Comparative impact of different binder addition methods, binders and diluents on resulting granule and tablet attributes via high shear wet granulation

The effect of polymeric binder type and concentration on flow and dissolution properties of SMEDDS loaded mesoporous silica-based granules

Self-microemulsifying drug delivery systems (SMEDDS) are lipid-based formulations, designed to improve the solubility of poorly-water soluble drugs. Mesoporous silica is frequently used for SMEDDS solidification by various techniques. One of them is wet granulation, which enables achieving both high SMEDDS load and good flow properties. This study investigated the effect of six polymeric binders' addition to granulation dispersion (GD) (povidone K30, povidone K90, copovidone, Pharmacoat® 603, Pharmacoat® 615 and Methocel™ K100 Premium LV) on characteristics of produced SMEDDS granules, prepared by wet granulation. By incorporation of polymer in GD, it was possible to produce mesoporous silica-based free-flowing granules, with preserved self-microemulsifying properties, responsible for improved in vitro release of carvedilol. The incorporation of higher molecular weight binders resulted in slower in vitro release, while high binder concentration was related to faster drug release. The highest release rate was achieved with povidone K30 at 7.45 % binder concentration, as corresponding granules exhibited complete drug release already in 5 min. Granulation method (manual vs. high-shear) influenced the release rate of carvedilol as it was released slower from SMEDDS granules prepared using the granulator. Finally, SMEDDS tablet formulation was optimized to achieve maximum granule content and adequate tablet hardness. Increased granule content found to negatively influence tablet hardness, as maximum granule content of 25 % was needed to obtain appropriate hardness. Such tablets exhibited short disintegration time, so this final prototype can be considered as orodispersible tablet.

Attribute transmission and effects of diluents and granulation liquids on granule properties and tablet quality for high shear wet granulation and tableting process

This study aims to examine (i) the effect of diluent types (lactose monohydrate, corn starch, and microcrystalline cellulose) and granulation liquids (20% polyvinylpyrrolidone-k30, 65% alcohol, and dispersion containing 40% model drug- Pithecellobium clypearia Benth extracted powder) on granule properties and tablet quality for high shear wet granulation and tableting (HSWG-T) and, more importantly, (ii) the attribute transmission in the process. In general, the impact of diluents on granule properties and tablet quality was more dominant than that of granulation liquids. Attribute transmission patterns were revealed as follows. The granules' ISO. Roundness and density correlated with raw material (i.e., model drug, diluent, and/or granulation liquid) properties such as density and viscosity. The granules' compressibility parameter a correlated with the granules' Span, and parameter y₀ correlated with the granules' flowability and friability. Compactibility parameters k_a and k_b correlated mainly with granule flowability and density, and parameter b correlated significantly and positively with tablet tensile strength. The compressibility correlated negatively with tablet solid fraction (SF) and friability, while the compactibility correlated positively with tablet disintegration time. Moreover, the rearrangement and elasticity of granules correlated positively with SF and friability, respectively. Overall, this study provides some guides for achieving high-quality tablets via HSWG-T.

Effect of Various Binders on the Properties of Microalgae-Enriched Urea Granules

As the human population grows and the demand for food grows with it, the recycling, or containment of materials is important for resource consumption. Nitrogen is one of the main plant nutrients, most commonly used as the chemical substance urea. Because urea is very soluble and at a relatively low temperature (50-60 °C) it hydrolyses easily (releases N₂ and CO₂) in soil solutions; this is why very large amounts of nitrogen are lost and greenhouse gases are released and this causes serious environmental problems. Therefore, the aim of this study was to create microalgae-enriched nitrogen fertilizers with different binders that inhibit nitrogen leaching from the soil. Binders such as water (W), polyvinyl acetate dispersion (PVAD), molasses (M), potato starch (S), and carboxymethyl cellulose (CMC) were used in this study and their influence on leaching was analysed. Granular fertilizers were produced in a drum granulator and dryer under equal conditions: granulation time was 7 min, granulation took place at a temperature of 50-60 °C, at a drum rotation speed of 26 rpm, with a 5° inclination angle of the drum. The results show that the highest quantity of the marketable fraction was 43.01 (±3.068%) and it was obtained using urea, with 10% (w/w) microalgae additive, and 11.4% (w/w) of 5% concentration molasses solution. The granules of the fertilizer marketable fraction are similar in size because the size guide number (SGN) of the granules vary in a narrow range and fall within the interval of 287 to 304; this means that the average particle size is ~3 mm. When different binders were used, the average static crushing strength of the granulated fertilizers was lower (approximately 6-12 MPa) than using water alone (approximately 12-16 MPa), but the lower values still fell into the required range. Additives of PVAD solutions and molasses solutions have been found to retain nitrogen in sand. The method of one-way analysis of variance (ANOVA) was used to evaluate the results.

