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Arthur TB, Rahmanian N. Process Simulation of Twin-Screw Granulation: A Review. Pharmaceutics 2024; 16:706. [PMID: 38931829 PMCID: PMC11206687 DOI: 10.3390/pharmaceutics16060706] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2024] [Revised: 05/19/2024] [Accepted: 05/21/2024] [Indexed: 06/28/2024] Open
Abstract
Twin-screw granulation has emerged as a key process in powder processing industries and in the pharmaceutical sector to produce granules with controlled properties. This comprehensive review provides an overview of the simulation techniques and approaches that have been employed in the study of twin-screw granulation processes. This review discusses the major aspects of the twin-screw granulation process which include the fundamental principles of twin-screw granulation, equipment design, process parameters, and simulation methodologies. It highlights the importance of operating conditions and formulation designs in powder flow dynamics, mixing behaviour, and particle interactions within the twin-screw granulator for enhancing product quality and process efficiency. Simulation techniques such as the population balance model (PBM), computational fluid dynamics (CFD), the discrete element method (DEM), process modelling software (PMS), and other coupled techniques are critically discussed with a focus on simulating twin-screw granulation processes. This paper examines the challenges and limitations associated with each simulation approach and provides insights into future research directions. Overall, this article serves as a valuable resource for researchers who intend to develop their understanding of twin-screw granulation and provides insights into the various techniques and approaches available for simulating the twin-screw granulation process.
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Affiliation(s)
| | - Nejat Rahmanian
- Chemical Engineering, Faculty of Engineering, and Digital Technologies, University of Bradford, Bradford BD7 1DP, UK;
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2
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Forster SP, Dippold E, Haser A, Emanuele D, Meier R. Integrated Continuous Wet Granulation and Drying: Process Evaluation and Comparison with Batch Processing. Pharmaceutics 2023; 15:2317. [PMID: 37765286 PMCID: PMC10537298 DOI: 10.3390/pharmaceutics15092317] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/08/2023] [Revised: 09/11/2023] [Accepted: 09/12/2023] [Indexed: 09/29/2023] Open
Abstract
The pharmaceutical industry is in the midst of a transition from traditional batch processes to continuous manufacturing. However, the challenges in making this transition vary depending on the selected manufacturing process. Compared with other oral solid dosage processes, wet granulation has been challenging to move towards continuous processing since traditional equipment has been predominantly strictly batch, instead of readily adapted to material flow such as dry granulation or tablet compression, and there have been few equipment options for continuous granule drying. Recently, pilot and commercial scale equipment combining a twin-screw wet granulator and a novel horizontal vibratory fluid-bed dryer have been developed. This study describes the process space of that equipment and compares the granules produced with batch high-shear and fluid-bed wet granulation processes. The results of this evaluation demonstrate that the equipment works across a range of formulations, effectively granulates and dries, and produces granules of similar or improved quality to batch wet granulation and drying.
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Affiliation(s)
| | | | - Abbe Haser
- Organon & Co., Inc., Jersey City, NJ 07302, USA
| | - Daniel Emanuele
- L.B. Bohle Maschinen und Verfahren GmbH, 59320 Ennigerloh, Germany
| | - Robin Meier
- L.B. Bohle Maschinen und Verfahren GmbH, 59320 Ennigerloh, Germany
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3
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Haser A, Kittikunakorn N, Dippold E, DiNunzio JC, Blincoe W. Continuous Twin-Screw wet granulation process with In-Barrel drying and NIR setup for Real-Time Moisture Monitoring. Int J Pharm 2022; 630:122377. [PMID: 36368607 DOI: 10.1016/j.ijpharm.2022.122377] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/05/2022] [Revised: 10/27/2022] [Accepted: 11/03/2022] [Indexed: 11/11/2022]
Abstract
The purpose of this study was to evaluate if wet granule formation and drying could take place in a single operation by utilizing in-barrel drying. The drying kinetics of the formulation were studied in order to select appropriate processing parameters and assess feasibility with short residence times in the extruder. The 18-mm extruder was operated in a 40:1 L:D ratio with 8 zones. The first two zones were used for material feeding and wet granule formation and the remaining zones were used for drying at elevated temperature. The impact of screw configuration as well as screw speed, feed rate, and residence time were all studied to optimize the drying process. Due to limitations of temperature and residence time, vacuum was added to enable sufficient drying. In-line NIR spectroscopy was incorporated into the twin-screw wet granulation (TSWG) process to monitor the moisture content of wet granules in real-time. The set-up was optimized and a predictive model was developed for future experiments. This study demonstrated the success of this technique on a pilot-scale (18-mm) extruder for the first time. Granules were formed and dried to a target loss on drying (LOD) of less than 2 % at moderate temperatures (100 °C - 110 °C) with one single operation. Streamlining wet granulation and drying into one unit operation can have a profound impact on pharmaceutical manufacturing reducing time, footprint, and environmental exposure due to reduced product transfers.
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Affiliation(s)
- Abbe Haser
- Oral Formulation Sciences and Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA.
