Magnesium stearate surface coverage on tablets and drug crystals: Insights from SEM-EDS elemental mapping

Tablet ejection: A systematic comparison between force, static friction, and kinetic friction

The magnitude of the frictional forces during the ejection of porous pharmaceutical tablets plays an important role in determining the occurrence of tabletting defects. Here, we perform a systematic comparison between the maximum ejection force, static friction coefficient, and kinetic friction coefficient. All of these metrics have different physical meanings, corresponding to different stages of ejection. However, experimental limitations have previously complicated comparisons, as static and kinetic friction could not be measured simultaneously. This study presents a method for simultaneously measuring the maximum ejection force, static friction coefficient, and kinetic friction coefficient in situ during tablet ejection in routine compaction simulator experiments. Using this method, we performed a systematic comparison, including variations of (1) ejection speed, (2) compaction pressure, (3) material, and (4) lubrication method. The relative importance of each variable is discussed in detail, including how ejection speed alone can be a decisive factor in tablet chipping. The reliability of the newly developed method is supported by excellent agreement with previous studies and finite element method (FEM) simulations. Finally, we discuss the suitability of friction coefficients derived from Janssen-Walker theory and explanations for the phenomenon of die-wall static friction coefficients with apparent values far above unity.

Effect of particle size on the dispersion behavior of magnesium stearate blended with microcrystalline cellulose

The majority of tablets manufactured contain lubricants to reduce friction during ejection. However, especially for plastically deforming materials, e.g., microcrystalline cellulose (MCC), the internal addition of lubricants is known to reduce tablet tensile strength. This reduction is caused by the surface coverage by lubricant particles, the extent of which depends on both process and formulation parameters. Previously published models to predict the lubrication effect on mechanical strength do not account for changes in the excipient particle size. In this study, the impact of both lubricant concentration and mixing time on the tensile strength of tablets consisting of three different grades of MCC and four grades of magnesium stearate (MgSt) was evaluated. By taking into account the particle size of the applied excipients, a unifying relationship between the theoretically estimated surface coverage and compactibility reduction was identified. Evaluating the dispersion kinetics of MgSt as a function of time reveals a substantial impact of the initial surface coverage on the dispersion rate, while the minimal tensile strength was found to be comparable for the majority of formulations. In summary, the presented work extends the knowledge of lubricant dispersion and facilitates the reduction of necessary experiments during the development of new tablet formulations.

Understanding the role of magnesium stearate in lowering punch sticking propensity of drugs during compression

The sticking of active pharmaceutical ingredient (API) to the surfaces of compaction tooling, frequently referred to as punch sticking, causes costly downtime or product failures in commercial tablet manufacturing. Magnesium stearate (MgSt) is a common tablet lubricant known to ameliorate the sticking problem, even though there exist exceptions. The mechanism by which MgSt lowers punch sticking propensity (PSP) by covering API surface is sensible but not yet experimentally proven. This work was aimed at elucidating the link between PSP and surface area coverage (SAC) of tablets by MgSt, in relation to some key formulation properties and process parameters, namely MgSt concentration, API loading, API particle size, and mixing conditions. The study was conducted using two model APIs with known high PSPs, tafamidis (TAF) and ertugliflozin-pyroglutamic acid (ERT). Results showed that PSP decreases exponentially with increasing SAC by MgSt. The composition of material stuck to punch face was also explored to better understand the onset of punch sticking and the impact of possible MgSt-effected punch conditioning event.