables, leading to a difference in the final tablet strength and porosity. The granule porosity was linked to the L/S ratio and used instead for the model fitting. The effect of moisture content and granule porosity was added to the model using a 3d plane relationship between the compressibility constant, the moisture content and porosity of the granules. The tablet tensile strength model, considering the effect of moisture and granule porosity, performed well averaging a root mean squared error across the different conditions of 0.17 MPa.
Collapse
Affiliation(s)
- Daniele Monaco
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, UK.
| | - Gavin K Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, AstraZeneca, Macclesfield, UK
| | - Pirjo Tajarobi
- Early Product Development and Manufacture, Pharmaceutical Sciences, AstraZeneca, Gothenburg, Sweden
| | - James D Litster
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, UK
| | - Agba D Salman
- Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, UK
| |
Collapse
|
7
|
Matsunami K, Miura T, Yaginuma K, Tanabe S, Badr S, Sugiyama H. Surrogate modeling of dissolution behavior toward efficient design of tablet manufacturing processes. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2023.108141] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/18/2023]
|
8
|
Ge Wang L, Omar C, Litster J, Slade D, Li J, Salman A, Bellinghausen S, Barrasso D, Mitchell N. Model Driven Design for Integrated Twin Screw Granulator and Fluid Bed Dryer via Flowsheet Modelling. Int J Pharm 2022; 628:122186. [PMID: 36130681 DOI: 10.1016/j.ijpharm.2022.122186] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2022] [Revised: 09/02/2022] [Accepted: 09/03/2022] [Indexed: 11/27/2022]
Abstract
This paper presents a flowsheet modelling of an integrated twin screw granulation (TSG) and fluid bed dryer (FBD) process using a Model Driven Design (MDD) approach. The MDD approach is featured by appropriate process models and efficient model calibration workflow to ensure the product quality. The design space exploration is driven by the physics of the process instead of extensive experimental trials. By means of MDD, the mechanistic-based process kernels are first defined for the TSG and FBD processes. With the awareness of the underlying physics, the complementary experiments are carried out with relevance to the kinetic parameters in the defined models. As a result, the experiments are specifically purposeful for model calibration and validation. The L/S ratio (liquid to solid ratio) and inlet air temperature are selected as the Critical Process Parameters (CPPs) in TSG and FBD for model validation, respectively. Global System Analysis (GSA) is further performed to assess the uncertainty of CPPs imposed on the Critical Quality Attributes (CQAs), which provides significant insights to the exploration of the design space considering both TSG and FBD process parameters.
Collapse
Affiliation(s)
- Li Ge Wang
- Siemens Process Systems Engineering, Hammersmith, London, UK; Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - Chalak Omar
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - James Litster
- Department of Chemical and Biological Engineering, University of Sheffield, UK.
| | - David Slade
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Jianfeng Li
- Siemens Process Systems Engineering, Parsippany, New Jersey, USA
| | - Agba Salman
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | | | - Dana Barrasso
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Niall Mitchell
- Siemens Process Systems Engineering, Hammersmith, London, UK
| |
Collapse
|
9
|
Hirono K, A. Udugama I, Hayashi Y, Kino-oka M, Sugiyama H. A Dynamic and Probabilistic Design Space Determination Method for Mesenchymal Stem Cell Cultivation Processes. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.2c00374] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Keita Hirono
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Isuru A. Udugama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Yusuke Hayashi
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Masahiro Kino-oka
- Department of Biotechnology, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| |
Collapse
|
10
|
Han JK, Kim JY, Choi DH, Park ES. A formulation development strategy for dual-release bilayer tablets: An integrated approach of quality by design and a placebo layer. Int J Pharm 2022; 618:121659. [PMID: 35292397 DOI: 10.1016/j.ijpharm.2022.121659] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/27/2021] [Revised: 02/20/2022] [Accepted: 03/09/2022] [Indexed: 10/18/2022]
Abstract
Although dual-release mechanism bilayer tablets containing one drug in both immediate- and sustained-release layers are widely used to improve therapeutic efficiency, studies quantitatively analyzing the drug amount released from each layer and the mutual effect of each layer's mechanical properties on drug product quality are limited. Here, the formulation of a dual-release bilayer tablet containing sarpogrelate HCl was optimized with a placebo layer and quality by design (QbD) approach. The placebo layer was developed to replace the active pharmaceutical ingredient and its mechanical properties were evaluated. The formulation was developed using the placebo layer to quantitatively analyze the drug released from each layer. The mixture design and Monte Carlo simulation enabled robust design space identification. The mutual effect of each layer's mechanical properties on drug product quality was confirmed by multivariate analysis using the optimal settings in the design space. The optimized formulation was characterized by comparison with a reference drug for various quality attributes and in vivo pharmacokinetic parameters, which ensured the bioequivalence of the optimized bilayer tablet with the reference drug. This study shows that the integration of QbD and a placebo layer is an effective optimization strategy for dual-release bilayer tablets containing one drug in different layers.
