Dynamics of size segregation and mixing of granular materials in a 3D-blender by NMR imaging investigation

Residence time distribution modelling and in line monitoring of drug concentration in a tablet press feed frame containing dead zones

The presence of a 'significant dead zone' in any continuous manufacturing equipment may affect the product quality and need to be investigated systematically. Dead zone will affect the residence time distribution (RTD) of continuous manufacturing and thus the mixing and product quality. Tablet press (feed frame) is one of unit operations that directly influence the critical quality attributes (CQA's). However, currently no systematic methods and tools are available to characterize and model the feed frame dead zone. In this manuscript, the RTD of the tablet press feed frame containing dead zone is investigated. Step-change experiments revealed that the feed frame could be expressed as a traditional continuous stirred tank model. The volume fractions of the dead zones are determined experimentally as well as using RTD model. In addition, an in-line NIR method for drug concentration monitoring inside the feed frame is also developed. The developed NIR calibration model enables to monitor the drug concentration precisely and detect the variation immediately with the probe positioned right above the left paddle. It is also found that the feed frame paddle speed slightly affects the predictive accuracy of NIR, while the die disc speed has no significant effect.

The Comparison of Two Challenging Low Dose APIs in a Continuous Direct Compression Process

Segregation is a common problem in batch-based direct compression (BDC) processes, especially with low-dose tablet products, as is the preparation of a homogenous mixture. The scope of the current work was to explore if a continuous direct compression (CDC) process could serve as a solution for these challenges. Furthermore, the principle of a platform formulation was demonstrated for low dose tablets. The combination of filler excipients and the API in the formulation used was suitable for direct compression, but also prone to induce segregation in BDC process. The CDC process was found to be very promising; it was shown that tablets with the desired quality parameters could be manufactured successfully with both of the APIs studied. Powder analysis indicated that the APIs display some fundamental differences in their physical properties, which was also reflected in powder mixture properties and, hence, eventually in processing. However, process parameters, especially mixer impeller speed, were not found to have any significant influence on end product quality. The study suggests that a CDC process can be a viable solution to resolve the challenges described. Moreover, manufacturing by using a universal platform formulation seems to be a feasible way for producing low-dose tablets.

Monitoring Magnesium Stearate Blending in a V-Blender Through Passive Vibration Measurements

Process analytical technologies are implemented within the pharmaceutical manufacturing process to rectify issues associated with current sampling methods. These include inline monitoring methods such as passive vibration measurements which are non-intrusive and less costly to other methods. In the final mixing stage of the tablet manufacturing process, a lubricant is added to ensure the mixture is ejected from the tablet die cleanly. To monitor this process, an accelerometer was attached to the lid of the V-blender loaded with various particles and magnesium stearate. At a fixed fill level, the lubricant concentration and particle mass were varied to investigate the effects of changes in process parameters on the signal vibrations measured by the sensor, the coefficient of restitution, and the flowability. It was found that measured vibrations from stress waves propagated upon collisions of the particles with the V-shell respond to and can distinguish differences in particles. As well, the magnesium stearate layer around particles alters energy dissipation and subsequently the measured vibrations. A mixing endpoint of uniform distribution of magnesium stearate with primary particles can be identified from vibrations measured by an accelerometer attached to the lid of the V-blender. The flowability change was considered negligible in the particles due to their physical morphology. These findings indicate that passive vibration measurements can be a viable, non-intrusive monitoring method while providing insight into V-blender mixing behaviors as well as improving process efficiency.

An Investigation of Magnesium Stearate Mixing Performance in a V-Blender Through Passive Vibration Measurements

Prior to compression in tablet manufacturing, a lubricant is added and mixed in a V-blender to ensure the mixture is ejected from the tablet die smoothly. Mixing is conducted batch-wise and must be analyzed offline afterwards to ensure the mixture is uniform and will produce desired tablet properties, thereby a costly and time-consuming step within the manufacturing process. To improve process efficiency, inline monitoring methods using passive acoustic emissions or vibration measurements could be implemented. Methods are non-destructive, non-invasive, and have a reduced capital cost compared to traditional methods. Using an accelerometer affixed to the lid of the V-shell, magnesium stearate was added to glass beads and monitored to determine the effect of loading configuration and fill level on mixing performance and measured vibrations. Axial loading configurations performed better than radial configurations due to the limited axial dispersion from the geometry of the V-shell. Mixing was hindered at an increased fill level due to convective and axial dispersion. The optimal fill level of a V-blender was found to be 21-23% by volume. Monitoring magnesium stearate mixing using passive vibration measurements is a non-intrusive and potentially inline method that could significantly improve pharmaceutical process efficiency.

Methods to Assess Mixing of Pharmaceutical Powders

The pharmaceutical manufacturing process consists of several steps, each of which must be monitored and controlled to ensure quality standards are met. The level of blending has an impact on the final product quality; therefore, it is important to be able to monitor blending progress and identify an end-point. Currently, the pharmaceutical industry assesses blend content and uniformity through the extraction of samples using thief probes followed by analytical methods, such as spectroscopy, to determine the sample composition. The development of process analytical technologies (PAT) can improve product monitoring with the aim of increasing efficiency, product quality and consistency, and creating a better understanding of the manufacturing process. Ideally, these are inline methods to remove issues related to extractive sampling and allow direct monitoring of the system using various sensors. Many technologies have been investigated, including spectroscopic techniques such as near-infrared spectroscopy, velocimetric techniques that may use tracers, tomographic techniques, and acoustic emissions monitoring. While some techniques have demonstrated potential, many have significant disadvantages including the need for equipment modification, specific requirements of the material, expensive equipment, extensive analysis, the location of the probes may be critical and/or invasive, and lastly, the technique may only be applicable to the development phase. Both the advantages and disadvantages of the technologies should be considered in application to a specific system.

