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Le Grill S, Drouet C, Marsan O, Coppel Y, Mazel V, Barthelemy MC, Brouillet F. Consolidation of Spray-Dried Amorphous Calcium Phosphate by Ultrafast Compression: Chemical and Structural Overview. NANOMATERIALS (BASEL, SWITZERLAND) 2024; 14:152. [PMID: 38251117 PMCID: PMC10819566 DOI: 10.3390/nano14020152] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/04/2023] [Revised: 01/08/2024] [Accepted: 01/08/2024] [Indexed: 01/23/2024]
Abstract
A large amount of research in orthopedic and maxillofacial domains is dedicated to the development of bioactive 3D scaffolds. This includes the search for highly resorbable compounds, capable of triggering cell activity and favoring bone regeneration. Considering the phosphocalcic nature of bone mineral, these aims can be achieved by the choice of amorphous calcium phosphates (ACPs). Because of their metastable property, these compounds are however to-date seldom used in bulk form. In this work, we used a non-conventional "cold sintering" approach based on ultrafast low-pressure RT compaction to successfully consolidate ACP pellets while preserving their amorphous nature (XRD). Complementary spectroscopic analyses (FTIR, Raman, solid-state NMR) and thermal analyses showed that the starting powder underwent slight physicochemical modifications, with a partial loss of water and local change in the HPO42- ion environment. The creation of an open porous structure, which is especially adapted for non-load bearing bone defects, was also observed. Moreover, the pellets obtained exhibited sufficient mechanical resistance allowing for manipulation, surgical placement and eventual cutting/reshaping in the operation room. Three-dimensional porous scaffolds of cold-sintered reactive ACP, fabricated through this low-energy, ultrafast consolidation process, show promise toward the development of highly bioactive and tailorable biomaterials for bone regeneration, also permitting combinations with various thermosensitive drugs.
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Affiliation(s)
- Sylvain Le Grill
- CIRIMAT, Toulouse INP, Université Toulouse 3 Paul Sabatier, CNRS, Université de Toulouse, 4 Allée Emile Monso, BP44362, CEDEX 4, 31030 Toulouse, France
| | - Christophe Drouet
- CIRIMAT, Toulouse INP, Université Toulouse 3 Paul Sabatier, CNRS, Université de Toulouse, 4 Allée Emile Monso, BP44362, CEDEX 4, 31030 Toulouse, France
| | - Olivier Marsan
- CIRIMAT, Toulouse INP, Université Toulouse 3 Paul Sabatier, CNRS, Université de Toulouse, 4 Allée Emile Monso, BP44362, CEDEX 4, 31030 Toulouse, France
| | - Yannick Coppel
- LCC, UPR 8241 CNRS, Université de Toulouse, 205 Route de Narbonne, CEDEX 4, 31077 Toulouse, France
| | - Vincent Mazel
- Université de Bordeaux, CNRS, Bordeaux INP, I2M, UMR 5295, 33400 Talence, France
- Arts et Metiers Institute of Technology, CNRS, Bordeaux INP, Hesam Universite, I2M, UMR 5295, 33400 Talence, France
| | - Marie-Claire Barthelemy
- CIRIMAT, Toulouse INP, Université Toulouse 3 Paul Sabatier, CNRS, Université de Toulouse, 118 Route de Narbonne, CEDEX 9, 31062 Toulouse, France
| | - Fabien Brouillet
- CIRIMAT, Toulouse INP, Université Toulouse 3 Paul Sabatier, CNRS, Université de Toulouse, 118 Route de Narbonne, CEDEX 9, 31062 Toulouse, France
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Implementing Feedback Granule Size Control in a Continuous Dry Granulation Line Using Controlled Impeller Speed of the Granulation Unit, Compaction Force and Gap Width. J Pharm Innov 2020. [DOI: 10.1007/s12247-020-09524-3] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
Abstract
Abstract
Purpose
In continuous manufacturing of pharmaceuticals, dry granulation is of interest because of its large throughput capacity and energy efficiency. In order to manufacture solid oral dosage forms continuously, valid control strategies for critical quality attributes should be established. To this date, there are no published control strategies for granule size distribution in continuous dry granulation.