| | - Nada Kittikunakorn
- Oral Formulation Sciences and Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
| | - Erin Dippold
- Process Commercialization Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
| | - James C DiNunzio
- Oral Formulation Sciences and Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
| | - William Blincoe
- Process Analytical Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
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4
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Arai H, Nagato T, Koide T, Yonemochi E, Yamamoto H, Sugiyama H. Tablet Quality-Prediction Model Using Quality Material Attributes: Toward Flexible Switching Between Batch and Continuous Granulation. J Pharm Innov 2021. [DOI: 10.1007/s12247-020-09466-w] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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5
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Macho O, Gabrišová Ľ, Peciar P, Juriga M, Kubinec R, Rajniak P, Svačinová P, Vařilová T, Šklubalová Z. Systematic Study of the Effects of High Shear Granulation Parameters on Process Yield, Granule Size, and Shape by Dynamic Image Analysis. Pharmaceutics 2021; 13:pharmaceutics13111894. [PMID: 34834308 PMCID: PMC8623888 DOI: 10.3390/pharmaceutics13111894] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2021] [Revised: 11/02/2021] [Accepted: 11/03/2021] [Indexed: 11/16/2022] Open
Abstract
The aim of the work was to analyze the influence of process parameters of high shear granulation on the process yield and on the morphology of granules on the basis of dynamic image analysis. The amount of added granulation liquid had a significant effect on all monitored granulometric parameters and caused significant changes in the yield of the process. In regard of the shape, the most spherical granules with the smoothest surface were formed at a liquid to solid ratio of ≈1. The smallest granules were formed at an impeller speed of 700 rpm, but the granules formed at 500 rpm showed both the most desirable shape and the highest process yield. Variation in the shape factors relied not only on the process parameters, but also on the area equivalent diameter of the individual granules in the batch. A linear relationship was found between the amount of granulation liquid and the compressibility of the granules. Using response surface methodology, models for predicting the size of granules and process yield related to the amount of added liquid and the impeller speed were generated, on the basis of which the size of granules and yield can be determined with great accuracy.
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Affiliation(s)
- Oliver Macho
- Institute of Process Engineering, Faculty of Mechanical Engineering, Slovak University of Technology in Bratislava, Námestie Slobody 17, 812 31 Bratislava, Slovakia; (Ľ.G.); (P.P.); (M.J.)
- Correspondence:
| | - Ľudmila Gabrišová
- Institute of Process Engineering, Faculty of Mechanical Engineering, Slovak University of Technology in Bratislava, Námestie Slobody 17, 812 31 Bratislava, Slovakia; (Ľ.G.); (P.P.); (M.J.)
| | - Peter Peciar
- Institute of Process Engineering, Faculty of Mechanical Engineering, Slovak University of Technology in Bratislava, Námestie Slobody 17, 812 31 Bratislava, Slovakia; (Ľ.G.); (P.P.); (M.J.)
| | - Martin Juriga
- Institute of Process Engineering, Faculty of Mechanical Engineering, Slovak University of Technology in Bratislava, Námestie Slobody 17, 812 31 Bratislava, Slovakia; (Ľ.G.); (P.P.); (M.J.)
| | - Róbert Kubinec
- Department of Analytical Chemistry, Faculty of Natural Sciences, Comenius University in Bratislava, Ilkovičova 6, 842 15 Bratislava 4, Slovakia;
| | - Pavol Rajniak
- Department of Chemical and Biochemical Engineering, Faculty of Chemical and Food Technology, Slovak University of Technology in Bratislava, Radlinského 9, 812 37 Bratislava, Slovakia;
| | - Petra Svačinová
- Department of Pharmaceutical Technology, Faculty of Pharmacy in Hradec Králové, Charles University, Ak. Heyrovského 1203, 500 05 Hradec Králové, Czech Republic; (P.S.); (T.V.); (Z.Š.)
| | - Tereza Vařilová
- Department of Pharmaceutical Technology, Faculty of Pharmacy in Hradec Králové, Charles University, Ak. Heyrovského 1203, 500 05 Hradec Králové, Czech Republic; (P.S.); (T.V.); (Z.Š.)
| | - Zdenka Šklubalová
- Department of Pharmaceutical Technology, Faculty of Pharmacy in Hradec Králové, Charles University, Ak. Heyrovského 1203, 500 05 Hradec Králové, Czech Republic; (P.S.); (T.V.); (Z.Š.)
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7
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Portier C, Vervaet C, Vanhoorne V. Continuous Twin Screw Granulation: A Review of Recent Progress and Opportunities in Formulation and Equipment Design. Pharmaceutics 2021; 13:668. [PMID: 34066921 PMCID: PMC8148523 DOI: 10.3390/pharmaceutics13050668] [Citation(s) in RCA: 23] [Impact Index Per Article: 7.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 04/30/2021] [Accepted: 05/02/2021] [Indexed: 11/16/2022] Open
Abstract
Continuous twin screw wet granulation is one of the key continuous manufacturing technologies that have gained significant interest in the pharmaceutical industry as well as in academia over the last ten years. Given its considerable advantages compared to wet granulation techniques operated in batch mode such as high shear granulation and fluid bed granulation, several equipment manufacturers have designed their own manufacturing setup. This has led to a steep increase in the research output in this field. However, most studies still focused on a single (often placebo) formulation, hence making it difficult to assess the general validity of the obtained results. Therefore, current review provides an overview of recent progress in the field of continuous twin screw wet granulation, with special focus on the importance of the formulation aspect and raw material properties. It gives practical guidance for novel and more experienced users of this technique and highlights some of the unmet needs that require further research.
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Affiliation(s)
| | | | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium; (C.P.); (C.V.)
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8
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Zhang Y, Liu T, Kashani-Rahimi S, Zhang F. A review of twin screw wet granulation mechanisms in relation to granule attributes. Drug Dev Ind Pharm 2021; 47:349-360. [PMID: 33507106 DOI: 10.1080/03639045.2021.1879844] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
Abstract
Due to the trend of continuous pharmaceutical manufacturing, twin screw wet granulation (TSWG), a continuous process, has gained increased research interest as a potential substitution of traditional batch granulation processes. Despite the complex nature of TSWG, its mechanisms have been gradually unveiled with the aid of innovative research strategies. This review synthesizes these recent findings to provide a comprehensive and mechanistic understanding of TSWG. We explain the impact of screw profiles (i.e. conveying, kneading, turbine mixing, and screw mixing elements) and process conditions (i.e. screw speed, feed rate, and liquid-to-solid ratio) on TSWG mixing performance and granule growth along the barrel, both of which ultimately affect critical granule attributes such as content uniformity, size distribution, strength, and compaction properties.
