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Lin Z, Cabello B, Kossor C, Davé R. Facilitating direct compaction tableting of fine cohesive APIs using dry coated fine excipients: Effect of the excipient size and amount of coated silica. Int J Pharm 2024; 660:124359. [PMID: 38901539 DOI: 10.1016/j.ijpharm.2024.124359] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/04/2024] [Revised: 06/06/2024] [Accepted: 06/16/2024] [Indexed: 06/22/2024]
Abstract
The possibility of attaining direct compression (DC) tableting using silica coated fine particle sized excipients was examined for high drug loaded (DL) binary blends of APIs. Three APIs, very-cohesive micronized acetaminophen (mAPAP, 7 μm), cohesive acetaminophen (cAPAP, 23 μm), and easy-flowing ibuprofen (IBU, 53 μm), were selected. High DL (60 wt%) binary blends were prepared with different fine-milled MCC-based excipients (ranging 20- 37 μm) with or without A200 silica coating during milling. The blend flowability (flow function coefficient -FFC) and bulk density (BD) of the blends for all three APIs were significantly improved by 1 wt% A200 dry coated MCCs; reaching FFC of 4.28 from 2.14, 7.82 from 2.96, and > 10 from 5.57, for mAPAP, cAPAP, and IBU blends, respectively, compared to the uncoated MCC blends. No negative impact was observed on the tablet tensile strength (TS) by using dry coated MCCs despite lower surface energy of silica. Instead, the desired tablet TS levels were reached or exceeded, even above that for the blends with uncoated milled MCCs. The novelty here is that milled and silica coated fine MCCs could promote DC tableting for cAPAP and IBU blends at 60 wt% DL through adequate flowability and tensile strength, without having to dry coat the APIs. The effect of the silica amount was investigated, indicating lesser had a positive impact on TS, whereas the higher amount had a positive impact on flowability. Thus, the finer excipient size and silica amounts may be adjusted to potentially attain blend DC processability for high DL blends of fine APIs.
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Affiliation(s)
- Zhixing Lin
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA
| | - Bian Cabello
- 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 Davé
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ 07102, USA.
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Friebel JM, Ditscherlein R, Ditscherlein L, Peuker UA. Three-Dimensional Characterization of Dry Particle Coating Structures Originating from the Mechano-fusion Process. MICROSCOPY AND MICROANALYSIS : THE OFFICIAL JOURNAL OF MICROSCOPY SOCIETY OF AMERICA, MICROBEAM ANALYSIS SOCIETY, MICROSCOPICAL SOCIETY OF CANADA 2024; 30:179-191. [PMID: 38457218 DOI: 10.1093/mam/ozae009] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/10/2023] [Revised: 01/09/2023] [Accepted: 02/04/2024] [Indexed: 03/09/2024]
Abstract
Dry particle coating processes are of key importance for creating functionalized materials. By a change in surface structure, initiated during coating, a surface property change and thus functionalization can be achieved. This study introduces an innovative approach employing 3D X-ray micro-computed tomography (micro-CT) to characterize coated particles, consisting of spherical alumina particles (d50 = 45.64 μm), called hosts, surrounded by spherical polystyrene particles (d50 = 3.5 μm), called guests. The formed structures, hetero-aggregates, are generated by dry particle coating using mechano-fusion (MF). A deeper understanding of the influence of MF process parameters on the coating structures is a crucial step toward tailoring of coating structure, resulting surface property and functionalization. Therefore, the influence of rotational speed, process time, and total mechanical energy input during MF is explored. Leveraging micro-CT data, acquired of coated particles, enables non-stereologically biased and quantitative coating structure analysis. The guest's coating thickness is analyzed using the maximum inscribed sphere and ray method, two different local thickness measurement approaches. Particle-discrete information of the coating structure are available after a proper image processing workflow is implemented. Coating efficiency and guest's neighboring relations (nearest neighbor distance and number of neighbors inside search radius) are evaluated.
