1
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Jajcevic D, Remmelgas J, Toson P, Matić M, Hörmann-Kincses T, Beretta M, Rehrl J, Poms J, O'Connor T, Koolivand A, Tian G, Krull SM, Khinast JG. Development of a high-fidelity digital twin using the discrete element method for a continuous direct compression process. Part 1. Calibration workflow. Int J Pharm 2024:124796. [PMID: 39366530 DOI: 10.1016/j.ijpharm.2024.124796] [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: 07/16/2024] [Revised: 09/30/2024] [Accepted: 10/01/2024] [Indexed: 10/06/2024]
Abstract
In this work, a high-fidelity digital twin was developed to support the design and testing of control strategies for drug product manufacturing via direct compression. The high-fidelity digital twin platform was based on typical pharmaceutical equipment, materials, and direct compression continuous processes. The paper describes in detail the material characterization, the Discrete Element Method (DEM) model and the DEM model parameter calibration approach and provides a comparison of the system's response to the experimental results for stepwise changes in the API concentration at the mixer inlet. A calibration method for a cohesive DEM contact model parameter estimation was introduced. To assure a correct prediction for a wide range of processes, the calibration approach contained four characterization experiments using different stress states and different measurement principles, namely the bulk density test, compression with elastic recovery, the shear cell, and the rotating drum. To demonstrate the sensitivity of the DEM contact parameters to the process response, two powder characterization data sets with different powder flowability were applied. The results showed that the calibration method could differentiate between the different material batches of the same blend and that small-scale material characterization tests could be used to predict the residence time distribution in a continuous manufacturing process.
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Affiliation(s)
| | - Johan Remmelgas
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria.
| | - Peter Toson
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Marko Matić
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | | | - Michela Beretta
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Thomas O'Connor
- Office of Pharmaceutical Quality, US Food and Drug Administration, Austria
| | - Abdollah Koolivand
- Office of Pharmaceutical Quality, US Food and Drug Administration, Austria
| | - Geng Tian
- Office of Pharmaceutical Quality, US Food and Drug Administration, Austria
| | - Scott M Krull
- Office of Pharmaceutical Quality, US Food and Drug Administration, Austria
| | - Johannes G Khinast
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, Austria
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2
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Boehling P, Remmelgas J, Salehi M, Poms J, Martins Fraga R, Bautista M, Khinast JG, Gavi E, Beretta M. Demonstrating scalability between two blender types using DEM. Int J Pharm 2024; 666:124773. [PMID: 39343328 DOI: 10.1016/j.ijpharm.2024.124773] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/05/2024] [Revised: 09/24/2024] [Accepted: 09/26/2024] [Indexed: 10/01/2024]
Abstract
Powder blending is a critical step in pharmaceutical manufacturing that can impact product quality such as tablet tensile strength. This study utilized the Discrete Element Method (DEM) to investigate blending in a 5-liter mini-batch and a 2-liter Turbula blender. DEM parameters were calibrated using small-scale powder characterization tests, so that the particle behavior in the DEM simulations matches the measured behavior. The research explored the effects of blender designs and process conditions on blending and lubricant dispersion. A predictive model for tablet tensile strength was developed. The model takes the lubricant's dispersion via the lubrication energy into account. The model is then used to predict the tablet tensile strength depending on the chosen process parameters, blending speed, duration, and fill level. DEM simulations enabled scaling between the two blenders, providing valuable insights for a semi-continuous manufacturing process based on mini-batch blending. The findings contribute to a deeper understanding of blending mechanics, offering potential enhancements in pharmaceutical manufacturing efficiency and product consistency.
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Affiliation(s)
- Peter Boehling
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Johan Remmelgas
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | | | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | | | - Manel Bautista
- Pharmaceutical Technical Development Synthetic Molecules, F. Hoffmann-La Roche, Basel, Switzerland
| | - Johannes G Khinast
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; IPPT, Graz University of Technology, Graz, Austria
| | - Emmanuela Gavi
- Pharmaceutical Technical Development Synthetic Molecules, F. Hoffmann-La Roche, Basel, Switzerland
| | - Michela Beretta
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria.
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3
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Kim SS, Seetahal A, Amores N, Kossor C, Davé RN. Impact of Silica Dry Coprocessing with API and Blend Mixing Time on Blend Flowability and Drug Content Uniformity. J Pharm Sci 2023; 112:2124-2136. [PMID: 37230252 DOI: 10.1016/j.xphs.2023.05.016] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2023] [Revised: 05/18/2023] [Accepted: 05/18/2023] [Indexed: 05/27/2023]
Abstract
This paper considers two fine-sized (d50 ∼10 µm) model drugs, acetaminophen (mAPAP) and ibuprofen (Ibu), to examine the effect of API dry coprocessing on their multi-component medium DL (30 wt%) blends with fine excipients. The impact of blend mixing time on the bulk properties such as flowability, bulk density, and agglomeration was studied. The hypothesis tested is that blends with fine APIs at medium DL require good blend flowability to have good blend uniformity (BU). Moreover, the good flowability could be achieved through dry coating with hydrophobic (R972P) silica, which reduces agglomeration of not only fine API, but also of its blends while using fine excipients. For uncoated APIs, the blend flowability was poor, i.e. cohesive regime at all mixing times, and the blends failed to achieve acceptable BU. In contrast, for dry coated APIs, their blend flowability improved to easy-flow regime or better, improving with mixing time, and as hypothesized, all blends consequently achieved desired BU. All dry coated API blends exhibited improved bulk density and reduced agglomeration, attributed to mixing induced synergistic property enhancements, likely due to silica transfer. Despite coating with hydrophobic silica, tablet dissolution was improved, attributed to the reduced agglomeration of fine API.
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Affiliation(s)
- Sangah S Kim
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Ameera Seetahal
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Nicholas Amores
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Christopher Kossor
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Rajesh N Davé
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA.