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Affiliation(s)
- Yi Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
| | - Tongzhou Liu
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
| | - Shahab Kashani-Rahimi
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX, USA
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9
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Melt granulation: A comparison of granules produced via high-shear mixing and twin-screw granulation. Int J Pharm 2020; 591:119941. [PMID: 33065223 DOI: 10.1016/j.ijpharm.2020.119941] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/22/2020] [Revised: 09/25/2020] [Accepted: 09/28/2020] [Indexed: 11/22/2022]
Abstract
Melt granules of DI-CAFOS® A12 and 15% (w/w) Kolliphor® P407 were manufactured in a twin-screw granulator (TSG) at five different conditions (screw speed and throughput varied) and compared to granules manufactured in a high-shear granulator (HSG) (rotation speed of chopper/impeller and granulation time varied). Evaluated granules characteristics were process yield, particle-size distribution (PSD), particle morphology, flowability, porosity, specific surface area (SSA), tabletability, compressibility and binder distribution. Compared to TSG, granules produced from HSG were more spherical in shape with lower porosity, smaller mean particle size and a superior flowability. Granules made by TSG showed a more elongated structure, higher porosity and larger mean particle size with smaller SSA instead. Concerning the compression process of granules, tablets made of TSG granules exhibited a higher tabletability compared to HSG granules, whereas the compressibility remained similar. In the case of the TSG granules, energy-dispersive-X-ray (EDX) measurements of the tablet surface indicated an enhanced homogenous binder distribution. Additionally, the EDX-analyses determined that more binder was available between the individual particles, resulting in a stronger bonding.
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10
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Comparison between twin-screw and high-shear granulation - The effect of filler and active pharmaceutical ingredient on the granule and tablet properties. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.08.030] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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11
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Megarry A, Taylor A, Gholami A, Wikström H, Tajarobi P. Twin-screw granulation and high-shear granulation: The influence of mannitol grade on granule and tablet properties. Int J Pharm 2020; 590:119890. [PMID: 32946976 DOI: 10.1016/j.ijpharm.2020.119890] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/24/2020] [Revised: 09/05/2020] [Accepted: 09/14/2020] [Indexed: 01/27/2023]
Abstract
Granule structure has a key influence on tablet critical quality attributes. The ability to control this structure through excipient choice is an important part of formulation development. Mannitol is a popular diluent and the choice of input grade has been shown to impact granule properties. Allopurinol formulations containing two grades of mannitol (Pearlitol 160C and 200SD) were prepared by wet-granulation (twin-screw and high-shear) at different liquid/solid ratios (0.3 and 0.6 g/g). The particle and bulk properties were characterised by a range of techniques and linked to flow performance and tablet tensile strength during compression on a rotary tablet press. During granulation, 200SD underwent a polymorphic transition from a mixture of α and β to predominantly β. This transition was accompanied by a morphology change. Mannitol needles were formed, giving more porous granules with a higher specific surface area, which led to poorer flow properties but higher tablet tensile strength. This study concludes that understanding the effect of mannitol grade is a crucial part of formulation selection.
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Affiliation(s)
- Andrew Megarry
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden.
| | - Agnes Taylor
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
| | - Aida Gholami
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
| | - Håkan Wikström
- Oral Product Development, Pharmaceutical Technology and Development, Operations & IT, AstraZeneca, Gothenburg, Sweden
| | - Pirjo Tajarobi
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
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12
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Liu T, Paul S, Beeson BT, Alexander J, Yang F, Bi V, Durig T, Sun CC, Zhang F. Effect of Hydroxypropyl Cellulose Level on Twin-Screw Melt Granulation of Acetaminophen. AAPS PharmSciTech 2020; 21:240. [PMID: 32839891 DOI: 10.1208/s12249-020-01785-y] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/22/2020] [Accepted: 08/10/2020] [Indexed: 11/30/2022] Open
Abstract
This study investigated the effect of binder level on the physicochemical changes and tabletability of acetaminophen (APAP)-hydroxypropyl cellulose (HPC) granulated using twin-screw melt granulation. Even at 5% HPC level, the tablet tensile strength achieved up to 3.5 MPa. A minimum of 10% HPC was required for the process robustness. However, 20% HPC led to tabletability loss, attributable to the high mechanical strength of APAP granules. The over-granulated APAP granules had thick connected HPC scaffold and low porosity. Consequently, these granules were so strong that they underwent a lower degree of fracture under compression and higher elastic recovery during decompression. HPC was enriched on the surface of APAP extrudates at all HPC levels. Amorphous APAP was also observed on the extrudate surface at 20% HPC level, and it recrystallized within 24 h storage. To achieve a robust process and optimal improvement in APAP tabletability, the preferred HPC level was 10 to 15%.
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13
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Vanhoorne V, Almey R, De Beer T, Vervaet C. Delta-mannitol to enable continuous twin-screw granulation of a highly dosed, poorly compactable formulation. Int J Pharm 2020; 583:119374. [PMID: 32339631 DOI: 10.1016/j.ijpharm.2020.119374] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/03/2020] [Revised: 04/22/2020] [Accepted: 04/23/2020] [Indexed: 11/29/2022]
Abstract
In current study, it was investigated if the moisture-mediated polymorphic transition from δ- to β-mannitol during twin screw granulation (TSG) also took place in high drug loaded formulations and if the specific granule morphology associated with the polymorphic transition could enable tableting of granules comprising 75% paracetamol, a poorly compactable drug. Experiments were performed on an integrated continuous manufacturing line, including a twin screw granulator, fluid bed dryer, mill and tablet press. The polymorphic transition of δ- to β-mannitol was observed during twin screw granulation and granules exhibited the needle-shaped morphology, typical of this transition. TSG at low liquid-to-solid (L/S) ratios and use of polyvinylpyrrolidone or hydroxypropylmethylcellulose as binders inhibited the polymorphic transition, whereas screw speed, drying time, drying temperature and airflow did not affect the solid state of mannitol in the granules. Without binder and despite the high paracetamol drug load in the formulation, limited breakage and attrition was observed during drying and milling. In contrast to granules manufactured from a formulation containing paracetamol/β-mannitol which could not be tableted due to extensive capping, granules prepared from a paracetamol/δ-mannitol formulation showed good tabletability. In conclusion, δ-mannitol is a promising TSG excipient, especially for high drug-loaded formulations with poor tabletability.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - R Almey
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium.