Surface Modifiers on Composite Particles for Direct Compaction

Direct compaction (DC) is considered to be the most effective method of tablet production. However, only a small number of the active pharmaceutical ingredients (APIs) can be successfully manufactured into tablets using DC since most APIs lack adequate functional properties to meet DC requirements. The use of suitable modifiers and appropriate co-processing technologies can provide a promising approach for the preparation of composite particles with high functional properties. The purpose of this review is to provide an overview and classification of different modifiers and their multiple combinations that may improve API tableting properties or prepare composite excipients with appropriate co-processed technology, as well as discuss the corresponding modification mechanism. Moreover, it provides solutions for selecting appropriate modifiers and co-processing technologies to prepare composite particles with improved properties.

Formulation and Quality Control of Orally Disintegrating Tablets (ODTs): Recent Advances and Perspectives

Orally disintegrating tablets (ODTs) rapidly disintegrate or dissolve in the oral cavity without using water. Demand for ODTs has increased, and the field has overgrown in the pharmaceutical industry and academia. It is reported that ODTs have several advantages over other conventional tablets. Since some of them are absorbed from the mouth, pharynx, and esophagus as the saliva passes down into the stomach, in such cases, the bioavailability of the drug improves meaningfully. Furthermore, the immediate release property of ODTs makes them a popular oral dosage form in patients with swallowing challenges, children, and for cases with a need for rapid onset of action. The current review article explains the features of active ingredients and excipients used in the formulation of ODTs, discusses multiple ODT formulation and preparation techniques with their merits and demerits, and also, offers remedies for problems associated with ODTs. Moreover, quality control steps and required considerations are presented.

Blend Segregation in Tablets Manufacturing and Its Effect on Drug Content Uniformity-A Review

Content uniformity (CU) of the active pharmaceutical ingredient is a critical quality attribute of tablets as a dosage form, ensuring reproducible drug potency. Failure to meet the accepted uniformity in the final product may be caused either by suboptimal mixing and insufficient initial blend homogeneity, or may result from further particle segregation during storage, transfer or the compression process itself. This review presents the most relevant powder segregation mechanisms in tablet manufacturing and summarizes the currently available, up-to-date research on segregation and uniformity loss at the various stages of production process—the blend transfer from the bulk container to the tablet press, filling and discharge from the feeding hopper, as well as die filling. Formulation and processing factors affecting the occurrence of segregation and tablets’ CU are reviewed and recommendations for minimizing the risk of content uniformity failure in tablets are considered herein, including the perspective of continuous manufacturing.

Systematic Study of the Effects of High Shear Granulation Parameters on Process Yield, Granule Size, and Shape by Dynamic Image Analysis

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.

Effect of Various Types of Sugar Binder on the Physical Properties of Gum Powders Prepared via Fluidized-Bed Agglomeration

Particle agglomeration of fine gum powders to improve their physical and morphological characteristics is of crucial importance. Changes in the physical properties of guar gum, locust bean gum, and carboxymethyl cellulose powders subjected to fluidized-bed agglomeration with various sugar types as the binder were examined. The agglomerates with sugar binders had much larger particles (D₅₀) and higher porosity (ε) than the corresponding fine gum powders, as confirmed by particle-size-distribution analysis and scanning electron microscopy. In particular, the carboxymethyl cellulose agglomerate exhibited much higher D₅₀ and ε values than the original fine gum powder, with sorbitol as the binder resulting in the highest D₅₀ and ε values. Except for guar gum with sorbitol as the binder, the guar gum and locust bean gum agglomerates with the other sugar binders showed lower Carr index and Hausner ratio values (thus exhibiting better flowability and lower cohesiveness) than the original powders, whereas those of the carboxymethyl cellulose agglomerates were higher. These findings indicate that the physical and structural properties of gum powders can be greatly improved according to the type of gum and sugar solution used in the agglomeration process.

