Optimization of screw design for continuous wet granulation: A Case Study of metoprolol succinate ER tablets

Investigating the Effects of Mixing Dynamics on Twin-Screw Granule Quality Attributes via the Development of a Physics-Based Process Map

Twin-screw granulation (TSG) is an emerging continuous wet granulation technique that has not been widely applied in the industry due to a poor mechanistic understanding of the process. This study focuses on improving this mechanistic understanding by analyzing the effects of the mixing dynamics on the granule quality attributes (PSD, content uniformity, and microstructure). Mixing is an important dynamic process that simultaneously occurs along with the granulation rate mechanisms during the wet granulation process. An improved mechanistic understanding was achieved by identifying and quantifying the physically relevant intermediate parameters that affect the mixing dynamics in TSG, and then their effects on the granule attributes were analyzed by investigating their effects on the granulation rate mechanisms. The fill level, granule liquid saturation, extent of nucleation, and powder wettability were found to be the key physically relevant intermediate parameters that affect the mixing inside the twin-screw granulator. An improved geometrical model for the fill level was developed and validated against existing experimental data. Finally, a process map was developed to depict the effects of mixing on the temporal and spatial evolution of the materials inside the twin-screw granulator. This process map illustrates the mechanism of nucleation and the growth of the granules based on the fundamental material properties of the primary powders (solubility and wettability), liquid binders (viscosity), and mixing dynamics present in the system. Furthermore, it was shown that the process map can be used to predict the granule product quality based on the granule growth mechanism.

Characterizing a design space for a twin-screw wet granulation process: A case study of extended-release tablets

Twin-screw wet granulation is an emerging continuous manufacturing technology for solid oral dosage forms. This technology has been successfully employed for the commercial manufacture of immediate-released tablets. However, the higher polymer content in extended-release (ER) formulations may present challenges in developing and operating within a desired design space. The work described here used a systematic approach for defining the optimum design space by understanding the effects of the screw design, operating parameters, and their interactions on the critical characteristics of granules and ER tablets. The impacts of screw speed, powder feeding rate, and the number of kneading (KEs) and sizing elements on granules and tablets characteristics were investigated by employing a definitive screening design. A semi-mechanistic model was used to calculate the residence time distribution parameters and validated using the tracers. The results showed that an increase in screw speed decreased the mean residence time of the material within the barrel, while an increase in the powder feeding rate or number of KEs did the opposite and increased the barrel residence time. Screw design and operating parameters affected the flow and bulk characteristics of granules. The screw speed was the most significant factor impacting the tablet's breaking strength. The dissolution profiles revealed that granule characteristics mainly influenced the early phase of drug release. This study demonstrated that a simultaneous optimization of both operating and screw design parameters was beneficial in producing ER granules and tablets of desired performance characteristics while mitigating any failure risks, such as swelling during processing.

Optimization of key energy and performance metrics for drug product manufacturing

During the development of pharmaceutical manufacturing processes, detailed systems-based analysis and optimization are required to control and regulate critical quality attributes within specific ranges, to maintain product performance. As discussions on carbon footprint, sustainability, and energy efficiency are gaining prominence, the development and utilization of these concepts in pharmaceutical manufacturing are seldom reported, which limits the potential of pharmaceutical industry in maximizing key energy and performance metrics. Based on an integrated modeling and techno-economic analysis framework previously developed by the authors (Sampat et al., 2022), this study presents the development of a combined sensitivity analysis and optimization approach to minimize energy consumption while maintaining product quality and meeting operational constraints in a pharmaceutical process. The optimal input process conditions identified were validated against experiments and good agreement resulted between simulated and experimental data. The results also allowed for a comparison of the capital and operational costs for batch and continuous manufacturing schemes under nominal and optimized conditions. Using the nominal batch operations as a basis, the optimized batch operation results in a 71.7% reduction of energy consumption, whereas the optimized continuous case results in an energy saving of 83.3%.

Analysis of Erhu Performance Effect in Public Health Music Works Based on Artificial Intelligence Technology

With the rise of Erhu teaching in recent years, a large number of people have joined the team to learn Erhu playing. However, due to the high cost of teaching and the unique one-to-one teaching mode between teachers and students, Erhu education resources are very scarce. Learning Erhu performance has become a luxury activity. Nowadays, with the rise of artificial intelligence, computer music is developing rapidly. Music has two important aspects: composition and performance. Different kinds of instruments convey different styles, and players inject different rhythms and dynamics into their performance, thus producing rich expressive force. The development of image style conversion, which opens people's evaluation of music performance, is an important issue in many fields of artificial intelligence (it is also known as intelligence, machine intelligence, referring to the intelligence shown by the machine made by people. Usually, artificial intelligence refers to the technique of presenting human intelligence through ordinary computer programs). For an Erhu song, there are various factors that affect its effectiveness, and there are many indexes to evaluate it, such as sense of rhythm, expressive force, musical sense, style, and so on. Using a computer to simulate the evaluation process is essential to find out the mathematical relationship between the factors that affect the performance of music and the evaluation indexes. Neural network is a kind of mathematical model proposed by simulating the way of thinking of human brain in artificial intelligence. It has the advantages of not having strict requirements on data distribution, nonlinear data processing method, strong robustness, and dynamics and is very suitable for the mathematical model of evaluation system. In addition, the neural network also has a strong theoretical basis, and their application in various industries has developed basically mature. This paper tries to introduce a deep neural network mathematical model into the evaluation system of Erhu performance, and the experimental results prove the reliability and practicality of the method in this paper. It can provide a method basis and theoretical reference for evaluation of Erhu performance effect.