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14
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High shear seeded granulation: Its preparation mechanism, formulation, process, evaluation, and mathematical simulation. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.03.020] [Citation(s) in RCA: 12] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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15
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Wang LG, Pradhan SU, Wassgren C, Barrasso D, Slade D, Litster JD. A breakage kernel for use in population balance modelling of twin screw granulation. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.01.024] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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16
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Determining key parameters of continuous wet granulation for tablet quality and productivity: A case in ethenzamide. Int J Pharm 2020; 579:119160. [PMID: 32081803 DOI: 10.1016/j.ijpharm.2020.119160] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2019] [Revised: 01/29/2020] [Accepted: 02/16/2020] [Indexed: 11/24/2022]
Abstract
This paper aims to determine key parameters that affect tablet quality and productivity in continuous tablet manufacturing. Experiments were performed based on design of experiments using a continuous high-shear granulator and ethenzamide as the active pharmaceutical ingredient. To guide a systematic and comprehensive parameter analysis, a parameter framework was defined that comprised five input parameters on raw material properties and process parameters, 11 intermediate parameters on granule properties, and 11 output parameters on tablet quality and productivity. The interrelationships were analyzed statistically and were described as matrix functions. The liquid/solid ratio was the key parameter that affected circularity, density, and flowability as the granule properties, and disintegration and dissolution as the tablet quality. The maximum acceptable manufacturing rate that governs productivity was also affected by the liquid/solid ratio. Circularity was found to affect disintegration and dissolution. This result was specific to the setup of the study, but suggested development opportunities for a new process analytical technology system/quality-by-design application based on circularity. In addition, practical findings were obtained as follows: (1) high-speed manufacturing favored a lower liquid/solid ratio, and (2) high circularity slowed down disintegration/dissolution. This obtained knowledge will enhance the applicability of continuous technology in an actual manufacturing environment.
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Miyazaki Y, Lenhart V, Kleinebudde P. Switch of tablet manufacturing from high shear granulation to twin-screw granulation using quality by design approach. Int J Pharm 2020; 579:119139. [PMID: 32061724 DOI: 10.1016/j.ijpharm.2020.119139] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/30/2019] [Revised: 02/10/2020] [Accepted: 02/11/2020] [Indexed: 11/28/2022]
Abstract
This study aimed to transfer a high shear granulation (HSG) process to a twin-screw granulation (TSG) process while maintaining equivalent dissolution profiles. Ibuprofen (IBP) was used as poorly soluble model drug. Granules were obtained by HSG or TSG according to a full factorial design. The liquid-to-solid ratio and wet massing time (HSG) or powder throughput (TSG) were selected as factors. The granules were compressed to tablets with immediate release and a drug load of 50% (w/w). Quality attributes (QAs) of the granules, especially the granule strength (GS), and the resulting tablets were evaluated. The effect of process parameters on the QAs was statistically analyzed. The comparison of HSG tablets with TSG tablets revealed that TSG tablets showed higher tensile strength and lower ejection force than HSG tablets. The dissolution profiles of the tablets in different pH media were also evaluated. Equivalent dissolution profiles in all four media (e.g., f2 values ≥ 54 in pH5.5) were obtained by adjusting process parameters. It was concluded that the GS was the most important QA for dissolution.
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Affiliation(s)
- Yuta Miyazaki
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstr. 1, 40225 Duesseldorf, Germany; ONO Pharmaceutical Co., Ltd., CMC & Production HQs, Pharmaceutical Product Development & Management, Pharmaceutical Product Development, Non-Sterile Product, 15-26 Kamiji 1-Chome Higashinari-ku, 537-0003 Osaka, Japan
| | - Vincent Lenhart
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstr. 1, 40225 Duesseldorf, Germany
| | - Peter Kleinebudde
- Heinrich Heine University, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstr. 1, 40225 Duesseldorf, Germany.