Methods
In-line laser diffraction was used to determine the size of granules in a continuous roll compaction/dry granulation line (QbCon® dry). Different process parameters were evaluated regarding their influences on granule size. The identified critical process parameters were then incorporated into control strategies. The uncontrolled and the controlled processes were compared based on the resulting granule size. In both processes, a process parameter was changed to induce a shift in median particle size and the controller had to counteract this shift.
Results
In principle, all process parameters that affect the median particle size could also be used to control the particle size in a dry granulation process. The sieve impeller speed was found to be well suited to control the median particle size as it reacts fast and can be controlled independently of the throughput or material.
Conclusion
The median particle size in continuous roll compaction can be controlled by adjusting process parameters depending on real-time granule size measurements. The method has to be validated and explored further to identify critical requirements to the material and environmental conditions.
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Vanhoorne V, Vervaet C. Recent progress in continuous manufacturing of oral solid dosage forms. Int J Pharm 2020; 579:119194. [PMID: 32135231 DOI: 10.1016/j.ijpharm.2020.119194] [Citation(s) in RCA: 44] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/20/2019] [Revised: 02/28/2020] [Accepted: 02/29/2020] [Indexed: 12/28/2022]
Abstract
Continuous drug product manufacturing is slowly being implemented in the pharmaceutical industry. Although the benefits related to the quality and cost of continuous manufacturing are widely recognized, several challenges hampered the widespread introduction of continuous manufacturing of drug products. Current review presents an overview of state-of-the art research, equipment, process analytical technology implementations and advanced control strategies. Additionally, guidelines and regulatory viewpoints on implementation of continuous manufacturing in the pharmaceutical industry are discussed.
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Affiliation(s)
- V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University.
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Wiedey R, Šibanc R, Wilms A, Kleinebudde P. How relevant is ribbon homogeneity in roll compaction/dry granulation and can it be influenced? Eur J Pharm Biopharm 2018; 133:232-239. [PMID: 30385418 DOI: 10.1016/j.ejpb.2018.10.021] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/16/2018] [Revised: 09/05/2018] [Accepted: 10/28/2018] [Indexed: 11/27/2022]
Abstract
A homogeneous distribution of solid fraction in ribbons is generally assumed to be beneficial during roll compaction/dry granulation. Numerous attempts have been made to increase this homogeneity by modification of the machine, i.e. the roll design and the design of the feeding unit. It has however not been critically tested how relevant this homogeneity really is during subsequent processing. This study investigated two resulting questions: How can process parameters used to increase homogeneity in ribbons and how relevant is this homogeneity for properties of resulting tablets? For that, a statistically designed experiment were performed and ribbon homogeneity analyzed using X-ray micro-computed tomography. Independent from the sealing system used during manufacturing, larger gap widths led to higher homogeneity. The effect of specific compaction force was strongly dependent on the sealing system. When using the cheek plate system, higher specific compaction forces decreased the ribbon homogeneity, while it had no influence when rim rolls were used. In a subsequent study, ribbons of different homogeneity were milled and the resulting granules compressed to tablets. Tablets from homogeneous and inhomogeneous ribbons showed comparable strength and tablet mass variability. Reduced tabletability from highly densified regions of inhomogeneous ribbons was compensated by higher amounts of fines which originate from the more porous regions of ribbons. It was concluded that the relevance of ribbon homogeneity in roll compaction might generally be overestimated.
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Affiliation(s)
- Raphael Wiedey
- Heinrich Heine University, Universitaetsstrasse 1, 40225 Duesseldorf, Germany.
| | - Rok Šibanc
- Heinrich Heine University, Universitaetsstrasse 1, 40225 Duesseldorf, Germany
| | - Annika Wilms
- Heinrich Heine University, Universitaetsstrasse 1, 40225 Duesseldorf, Germany; INVITE GmbH, Otto-Bayer-Straße 32, 51061 Cologne, Germany
| | - Peter Kleinebudde
- Heinrich Heine University, Universitaetsstrasse 1, 40225 Duesseldorf, Germany
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