Continuous quantitative monitoring of powder mixing dynamics by near-infrared spectroscopy

A comprehensive review of the application of DEM in the investigation of batch solid mixers

Powder mixing is a vital operation in a wide range of industries, such as food, pharmaceutical, and cosmetics. Despite the common use of mixing systems in various industries, often due to the complex nature of mixing systems, the effects of operating and design parameters on the mixers’ performance and final blend are not fully known, and therefore optimal parameters are selected through experience or trial and error. Experimental and numerical techniques have been widely used to analyze mixing systems and to gain a detailed understanding of mixing processes. The limitations associated with experimental techniques, however, have made discrete element method (DEM) a valuable complementary tool to obtain comprehensive particle level information about mixing systems. In the present study, the fundamentals of solid-solid mixing, segregation, and characteristics of different types of batch solid mixers are briefly reviewed. Previously published papers related to the application of DEM in studying mixing quality and assessing the influence of operating and design parameters on the mixing performance of various batch mixing systems are summarized in detail. The challenges with regards to the DEM simulation of mixing systems, the available solutions to address those challenges and our recommendations for future simulations of solid mixing are also presented and discussed.

Challenges in tracing material flow passing a loss-in-weight feeder in continuous manufacturing processes

Loss-in-weight feeders are an integral part of most continuous manufacturing processes, ensuring a constant mass flow. The feeders cause a significant degree of back-mixing in such lines. Understanding back-mixing is essential for the treatment of disturbances. However, feeders refilled semi-continuously contradict the common theory assuming steady-state. This study aims at understanding dynamic back-mixing and related phenomena. Low filling levels of a feeder are investigated using a fluorescent tracer. These investigations prove an impact of the addition of material probably caused by a non-uniform draw-in of the screws and dead material in the hopper. In turn, the dead material accounts for up to 50 % of the material in the hopper. Possible evidence of dead zones at higher filling levels and in feeders from literature are discussed additionally. Steady-state models from literature are extended to represent the observations and back-mixing at all filling levels. This extension reduces the root-mean-squared deviation of the model from the experimental data by 41%. The model predicts different responses to similar disturbances depending on the filling. This state-dependent back-mixing and the observed dead zones are challenging for diverting non-conforming material and material traceability. Therefore, these phenomena should be considered in selecting and operating feeders.

Continuous downstream processing of milled electrospun fibers to tablets monitored by near-infrared and Raman spectroscopy

Electrospinning is a technology for manufacture of nano- and micro-sized fibers, which can enhance the dissolution properties of poorly water-soluble drugs. Tableting of electrospun fibers have been demonstrated in several studies, however, continuous manufacturing of tablets have not been realized yet. This research presents the first integrated continuous processing of milled drug-loaded electrospun materials to tablet form supplemented by process analytical tools for monitoring the active pharmaceutical ingredient (API) content. Electrospun fibers of an amorphous solid dispersion (ASD) of itraconazole and poly(vinylpyrrolidone-co-vinyl acetate) were produced using high speed electrospinning and afterwards milled. The milled fibers with an average fiber diameter of 1.6 ± 0.9 µm were continuously fed with a vibratory feeder into a twin-screw blender, which was integrated with a tableting machine to prepare tablets with ~ 10 kN compression force. The blend of fibers and excipients leaving the continuous blender was characterized with a bulk density of 0.43 g/cm³ and proved to be suitable for direct tablet compression. The ASD content, and thus the API content was determined in-line before tableting and at-line after tableting using near-infrared and Raman spectroscopy. The prepared tablets fulfilled the USP <905> content uniformity requirement based on the API content of ten randomly selected tablets. This work highlights that combining the advantages of electrospinning (e.g. less solvent, fast and gentle drying, low energy consumption, and amorphous products with high specific surface area) and the continuous technologies opens a new and effective way in the field of manufacturing of the poorly water-soluble APIs.

Determination of Residence Time Distribution in a Continuous Powder Mixing Process With Supervised and Unsupervised Modeling of In-line Near Infrared (NIR) Spectroscopic Data

Successful implementation of continuous manufacturing processes requires robust methods to assess and control product quality in a real-time mode. In this study, the residence time distribution of a continuous powder mixing process was investigated via pulse tracer experiments using near infrared spectroscopy for tracer detection in an in-line mode. The residence time distribution was modeled by applying the continuous stirred tank reactor in series model for achieving the tracer (paracetamol) concentration profiles. Partial least squares discriminant analysis and principal component analysis of the near infrared spectroscopy data were applied to investigate both supervised and unsupervised chemometric modeling approaches. Additionally, the mean residence time for three powder systems was measured with different process settings. It was found that a significant change in the mean residence time occurred when comparing powder systems with different flowability and mixing process settings. This study also confirmed that the partial least squares discriminant analysis applied as a supervised chemometric model enabled an efficient and fast estimate of the mean residence time based on pulse tracer experiments.