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18
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Kashani Rahimi S, Paul S, Sun CC, Zhang F. The role of the screw profile on granular structure and mixing efficiency of a high-dose hydrophobic drug formulation during twin screw wet granulation. Int J Pharm 2020; 575:118958. [DOI: 10.1016/j.ijpharm.2019.118958] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2019] [Revised: 12/10/2019] [Accepted: 12/12/2019] [Indexed: 11/24/2022]
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19
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Mundozah AL, Yang J, Tridon CC, Cartwright JJ, Omar CS, Salman AD. Assessing Particle Segregation Using Near-Infrared Chemical Imaging in Twin Screw Granulation. Int J Pharm 2019; 568:118541. [DOI: 10.1016/j.ijpharm.2019.118541] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/26/2019] [Revised: 07/16/2019] [Accepted: 07/17/2019] [Indexed: 10/26/2022]
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Matsui Y, Ando Y, Yamamoto K, Watano S. Analysis of Microstructure of Granules Prepared by Continuous Twin Screw Granulator Using X-Ray Micro-computed Tomography. Chem Pharm Bull (Tokyo) 2019; 67:801-809. [DOI: 10.1248/cpb.c19-00076] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Affiliation(s)
- Yasuhiro Matsui
- Formulation Research & Development Laboratories, Sumitomo Dainippon Pharma Co., Ltd
| | - Yuta Ando
- Formulation Research & Development Laboratories, Sumitomo Dainippon Pharma Co., Ltd
| | - Koji Yamamoto
- Analytical Research & Development Laboratories, Sumitomo Dainippon Pharma Co., Ltd
| | - Satoru Watano
- Department of Chemical Engineering, Graduate School of Engineering, Osaka Prefecture University
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Dahlgren G, Tajarobi P, Simone E, Ricart B, Melnick J, Puri V, Stanton C, Bajwa G. Continuous Twin Screw Wet Granulation and Drying-Control Strategy for Drug Product Manufacturing. J Pharm Sci 2019; 108:3502-3514. [PMID: 31276686 DOI: 10.1016/j.xphs.2019.06.023] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/03/2018] [Revised: 06/16/2019] [Accepted: 06/26/2019] [Indexed: 01/28/2023]
Abstract
The use of continuous manufacturing has been increasing within the pharmaceutical industry over the last few years. Continuous direct compression has been the focus of publications on the topic to date. The use of wet granulation can improve segregation resistance, uniformity, enhance density, and flow properties for improved tabletability, or improve stability of products that cannot be manufactured by using a direction compression process. This article focuses on development of appropriate control strategies for continuous wet granulation (especially twin screw wet granulation) through equipment design, material properties and manufacturing process along with areas where additional understanding is required. The article also discusses the use of process analytical technologies as part of the control and automation approach to ensure a higher assurance of product quality. Increased understanding of continuous wet granulation should result in increased utilization of the technique, thereby allowing for an increase in diversity of products manufactured by continuous manufacturing and the benefits that comes with a more complex process such as wet granulation compared with direct compression process.
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Affiliation(s)
| | | | - Eric Simone
- Agios Pharmaceuticals Inc., Cambridge, Massachusetts 02139
| | | | | | - Vibha Puri
- Genentech, Inc., San Francisco, California 94080
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22
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Meng W, Román-Ospino AD, Panikar SS, O'Callaghan C, Gilliam SJ, Ramachandran R, Muzzio FJ. Advanced process design and understanding of continuous twin-screw granulation via implementation of in-line process analytical technologies. ADV POWDER TECHNOL 2019. [DOI: 10.1016/j.apt.2019.01.017] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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23
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Matsunami K, Nagato T, Hasegawa K, Sugiyama H. A large-scale experimental comparison of batch and continuous technologies in pharmaceutical tablet manufacturing using ethenzamide. Int J Pharm 2019; 559:210-219. [DOI: 10.1016/j.ijpharm.2019.01.028] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/02/2018] [Revised: 12/14/2018] [Accepted: 01/11/2019] [Indexed: 10/27/2022]
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24
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Thapa P, Tripathi J, Jeong SH. Recent trends and future perspective of pharmaceutical wet granulation for better process understanding and product development. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.12.080] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
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25
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26
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Arndt OR, Baggio R, Adam AK, Harting J, Franceschinis E, Kleinebudde P. Impact of Different Dry and Wet Granulation Techniques on Granule and Tablet Properties: A Comparative Study. J Pharm Sci 2018; 107:3143-3152. [DOI: 10.1016/j.xphs.2018.09.006] [Citation(s) in RCA: 30] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/30/2018] [Revised: 09/04/2018] [Accepted: 09/10/2018] [Indexed: 11/26/2022]
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28
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Potter CB, Kollamaram G, Zeglinski J, Whitaker DA, Croker DM, Walker GM. Investigation of polymorphic transitions of piracetam induced during wet granulation. Eur J Pharm Biopharm 2017; 119:36-46. [DOI: 10.1016/j.ejpb.2017.05.012] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2017] [Revised: 05/19/2017] [Accepted: 05/25/2017] [Indexed: 10/19/2022]
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29
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Kim SH, Hwang KM, Cho CH, Nguyen TT, Seok SH, Hwang KM, Kim JY, Park CW, Rhee YS, Park ES. Application of continuous twin screw granulation for the metformin hydrochloride extended release formulation. Int J Pharm 2017; 529:410-422. [PMID: 28705620 DOI: 10.1016/j.ijpharm.2017.07.019] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2017] [Revised: 06/17/2017] [Accepted: 07/07/2017] [Indexed: 11/17/2022]
Abstract
This study focuses on evaluating the potential of transferring from a batch process to continuous process for manufacturing of the extended release formulation. Metformin hydrochloride (HCl) was used in the model formulation which was intended to contain the high amount of hydrophilic drug. The effects of barrel temperature, binder type, powder feed rate, and screw speed on granule properties (size and strength) and torque value in twin screw granulation were investigated. Due to the high content of hydrophilic model drug, the granules prepared at a higher temperature with HPMC binding solution had the narrower size distribution and greater strength than the granules prepared with distilled water as a binding solution. After continuous drying and milling steps, the granules (continuous process) satisfied the fundamental purpose of granulation with size and flowability, despite different shape compared with the granules (batch process). Furthermore, there were no significant differences between two granulation processes in tablet properties, such as tablet hardness and in vitro release. The considerations and strategies used in this study to transfer from a batch to continuous process can be applied to other existing formulations based on high shear granulation to enable rapid process transfer in the pharmaceutical industry.
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Affiliation(s)
- Su-Hyeon Kim
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Kyu-Min Hwang
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Cheol-Hee Cho
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Thi-Tram Nguyen
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Su Hyun Seok
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Kyu-Mok Hwang
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Ju-Young Kim
- College of Pharmacy, Woosuk University, Wanju-gun 55338, Republic of Korea
| | - Chun-Woong Park
- College of Pharmacy, Chungbuk National University, Cheongju 19421, Republic of Korea
| | - Yun-Seok Rhee
- College of Pharmacy and Research Institute of Pharmaceutical Sciences, Gyeongsang National University, Jinju 52828, Republic of Korea
| | - Eun-Seok Park
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea.