Collapse
Affiliation(s)
- Jong Kwon Han
- School of Pharmacy, Sungkyunkwan University, Suwon-si 16419, Republic of Korea
| | - Ji Yeon Kim
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si 50819, Republic of Korea
| | - Du Hyung Choi
- Department of Pharmaceutical Engineering, Inje University, Gimhae-si 50819, Republic of Korea.
| | - Eun-Seok Park
- School of Pharmacy, Sungkyunkwan University, Suwon-si 16419, Republic of Korea.
| |
Collapse
|
11
|
Casian T, Iurian S, Gâvan A, Porfire A, Pop AL, Crișan S, Pușcaș AM, Tomuță I. In-Depth Understanding of Granule Compression Behavior under Variable Raw Material and Processing Conditions. Pharmaceutics 2022; 14:pharmaceutics14010177. [PMID: 35057072 PMCID: PMC8780340 DOI: 10.3390/pharmaceutics14010177] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/13/2021] [Revised: 01/06/2022] [Accepted: 01/11/2022] [Indexed: 12/25/2022] Open
Abstract
Tablet manufacturing involves the processing of raw materials through several unit operations. Thus, the mitigation of input-induced variability should also consider the downstream processability of intermediary products. The objective of the present work was to study the effect of variable raw materials and processing conditions on the compression properties of granules containing two active pharmaceutical ingredients (APIs) and microcrystalline cellulose. Differences in compressibility and tabletability of granules were highlighted in function of the initial particle size of the first API, granule polydispersity and fragmentation. Moreover, interactions were underlined with the atomizing pressure. Changing the supplier of the second API was efficiently controlled by adapting the binder addition rate and atomizing pressure during granulation, considering the starting crystal size. By fitting mathematical models on the available compression data, the influence of diluent source on granule compactibility and tabletability was identified. These differences resumed to the ease of compaction, tableting capacity and pressure sensitivity index due to variable water binding capacity of microcrystalline cellulose. Building the design space enabled the identification of suitable API types and the appropriate processing conditions (spray rate, atomizing pressure, compression force) required to ensure the desired tableting performance.
Collapse
Affiliation(s)
- Tibor Casian
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, “Iuliu Hațieganu” University of Medicine and Pharmacy, 400000 Cluj-Napoca, Romania; (T.C.); (A.G.); (A.P.); (A.M.P.); (I.T.)
| | - Sonia Iurian
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, “Iuliu Hațieganu” University of Medicine and Pharmacy, 400000 Cluj-Napoca, Romania; (T.C.); (A.G.); (A.P.); (A.M.P.); (I.T.)
- Correspondence:
| | - Alexandru Gâvan
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, “Iuliu Hațieganu” University of Medicine and Pharmacy, 400000 Cluj-Napoca, Romania; (T.C.); (A.G.); (A.P.); (A.M.P.); (I.T.)
| | - Alina Porfire
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, “Iuliu Hațieganu” University of Medicine and Pharmacy, 400000 Cluj-Napoca, Romania; (T.C.); (A.G.); (A.P.); (A.M.P.); (I.T.)
| | - Anca Lucia Pop
- Department of Clinical Laboratory, Faculty of Pharmacy, “Carol Davila” University of Medicine and Pharmacy, 050474 Bucharest, Romania;
- RD Center, AC HELCOR, 430092 Baia Mare, Romania;
| | | | - Anda Maria Pușcaș
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, “Iuliu Hațieganu” University of Medicine and Pharmacy, 400000 Cluj-Napoca, Romania; (T.C.); (A.G.); (A.P.); (A.M.P.); (I.T.)