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4
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Digital twin of a continuous direct compression line for drug product and process design using a hybrid flowsheet modelling approach. Int J Pharm 2022; 628:122336. [DOI: 10.1016/j.ijpharm.2022.122336] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/13/2022] [Revised: 10/19/2022] [Accepted: 10/20/2022] [Indexed: 11/06/2022]
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5
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Shi Q, Sakai M. Recent progress on the discrete element method simulations for powder transport systems: A review. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103664] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/01/2022]
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6
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Forgber T, Rehrl J, Matic M, Sibanc R, Sivanesapillai R, Khinast J. Experimental and numerical investigations of the RTD in a GEA ConsiGma CTL25 tablet press. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117507] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
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7
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Zhao LL, Duan CL, Jiang HS, Li HX, Zhao YM, Zheng QJ. DEM simulation of size segregation of binary mixtures of cohesive particles under a horizontal swirling vibration. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117456] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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8
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Zimmermann M, Raffel C, Bartsch J, Thommes M. Simulation of Powder Flow Behavior in an Artificial Feed Frame Using an Euler‐Euler Model. Chem Eng Technol 2022. [DOI: 10.1002/ceat.202100580] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Maren Zimmermann
- TU Dortmund University Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering Emil-Figge-Strasse 68 44227 Dortmund Germany
| | - Carola Raffel
- TU Dortmund University Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering Emil-Figge-Strasse 68 44227 Dortmund Germany
| | - Jens Bartsch
- TU Dortmund University Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering Emil-Figge-Strasse 68 44227 Dortmund Germany
| | - Markus Thommes
- TU Dortmund University Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering Emil-Figge-Strasse 68 44227 Dortmund Germany
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9
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de Backere C, De Beer T, Vervaet C, Vanhoorne V. Effect of feed frame on lubricant sensitivity during upscaling from a compaction simulator to a rotary tablet press. Int J Pharm 2022; 616:121562. [PMID: 35150846 DOI: 10.1016/j.ijpharm.2022.121562] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/09/2021] [Revised: 01/26/2022] [Accepted: 02/05/2022] [Indexed: 11/18/2022]
Abstract
Internal lubrication can be associated with reduced tabletability. Deformation mechanism, lubricant type, lubricant blending time and paddle speed (PS) of the forced feeder are known to be influenceable factors. This study investigated the effect of lubricant blending time and PS of forced feeders on the tensile strength of lubricated microcrystalline cellulose (MCC) and lactose tablets. Magnesium stearate (MgSt), sodium stearyl fumarate (SSF) and stearic acid (SA) were used as lubricants. Tablets were produced on a compaction simulator and a rotary tablet press to investigate lubricant sensitivity during upscaling. Lubricant sensitivity was found higher for MCC compared to lactose which was attributed to the higher plasticity of MCC. The reduction in tensile strength upon lubricant addition followed the order: MgSt > SSF > SA; which could be linked to particle size, specific surface area and particle shape of the lubricants. Although differences in tensile strength were observed between the lubricant types, comparable ejection forces were obtained. The impact of PS on tensile strength was higher compared to lubricant blending time for both tableting machines. A good correlation of tensile strength and lubricant sensitivity between the compaction simulator and rotary tablet press was observed based on the calculation of paddle passes (NPP).
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Affiliation(s)
- Cedrine de Backere
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium
| | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Ghent, Belgium.
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10
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Russell A, Strong J, Garner S, Ketterhagen W, Long M, Capece M. Direct Compaction Drug Product Process Modeling. AAPS PharmSciTech 2022; 23:67. [PMID: 35102457 PMCID: PMC8816834 DOI: 10.1208/s12249-021-02206-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2021] [Revised: 12/01/2021] [Accepted: 12/21/2021] [Indexed: 11/30/2022] Open
Abstract
Most challenges during the development of solid dosage forms are related to the impact of any variations in raw material properties, batch size, or equipment scales on the product quality and the control of the manufacturing process. With the ever pertinent restrictions on time and resource availability versus heightened expectations to develop, optimize, and troubleshoot manufacturing processes, targeted and robust science-based process modeling platforms are essential. This review focuses on the modeling of unit operations and practices involved in batch manufacturing of solid dosage forms by direct compaction. An effort is made to highlight the key advances in the past five years, and to propose potentially beneficial future study directions.
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Affiliation(s)
- Alexander Russell
- Operations Science & Technology, AbbVie, 67061, Ludwigshafen, Germany.
| | - John Strong
- R&D Drug Product Development, AbbVie, North Chicago, Illinois, 60064, USA
| | - Sean Garner
- R&D Drug Product Development, AbbVie, North Chicago, Illinois, 60064, USA
| | | | - Michelle Long
- Operations Science & Technology, AbbVie, North Chicago, Illinois, 60064, USA
| | - Maxx Capece
- R&D Drug Product Development, AbbVie, North Chicago, Illinois, 60064, USA
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11
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NIR spectroscopic methods for monitoring blend potency in a feed frame - calibration transfer between offline and inline using a continuum regression filter. Int J Pharm 2021; 614:121363. [PMID: 34954005 DOI: 10.1016/j.ijpharm.2021.121363] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/04/2021] [Revised: 11/29/2021] [Accepted: 12/05/2021] [Indexed: 11/22/2022]
Abstract
A material sparing method for near-infrared (NIR) calibration was developed using an offline apparatus coupled with a calibration transfer method to enable a partial least squares (PLS) model to monitor the concentration of active pharmaceutical ingredients (API) in the feed frame of a rotary tablet press. The offline apparatus was designed to simulate the powder flow dynamic and NIRS measurement environment of a tablet-press feed frame. A comprehensive experimental design, including calibration and testing, was employed to determine blend inhomogeneity. NIR spectra were collected at both the feed frame (inline) conditions and the simulator (offline) conditions. The simulator conditions were designed to mimic the density and powder flow in the feed frame during the actual tableting process. The offline data were pretreated by an orthogonalization-based calibration transfer algorithm, a continuum regression filter (CR filter), before being subjected to PLS modeling. This study demonstrated: (1) calibration for inline application can be generated using an offline apparatus, and (2) the CR filter, as an innovative calibration transfer method, can generalize the offline method for multiple feed frame conditions.