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30
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Pradhan SU, Sen M, Li J, Litster JD, Wassgren CR. Granule breakage in twin screw granulation: Effect of material properties and screw element geometry. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2017.04.011] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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31
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Liu H, Galbraith SC, Ricart B, Stanton C, Smith-Goettler B, Verdi L, O'Connor T, Lee S, Yoon S. Optimization of critical quality attributes in continuous twin-screw wet granulation via design space validated with pilot scale experimental data. Int J Pharm 2017; 525:249-263. [PMID: 28450171 DOI: 10.1016/j.ijpharm.2017.04.055] [Citation(s) in RCA: 43] [Impact Index Per Article: 6.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/16/2017] [Revised: 04/20/2017] [Accepted: 04/22/2017] [Indexed: 11/30/2022]
Abstract
In this study, the influence of key process variables (screw speed, throughput and liquid to solid (L/S) ratio) of a continuous twin screw wet granulation (TSWG) was investigated using a central composite face-centered (CCF) experimental design method. Regression models were developed to predict the process responses (motor torque, granule residence time), granule properties (size distribution, volume average diameter, yield, relative width, flowability) and tablet properties (tensile strength). The effects of the three key process variables were analyzed via contour and interaction plots. The experimental results have demonstrated that all the process responses, granule properties and tablet properties are influenced by changing the screw speed, throughput and L/S ratio. The TSWG process was optimized to produce granules with specific volume average diameter of 150μm and the yield of 95% based on the developed regression models. A design space (DS) was built based on volume average granule diameter between 90 and 200μm and the granule yield larger than 75% with a failure probability analysis using Monte Carlo simulations. Validation experiments successfully validated the robustness and accuracy of the DS generated using the CCF experimental design in optimizing a continuous TSWG process.
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Affiliation(s)
- Huolong Liu
- Department of Chemical Engineering, University of Massachusetts Lowell, 1 University Avenue, Lowell, MA 01854, United States
| | - S C Galbraith
- Department of Chemical Engineering, University of Massachusetts Lowell, 1 University Avenue, Lowell, MA 01854, United States
| | | | | | | | - Luke Verdi
- Merck & Co., Inc., West Point, PA 19486, United States
| | - Thomas O'Connor
- Food and Drug Administration, Center for Drug Evaluation and Research, Office of Generics Drug, Silver Spring, MD 19486, United States
| | - Sau Lee
- Food and Drug Administration, Center for Drug Evaluation and Research, Office of Generics Drug, Silver Spring, MD 19486, United States
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts Lowell, 1 University Avenue, Lowell, MA 01854, United States.
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32
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Mendez Torrecillas C, Halbert GW, Lamprou DA. A novel methodology to study polymodal particle size distributions produced during continuous wet granulation. Int J Pharm 2017; 519:230-239. [PMID: 28104406 DOI: 10.1016/j.ijpharm.2017.01.023] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/19/2016] [Revised: 01/10/2017] [Accepted: 01/11/2017] [Indexed: 11/26/2022]
Abstract
It is important during powder granulation to obtain particles of a homogeneous size especially in critical situations such as pharmaceutical manufacture. To date, homogeneity of particle size distribution has been defined by the use of the d50 combined with the span of the particle size distribution, which has been found ineffective for polymodal particle size distributions. This work focuses on demonstrating the limitations of the span parameter to quantify homogeneity and proposes a novel improved metric based on the transformation of a typical particle size distribution curve into a homogeneity factor which can vary from 0 to 100%. The potential of this method as a characterisation tool has been demonstrated through its application to the production of granules using two different materials. The workspace of an 11mm twin screw granulator was defined for two common excipients (α-lactose monohydrate and microcrystalline cellulose). Homogeneity of the obtained granules varied dramatically from 0 to 95% in the same workspace, allowing identification of critical process parameters (e.g. feed rate, liquid/solid ratio, torque velocities). In addition it defined the operational conditions required to produce the most homogeneous product within the range 5μm-2.2mm from both materials.
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Affiliation(s)
- Carlota Mendez Torrecillas
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom.
| | - Gavin W Halbert
- EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, G1 1RD Glasgow, United Kingdom; Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom
| | - Dimitrios A Lamprou
- Strathclyde Institute of Pharmacy and Biomedical Sciences (SIPBS), University of Strathclyde, 161 Cathedral Street, G4 0RE Glasgow, United Kingdom; Medway School of Pharmacy, University of Kent, Medway Campus, Anson Building, Central Avenue, Chatham Maritime, Chatham, Kent, ME4 4TB, United Kingdom.
