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Shi G, Lin L, Liu Y, Chen G, Luo Y, Wu Y, Li H. Pharmaceutical application of multivariate modelling techniques: a review on the manufacturing of tablets. RSC Adv 2021; 11:8323-8345. [PMID: 35423324 PMCID: PMC8695199 DOI: 10.1039/d0ra08030f] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/20/2020] [Accepted: 01/26/2021] [Indexed: 11/21/2022] Open
Abstract
The tablet manufacturing process is a complex system, especially in continuous manufacturing (CM). It includes multiple unit operations, such as mixing, granulation, and tableting. In tablet manufacturing, critical quality attributes are influenced by multiple factorial relationships between material properties, process variables, and interactions. Moreover, the variation in raw material attributes and manufacturing processes is an inherent characteristic and seriously affects the quality of pharmaceutical products. To deepen our understanding of the tablet manufacturing process, multivariable modeling techniques can replace univariate analysis to investigate tablet manufacturing. In this review, the roles of the most prominent multivariate modeling techniques in the tablet manufacturing process are discussed. The review mainly focuses on applying multivariate modeling techniques to process understanding, optimization, process monitoring, and process control within multiple unit operations. To minimize the errors in the process of modeling, good modeling practice (GMoP) was introduced into the pharmaceutical process. Furthermore, current progress in the continuous manufacturing of tablets and the role of multivariate modeling techniques in continuous manufacturing are introduced. In this review, information is provided to both researchers and manufacturers to improve tablet quality.
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Affiliation(s)
- Guolin Shi
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Longfei Lin
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Yuling Liu
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Gongsen Chen
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Yuting Luo
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Yanqiu Wu
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
| | - Hui Li
- Institute of Chinese Materia Medica, China Academy of Chinese Medical Sciences Beijing 100700 China
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2
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Feng H, Mohan S. Application of Process Analytical Technology for Pharmaceutical Coating: Challenges, Pitfalls, and Trends. AAPS PharmSciTech 2020; 21:179. [PMID: 32596747 DOI: 10.1208/s12249-020-01727-8] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2020] [Accepted: 06/08/2020] [Indexed: 12/31/2022] Open
Abstract
Coating process is a critical unit operation for manufacturing solid oral dosage forms. For a long time, the coating weight gain has been discerned as the most important, if not only, characteristic describing the coating quality. As the introduction of quality by design (QbD) and advancement of process analytical technology (PAT), nowadays more techniques are available to analyze other quality attributes which have been overlooked but have substantial impacts on the performance of coated products. The techniques that permit rapid and non-destructive measurements are of particular importance to improve process operation and product quality. This article reviews the analytical techniques that have been and potentially could be used as PAT tools for characterizing the quality of pharmaceutical coating product. By identifying the challenges and pitfalls encountered during PAT application, the review aims at fostering the adoption of PAT for paving the way to enhanced quality and efficiency of the coating processes.
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Affiliation(s)
- Hanzhou Feng
- Process analytical technology, Merck & Co., Inc., Rahway, New Jersey, USA.
| | - Shikhar Mohan
- Graduate School of Pharmaceutical Sciences, Duquesne University, 600 Forbes Avenue, Pittsburgh, Pennsylvania, USA
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3
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A Reliable Automated Sampling System for On-Line and Real-Time Monitoring of CHO Cultures. Processes (Basel) 2020. [DOI: 10.3390/pr8060637] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/11/2023] Open
Abstract
Timely monitoring and control of critical process parameters and product attributes are still the basic tasks in bioprocess development. The current trend of automation and digitization in bioprocess technology targets an improvement of these tasks by reducing human error and increasing through-put. The gaps in such automation procedures are still the sampling procedure, sample preparation, sample transfer to analyzers, and the alignment of process and sample data. In this study, an automated sampling system and the respective data management software were evaluated for system performance; applicability with HPLC for measurement of vitamins, product and amino acids; and applicability with a biochemical analyzer. The focus was especially directed towards the adaptation and assessment of an appropriate amino acid method, as these substances are critical in cell culture processes. Application of automated sampling in a CHO fed-batch revealed its potential with regard to data evaluation. The higher sampling frequency compared to manual sampling increases the generated information content, which allows easier interpretation of the metabolism, extraction of e.g., ks values, application of smoothing algorithms, and more accurate detection of process events. A comparison with sensor technology shows the advantages and disadvantages in terms of measurement errors and measurement frequency.