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12
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Sacher S, Poms J, Rehrl J, Khinast JG. PAT implementation for advanced process control in solid dosage manufacturing - A practical guide. Int J Pharm 2021; 613:121408. [PMID: 34952147 DOI: 10.1016/j.ijpharm.2021.121408] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2021] [Revised: 12/10/2021] [Accepted: 12/16/2021] [Indexed: 01/14/2023]
Abstract
The implementation of continuous pharmaceutical manufacturing requires advanced control strategies rather than traditional end product testing or an operation within a small range of controlled parameters. A high level of automation based on process models and hierarchical control concepts is desired. The relevant tools that have been developed and successfully tested in academic and industrial environments in recent years are now ready for utilization on the commercial scale. To date, the focus in Process Analytical Technology (PAT) has mainly been on achieving process understanding and quality control with the ultimate goal of real-time release testing (RTRT). This work describes the workflow for the development of an in-line monitoring strategy to support PAT-based real-time control actions and its integration into solid dosage manufacturing. All stages are discussed in this paper, from process analysis and definition of the monitoring task to technology assessment and selection, its process integration and the development of data acquisition.
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Affiliation(s)
- Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria.
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria
| | - Johannes G Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13/2, 8010 Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
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13
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Furukawa R, Singh R, Ierapetritou M. Experimental investigation and modelling of tensile strength of pharmaceutical tablets based on shear force applied by feed frame paddles. Int J Pharm 2021; 606:120908. [PMID: 34298106 DOI: 10.1016/j.ijpharm.2021.120908] [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: 05/09/2021] [Revised: 07/13/2021] [Accepted: 07/18/2021] [Indexed: 02/02/2023]
Abstract
The feed frame is an essential device used in a rotary tablet press and it improves the performance of the powder filling process into dies. However, the feed frame affects critical quality attributes such as a tensile strength and a dissolution negatively due to a shear applied to powders from feed frame paddles, leading to over-lubrication. This effects may be significant for shear sensitive materials. The work focuses on the effect of tablet press parameters (die disk speed and feed frame speed) and mixture composition (amount of magnesium stearate) on the tensile strength and the prediction of the tensile strength by considering the extent of shear. It is found that within the investigated range of tablet press parameters and the amount of magnesium stearate, the feed frame speed and the amount of magnesium stearate have an impact on the tensile strength. Furthermore, a lubrication model based on the extent of shear is presented to predict the decreasing trend of the tensile strength of tablets during tableting process and the results demonstrate that the prediction of tensile strength is in good agreement with experimental measurements.
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Affiliation(s)
- Ryoichi Furukawa
- Pharmaceutical Research Department, Mitsubishi Tanabe Pharma Corporation, 3-16-89, Kashima, Yodogawa-ku, Osaka 532-8505, Japan
| | - Ravendra Singh
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA.
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, 150 Academy St, Newark, DE 19716, USA.
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14
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Peddapatla RVG, Sheridan G, Slevin C, Swaminathan S, Browning I, O’Reilly C, Worku ZA, Egan D, Sheehan S, Crean AM. Process Model Approach to Predict Tablet Weight Variability for Direct Compression Formulations at Pilot and Production Scale. Pharmaceutics 2021; 13:pharmaceutics13071033. [PMID: 34371725 PMCID: PMC8308976 DOI: 10.3390/pharmaceutics13071033] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/17/2021] [Revised: 06/29/2021] [Accepted: 07/01/2021] [Indexed: 11/16/2022] Open
Abstract
Optimizing processing conditions to achieve a critical quality attribute (CQA) is an integral part of pharmaceutical quality by design (QbD). It identifies combinations of material and processing parameters ensuring that processing conditions achieve a targeted CQA. Optimum processing conditions are formulation and equipment-dependent. Therefore, it is challenging to translate a process design between formulations, pilot-scale and production-scale equipment. In this study, an empirical model was developed to determine optimum processing conditions for direct compression formulations with varying flow properties, across pilot- and production-scale tablet presses. The CQA of interest was tablet weight variability, expressed as percentage relative standard deviation. An experimental design was executed for three model placebo blends with varying flow properties. These blends were compacted on one pilot-scale and two production-scale presses. The process model developed enabled the optimization of processing parameters for each formulation, on each press, with respect to a target tablet weight variability of <1%RSD. The model developed was successfully validated using data for additional placebo and active formulations. Validation formulations were benchmarked to formulations used for model development, employing permeability index values to indicate blend flow.
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Affiliation(s)
- Raghu V. G. Peddapatla
- SSPC Pharmaceutical Research Centre, School of Pharmacy, University College Cork, T12 K8AF Cork, Ireland; (R.V.G.P.); (A.M.C.)
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
| | - Gerard Sheridan
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
- Pharmaceutical Manufacturing Technology Centre (PMTC), Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland;
| | - Conor Slevin
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
- Pharmaceutical Manufacturing Technology Centre (PMTC), Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland;
| | | | - Ivan Browning
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
| | - Clare O’Reilly
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
| | - Zelalem A. Worku
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
| | - David Egan
- Pharmaceutical Manufacturing Technology Centre (PMTC), Bernal Institute, University of Limerick, V94 T9PX Limerick, Ireland;
| | - Stephen Sheehan
- Alkermes Pharma Ireland Limited, N37 EA09 Athlone, Ireland; (G.S.); (C.S.); (I.B.); (C.O.); (Z.A.W.)
- Correspondence: ; Tel.: +353-877-413-140
| | - Abina M. Crean
- SSPC Pharmaceutical Research Centre, School of Pharmacy, University College Cork, T12 K8AF Cork, Ireland; (R.V.G.P.); (A.M.C.)