Fluorescence in the assessment of the share of a key component in the mixing of feed

This paper presents the results of the mixing of a multicomponent feed for cattle. Three types of mixtures with different proportions of individual components and granulometric composition were selected. After the mixing process, the fraction of the key component (tracer) was determined. Tracer consisted of crushed grains of yellow maize, which was wet treated with a 0.01% solution of Rhodamine B. A tracer with two different average particle sizes d1 = 2.0 mm and d2 = 1.25 mm was introduced into the mixture. Then, the sample was illuminated with UV light, and the content of the tracer in the sample was evaluated using the computer image analysis. In addition, the tracer was separated to determine its fraction using a laboratory scale. From the obtained results, the high reliability of the fluorescence optical method for the evaluation of the homogeneity of granular multicomponent mixtures was proved. It was also observed that slightly better results were obtained for a tracer with a larger average particle size (d = 2.0 mm), although the comparative analysis did not indicate a significant statistical difference in the results in each series of tests.

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.

Using 3D Printing for Rapid Prototyping of Characterization Tools for Investigating Powder Blend Behavior

There is an increasing need to provide more detailed insight into the behavior of particulate systems. The current powder characterization tools are developed empirically and in many cases, modification of existing equipment is difficult. More flexible tools are needed to provide understanding of complex powder behavior, such as mixing process and segregation phenomenon. An approach based on the fast prototyping of new powder handling geometries and interfacing solutions for process analytical tools is reported. This study utilized 3D printing for rapid prototyping of customized geometries; overall goal was to assess mixing process of powder blends at small-scale with a combination of spectroscopic and mechanical monitoring. As part of the segregation evaluation studies, the flowability of three different paracetamol/filler-blends at different ratios was investigated, inter alia to define the percolation thresholds. Blends with a paracetamol wt% above the percolation threshold were subsequently investigated in relation to their segregation behavior. Rapid prototyping using 3D printing allowed designing two funnels with tailored flow behavior (funnel flow) of model formulations, which could be monitored with an in-line near-infrared (NIR) spectrometer. Calculating the root mean square (RMS) of the scores of the two first principal components of the NIR spectra visualized spectral variation as a function of process time. In a same setup, mechanical properties (basic flow energy) of the powder blend were monitored during blending. Rapid prototyping allowed for fast modification of powder testing geometries and easy interfacing with process analytical tools, opening new possibilities for more detailed powder characterization.

PAT-Based Control of Fluid Bed Coating Process Using NIR Spectroscopy to Monitor the Cellulose Coating on Pharmaceutical Pellets

Current endeavor was aimed towards monitoring percent weight build-up during functional coating process on drug-layered pellets. Near-infrared (NIR) spectroscopy is an emerging process analytical technology (PAT) tool which was employed here within quality by design (QbD) framework. Samples were withdrawn after spraying every 15-Kg cellulosic coating material during Wurster coating process of drug-loaded pellets. NIR spectra of these samples were acquired using cup spinner assembly of Thermoscientific Antaris II, followed by multivariate analysis using partial least squares (PLS) calibration model. PLS model was built by selecting various absorption regions of NIR spectra for Ethyl cellulose, drug and correlating the absorption values with actual percent weight build up determined by HPLC. The spectral regions of 8971.04 to 8250.77 cm^-1, 7515.24 to 7108.33 cm^-1, and 5257.00 to 5098.87 cm^-1 were found to be specific to cellulose, where as the spectral region of 6004.45 to 5844.14 cm^-1was found to be specific to drug. The final model gave superb correlation co-efficient value of 0.9994 for calibration and 0.9984 for validation with low root mean square of error (RMSE) values of 0.147 for calibration and 0.371 for validation using 6 factors. The developed correlation between the NIR spectra and cellulose content is useful in precise at-line prediction of functional coat value and can be used for monitoring the Wurster coating process.

