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Jolliffe HG, Prostredny M, Mendez Torrecillas C, Bordos E, Tierney C, Ojo E, Elkes R, Reynolds G, Li Song Y, Meir B, Fathollahi S, Robertson J. A modified Kushner-Moore approach to characterising small-scale blender performance impact on tablet compaction. Int J Pharm 2024; 659:124232. [PMID: 38759740 DOI: 10.1016/j.ijpharm.2024.124232] [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: 01/30/2024] [Revised: 05/02/2024] [Accepted: 05/14/2024] [Indexed: 05/19/2024]
Abstract
Continuous Direct Compaction (CDC) has emerged as a promising route towards producing solid dosage forms while reducing material, development time and energy consumption. Understanding the response of powder processing unit operations, especially blenders, is crucial. There is a substantial body of work around how lubrication via batch blender operation affects tablet critical quality attributes such as hardness and tensile strength. But, aside from being batch operations, the design of these blenders is such that they operate with low-shear, low-intensity mixing at Froude number values significantly below 0.4 (Froude number Fr being the dimensionless ratio of inertial to gravitational forces). The present work explores the performance of a mini-blender which has a fundamentally different mode of operation (static vessel with rotating blades around a mixing shaft as opposed to rotating vessel with no mixing shaft). This difference allows a substantially wider operating range in terms of speed and shear (and Fr values). The present work evaluates how its performance compares to other blenders studied in the literature. Tablet compaction data from blends produced at various intensities and regimes of mixing in the mini-blender follow a common trajectory. Model equations from literature are suitably modified by inclusion of the Froude number Fr, but only for situations where the Froude number was sufficiently high (1 < Fr). The results suggest that although a similar lubrication extent plateau is eventually reached it is the intensity of mixing (i.e. captured using the Froude number as a surrogate) which is important for the lubrication dynamics in the mini-blender, next to the number of revolutions. The degree of fill or headspace, on the other hand, is only crucial to the performance of common batch blenders. Testing using alternative formulations shows the same common trend across mixing intensities, suggesting the validity of the approach to capture lubrication dynamics for this system.
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Affiliation(s)
- Hikaru G Jolliffe
- CMAC, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK
| | - Martin Prostredny
- CMAC, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK
| | | | - Ecaterina Bordos
- CMAC, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK
| | - Collette Tierney
- CMAC, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK
| | - Ebenezer Ojo
- CMAC, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK
| | - Richard Elkes
- GSK Ware R&D, Harris's Lane, Ware, Hertfordshire SG12 0GX, UK
| | - Gavin Reynolds
- Oral Product Development, PT&D, Operations, AstraZeneca UK Limited, Charter Way, Macclesfield SK10 2NA, UK
| | - Yunfei Li Song
- GSK Ware R&D, Harris's Lane, Ware, Hertfordshire SG12 0GX, UK
| | - Bernhard Meir
- Gericke AG, Althardstrasse 120, CH-8105 Regensdorf, Switzerland
| | - Sara Fathollahi
- DFE Pharma GmbH & Co. KG, Kleverstrasse 187, 47568 Goch, Germany
| | - John Robertson
- CMAC, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK.
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Jin C, Zhao L, Feng Y, Hong Y, Shen L, Lin X. Simultaneous modeling prediction of three key quality attributes of tablets by powder physical properties. Int J Pharm 2022; 628:122344. [DOI: 10.1016/j.ijpharm.2022.122344] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2022] [Revised: 10/11/2022] [Accepted: 10/22/2022] [Indexed: 11/06/2022]
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Puckhaber D, Kathrin Schomberg A, Kwade A, Henrik Finke J. A compactibility-based lubricant dispersion model describing the effect of formulation and paddle speed. Int J Pharm 2022; 628:122300. [DOI: 10.1016/j.ijpharm.2022.122300] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/01/2022] [Revised: 10/08/2022] [Accepted: 10/10/2022] [Indexed: 10/31/2022]
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Streamlining tablet lubrication design via model-based design of experiments. Int J Pharm 2021; 614:121435. [PMID: 34974150 DOI: 10.1016/j.ijpharm.2021.121435] [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: 11/11/2021] [Revised: 12/24/2021] [Accepted: 12/26/2021] [Indexed: 11/21/2022]
Abstract
In oral solid dosage production through direct compression powder lubrication must be carefully selected to facilitate the manufacturing of tablets without degrading product manufacturability and quality (e.g. dissolution). To do so, several semi-empirical models relating compression performance to process operating conditions have been developed. Among them, we consider an extension of the Kushner and Moore model (Kushner and Moore, 2010, International Journal Pharmaceutics, 399:19) that is useful for the purpose, but requires an extensive experimental campaign for parameters identification. This implies the preparation and compression of multiple powder blends, each one with a different lubrication extent. In turn, this translates into a considerable consumption of Active Pharmaceutical Ingredient (API), and into time-consuming experiments. We tackled this issue by proposing a novel model-based design of experiments (MBDoE) approach, which minimizes the number of optimal blends for model calibration, while obtaining statistically sound parameters estimates and model predictions. Both sequential and parallel MBDoE configurations were compared. Experimental results involving two placebo blends with different lubrication sensitivity showed that this methodology is able to reduce the experimental effort by 60-70% with respect to the standard industrial practice independently of the formulation considered and configuration (i.e. parallel vs. sequential) adopted.
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Wang LG, Omar C, Litster JD, Li J, Mitchell N, Bellinghausen S, Barrasso D, Salman A, Slade D. Tableting model assessment of porosity and tensile strength using a continuous wet granulation route. Int J Pharm 2021; 607:120934. [PMID: 34310957 DOI: 10.1016/j.ijpharm.2021.120934] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/23/2021] [Revised: 07/20/2021] [Accepted: 07/21/2021] [Indexed: 01/17/2023]
Abstract
This paper presents a comprehensive assessment of the most widely used tablet compaction models in a continuous wet granulation tableting process. The porosity models, tensile strength models and lubricant models are reviewed from the literature and classified based on their formulations i.e. empirical or theoretical and applications, i.e. batch or continuous. The majority of these models are empirical and were initially developed for batch tabletting process. To ascertain their effectiveness and serviceability in the continuous tableting process, a continuous powder processing line of Diamond Pilot Plant (DiPP) installed at The University of Sheffield was used to provide the quantitative data for tablet model assessment. Magnesium stearate (MgSt) is used as a lubricant to investigate its influence on the tensile strength. Whilst satisfactory predictions from the tablet models can be produced, a compromise between the model fidelity and model simplicity needs to be made for a suitable model selection. The Sonnergaard model outperforms amongst the porosity models whilst the Reynolds model produces the best goodness of fitting for two parameters fitting porosity models. An improved tensile strength model is proposed to consider the influence of powder size and porosity in the continuous tableting process.
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Affiliation(s)
- Li Ge Wang
- Department of Chemical and Biological Engineering, University of Sheffield, UK; Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Chalak Omar
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - James D Litster
- Department of Chemical and Biological Engineering, University of Sheffield, UK.
| | - Jianfeng Li
- Siemens Process Systems Engineering, Parsippany, NJ Office, USA
| | - Niall Mitchell
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | | | - Dana Barrasso
- Siemens Process Systems Engineering, Parsippany, NJ Office, USA
| | - Agba Salman
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - David Slade
- Siemens Process Systems Engineering, Hammersmith, London, UK
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