| | - Ioan Tomuță
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, “Iuliu Hațieganu” University of Medicine and Pharmacy, 400000 Cluj-Napoca, Romania; (T.C.); (A.G.); (A.P.); (A.M.P.); (I.T.)
| |
Collapse
|
12
|
Arai H, Nagato T, Koide T, Yonemochi E, Yamamoto H, Sugiyama H. Tablet Quality-Prediction Model Using Quality Material Attributes: Toward Flexible Switching Between Batch and Continuous Granulation. J Pharm Innov 2021. [DOI: 10.1007/s12247-020-09466-w] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
|
13
|
Analysis of the Effects of Process Parameters on Start-Up Operation in Continuous Wet Granulation. Processes (Basel) 2021. [DOI: 10.3390/pr9091502] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Toward further implementation of continuous tablet manufacturing, one key issue is the time needed for start-up operation because it could lead to lower product yield and reduced economic performance. The behavior of the start-up operation is not well understood; moreover, the definition of the start-up time is still unclear. This work investigates the effects of process parameters on the start-up operation in continuous wet granulation, which is a critical unit operation in solid drug manufacturing. The profiles of torque and granule size distribution were monitored and measured for the first hour of operation, including the start-up phase. We analyzed the impact of process parameters based on design of experiments and performed an economic assessment to see the effects of the start-up operation. The torque profiles indicated that liquid-to-solid ratio and screw speed would affect the start-up operation, whereas different start-up behavior resulted in different granule size. Depending on the indicator used to define the start-up operation, the economic optimal point was significantly different. The results of this study stress that the start-up time differs according to the process parameters and used definition, e.g., indicators and criteria. This aspect should be considered for the further study and regulation of continuous manufacturing.
Collapse
|
14
|
Characteristics of residence time distribution in a continuous high shear mixer granulation using scraper rotation. Int J Pharm 2021; 605:120789. [PMID: 34116178 DOI: 10.1016/j.ijpharm.2021.120789] [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: 03/08/2021] [Revised: 05/22/2021] [Accepted: 06/06/2021] [Indexed: 11/20/2022]
Abstract
Characteristics of residence time distribution (RTD) in a continuous high shear mixer granulation were investigated to promote the development of a continuous manufacturing process in the pharmaceutical industry. A continuous granulator with an impeller and a scraper was utilized. The tracer behavior in the continuous wet granulation was verified in impulse-response experiments with acetaminophen. The RTD of acetaminophen changed depending on the scraper speed (15-50 rpm), and the mean residence time could be adjusted by the scraper speed in the wet granulation. The impact of changes in the liquid-to-solid ratio (0.10-0.20) and the addition of binder were also examined, and the variance of RTD was influenced by both. The degree of axial mixing was quantitatively evaluated with a dimensionless index, the Peclet number (Pe). Higher scraper speed was found to suppress fluctuations of the axial mixing that occurred with changes in the liquid feed. Moreover, the transition of granule size distribution with the change in liquid feed reached a steady state more quickly under the higher scraper speed. These results show that scraper rotation can help to adjust the RTD and the axial mixing, leading to a more robust continuous granulation.
Collapse
|
15
|
Strategies and formulations of freeze-dried tablets for controlled drug delivery. Int J Pharm 2021; 597:120373. [PMID: 33577912 DOI: 10.1016/j.ijpharm.2021.120373] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/07/2020] [Revised: 01/24/2021] [Accepted: 02/05/2021] [Indexed: 11/21/2022]
Abstract
The freeze-drying process has been particularly attractive for preparing tablets for controlled drug release. Although traditional methods, such as granulation or direct compression methods, have been used in various studies to produce tablets with controlled release, freeze-drying processes have been utilized in certain circumstances due to their distinct advantages. However, overall, further development of these strategies, which started with early studies on orally disintegrating tablets, is still necessary. In this review, the incorporation of different formulations into freeze-dried tablets will be discussed. Moreover, the use of excipients, freeze-drying conditions, formulation reconstitution and tablet structure for optimizing the performance of freeze-dried tablets will be reported, including strategies with nanoformulations and natural materials. Generally, this discussion with potential approaches will benefit further development of freeze-dried tablets containing drugs in the pharmaceutical industry.
Collapse
|