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Ismail O, Zheng C, Chamberlain T, Zakhvatayeva A, Hare C, Yost E, Muliadi AR, Wu CY. An experimental study on flow behaviour of pharmaceutical powders during suction filling. Int J Pharm 2024; 662:124527. [PMID: 39079593 DOI: 10.1016/j.ijpharm.2024.124527] [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: 02/07/2024] [Revised: 07/24/2024] [Accepted: 07/25/2024] [Indexed: 08/09/2024]
Abstract
Die filling is a crucial step in the pharmaceutical tablet manufacturing process. For industrial-scale production using rotary presses, suction filling is typically employed due to its significant efficiency advantages over gravity filling. Despite its widespread use, our understanding of the suction filling process remains limited. Specifically, there is insufficient comprehension of how filling performance is influenced by factors such as suction velocity, filling velocity, and the properties of the powder materials. Building on our previous research, this study aims to further investigate the effects of powder properties and process parameters (e.g., filling velocity, suction velocity, fill depth) on suction filling behaviour. A systematic experimental investigation was conducted using a model suction filling system, considering both cohesive and free-flowing pharmaceutical powders. The effect of fill depth on suction filling of these powders was examined at different filling and suction velocities. The results demonstrate that two distinctive flow regimes for suction filling can be identified: slow filling and fast filling. These regimes are delineated by a critical filling-to-suction velocity ratio. In the slow filling regime, the filling-to-suction velocity ratio is lower than the critical ratio, meaning that the filling phase is slower than the suction phase. Conversely, the fast filling regime occurs when the filling-to-suction velocity ratio exceeds the critical ratio, implying that the filling phase is faster than the suction phase. This study reveals, for the first time, that when the powder flow pattern during suction filling is dominated by plug flow, full die fill (i.e., the fill ratio equals unity) is achieved in the slow filling regime. However, in the fast filling regime, incomplete die fill is obtained. It is also found that when plug flow prevails during fast filling, the fill ratio has an inverse correlation with the filling-to-suction velocity ratio. This study further reveals that when the plug flow assumption is valid, the filling ratio at various fill-to-suction velocity ratios can be well predicted mathematically. Furthermore, it is also found that once the powder flow pattern differs from the ideal plug flow, which could be induced by the filling conditions and powder cohesion, the fill ratio can be overpredicted.
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Affiliation(s)
- Omar Ismail
- School of Chemistry and Chemical Engineering, University of Surrey, Guildford, Surrey GU2 7XH, UK
| | - Chao Zheng
- School of Chemistry and Chemical Engineering, University of Surrey, Guildford, Surrey GU2 7XH, UK
| | - Thomas Chamberlain
- School of Chemistry and Chemical Engineering, University of Surrey, Guildford, Surrey GU2 7XH, UK
| | - Anastasiya Zakhvatayeva
- School of Chemistry and Chemical Engineering, University of Surrey, Guildford, Surrey GU2 7XH, UK
| | - Colin Hare
- School of Chemistry and Chemical Engineering, University of Surrey, Guildford, Surrey GU2 7XH, UK; School of Chemical Engineering, Newcastle University, Newcastle upon Tyne, NE1 7RU, UK
| | - Edward Yost
- Synthetic Molecule Pharmaceutics, Genentech Inc., One DNA Way, South San Francisco, CA 94080, USA
| | - Ariel R Muliadi
- Synthetic Molecule Pharmaceutics, Genentech Inc., One DNA Way, South San Francisco, CA 94080, USA
| | - Chuan-Yu Wu
- School of Chemistry and Chemical Engineering, University of Surrey, Guildford, Surrey GU2 7XH, UK.
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Jakubowska E, Ciepluch N. Blend Segregation in Tablets Manufacturing and Its Effect on Drug Content Uniformity-A Review. Pharmaceutics 2021; 13:pharmaceutics13111909. [PMID: 34834324 PMCID: PMC8620778 DOI: 10.3390/pharmaceutics13111909] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/18/2021] [Revised: 11/02/2021] [Accepted: 11/08/2021] [Indexed: 11/26/2022] Open
Abstract
Content uniformity (CU) of the active pharmaceutical ingredient is a critical quality attribute of tablets as a dosage form, ensuring reproducible drug potency. Failure to meet the accepted uniformity in the final product may be caused either by suboptimal mixing and insufficient initial blend homogeneity, or may result from further particle segregation during storage, transfer or the compression process itself. This review presents the most relevant powder segregation mechanisms in tablet manufacturing and summarizes the currently available, up-to-date research on segregation and uniformity loss at the various stages of production process—the blend transfer from the bulk container to the tablet press, filling and discharge from the feeding hopper, as well as die filling. Formulation and processing factors affecting the occurrence of segregation and tablets’ CU are reviewed and recommendations for minimizing the risk of content uniformity failure in tablets are considered herein, including the perspective of continuous manufacturing.
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Affiliation(s)
- Emilia Jakubowska
- Chair and Department of Pharmaceutical Technology, Faculty of Pharmacy, Poznan University of Medical Sciences, 6 Grunwaldzka Street, 60-780 Poznan, Poland
- Correspondence:
| | - Natalia Ciepluch
- Department of Medical Rescue, Chair of Emergency Medicine, Faculty of Health Sciences, Poznan University of Medical Sciences, 7 Rokietnicka Street, 60-806 Poznan, Poland;
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