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33
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Gorringe L, Kee G, Saleh M, Fa N, Elkes R. Use of the channel fill level in defining a design space for twin screw wet granulation. Int J Pharm 2017; 519:165-177. [DOI: 10.1016/j.ijpharm.2017.01.029] [Citation(s) in RCA: 28] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2016] [Revised: 12/23/2016] [Accepted: 01/13/2017] [Indexed: 11/29/2022]
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34
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Chaudhury A, Barrasso D, Pohlman D, Litster J, Ramachandran R. Mechanistic modeling of high-shear and twin screw mixer granulation processes. PREDICTIVE MODELING OF PHARMACEUTICAL UNIT OPERATIONS 2017:99-135. [DOI: 10.1016/b978-0-08-100154-7.00005-3] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 07/19/2023]
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35
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36
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Muley S, Nandgude T, Poddar S. Extrusion–spheronization a promising pelletization technique: In-depth review. Asian J Pharm Sci 2016. [DOI: 10.1016/j.ajps.2016.08.001] [Citation(s) in RCA: 74] [Impact Index Per Article: 9.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022] Open
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37
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Development and Optimization of a Wet Granulation Process at Elevated Temperature for a Poorly Compactible Drug Using Twin Screw Extruder for Continuous Manufacturing. J Pharm Sci 2016; 106:589-600. [PMID: 27890244 DOI: 10.1016/j.xphs.2016.10.020] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.9] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/19/2016] [Revised: 10/17/2016] [Accepted: 10/20/2016] [Indexed: 11/22/2022]
Abstract
The objective of this study was to enhance tabletability of a poorly compactible drug, acetaminophen, by wet granulation using twin screw extruder at high temperature. It was desired that there would be minimum amounts of excipients used and the granules obtained after extrusion would be dry and fall within a size range suitable for tableting without any further processing. Mixtures of acetaminophen (95%) with binders (5% povidone or partially pregelatinized starch) were wet granulated through twin screw extruder at 70°C by adding 7% w/w water. The process had a short granulation time (<1 min), and, on account of the elevated processing temperature used, no drying after extrusion was needed. By optimizing formulation and processing parameters, >90% granules in the size range of 125 to 1000 μm (<3% above 1000 μm and <7% below 125 μm) were obtained without any milling. When the granules were compressed by adding 1% disintegrant and 0.5% lubricant extragranularly, tablets produced (93.6% drug load) had good mechanical strength having hardness >1.7 MPa, which was superior to that of tablets prepared by conventional high shear wet granulation. As the granules could be extruded continuously and did not require drying and milling, the method was amenable to continuous processing.
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38
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Developing a miniaturized approach for formulation development using twin screw granulation. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.04.051] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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39
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Pashminehazar R, Kharaghani A, Tsotsas E. Three dimensional characterization of morphology and internal structure of soft material agglomerates produced in spray fluidized bed by X-ray tomography. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2016.03.053] [Citation(s) in RCA: 28] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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40
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Chan Seem T, Rowson NA, Gabbott I, de Matas M, Reynolds GK, Ingram A. Asymmetric distribution in twin screw granulation. Eur J Pharm Biopharm 2016; 106:50-8. [DOI: 10.1016/j.ejpb.2016.01.013] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/28/2015] [Revised: 01/08/2016] [Accepted: 01/19/2016] [Indexed: 11/30/2022]
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41
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Vanhoorne V, Janssens L, Vercruysse J, De Beer T, Remon JP, Vervaet C. Continuous twin screw granulation of controlled release formulations with various HPMC grades. Int J Pharm 2016; 511:1048-57. [PMID: 27521702 DOI: 10.1016/j.ijpharm.2016.08.020] [Citation(s) in RCA: 25] [Impact Index Per Article: 3.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/21/2016] [Revised: 08/08/2016] [Accepted: 08/09/2016] [Indexed: 10/21/2022]
Abstract
HPMC is a popular matrix former to formulate tablets with extended drug release. Tablets with HPMC are preferentially produced by direct compression. However, granulation is often required prior to tableting to overcome poor flowability of the formulation. While continuous twin screw granulation has been extensively evaluated for granulation of immediate release formulations, twin screw granulation of controlled release formulations including the dissolution behavior of the formulations received little attention. Therefore, the influence of the HPMC grade (viscosity and substitution degree) and the particle size of theophylline on critical quality attributes of granules (continuously produced via twin screw granulation) and tablets was investigated in the current study. Formulations with 20 or 40% HPMC, 20% theophylline and lactose were granulated with water at fixed process parameters via twin screw granulation. The torque was influenced by the viscosity and substitution degree of HPMC, but was not a limiting factor for the granulation process. An optimal L/S ratio was selected for each formulation based on the granule size distribution. The granule size distributions were influenced by the substitution degree and concentration of HPMC and the particle size of theophylline. Raman and UV spectroscopic analysis on 8 sieve fractions of granules indicated an inhomogeneous distribution of theophylline over the size fractions. However, this phenomenon was not correlated with the hydration rate or viscosity of HPMC. Controlled release of theophylline could be obtained over 24h with release profiles close to zero-order. The release of theophylline could be tailored via selection of the substitution degree and viscosity of HPMC.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University Belgium
| | - L Janssens
- Laboratory of Pharmaceutical Technology, Ghent University Belgium
| | - J Vercruysse
- Laboratory of Pharmaceutical Technology, Ghent University Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Belgium
| | - J P Remon
- Laboratory of Pharmaceutical Technology, Ghent University Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University Belgium.
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42
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Vanhoorne V, Vanbillemont B, Vercruysse J, De Leersnyder F, Gomes P, Beer TD, Remon JP, Vervaet C. Development of a controlled release formulation by continuous twin screw granulation: Influence of process and formulation parameters. Int J Pharm 2016; 505:61-8. [PMID: 27041123 DOI: 10.1016/j.ijpharm.2016.03.058] [Citation(s) in RCA: 31] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/04/2016] [Revised: 03/18/2016] [Accepted: 03/29/2016] [Indexed: 10/22/2022]
Abstract
The aim of this study was to evaluate the potential of twin screw granulation for the continuous production of controlled release formulations with hydroxypropylmethylcellulose as hydrophilic matrix former. Metoprolol tartrate was included in the formulation as very water soluble model drug. A premix of metoprolol tartrate, hydroxypropylmethylcellulose and filler (ratio 20/20/60, w/w) was granulated with demineralized water via twin screw granulation. After oven drying and milling, tablets were produced on a rotary Modul™ P tablet press. A D-optimal design (29 experiments) was used to assess the influence of process (screw speed, throughput, barrel temperature and screw design) and formulation parameters (starch content of the filler) on the process (torque), granule (size distribution, shape, friability, density) and tablet (hardness, friability and dissolution) critical quality attributes. The torque was dominated by the number of kneading elements and throughput, whereas screw speed and filling degree only showed a minor influence on torque. Addition of screw mixing elements after a block of kneading elements improved the yield of the process before milling as it resulted in less oversized granules and also after milling as less fines were present. Temperature was also an important parameter to optimize as a higher temperature yielded less fines and positively influenced the aspect ratio. The shape of hydroxypropylmethylcellulose granules was comparable to that of immediate release formulations. Tensile strength and friability of tablets were not dependent on the process parameters. The use of starch as filler was not beneficial with regard to granule and tablet properties. Complete drug release was obtained after 16-20h and was independent of the design's parameters.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - B Vanbillemont
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - J Vercruysse
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - F De Leersnyder
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Belgium
| | - P Gomes
- Laboratory of Nanotechnology, Centro Universitário Franciscano, Brazil
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Belgium
| | - J P Remon
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Belgium.