Blend uniformity evaluation during continuous mixing in a twin screw granulator by in-line NIR using a moving F-test

This study focuses on the twin screw granulator of a continuous from-powder-to-tablet production line. Whereas powder dosing into the granulation unit is possible from a container of preblended material, a truly continuous process uses several feeders (each one dosing an individual ingredient) and relies on a continuous blending step prior to granulation. The aim of the current study was to investigate the in-line blending capacity of this twin screw granulator, equipped with conveying elements only. The feasibility of in-line NIR (SentroPAT, Sentronic GmbH, Dresden, Germany) spectroscopy for evaluating the blend uniformity of powders after the granulator was tested. Anhydrous theophylline was used as a tracer molecule and was blended with lactose monohydrate. Theophylline and lactose were both fed from a different feeder into the twin screw granulator barrel. Both homogeneous mixtures and mixing experiments with induced errors were investigated. The in-line spectroscopic analyses showed that the twin screw granulator is a useful tool for in-line blending in different conditions. The blend homogeneity was evaluated by means of a novel statistical method being the moving F-test method in which the variance between two blocks of collected NIR spectra is evaluated. The α- and β-error of the moving F-test are controlled by using the appropriate block size of spectra. The moving F-test method showed to be an appropriate calibration and maintenance free method for blend homogeneity evaluation during continuous mixing.

The Future of Pharmaceutical Manufacturing Sciences

The entire pharmaceutical sector is in an urgent need of both innovative technological solutions and fundamental scientific work, enabling the production of highly engineered drug products. Commercial-scale manufacturing of complex drug delivery systems (DDSs) using the existing technologies is challenging. This review covers important elements of manufacturing sciences, beginning with risk management strategies and design of experiments (DoE) techniques. Experimental techniques should, where possible, be supported by computational approaches. With that regard, state-of-art mechanistic process modeling techniques are described in detail. Implementation of materials science tools paves the way to molecular-based processing of future DDSs. A snapshot of some of the existing tools is presented. Additionally, general engineering principles are discussed covering process measurement and process control solutions. Last part of the review addresses future manufacturing solutions, covering continuous processing and, specifically, hot-melt processing and printing-based technologies. Finally, challenges related to implementing these technologies as a part of future health care systems are discussed.

Passive acoustic emissions from particulates in a V-blender

CONTEXT

Regulatory agencies are recommending the development of process analytical technologies (PAT) to improve the efficiency and product quality during pharmaceutical manufacturing.

OBJECTIVE

The objective of the research was to investigate the potential application of passive acoustic emission monitoring of a V-blender.

MATERIALS AND METHODS

Trials were conducted with sugar spheres, lactose or MCC in a V-blender. Vibrations from acoustic emissions were measured using PCB Piezotronics accelerometers with ICP signal conditioners.

RESULTS AND DISCUSSION

A wavelet filter was applied to the measured acoustic emissions to remove vibrations from the tumbling motion of the V-shell, allowing a focus on information about particle motion and interactions within the V-shell. The ideal sensor location was determined to be the lid of one of the V-shell arms due to the impact of the tumbling particles on the lid and transmission of the vibrations from other particle motion within the V-shell. The amplitude of vibrations increased with particle size due to larger particle momentum before a collision. The fill level and the V-shell scale also influenced the measured vibrations as particle motion was affected which in turn affected momentum. Changes in particle flowability could be detected through variations in the measured acoustic emissions.

CONCLUSION

The measured vibrations from passive acoustic emissions reflected particle motion and interactions within a V-blender demonstrating potential as a monitoring method.

Optical coherence tomography as a novel tool for in-line monitoring of a pharmaceutical film-coating process

Optical coherence tomography (OCT) is a contact-free non-destructive high-resolution imaging technique based on low-coherence interferometry. This study investigates the application of spectral-domain OCT as an in-line quality control tool for monitoring pharmaceutical film-coated tablets. OCT images of several commercially-available film-coated tablets of different shapes, formulations and coating thicknesses were captured off-line using two OCT systems with centre wavelengths of 830nm and 1325nm. Based on the off-line image evaluation, another OCT system operating at a shorter wavelength was selected to study the feasibility of OCT as an in-line monitoring method. Since in spectral-domain OCT motion artefacts can occur as a result of the tablet or sensor head movement, a basic understanding of the relationship between the tablet speed and the motion effects is essential for correct quantifying and qualifying of the tablet coating. Experimental data was acquired by moving the sensor head of the OCT system across a static tablet bed. Although examining the homogeneity of the coating turned more difficult with increasing transverse speed of the tablets, the determination of the coating thickness was still highly accurate at a speed up to 0.7m/s. The presented OCT setup enables the investigation of the intra- and inter-tablet coating uniformity in-line during the coating process.