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15
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Process Modeling and Simulation of Tableting-An Agent-Based Simulation Methodology for Direct Compression. Pharmaceutics 2021; 13:pharmaceutics13070996. [PMID: 34209261 PMCID: PMC8308958 DOI: 10.3390/pharmaceutics13070996] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2021] [Revised: 06/10/2021] [Accepted: 06/22/2021] [Indexed: 11/17/2022] Open
Abstract
In pharmaceutical manufacturing, the utmost aim is reliably producing high quality products. Simulation approaches allow virtual experiments of processes in the planning phase and the implementation of digital twins in operation. The industrial processing of active pharmaceutical ingredients (APIs) into tablets requires the combination of discrete and continuous sub-processes with complex interdependencies regarding the material structures and characteristics. The API and excipients are mixed, granulated if required, and subsequently tableted. Thereby, the structure as well as the properties of the intermediate and final product are influenced by the raw materials, the parametrized processes and environmental conditions, which are subject to certain fluctuations. In this study, for the first time, an agent-based simulation model is presented, which enables the prediction, tracking, and tracing of resulting structures and properties of the intermediates of an industrial tableting process. Therefore, the methodology for the identification and development of product and process agents in an agent-based simulation is shown. Implemented physical models describe the impact of process parameters on material structures. The tablet production with a pilot scale rotary press is experimentally characterized to provide calibration and validation data. Finally, the simulation results, predicting the final structures, are compared to the experimental data.
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16
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Zimmermann M, Thommes M. Residence time and mixing capacity of a rotary tablet press feed frame. Drug Dev Ind Pharm 2021; 47:790-798. [PMID: 34042546 DOI: 10.1080/03639045.2021.1934871] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
Abstract
PURPOSE Most rotary tablet presses contain a feed frame to provide a continuous powder flow and to feed powder into the dies. The wide residence time distribution (RTD) of these feed frames is problematic, because it negatively affects material traceability in continuous manufacturing. In a rotary tablet press, different machine settings influence the RTD, which is characterized by the mean and the width of the distribution. This study focused on the effects of the rotational speed of the feed frame paddles and the rotary tablet press throughput on the RTD. METHODS An in-line UV/Vis measurement method was developed for determining the RTD in the feed frame. A model based on a plug flow and a continuous stirred tank reactor was adapted to model the experimentally determined RTDs. Finally, the mixing capacity of a feed frame was evaluated and correlated with a model parameter of the RTD. RESULTS Overall, the developed UV/Vis measurement method was suitable and could be used to obtain process information regarding content uniformity in real time. The experimentally-determined RTDs were described well by fitting an inverse mixing and a transport time. In addition, a correlation between the location and the shape of measured RTDs and tablet press throughput was found. In contrast, rotational feed frame paddle speed did not affect the RTDs. Split-feeding experiments indicated the mixing capacity of the rotary tablet press feed frame. CONCLUSION The inverse mixing time can be used as an initial indicator for estimating the mixing capacity.
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Affiliation(s)
- Maren Zimmermann
- Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering, TU Dortmund University, Dortmund, Germany
| | - Markus Thommes
- Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering, TU Dortmund University, Dortmund, Germany
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17
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Louge MY, Mandur J, Blincoe W, Tantuccio A, Meyer RF. Non-invasive, continuous, quantitative detection of powder level and mass holdup in a metal feed tube. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.12.068] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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18
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Nauka E, So C, Yost E, Mao C, Narang AS. A Scale-Up, Phenomenological Model Incorporating the Effect of Both Feed Frame Lubrication and Tumble Blending-Driven Lubrication on Tablet Mechanical Strength. J Pharm Sci 2021; 110:2669-2676. [PMID: 33610569 DOI: 10.1016/j.xphs.2021.02.020] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/01/2020] [Revised: 02/10/2021] [Accepted: 02/15/2021] [Indexed: 11/30/2022]
Abstract
In tablet manufacturing, mixing operations in tumble blending (TB) and in the feed frame (FF) of the rotary press can both increase lubricity, negatively influencing the tablet mechanical strength. While the TB-driven lubrication was systematically studied, no reliable bench-scale methods exist for the effect of FF lubrication. Because TB and FF mixing are usually two successive operations in tablet manufacturing, we developed a phenomenological model to incorporate the impact of TB-driven lubrication and the FF lubrication on the tablet tensile strength (TS). We noted that exponential decay functions can describe the evolution of the tablet TS as the function of the extent of TB, as well as the residence time in FF. Hence, the overall lubrication sensitivity can be modeled by incorporating two distinct exponential decay functions. The model can be calibrated through bench-scale experiments. Using an investigational powder blend, we showed that this approach accurately predicted the tablet TS in a scale-up tablet compression study, thereby verifying its utility. This model can serve as a scale-up diagnostic and risk-assessment tool, with the ability to adjust the overall effect of lubrication by changing the TB scale and the FF residence time commensurate with the large-scale operations.
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Affiliation(s)
- Ewa Nauka
- Small Molecule Pharmaceutical Sciences, Genentech, Inc, One DNA Way, South San Francisco, CA 94080, USA
| | - Chi So
- Small Molecule Pharmaceutical Sciences, Genentech, Inc, One DNA Way, South San Francisco, CA 94080, USA
| | - Edward Yost
- Small Molecule Pharmaceutical Sciences, Genentech, Inc, One DNA Way, South San Francisco, CA 94080, USA
| | - Chen Mao
- Small Molecule Pharmaceutical Sciences, Genentech, Inc, One DNA Way, South San Francisco, CA 94080, USA.
| | - Ajit S Narang
- Small Molecule Pharmaceutical Sciences, Genentech, Inc, One DNA Way, South San Francisco, CA 94080, USA.