Activity of Povidone in Recent Biomedical Applications with Emphasis on Micro- and Nano Drug Delivery Systems

Due to the unwanted toxic properties of some drugs, new efficient methods of protection of the organisms against that toxicity are required. New materials are synthesized to effectively disseminate the active substance without affecting the healthy cells. Thus far, a number of polymers have been applied to build novel drug delivery systems. One of interesting polymers for this purpose is povidone, pVP. Contrary to other polymeric materials, the synthesis of povidone nanoparticles can take place under various condition, due to good solubility of this polymer in several organic and inorganic solvents. Moreover, povidone is known as nontoxic, non-carcinogenic, and temperature-insensitive substance. Its flexible design and the presence of various functional groups allow connection with the hydrophobic and hydrophilic drugs. It is worth noting, that pVP is regarded as an ecofriendly substance. Despite wide application of pVP in medicine, it was not often selected for the production of drug carriers. This review article is focused on recent reports on the role povidone can play in micro- and nano drug delivery systems. Advantages and possible threats resulting from the use of povidone are indicated. Moreover, popular biomedical aspects are discussed.

A Semi-Mechanistic Prediction of Residence Time Metrics in Twin Screw Granulation

This work is concerned with the semi-mechanistic prediction of residence time metrics using historical data from mono-component twin screw wet granulation processes. From the data, several key parameters such as powder throughput rate, shafts rotation speed, liquid binder feed ratio, number of kneading elements in the shafts and the stagger angle between the kneading elements were identified and physical factors were developed to translate those varying parameters into expressions affecting the key intermediate phenomena in the equipment, holdup, flow and mixing. The developed relations were then tested across datasets to evaluate the performance of the model, applying a k-fold optimization technique. The semi-mechanistic predictions were evaluated both qualitatively through the main effects plots and quantitatively through the parity plots and correlations between the tuning constants across datasets. The root mean square error (RMSE) was used as a metric to compare the degree of goodness of fit for different datasets using the developed semi-mechanistic relations. In summary this paper presents a new approach at estimating both the residence time metrics in twin screw wet granulation, mean residence time (MRT) and variance through semi-mechanistic relations, the validity of which have been tested for different datasets.

Evaluation of Binders in Twin-Screw Wet Granulation

The binders povidone (Kollidon 30), copovidone (Kollidon VA64), hypromellose (Pharmacoat 606), and three types of hyprolose (HPC SSL‑SFP, HPC SSL, and HPC SL‑FP) were evaluated regarding their suitability in twin-screw wet granulation. Six mixtures of lactose and binder as well as lactose without binder were twin-screw granulated with demineralized water at different barrel fill levels and subsequently tableted. A screening run with HPC SSL determined the amount of water as an influential parameter for oversized agglomerates. Subsequent examination of different binders, especially Kollidon 30 and Kollidon VA64 resulted in large granules. All binders, except Pharmacoat 606, led to a reduction of fines compared to granulation without a binder. The molecular weight of applied hyproloses did not appear as influential. Tableting required an upstream sieving step to remove overlarge granules. Tableting was possible for all formulations at sufficient compression pressure. Most binders resulted in comparable tensile strengths, while Pharmacoat 606 led to lower and lactose without a binder to the lowest tensile strength. Tablets without a binder disintegrated easily, whereas binder containing tablets of sufficient tensile strength often nearly failed or failed the disintegration test. Especially tablets containing Pharmacoat 606 and HPC SL‑FP disintegrated too slowly.