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4
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McAvan BS, France AP, Bellina B, Barran PE, Goodacre R, Doig AJ. Quantification of protein glycation using vibrational spectroscopy. Analyst 2020; 145:3686-3696. [DOI: 10.1039/c9an02318f] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
FTIR-ATR and Raman spectroscopy can distinguish between glycated and non-glycated proteins.
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Affiliation(s)
- Bethan S. McAvan
- School of Chemistry
- Manchester Institute of Biotechnology
- University of Manchester
- Manchester
- UK
| | - Aidan P. France
- School of Chemistry
- Manchester Institute of Biotechnology
- University of Manchester
- Manchester
- UK
| | - Bruno Bellina
- School of Chemistry
- Manchester Institute of Biotechnology
- University of Manchester
- Manchester
- UK
| | - Perdita E. Barran
- School of Chemistry
- Manchester Institute of Biotechnology
- University of Manchester
- Manchester
- UK
| | - Royston Goodacre
- Department of Biochemistry
- Institute of Integrative Biology
- University of Liverpool
- Liverpool L69 7ZB
- UK
| | - Andrew J. Doig
- Manchester Institute of Biotechnology and Division of Neuroscience and Experimental Psychology
- Michael Smith Building
- School of Biological Sciences
- Faculty of Biology
- Medicine and Health
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5
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Hossain MN, Igne B, Anderson CA, Drennen JK. Influence of moisture variation on the performance of Raman spectroscopy in quantitative pharmaceutical analyses. J Pharm Biomed Anal 2019; 164:528-535. [DOI: 10.1016/j.jpba.2018.10.022] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/27/2018] [Revised: 10/12/2018] [Accepted: 10/12/2018] [Indexed: 10/28/2022]
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6
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Nagy B, Farkas A, Borbás E, Vass P, Nagy ZK, Marosi G. Raman Spectroscopy for Process Analytical Technologies of Pharmaceutical Secondary Manufacturing. AAPS PharmSciTech 2018; 20:1. [PMID: 30560395 DOI: 10.1208/s12249-018-1201-2] [Citation(s) in RCA: 64] [Impact Index Per Article: 9.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/01/2018] [Accepted: 10/01/2018] [Indexed: 01/03/2023] Open
Abstract
As the process analytical technology (PAT) mindset is progressively introduced and adopted by the pharmaceutical companies, there is an increasing demand for effective and versatile real-time analyzers to address the quality assurance challenges of drug manufacturing. In the last decades, Raman spectroscopy has emerged as one of the most promising tools for non-destructive and fast characterization of the pharmaceutical processes. This review summarizes the achieved results of the real-time application of Raman spectroscopy in the field of the secondary manufacturing of pharmaceutical solid dosage forms, covering the most common secondary process steps of a tablet production line. In addition, the feasibility of Raman spectroscopy for real-time control is critically reviewed, and challenges and possible approaches to moving from real-time monitoring to process analytically controlled technologies (PACT) are discussed.