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Xu Z, Yoshinaga S, Tsunazawa Y, Tokoro C. Numerical investigation of segregation behavior of multi-sized particles during pharmaceutical mini-tablet die filling. J Drug Deliv Sci Technol 2021. [DOI: 10.1016/j.jddst.2020.102301] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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20
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Furukawa R, Singh R, Ierapetritou M. Effect of material properties on the residence time distribution (RTD) of a tablet press feed frame. Int J Pharm 2020; 591:119961. [DOI: 10.1016/j.ijpharm.2020.119961] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/27/2020] [Revised: 09/18/2020] [Accepted: 10/05/2020] [Indexed: 11/24/2022]
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21
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Sierra-Vega NO, Romañach RJ, Méndez R. Real-time quantification of low-dose cohesive formulations within a sampling interface for flowing powders. Int J Pharm 2020; 588:119726. [DOI: 10.1016/j.ijpharm.2020.119726] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/25/2020] [Revised: 07/29/2020] [Accepted: 07/31/2020] [Indexed: 11/27/2022]
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23
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Ramírez-Aragón C, Alba-Elías F, González-Marcos A, Ordieres-Meré J. Improving the feeder shoe design of an eccentric tablet press machine. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.05.104] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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24
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In-line monitoring of low drug concentration of flowing powders in a new sampler device. Int J Pharm 2020; 583:119358. [DOI: 10.1016/j.ijpharm.2020.119358] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2020] [Revised: 04/15/2020] [Accepted: 04/19/2020] [Indexed: 01/18/2023]
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25
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Impact of Particle and Equipment Properties on Residence Time Distribution of Pharmaceutical Excipients in Rotary Tablet Presses. Pharmaceutics 2020; 12:pharmaceutics12030283. [PMID: 32245219 PMCID: PMC7151020 DOI: 10.3390/pharmaceutics12030283] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2020] [Revised: 03/18/2020] [Accepted: 03/19/2020] [Indexed: 11/17/2022] Open
Abstract
Paddle feeders are devices commonly used in rotary tablet presses to facilitate constant and efficient die filling. Adversely, the shear stress applied by the rotating paddles is known to affect the bulk properties of the processed powder dependent on the residence time. This study focuses on the residence time distribution (RTD) of two commonly applied excipients (microcrystalline cellulose, MCC; dicalcium phosphate, DCP), which exhibit different flow properties inside rotary tablet presses. To realistically depict the powder flow inside rotary tablet presses, custom-made tracer powder was developed. The applied method was proven to be appropriate as the tracer and bulk powder showed comparable properties. The RTDs of both materials were examined in two differently scaled rotary tablet presses and the influence of process parameters was determined. To analyze RTDs independent of the mass flow, the normalized variance was used to quantify intermixing. Substantial differences between both materials and tablet presses were found. Broader RTDs were measured for the poorer flowing MCC as well as for the production scale press. The obtained results can be used to improve the general understanding of powder flow inside rotary tablet presses and amplify scale-up and continuous production process development.
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26
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The Challenge of Die Filling in Rotary Presses-A Systematic Study of Material Properties and Process Parameters. Pharmaceutics 2020; 12:pharmaceutics12030248. [PMID: 32164230 PMCID: PMC7150958 DOI: 10.3390/pharmaceutics12030248] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/25/2020] [Revised: 03/03/2020] [Accepted: 03/05/2020] [Indexed: 11/20/2022] Open
Abstract
For the efficient and safe production of pharmaceutical tablets, a deep process understanding is of high importance. An essential process step during tableting is the die filling, as it is responsible for a consistent tablet weight and drug content. Furthermore, it affects the results of subsequent process steps, compaction and ejection, and thus critical quality attributes. This study focuses on understanding the influences of process parameters and material properties on die filling on a rotary tablet press. By the systematic variation in process parameters as the turret and paddle speeds as well as the fill and dosing depths, five formulations with differing properties are processed. Analysis of the normalized tablet weight, called filling yield, revealed different limitation mechanisms of the filling process, i.e., incomplete filled dies for certain parameter settings. Kinetic limitations occur due to a short residence time under the feed frame (filling time) caused by high turret speeds, which additionally induce high tablet weight variation coefficients. Characteristic maximum turret speeds at certain paddle speeds can be found to still achieve complete filling. At low turret speeds, densification of the powder inside the dies takes place, induced by two mechanisms: either high paddle speeds or high overfill ratios, or a combination of both. The challenge to fill the dies completely as well as avoid densification is dependent on material properties as the flowability. The mass discharge rate from an orifice was found to be in a linear correlation to the filling results of different formulations below complete filling.
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27
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Hildebrandt C, Gopireddy SR, Scherließ R, Urbanetz NA. A DEM approach to assess the influence of the paddle wheel shape on force feeding during pharmaceutical tableting. ADV POWDER TECHNOL 2020. [DOI: 10.1016/j.apt.2019.11.030] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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29
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Sierra-Vega NO, Romañach RJ, Méndez R. Feed frame: The last processing step before the tablet compaction in pharmaceutical manufacturing. Int J Pharm 2019; 572:118728. [PMID: 31682965 DOI: 10.1016/j.ijpharm.2019.118728] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/23/2019] [Revised: 09/19/2019] [Accepted: 09/21/2019] [Indexed: 10/25/2022]
Abstract
The feed frame is a force-feeding device used in the die filling process. The die filling process is crucial within pharmaceutical manufacturing to guarantee the critical quality attributes of the tablets. In recent years, interest in this unit has increased because it can affect the properties of the powder blend and tablets, and because of the success in real time monitoring of powder blend uniformity potential for Process Analytical Technology as described in this review. The review focuses on the recent advances in understanding the powder flow behavior inside the feed frame and how the residence time distribution of the powder within the feed frame is affected by the operating conditions and design parameters. Furthermore, this review also highlights the effect of the paddle wheel design and feed frame process parameters on the tablet weight, the principal variable for measuring die filling performance.
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Affiliation(s)
- Nobel O Sierra-Vega
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, PR 00681, United States
| | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico at Mayaguez, PR 00681 United States
| | - Rafael Méndez
- Department of Chemical Engineering, University of Puerto Rico at Mayaguez, PR 00681, United States.