Magnetic resonance imaging of granular materials

Magnetic Resonance Imaging (MRI) has become one of the most important tools to screen humans in medicine; virtually every modern hospital is equipped with a Nuclear Magnetic Resonance (NMR) tomograph. The potential of NMR in 3D imaging tasks is by far greater, but there is only "a handful" of MRI studies of particulate matter. The method is expensive, time-consuming, and requires a deep understanding of pulse sequences, signal acquisition, and processing. We give a short introduction into the physical principles of this imaging technique, describe its advantages and limitations for the screening of granular matter, and present a number of examples of different application purposes, from the exploration of granular packing, via the detection of flow and particle diffusion, to real dynamic measurements. Probably, X-ray computed tomography is preferable in most applications, but fast imaging of single slices with modern MRI techniques is unmatched, and the additional opportunity to retrieve spatially resolved flow and diffusion profiles without particle tracking is a unique feature.

Lubricant sensitivity in function of paddle movement in the forced feeder of a high-speed tablet press

CONTEXT

The negative impact of magnesium stearate (MgSt) on the hardness of tablets is a well-known phenomenon, but the influence of paddle movement in the forced feeder on the lubricant effect during tablet compression is often neglected.

OBJECTIVE

The purpose of this research was to investigate the influence of paddle speed in the forced feeder on tablet tensile strength (TS).

MATERIALS AND METHODS

Mixtures of microcrystalline cellulose (MCC) and MgSt (0.5%) were blended using different methods (low & high shear). After blending, the formulations were compressed into tablets. All parameters of the tableting cycle were kept constant except the speed of the paddles in the forced feeder.

RESULTS AND DISCUSSION

The blending technique affected the sensitivity of the formulation to the paddle speed. The TS of pure MCC tablets did not change in function of paddle speed, while tablets prepared by low shear mixing became softer at higher paddle speed. The TS of tablets manufactured using the high-shear mixed blend was low and did not vary in function of paddle speed, suggesting that overlubrication already occurred during the initial blending step. Furthermore, analysis of the machine parameters allowed evaluation of the influence of the paddles on the flowability, initial packing, and compactability of the powder mixtures.

CONCLUSION

The results elucidated that during manufacturing of tablets using MgSt-containing blends care should not only be taken during the blending step prior to tableting, but also during the tableting process itself, as paddle speed can affect tablet TS, a critical quality attribute.

Segregation in horizontal rotating cylinders using magnetic resonance imaging

The dynamics of granular materials, particularly radial and axial segregation in horizontal rotating cylinders containing large and small particles, is studied by Magnetic Resonance Imaging (MRI). Stationary three-dimensional (3D) images and real-time two-dimensional (2D) structural images showing radial segregation, band formation, and band merging are reported. Quantitative local particle concentrations are measured in a noninvasive manner from the different magnetic resonance responses of the seeds throughout segregation. Data are acquired with sufficiently high temporal (300 ms for 2D images) and spatial resolutions (0.94 mm cubic voxels), to give insights into the underlying mechanisms of both radial and axial segregation. In particular, the increasing rate of the local particle concentration during radial segregation is quantified. Particle migration is observed in the bulk material of the 75% and 82% full cylinders during both radial and axial segregation, showing that this region beneath the avalanche layer does not behave as a solid body. We also provide direct experimental evidence to support recent numerical simulations of band merging.

Chaotic mixing via streamline jumping in quasi-two-dimensional tumbled granular flows

We study, numerically and analytically, the singular limit of a vanishing flowing layer in tumbled granular flows in quasi-two-dimensional rotating containers. The limiting behavior is found to be identical under the two versions of the kinematic continuum model of such flows, and the transition to the limiting dynamics is analyzed in detail. In particular, we formulate the no-shear-layer dynamical system as a piecewise isometry. It is shown how such a discontinuous map, through the concordant mechanism of streamline jumping, leads to the physical mixing of granular matter. The dependence of the dynamics of Lagrangian particle trajectories on the tumbler fill fraction is also established through Poincaré sections, and, in the special case of a half-full tumbler, chaotic behavior is shown to disappear completely in the singular limit. At other fill levels, stretching in the sense of shear strain is replaced by spreading due to streamline jumping. Finally, we use finite-time Lyapunov exponents to establish the manifold structure and understand "how chaotic" the limiting piecewise isometry is.

Application of k- and q-space encoding NMR techniques on granular media in a 3D model fluidized bed reactor

A combination of PFG-NMR imaging and velocity encoding methods was applied to investigate the dynamic behavior of a bed of poppy seeds subjected to air flow, representing a model setup for fluidized bed reactors. The particle motion is described both from a statistical point of view, by determining propagators and dispersion coefficients representing an average over the whole bed volume, as well as combined with spatial resolution by generating velocity maps. Velocity images of different horizontal slices in the bed confirm the notion of a toroidal particle flow pattern inside the shallow granular bed. Despite the need of considerable averaging due to the random motion of the relatively few particles in the bed, quantitative velocity images and statistical information about the random particle motion can be obtained from monitoring the fluid component in the seeds by conventional spin-echo techniques.