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7
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Kim J, Lim YI, Han J, Woo YA. At-Line Raman Spectroscopy Determination of Tablet Mass Gains during the Tablet Coating Process. B KOREAN CHEM SOC 2018. [DOI: 10.1002/bkcs.11482] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Jaejin Kim
- Chong Kun Dang Pharm; Cheonan-si 330-831 Republic of Korea
| | - Young-Il Lim
- Chong Kun Dang Pharm; Cheonan-si 330-831 Republic of Korea
| | - Janghee Han
- Chong Kun Dang Pharm; Cheonan-si 330-831 Republic of Korea
| | - Young-Ah Woo
- Chong Kun Dang Pharm; Cheonan-si 330-831 Republic of Korea
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8
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Barimani S, Šibanc R, Kleinebudde P. Optimization of a semi-batch tablet coating process for a continuous manufacturing line by design of experiments. Int J Pharm 2018; 539:95-103. [DOI: 10.1016/j.ijpharm.2018.01.038] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/06/2017] [Revised: 01/16/2018] [Accepted: 01/20/2018] [Indexed: 10/18/2022]
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9
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Korasa K, Vrečer F. Overview of PAT process analysers applicable in monitoring of film coating unit operations for manufacturing of solid oral dosage forms. Eur J Pharm Sci 2018; 111:278-292. [DOI: 10.1016/j.ejps.2017.10.010] [Citation(s) in RCA: 34] [Impact Index Per Article: 4.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/08/2017] [Revised: 09/09/2017] [Accepted: 10/07/2017] [Indexed: 10/18/2022]
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10
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Koide T, Fukami T, Hisada H, Inoue M, Carriere J, Heyler R, Katori N, Okuda H, Goda Y. Identification of Pseudopolymorphism of Magnesium Stearate by Using Low-Frequency Raman Spectroscopy. Org Process Res Dev 2016. [DOI: 10.1021/acs.oprd.6b00199] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Tatsuo Koide
- Division
of Drugs, National Institute of Health Sciences, 1-18-1 Kamiyoga, Setagaya-ku, Tokyo 158-8501, Japan
| | - Toshiro Fukami
- Department
of Molecular Pharmaceutics, Meiji Pharmaceutical University, Kiyose, Tokyo 204-8588, Japan
| | - Hiroshi Hisada
- Department
of Molecular Pharmaceutics, Meiji Pharmaceutical University, Kiyose, Tokyo 204-8588, Japan
- TEK Analysis Inc. Neyagawa, Osaka 572-0020, Japan
| | - Motoki Inoue
- Department
of Molecular Pharmaceutics, Meiji Pharmaceutical University, Kiyose, Tokyo 204-8588, Japan
| | - James Carriere
- Ondax Inc. 850 Duarte Road, Monrovia, California 91016, United States
| | - Randy Heyler
- Ondax Inc. 850 Duarte Road, Monrovia, California 91016, United States
| | - Noriko Katori
- Division
of Drugs, National Institute of Health Sciences, 1-18-1 Kamiyoga, Setagaya-ku, Tokyo 158-8501, Japan
| | - Haruhiro Okuda
- Division
of Drugs, National Institute of Health Sciences, 1-18-1 Kamiyoga, Setagaya-ku, Tokyo 158-8501, Japan
| | - Yukihiro Goda
- Division
of Drugs, National Institute of Health Sciences, 1-18-1 Kamiyoga, Setagaya-ku, Tokyo 158-8501, Japan
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11
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Esmonde-White KA, Cuellar M, Uerpmann C, Lenain B, Lewis IR. Raman spectroscopy as a process analytical technology for pharmaceutical manufacturing and bioprocessing. Anal Bioanal Chem 2016; 409:637-649. [PMID: 27491299 PMCID: PMC5233728 DOI: 10.1007/s00216-016-9824-1] [Citation(s) in RCA: 163] [Impact Index Per Article: 18.1] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/23/2016] [Revised: 07/13/2016] [Accepted: 07/21/2016] [Indexed: 11/30/2022]
Abstract
Adoption of Quality by Design (QbD) principles, regulatory support of QbD, process analytical technology (PAT), and continuous manufacturing are major factors effecting new approaches to pharmaceutical manufacturing and bioprocessing. In this review, we highlight new technology developments, data analysis models, and applications of Raman spectroscopy, which have expanded the scope of Raman spectroscopy as a process analytical technology. Emerging technologies such as transmission and enhanced reflection Raman, and new approaches to using available technologies, expand the scope of Raman spectroscopy in pharmaceutical manufacturing, and now Raman spectroscopy is successfully integrated into real-time release testing, continuous manufacturing, and statistical process control. Since the last major review of Raman as a pharmaceutical PAT in 2010, many new Raman applications in bioprocessing have emerged. Exciting reports of in situ Raman spectroscopy in bioprocesses complement a growing scientific field of biological and biomedical Raman spectroscopy. Raman spectroscopy has made a positive impact as a process analytical and control tool for pharmaceutical manufacturing and bioprocessing, with demonstrated scientific and financial benefits throughout a product’s lifecycle.