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30
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Razavi SM, Scicolone J, Snee RD, Kumar A, Bertels J, Cappuyns P, Van Assche I, Cuitiño AM, Muzzio F. Prediction of tablet weight variability in continuous manufacturing. Int J Pharm 2019; 575:118727. [PMID: 31626923 DOI: 10.1016/j.ijpharm.2019.118727] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/12/2019] [Revised: 09/04/2019] [Accepted: 09/21/2019] [Indexed: 11/29/2022]
Abstract
This paper provides a method for prediction of weight variability of tablets made in rotary tablet presses as a function of material attributes and processing parameters. The goal was to be able to predict whether or not a formulation is suitable for direct compaction continuous manufacturing using the tablet weight variability as a criterion. The work focused on identifying the significant factors affecting the weight variability in tablets, within the design space studied. A wide range of blends with different powder properties were prepared. It was shown that among powder properties, cohesion, bulk density, and particle size were the most significant and sufficient material attributes to explain tablet weight variability. A response surface model was built and validated with three different blends. The model is not formulation dependent and can be expanded to include other blend properties or processing parameters effects.
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Affiliation(s)
- Sonia M Razavi
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA
| | - James Scicolone
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA
| | | | - Ashish Kumar
- Discovery, Product Development & Supply, Janssen, Pharmaceutical Companies of Johnson & Johnson, Beerse, Belgium
| | - Johny Bertels
- Discovery, Product Development & Supply, Janssen, Pharmaceutical Companies of Johnson & Johnson, Beerse, Belgium
| | - Philippe Cappuyns
- Discovery, Product Development & Supply, Janssen, Pharmaceutical Companies of Johnson & Johnson, Beerse, Belgium
| | - Ivo Van Assche
- Discovery, Product Development & Supply, Janssen, Pharmaceutical Companies of Johnson & Johnson, Beerse, Belgium
| | - Alberto M Cuitiño
- Department of Mechanical and Aerospace Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ, USA
| | - Fernando Muzzio
- Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA.
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31
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Li Y, Anderson CA, Drennen JK, Airiau C, Igne B. Development of an In-Line Near-Infrared Method for Blend Content Uniformity Assessment in a Tablet Feed Frame. APPLIED SPECTROSCOPY 2019; 73:1028-1040. [PMID: 30990067 DOI: 10.1177/0003702819842189] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/09/2023]
Abstract
Process analytical technology (PAT) has shown great potential for in-line tableting process monitoring. The study focuses on the development and validation of an in-line near-infrared (NIR) spectroscopic method for the determination of content uniformity of blends in a tablet feed frame. An in-line NIR method was developed after careful evaluation of the impact of potential experimental factors on the robustness and model accuracy and precision. The NIR method was validated according to the principles outlined in International Conference on Harmonization-Q2 for validation of analytical procedures and was demonstrated to be suitable for monitoring blend content for the formulation under evaluation. Reliable measurements of blend homogeneity rely on representative sampling. To reach the appropriate scale of scrutiny for a unit dose, the study assessed factors that influence the effective sample size measured by NIR. Spectral averaging, integration time, and feed frame paddle wheel speed were found to influence the effective sample size measured by the NIR probe. The effective sampling size was also estimated by comparing the distribution of predicted values with the reference values. The development of a robust, in-line PAT method was facilitated by thorough understanding of the sensitivity of PAT sensors to factors affecting pharmaceutical processes and products.
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Affiliation(s)
- Yi Li
- Duquesne University, Graduate School of Pharmaceutical Sciences, Pittsburgh, PA, USA
| | - Carl A Anderson
- Duquesne University, Graduate School of Pharmaceutical Sciences, Pittsburgh, PA, USA
| | - James K Drennen
- Duquesne University, Graduate School of Pharmaceutical Sciences, Pittsburgh, PA, USA
| | - Christian Airiau
- GlaxoSmithKline, Analytical Sciences and Development, Collegeville, PA, USA
| | - Benoît Igne
- GlaxoSmithKline, Analytical Sciences and Development, Collegeville, PA, USA
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32
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Zhao LL, Li YW, Yang XD, Jiao Y, Hou QF. DEM study of size segregation of wet particles under vertical vibration. ADV POWDER TECHNOL 2019. [DOI: 10.1016/j.apt.2019.04.019] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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33
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Tanabe S, Gopireddy SR, Minami H, Ando S, Urbanetz NA, Scherließ R. Influence of particle size and blender size on blending performance of bi-component granular mixing: A DEM and experimental study. Eur J Pharm Sci 2019; 134:205-218. [PMID: 31034985 DOI: 10.1016/j.ejps.2019.04.024] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/18/2018] [Revised: 04/16/2019] [Accepted: 04/25/2019] [Indexed: 10/26/2022]
Abstract
The effect of particle size enlargement and blender geometry down-scaling on the blend uniformity (BU) was evaluated by Discrete Element Method (DEM) to predict the blending performance of a binary granular mixture. Three 10 kg blending experiments differentiated by the physical properties specifically particle size were performed as reference for DEM simulations. The segregation behavior observed during the diffusion blending was common for all blends, while the sample BU, i.e., standard deviation of active ingredient content % was different among the three blends reflecting segregation due to the particle size differences between the components. Quantitative prediction of the sample BU probability density distribution in reality based on the DEM simulation results was successfully demonstrated. The average root mean square error normalized by the mean of the mean sample BU in the blends was 0.228. Beside the ratio of blender container to particle size, total number of particles in the blender and the number of particles in a sample were confirmed critical for the blending performance. These in-silico experiments through DEM simulations would help in setting a design space with respect to the particle size and in a broader sense with respect to the physical properties in general.