Multifunctional Role of Polyvinylpyrrolidone in Pharmaceutical Formulations

Polyvinylpyrrolidone (PVP), a non-ionic polymer, has been employed in multifarious fields such as paper, fibers and textiles, ceramics, and pharmaceutics due to its superior properties. Especially in pharmacy, the properties of inertness, non-toxicity, and biocompatibility make it a versatile excipient for both conventional formulations and novel controlled or targeted delivery systems, serving as a binder, coating agent, suspending agent, pore-former, solubilizer, stabilizer, etc. PVP with different molecular weights (MWs) and concentrations is used in a variety of formulations for different purposes. In this review, PVP-related researches mainly in recent 10 years were collected, and its main pharmaceutical applications were summarized as follows: (i) improving the bioavailability and stability of drugs, (ii) improving the physicomechanical properties of preparations, (iii) adjusting the release rate of drugs, and (iv) prolonging the in vivo circulation time of liposomes. Most of these applications could be explained by the viscosity, solubility, hydrophilicity, and hydrogen bond-forming ability of PVP, and the specific action mechanisms for each application were also tried to figure out. The effect of PVP on bioavailability improvement establishes it as a promising polymer in the emerging controlled or targeted formulations, attracting growing interest on it. Therefore, given its irreplaceability and tremendous opportunities for future developments, this review aims to provide an informative reference about current roles of PVP in pharmacy for interested readers.

Tablet Scoring: Current Practice, Fundamentals, and Knowledge Gaps

Oral solid dosage formulations and/or tablets have remained the preferred route of administration by both patients and health care practitioners. Oral tablets are easy to administer, they are non-invasive and cause less risk adversity. Because of the lack of commercially available tablet dose options, tablets are being split or partitioned by users. Tablet scoring refers to the breakage of a tablet to attain a desired efficacy dose and is an emerging concept in the pharmaceutical industry. The primary reason for the tablet scoring practice is to adjust the dose: dose tapering or dose titrating. Other reasons for tablet partitioning are to facilitate dose administration, particularly among the pediatric and the geriatric patient population, and to mitigating the high cost of prescription drugs. The scope of this review is to: (1) evaluate the advantages and inconveniences associated with tablet scoring/portioning, and (2) identify factors in the formulation and the manufacturing of tablets that influence tablet splitting. Whereas tablet partitioning has been a common practice, there is a lack of understanding regarding the fundamentals underpinning the performance of tablets with respect to splitting. Several factors can influence tablet partitioning: tablet size, shape, and thickness. A requirement has recently been set by the European Pharmacopoeia and the U.S. Food and Drug Administration for the uniformity of mass of subdivided tablets. For breaking ease, an in-vivo reference test and a routinely applicable in-vitro test need to be established.

The Effects of Fillers and Binders on the Accuracy of Tablet Subdivision

The effects of excipients on the accuracy of tablet subdivision are severely underinvestigated. In this study, placebo tablets were prepared using a combined mixture design of fillers and binders to evaluate the effect of these excipients on subdivision accuracy. The responses assessed were mass loss, mass variation, tablet fragmentation, and increased friability. Dicalcium phosphate dihydrate (DCP) gave rise to more uniform and denser tablets than microcrystalline cellulose (MCC), thus resulting in greater subdivision accuracy. The binder type, hydroxypropylcellulose (HPC) or polyvinylpyrrolidone (PVP), did not affect the subdivision of DCP tablets. On the contrary, the structural similarity between HPC and MCC led to improved subdivision accuracy for MCC tablets. A less accurate subdivision was observed in tablets prepared with a DCP-MCC combination; this finding could be attributed to irregular binder distribution in this matrix. An optimized response was built using desirability analysis. This study helps to illuminate the relationship between fillers and binders to guide formulation scientists in the development of tablets with better subdivision performance.

Mixing of low-dose cohesive drug and overcoming of pre-blending step using a new gentle-wing high-shear mixer granulator