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Affiliation(s)
- Karen A Esmonde-White
- Kaiser Optical System, Inc, 371 Parkland Plaza, Ann Arbor, MI, 48103, USA.
- University of Michigan Medical School, Ann Arbor, MI, 48109-5624, USA.
| | - Maryann Cuellar
- Kaiser Optical System, Inc, 371 Parkland Plaza, Ann Arbor, MI, 48103, USA
| | - Carsten Uerpmann
- Kaiser Optical Systems SARL, 5 Allée Moulin Berger, 69130, Ecully, France
| | - Bruno Lenain
- Kaiser Optical Systems SARL, 5 Allée Moulin Berger, 69130, Ecully, France
| | - Ian R Lewis
- Kaiser Optical System, Inc, 371 Parkland Plaza, Ann Arbor, MI, 48103, USA
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12
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Agrawal AM, Pandey P. Scale Up of Pan Coating Process Using Quality by Design Principles. J Pharm Sci 2015. [DOI: 10.1002/jps.24582] [Citation(s) in RCA: 30] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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13
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PAT-tools for process control in pharmaceutical film coating applications. Int J Pharm 2013; 457:527-36. [DOI: 10.1016/j.ijpharm.2013.01.062] [Citation(s) in RCA: 82] [Impact Index Per Article: 6.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/31/2012] [Revised: 01/22/2013] [Accepted: 01/25/2013] [Indexed: 11/18/2022]
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14
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Shin K, Chung H. Wide area coverage Raman spectroscopy for reliable quantitative analysis and its applications. Analyst 2013; 138:3335-46. [PMID: 23636144 DOI: 10.1039/c3an36843b] [Citation(s) in RCA: 36] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
This review summarizes recent studies to improve sample representation in Raman measurement by covering a large area of a sample in spectral collection. Three different schemes have been mainly investigated to fulfill the goal: (1) averaging of Raman spectra collected at many different locations on a sample, (2) rotation of a sample during spectral collection and (3) simultaneous wide area illumination (WAI) for spectral collection. The use of a wide area illumination scheme, simultaneously illuminating a laser over a large area for spectral acquisition without any further assistance such as sample rotation, has increased in diverse fields. Applications employing the WAI scheme in pharmaceutical, polymer/chemical/petrochemical and other areas are described in this review.
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Affiliation(s)
- Kayeong Shin
- Department of Chemistry, College of Natural Sciences, Hanyang University, Seoul, 133-791, Korea
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15
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Development and in-line validation of a Process Analytical Technology to facilitate the scale up of coating processes. J Pharm Biomed Anal 2013; 78-79:57-64. [DOI: 10.1016/j.jpba.2013.01.037] [Citation(s) in RCA: 30] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/05/2012] [Revised: 01/18/2013] [Accepted: 01/19/2013] [Indexed: 11/19/2022]
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16
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Wirges M, Funke A, Serno P, Knop K, Kleinebudde P. Monitoring of an Active Coating Process for Two-Layer Tablets-Model Development Strategies. J Pharm Sci 2013. [DOI: 10.1002/jps.23383] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
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17
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A comparison of quality control methods for active coating processes. Int J Pharm 2012; 439:289-95. [PMID: 22989986 DOI: 10.1016/j.ijpharm.2012.09.021] [Citation(s) in RCA: 31] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/19/2012] [Revised: 09/05/2012] [Accepted: 09/08/2012] [Indexed: 11/20/2022]
Abstract
Terahertz pulsed imaging (TPI) is a recent and nondestructive technique to quantify coating thickness of pharmaceutical tablet film coatings. In this study, TPI is used for the first time to quantify the progress of an active coating process. The dosage form consisted of a push-pull osmotic system comprising a two-layer tablet core with a functional film coating and a laser drilled hole. On top of this system an active coating was applied. The coating thickness data acquired by TPI and optical microscopy was compared to the quantification of the active pharmaceutical ingredient (API) via HPLC. Good correlation of TPI and HPLC data was shown for coating thicknesses up to 500 μm. Due to the special structure of the dosage form, the TPI detection limit of 38 μm layer thickness was circumvented by analysing the coating thickness of active coating and functional subcoat in one. Therefore it was possible to monitor the active coating process from the very beginning of the process. Optical microscopy was no suitable reference technique for TPI thickness measurements. The active coating showed deformation artefacts during sample preparation, which biased the subsequent thickness measurements.