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Affiliation(s)
- Shuichi Tanabe
- Pharmaceutical Development, Daiichi Sankyo Europe GmbH, Pfaffenhofen 85276, Germany; Formulation Technology Research Laboratories, Daiichi Sankyo Co., Ltd., Hiratsuka 2540014, Japan; Department of Pharmaceutics and Biopharmaceutics, Kiel University, Grasweg 9a, 24118 Kiel, Germany.
| | - Srikanth R Gopireddy
- Pharmaceutical Development, Daiichi Sankyo Europe GmbH, Pfaffenhofen 85276, Germany
| | - Hidemi Minami
- Formulation Technology Research Laboratories, Daiichi Sankyo Co., Ltd., Hiratsuka 2540014, Japan
| | - Shuichi Ando
- Formulation Technology Research Laboratories, Daiichi Sankyo Co., Ltd., Hiratsuka 2540014, Japan
| | - Nora A Urbanetz
- Pharmaceutical Development, Daiichi Sankyo Europe GmbH, Pfaffenhofen 85276, Germany
| | - Regina Scherließ
- Department of Pharmaceutics and Biopharmaceutics, Kiel University, Grasweg 9a, 24118 Kiel, Germany
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34
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Dülle M, Özcoban H, Leopold C. Influence of the feed frame design on the powder behavior and the residence time distribution. Int J Pharm 2019; 565:523-532. [DOI: 10.1016/j.ijpharm.2019.05.026] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/27/2019] [Revised: 05/08/2019] [Accepted: 05/10/2019] [Indexed: 10/26/2022]
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35
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Dühlmeyer KP, Özcoban H, Leopold CS. Comparison of two paddle wheel geometries within the filling chamber of a rotary tablet press feed frame with regard to the distribution behavior of a model powder and the influence on the resulting tablet mass. Drug Dev Ind Pharm 2019; 45:1233-1241. [DOI: 10.1080/03639045.2019.1576725] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
Affiliation(s)
- Kym Patrick Dühlmeyer
- Division of Pharmaceutical Technology, Department of Chemistry, University of Hamburg, Hamburg, Germany
| | | | - Claudia S. Leopold
- Division of Pharmaceutical Technology, Department of Chemistry, University of Hamburg, Hamburg, Germany
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36
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A Computationally Efficient Surrogate-Based Reduction of a Multiscale Comill Process Model. J Pharm Innov 2019. [DOI: 10.1007/s12247-019-09388-2] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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37
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Investigation of powder flow within a pharmaceutical tablet press force feeder – A DEM approach. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.01.040] [Citation(s) in RCA: 22] [Impact Index Per Article: 4.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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38
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Assessment of material and process attributes' influence on tablet quality using a QbD and DEM combined approach. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.01.015] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
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Sierra-Vega NO, Román-Ospino A, Scicolone J, Muzzio FJ, Romañach RJ, Méndez R. Assessment of blend uniformity in a continuous tablet manufacturing process. Int J Pharm 2019; 560:322-333. [PMID: 30763679 DOI: 10.1016/j.ijpharm.2019.01.073] [Citation(s) in RCA: 45] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/12/2018] [Revised: 01/25/2019] [Accepted: 01/31/2019] [Indexed: 12/20/2022]
Abstract
Blend uniformity was monitored throughout a continuous manufacturing (CM) process by near infrared (NIR) spectroscopic measurements of flowing blends and compared to the drug concentration in the tablets. The NIR spectra were obtained through the chute after the blender and within the feed frame, while transmission spectra were obtained for the tablets. The CM process was performed with semi-fine acetaminophen blends at 10.0% (w/w). The blender was operated at 250 RPM, for best performance, and 106 and 495 rpm where a lower mixing efficiency was expected. The variation in blender RPM increased the variation in drug concentration at the chute but not at the feed frame. Statistical results show that the drug concentration of tablets can be predicted, with great accuracy, from blends within the feed frame. This study demonstrated a mixing effect within the feed frame, which contribute to a 60% decrease in the relative standard deviation of the drug concentration, when compared to the chute. Variographic analysis showed that the minimum sampling and analytical error was five times less in the feed frame than the chute. This study demonstrates that the feed frame is an ideal location for monitoring the drug concentration of powder blends for CM processes.
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Affiliation(s)
- Nobel O Sierra-Vega
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical Engineering, University of Puerto Rico at Mayaguez, PR 00681, United States
| | - Andrés Román-Ospino
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers University, New Jersey, Piscataway 08854, United States
| | - James Scicolone
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers University, New Jersey, Piscataway 08854, United States
| | - Fernando J Muzzio
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical and Biochemical Engineering, Rutgers University, New Jersey, Piscataway 08854, United States
| | - Rodolfo J Romañach
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemistry, University of Puerto Rico at Mayaguez, PR 00681, United States
| | - Rafael Méndez
- Center for Structured Organic Particulate Systems (C-SOPS), Department of Chemical Engineering, University of Puerto Rico at Mayaguez, PR 00681, United States.
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Dülle M, Özcoban H, Leopold C. The effect of different feed frame components on the powder behavior and the residence time distribution with regard to the continuous manufacturing of tablets. Int J Pharm 2019; 555:220-227. [DOI: 10.1016/j.ijpharm.2018.11.017] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/16/2018] [Revised: 10/30/2018] [Accepted: 11/07/2018] [Indexed: 10/27/2022]
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41
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Dülle M, Özcoban H, Leopold C. Analysis of the powder behavior and the residence time distribution within a production scale rotary tablet press. Eur J Pharm Sci 2018; 125:205-214. [DOI: 10.1016/j.ejps.2018.10.008] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/11/2018] [Revised: 09/28/2018] [Accepted: 10/08/2018] [Indexed: 10/28/2022]
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42
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Goh HP, Sia Heng PW, Liew CV. The Effects of Feed Frame Parameters and Turret Speed on Mini-Tablet Compression. J Pharm Sci 2018; 108:1161-1171. [PMID: 30237030 DOI: 10.1016/j.xphs.2018.09.005] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/19/2018] [Revised: 08/22/2018] [Accepted: 09/05/2018] [Indexed: 10/28/2022]
Abstract
Die filling is a critical process step during tablet production as it defines the tablet weight. Achieving die fill consistency during production of mini-tablets, tablets with diameters ≤6 mm, is considerably more challenging. Although die filling in rotary presses had been studied in relation to the feed paddle design, paddle speed, and turret speed, it is unclear how these process variables could impact mini-tablet production and product properties. In this study, 1.8 and 3 mm mini-tablets were prepared using a rotary press with multiple-tip tooling using different process configurations. Mini-tablet weight variation within and across compaction cycles were determined using data from compression roller displacement and mini-tablet weight. Higher die fill densities were achieved with a flat feed wheel paddle and high paddle speed. This was attributed to better granule fluidization in the feed frame, which also increased the intercycle weight variation and reduced tensile strength. The turret speed did not impact mini-tablet properties significantly. Granule overlubrication in the feed frame potentially reduced mini-tablet tensile strength during compaction. The number of paddle passes in the die fill region was correlated to mini-tablet die fill performance. Findings from this study could provide better insights into the relationship between process variables and mini-tablet product quality.