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43
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Multimodal approach to characterization of hydrophilic matrices manufactured by wet and dry granulation or direct compression methods. Int J Pharm 2016; 499:263-270. [DOI: 10.1016/j.ijpharm.2015.12.067] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/01/2015] [Accepted: 12/27/2015] [Indexed: 11/24/2022]
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44
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Qualitative Assessment of a Multi-Scale, Compartmental PBM-DEM Model of a Continuous Twin-Screw Wet Granulation Process. J Pharm Innov 2015. [DOI: 10.1007/s12247-015-9240-7] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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45
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Yan L, Chao M, Xiao J, Gao L, Wieβner S. Study on Preparation of BaSO4
-Containing Polytetrafluoroethylene Granular Powder. ADVANCES IN POLYMER TECHNOLOGY 2015. [DOI: 10.1002/adv.21623] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Luke Yan
- Polymer Materials & Chemistry Department; School of Materials Science & Engineering; Chang'an University; Xi'an 710064 People's Republic of China
- Leibniz Institute of Polymer Research Dresden; 01069 Dresden Germany
| | - Min Chao
- Polymer Materials & Chemistry Department; School of Materials Science & Engineering; Chang'an University; Xi'an 710064 People's Republic of China
| | - Jian Xiao
- Electronic Science & Technology Department; School of Electronics & Controls Engineering; Chang'an University; Xi'an 710064 People's Republic of China
| | - Lining Gao
- Polymer Materials & Chemistry Department; School of Materials Science & Engineering; Chang'an University; Xi'an 710064 People's Republic of China
| | - Sven Wieβner
- Leibniz Institute of Polymer Research Dresden; 01069 Dresden Germany
- Institute of Materials Science; Dresden University of Technology; 01069 Dresden Germany
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46
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Meier R, Thommes M, Rasenack N, Krumme M, Moll KP, Kleinebudde P. Simplified formulations with high drug loads for continuous twin-screw granulation. Int J Pharm 2015; 496:12-23. [PMID: 26024821 DOI: 10.1016/j.ijpharm.2015.05.060] [Citation(s) in RCA: 24] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/24/2015] [Revised: 05/19/2015] [Accepted: 05/23/2015] [Indexed: 10/23/2022]
Abstract
As different batches of the same excipients will be intermixed during continuous processes, the traceability of batches is complicated. Simplified formulations may help to reduce problems related to batch intermixing and traceability. Twin-screw granulation with subsequent tableting was used to produce granules and tablets, containing drug, disintegrant and binder (binary and ternary mixtures), only. Drug loads up to 90% were achieved and five different disintegrants were screened for keeping their disintegration suitability after wetting. Granule size distributions were consistently mono-modal and narrow. Granule strength reached higher values, using ternary mixtures. Tablets containing croscarmellose-Na as disintegrant displayed tensile strengths up to 3.1MPa and disintegration times from 400 to 466s, resulting in the most robust disintegrant. Dissolution was overall complete and above 96% within 30 min. Na-starch glycolate offers tensile strengths up to 2.8MPa at disintegration times from 25s to 1031s, providing the broadest application window, as it corresponds in some parts to different definitions of orodispersible tablets. Tablets containing micronized crospovidone are not suitable for immediate release, but showed possibilities to produce highly drug loaded, prolonged release tablets. Tablets and granules from simplified formulations offer great opportunities to improve continuous processes, present performances comparable to more complicated formulations and are able to correspond to requirements of the authorities.
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Affiliation(s)
- R Meier
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, Universitaetsstr. 1, 40225 Duesseldorf, Germany.
| | - M Thommes
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, Universitaetsstr. 1, 40225 Duesseldorf, Germany; Faculty of Bio- and Chemical Engineering, Technical University Dortmund, Emil-Figge-Str. 68, 44227 Dortmund, Germany.
| | | | - M Krumme
- Novartis AG, 4002 Basel, Switzerland.
| | - K-P Moll
- Novartis AG, 4002 Basel, Switzerland.
| | - P Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, Universitaetsstr. 1, 40225 Duesseldorf, Germany.
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47
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Seem TC, Rowson NA, Ingram A, Huang Z, Yu S, de Matas M, Gabbott I, Reynolds GK. Twin screw granulation — A literature review. POWDER TECHNOL 2015. [DOI: 10.1016/j.powtec.2015.01.075] [Citation(s) in RCA: 75] [Impact Index Per Article: 8.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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48
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Vercruysse J, Burggraeve A, Fonteyne M, Cappuyns P, Delaet U, Van Assche I, De Beer T, Remon J, Vervaet C. Impact of screw configuration on the particle size distribution of granules produced by twin screw granulation. Int J Pharm 2015; 479:171-80. [DOI: 10.1016/j.ijpharm.2014.12.071] [Citation(s) in RCA: 63] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2014] [Revised: 12/27/2014] [Accepted: 12/31/2014] [Indexed: 10/24/2022]
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49
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50
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Experimental investigation of granule size and shape dynamics in twin-screw granulation. Int J Pharm 2014; 475:485-95. [DOI: 10.1016/j.ijpharm.2014.09.020] [Citation(s) in RCA: 26] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/10/2014] [Revised: 09/10/2014] [Accepted: 09/11/2014] [Indexed: 11/20/2022]
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