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18
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Šašić S, Palm AS, Tang D. Monitoring the dissolution of Active Pharmaceutical Ingredient and TPGS in real time via IR spectroscopy during the manufacturing of liquid dosage formulation. J Pharm Biomed Anal 2012; 70:273-9. [PMID: 22871426 DOI: 10.1016/j.jpba.2012.07.010] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/25/2012] [Revised: 07/12/2012] [Accepted: 07/13/2012] [Indexed: 11/28/2022]
Abstract
Infrared spectroscopy is used to monitor the dissolution of the Active Pharmaceutical Ingredient (API) and an excipient (vitamin E - TPGS) during manufacturing of a liquid pharmaceutical formulation. The goal of the analysis is to explore options for real-time, on screen, and quantitative monitoring of these two components by using an iC10 instrument. As is common, the first step in the approach is to create respective calibration models for the two components and then apply those models on the spectra obtained from scale-up batches. Interestingly, while the API dissolves at the room temperature, TPGS dissolves at an acceptable rate at 50 °C so both temperatures have to be considered. It is shown that univariate models of sufficient accuracy can be developed with a straightforward applicability to the scale-up batches spectra and providing reasonably accurate estimates of the API and TPGS concentrations. Some limitations of the software on the employed instrument may diminish the prospect for the quantitative analysis of the components of interest in this formulation.
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Affiliation(s)
- Slobodan Šašić
- Pfizer Inc., Analytical Research and Development, Eastern Point Road, Groton, CT 06340, USA.
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19
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Non-destructive analysis of tablet coatings with optical coherence tomography. Eur J Pharm Sci 2011; 44:142-8. [PMID: 21787865 DOI: 10.1016/j.ejps.2011.06.017] [Citation(s) in RCA: 60] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/10/2011] [Revised: 05/31/2011] [Accepted: 06/30/2011] [Indexed: 11/22/2022]
Abstract
Optical coherence tomography (OCT) is a non-invasive analysis technique allowing fast and high-quality cross-sectional imaging of scattering media. OCT is based on the physical phenomenon of low coherence interferometry and is thus well suited to image layered structures. In this paper, high-speed spectral domain OCT was used for the characterization of pharmaceutical tablet coatings, sampled at different stages of an industrial drum spray coating process, comprising tablets with a coating thickness ranging from uncoated to a target coating thickness of about 70 μm. In addition to the OCT investigation of layer thickness and homogeneity, tablet weight gain and tablet diameters were determined on a single-tablet level. Scanning electron microscopy (SEM) was applied for referencing the coating thickness obtained with OCT. We demonstrated that OCT allows rapid evaluation of coating properties, such as thickness and homogeneity independently from variations of the tablet core. In contrast to indirect methods, deviations observed with OCT can be related directly to the coating properties. Furthermore, for an extended morphological coating characterization, three dimensional images were reconstructed. Pending further developments, the high axial resolution and fast data acquisition rate of OCT has the potential for highly accurate, fast and low-cost coating control during and after manufacturing.
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