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Affiliation(s)
- Hui Ping Goh
- Department of Pharmacy, GEA-NUS Pharmaceutical Processing Research Laboratory, National University of Singapore, 18 Science Drive 4, Singapore 117543, Singapore
| | - Paul Wan Sia Heng
- Department of Pharmacy, GEA-NUS Pharmaceutical Processing Research Laboratory, National University of Singapore, 18 Science Drive 4, Singapore 117543, Singapore
| | - Celine Valeria Liew
- Department of Pharmacy, GEA-NUS Pharmaceutical Processing Research Laboratory, National University of Singapore, 18 Science Drive 4, Singapore 117543, Singapore.
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43
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Goh HP, Heng PWS, Liew CV. Understanding effects of process parameters and forced feeding on die filling. Eur J Pharm Sci 2018; 122:105-115. [DOI: 10.1016/j.ejps.2018.06.026] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2018] [Revised: 05/30/2018] [Accepted: 06/25/2018] [Indexed: 11/26/2022]
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44
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Dühlmeyer KP, Özcoban H, Leopold CS. A novel method for determination of the filling level in the feed frame of a rotary tablet press. Drug Dev Ind Pharm 2018; 44:1744-1751. [PMID: 29961339 DOI: 10.1080/03639045.2018.1492609] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
Abstract
AIM The aim of this study was to investigate whether the filling level within the feed frame of a rotary tablet press can be quantified by laser triangulation combined with the angle recognition of one paddle wheel via rotary encoder. SIGNIFICANCE Rotary tablet press feed frames are supposed to assure a uniform die filling and, thus, to guarantee the weight and content uniformity of the resulting tablets. Therefore, a constant bulk availability and flow within the feed frame is crucial and has to be ensured by the feed frame design and the operating conditions. So far, there is no instrument available to monitor the bulk filling level or the bulk distribution within feed frames. METHODS Calcium phosphate dihydrate was used as model powder. The powder surface level was determined via laser triangulation and the angle position of the paddle wheel was monitored via incremental rotary encoder. The data of both parameters was acquired synchronously and evaluated by in-house written software. RESULTS Different powder masses led to significantly different filling level signals. The experiments showed a high reproducibility of the determined filling levels. Furthermore, an influence of the rotational speed on the powder distribution was observed. CONCLUSIONS The developed instrument may be used for quantification of the volumetric filling level within rotary tablet press feed frames. It may either be used to better understand the powder behavior within feed frames or for improvement of the die filling process by implementing the device into a feedback loop.
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Affiliation(s)
- K P Dühlmeyer
- a Division of Pharmaceutical Technology, Department of Chemistry , University of Hamburg , Hamburg , Germany
| | - H Özcoban
- b Fette Compacting GmbH , Schwarzenbek , Germany
| | - C S Leopold
- a Division of Pharmaceutical Technology, Department of Chemistry , University of Hamburg , Hamburg , Germany
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Martinetz M, Karttunen AP, Sacher S, Wahl P, Ketolainen J, Khinast J, Korhonen O. RTD-based material tracking in a fully-continuous dry granulation tableting line. Int J Pharm 2018; 547:469-479. [DOI: 10.1016/j.ijpharm.2018.06.011] [Citation(s) in RCA: 36] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2018] [Revised: 05/30/2018] [Accepted: 06/04/2018] [Indexed: 11/28/2022]
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Ketterhagen WR, Mullarney MP, Kresevic J, Blackwood D. Computational approaches to predict the effect of shear during processing of lubricated pharmaceutical blends. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.05.023] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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Investigations on the residence time distribution of a three-chamber feed frame with special focus on its geometric and parametric setups. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.03.019] [Citation(s) in RCA: 21] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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Segregation in the tank of a rotary tablet press machine using experimental and discrete element methods. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.01.054] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
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Simulation of particle size segregation in a pharmaceutical tablet press lab-scale gravity feeder. ADV POWDER TECHNOL 2018. [DOI: 10.1016/j.apt.2017.12.019] [Citation(s) in RCA: 23] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/29/2022]
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Hildebrandt C, Gopireddy SR, Scherließ R, Urbanetz N. Numerical Analysis of the Die Filling Process Within a Pharmaceutical Tableting Machine. CHEM-ING-TECH 2018. [DOI: 10.1002/cite.201700114] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Claudia Hildebrandt
- Kiel University; Department of Pharmaceutics and Biopharmaceutics; Grasweg 9a 24118 Kiel Germany
| | - Srikanth R. Gopireddy
- Daiichi-Sankyo Europe GmbH; Pharmaceutical Development; Luitpoldstraße 1 85276 Pfaffenhofen Germany
| | - Regina Scherließ
- Kiel University; Department of Pharmaceutics and Biopharmaceutics; Grasweg 9a 24118 Kiel Germany
| | - Nora Urbanetz
- Daiichi-Sankyo Europe GmbH; Pharmaceutical Development; Luitpoldstraße 1 85276 Pfaffenhofen Germany
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