Supervisory control system for monitoring a pharmaceutical hot melt extrusion process

Continuous pharmaceutical manufacturing processes are of increased industrial interest and require uni- and multivariate Process Analytical Technology (PAT) data from different unit operations to be aligned and explored within the Quality by Design (QbD) context. Real-time pharmaceutical process verification is accomplished by monitoring univariate (temperature, pressure, etc.) and multivariate (spectra, images, etc.) process parameters and quality attributes, to provide an accurate state estimation of the process, required for advanced control strategies. This paper describes the development and use of such tools for a continuous hot melt extrusion (HME) process, monitored with generic sensors and a near-infrared (NIR) spectrometer in real-time, using SIPAT (Siemens platform to collect, display, and extract process information) and additional components developed as needed. The IT architecture of such a monitoring procedure based on uni- and multivariate sensor systems and their integration in SIPAT is shown. SIPAT aligned spectra from the extrudate (in the die section) with univariate measurements (screw speed, barrel temperatures, material pressure, etc.). A multivariate supervisory quality control strategy was developed for the process to monitor the hot melt extrusion process on the basis of principal component analysis (PCA) of the NIR spectra. Monitoring the first principal component and the time-aligned reference feed rate enables the determination of the residence time in real-time.

Monitoring blending of pharmaceutical powders with multipoint NIR spectroscopy

Blending of powders is a crucial step in the production of pharmaceutical solid dosage forms. The active pharmaceutical ingredient (API) is often a powder that is blended with other powders (excipients) in order to produce tablets. The blending efficiency is influenced by several external factors, such as the desired degree of homogeneity and the required blending time, which mainly depend on the properties of the blended materials and on the geometry of the blender. This experimental study investigates the mixing behavior of acetyl salicylic acid as an API and α-lactose monohydrate as an excipient for different filling orders and filling levels in a blender. A multiple near-infrared probe setup on a laboratory-scale blender is used to observe the powder composition quasi-simultaneously and in-line in up to six different positions of the blender. Partial least squares regression modeling was used for a quantitative analysis of the powder compositions in the different measurement positions. The end point for the investigated mixtures and measurement positions was determined via moving block standard deviation. Observing blending in different positions helped to detect good and poor mixing positions inside the blender that are affected by convective and diffusive mixing.

Use of near-infrared spectroscopy to quantify drug content on a continuous blending process: influence of mass flow and rotation speed variations

The aim of this study was to develop a quantitative Near-Infrared (NIR) method which monitors the homogeneity of a pharmaceutical formulation coming out of a continuous blender. For this purpose, a NIR diode array spectrometer with fast data acquisition was selected. Additionally, the dynamic aspects of a continuous blending process were studied; the results showed a well-defined cluster for the steady state, and the paths for the start-up and emptying stages were clearly identified. The end point of the start-up phase was detected by moving block of standard deviation, relative standard deviation, and principal component analysis. A partial least square (PLS) model was generated for the quantification of the drug, with a standard error of prediction of 0.2% m/m. The PLS model was successfully applied for monitoring the drug level at the outlet of the continuous blender. Furthermore, the PLS model was tested under different flow and stirring rates. Flow and stirring rate variations caused different powder flow dynamics, which were reflected on the NIR measurements. Therefore, the PLS model was sensitive to changes in mass flow and rotation speeds.

An integrated Quality by Design (QbD) approach towards design space definition of a blending unit operation by Discrete Element Method (DEM) simulation

A combined Quality by Design (QbD) and Discrete Element Model (DEM) simulation-approach is presented to characterize a blending unit operation by evaluating the impact of formulation parameters and process variables on the blending quality and blending end point. Understanding the variability of both the API and the excipients, as well as their impact on the blending process are critical elements for blending QbD. In a first step, the QbD-methodology is systematically used to (1) establish the critical quality attribute content uniformity and to link this CQA to its surrogate blend homogeneity, (2) identify potentially critical input factors that may affect blending operation quality and (3) risk-rank these factors to define activities for process characterization. Subsequently, a DEM-simulation-based characterization of the blending process is performed. A statistical evaluation is finally presented, relating blend homogeneity of systems with low particle number to the regulatory requirements. Data are then used to map out a three-dimensional knowledge space, providing parameters to define a design space and set up an appropriate control strategy.