The objective of this study was to examine the influence of drug amount and mixing time on the homogeneity and content uniformity of a low-dose drug formulation during the dry mixing step using a new gentle-wing high-shear mixer. Moreover, the study investigated the influence of drug incorporation mode on the content uniformity of tablets manufactured by different methods. Albuterol sulfate was selected as a model drug and was blended with the other excipients at two different levels, 1% w/w and 5% w/w at impeller speed of 300 rpm and chopper speed of 3000 rpm for 30 min. Utilizing a 1 ml unit side-sampling thief probe, triplicate samples were taken from nine different positions in the mixer bowl at selected time points. Two methods were used for manufacturing of tablets, direct compression and wet granulation. The produced tablets were sampled at the beginning, middle, and end of the compression cycle. An analysis of variance analysis indicated the significant effect (p < .05) of drug amount on the content uniformity of the powder blend and the corresponding tablets. For 1% w/w and 5% w/w formulations, incorporation of the drug in the granulating fluid provided tablets with excellent content uniformity and very low relative standard deviation (∼0.61%) during the whole tableting cycle compared to direct compression and granulation method with dry incorporation mode of the drug. Overall, gentle-wing mixer is a good candidate for mixing of low-dose cohesive drug and provides tablets with acceptable content uniformity with no need for pre-blending step.

Particle agglomeration of chitosan-magnesium aluminum silicate nanocomposites for direct compression tablets

Exfoliated nanocomposites of chitosan-magnesium aluminum silicate (CS-MAS) particles are characterized by good compressibility but poor flowability. Thus, the aims of this study were to investigate agglomerates of CS-MAS nanocomposites prepared using the agglomerating agents water, ethanol, or polyvinylpyrrolidone (PVP) for flowability enhancement and to evaluate the agglomerates obtained as direct compression fillers for tablets. The results showed that the addition of agglomerating agents did not affect crystallinity, but slightly influenced thermal behavior of the CS-MAS nanocomposites. The agglomerates prepared using water were larger than those prepared using 95% ethanol because high swelling of the layer of chitosonium acetate occurred, allowing formation of solid bridges and capillary force between particles, leading to higher flowability and particle strength. Incorporation of PVP resulted in larger agglomerates with good flowability and high strength due to the binder hardening mechanism. The tablets prepared from agglomerates using water showed lower hardness, shorter disintegration times and faster drug release than those using 95% ethanol. In contrast, greater hardness and more prolonged drug release were obtained from the tablets prepared from agglomerates using PVP. Additionally, the agglomerates of CS-MAS nanocomposites showed good carrying capacity and provided desirable characteristics of direct compression tablets.

Production of Cornstarch Granules Enriched with Quercetin Liposomes by Aggregation of Particulate Binary Mixtures Using High Shear Process

Liposomes are colloidal structures capable of encapsulating, protecting, and releasing hydrophobic bioctives, as flavonoids. Quercetin is a flavonoid with high antioxidant activity that provides benefits to health. The wet-agglomeration processes in high-shear equipment are useful to produce granules from binary mixtures, obtaining a powder with homogeneous composition and without segregation or elutriation of fine particles. In this study, the binary mixtures containing microparticles of native cornstarch and nanoparticles of quercetin liposomes were aggregated in high-shear batches, using maltodextrin solution as binder agent. The cornstarch was enriched by agglomeration with 8%, 22%, and 30% (w/w) of quercetin-loaded lyophilized liposomes and the physical properties were evaluated. The moisture of all formulations showed similar values ranging from 4.42% to 4.57%. The values of hygroscopicity (g adsorbed water/100 g of dry matter) indicated the lyophilized liposomes were able to decrease the capacity of the agglomerated cornstarch to absorb water, decreasing the possibility of microbiological contamination. The addition of quercetin-loaded lyophilized liposomes improved the flowability and turned the powder (agglomerated cornstarch) less cohesive. The pasting properties of enriched agglomerated cornstarch decreased the pasting temperature about 10 °C, and the cornstarch agglomerated with 8% (w/w) of quercetin-loaded lyophilized liposomes showed no significance difference in the peak viscosity. Agglomeration of cornstarch with more than 8% (w/w) lyophilized liposomes decreased the tendency of starch to retrograde, which is very interesting for food products which requires low levels of retrogradation of granules for their stability.

PRACTICAL APPLICATION

This study is an unprecedent association of 2 technologies, nanoencapsulation and wet agglomeration, here used together to enrich cornstarch with quercetin. The agglomeration process was used to obtain granules of cornstarch, an ingredient extremely used in the food industry, enriched with quercetin-loaded lyophilized liposomes. The goals were both the improvement of the nutritional quality and the increase of the added value of the cornstarch.