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Affiliation(s)
- Judith M Friebel
- Institute of Mechanical Process Engineering and Mineral Processing, Technische Universität Bergakademie Freiberg, Agricolastraße 1, Freiberg 09599, Germany
| | - Ralf Ditscherlein
- Institute of Mechanical Process Engineering and Mineral Processing, Technische Universität Bergakademie Freiberg, Agricolastraße 1, Freiberg 09599, Germany
| | - Lisa Ditscherlein
- Institute of Mechanical Process Engineering and Mineral Processing, Technische Universität Bergakademie Freiberg, Agricolastraße 1, Freiberg 09599, Germany
| | - Urs A Peuker
- Institute of Mechanical Process Engineering and Mineral Processing, Technische Universität Bergakademie Freiberg, Agricolastraße 1, Freiberg 09599, Germany
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Tiwari A, Bose M. DEM simulation of dumbbell shaped particles under vertical vibration. PARTICULATE SCIENCE AND TECHNOLOGY 2023. [DOI: 10.1080/02726351.2023.2164877] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/27/2023]
Affiliation(s)
- Alok Tiwari
- Department of Energy Science and Engineering, Indian Institute of Technology Bombay, Mumbai, India
| | - Manaswita Bose
- Department of Energy Science and Engineering, Indian Institute of Technology Bombay, Mumbai, India
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Fan G, Liu Q, Kondo A, Naito M, Kushimoto K, Kano J, Tan Z, Li Z. Self-assembly of nanoparticles and flake powders by flake design strategy via dry particle coating. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118294] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/30/2023]
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Kim SS, Castillo C, Sayedahmed M, Davé RN. Reduced Fine API Agglomeration After Dry Coating for Enhanced Blend Uniformity and Processability of Low Drug Loaded Blends. Pharm Res 2022; 39:3155-3174. [PMID: 35882741 DOI: 10.1007/s11095-022-03343-6] [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: 02/12/2022] [Accepted: 07/13/2022] [Indexed: 12/27/2022]
Abstract
PURPOSE The impact of dry coating on reduced API agglomeration remains underexplored. Therefore, this work quantified fine cohesive API agglomeration reduction through dry coating and its impact on enhanced blend uniformity and processability, i.e., flowability and bulk density of multi-component blends API loading as low as 1 wt%. METHODS The impact of dry coating with two different types and amounts of silica was assessed on cohesion, agglomeration, flowability, bulk density, wettability, and surface energy of fine milled ibuprofen (~ 10 µm). API agglomeration, measured using Gradis/QicPic employing gentler gravity-based dispersion, resulted in excellent size resolution. Multi-component blends with fine-sized excipients, selected for reduced segregation potential, were tested for bulk density, cohesion, flowability, and blend content uniformity. Tablets formed using these blends were tested for tensile strength and dissolution. RESULT All dry coated ibuprofen powders exhibited dramatic agglomeration reduction, corroborated by corresponding decreased cohesion, unconfined yield strength, and improved flowability, regardless of the type and amount of silica coating. Their blends exhibited profound enhancement in flowability and bulk density even at low API loadings, as well as the content uniformity for the lowest drug loading. Moreover, hydrophobic silica coating improved drug dissolution rate without appreciably reducing tablet tensile strength. CONCLUSION The dry coating based reduced agglomeration of fine APIs for all three low drug loadings improved overall blend properties (uniformity, flowability, API release rate) due to the synergistic impact of a minute amount of silica (0.007 wt %), potentially enabling direct compression tableting and aiding manufacturing of other forms of solid dosing.
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Affiliation(s)
- Sangah S Kim
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ, 07102, USA
| | - Chelsea Castillo
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, NJ, 07102, USA
| | - Muhammad Sayedahmed
- 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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Kim S, Cheikhali M, Davé RN. Decoding Fine API Agglomeration as a Key Indicator of Powder Flowability and Dissolution: Impact of Particle Engineering. Pharm Res 2022; 39:3079-3098. [PMID: 35698012 DOI: 10.1007/s11095-022-03293-z] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/28/2022] [Accepted: 05/11/2022] [Indexed: 12/27/2022]
Abstract
PURPOSE Fine API agglomeration and its mitigation via particle engineering, i.e., dry coating, remains underexplored. The purpose was to investigate agglomeration before and after dry coating of fine cohesive APIs and impact on powder processability, i.e., flowability (FFC), bulk density (BD), and dissolution of BCS Class II drugs. METHOD Ibuprofen (three sizes), fenofibrate, and griseofulvin (5-20 µm), before and after dry coating with varying amounts of hydrophobic (R972P) or hydrophilic (A200) nano- silica, were assessed for agglomeration, FFC, BD, surface energy, wettability, and dissolution. The granular Bond number (Bog), a dimensionless parameter, evaluated through material-sparing particle-scale measures and particle-contact models, was used to express relative powder cohesion. RESULTS Significant powder processability improvements after dry coating were observed: FFC increased by multiple flow regimes, BD increased by 25-100%, agglomerate ratio (AR) reduction by over an order of magnitude, and greatly enhanced API dissolution rate even with hydrophobic (R972P) silica coating. Scrutiny of particle-contact models revealed non-triviality in estimating API surface roughness, which was managed through the assessment of measured bulk properties. A power-law correlation was identified between AR and Bog and subsequently, between AR and FFC & bulk density; AR below 5 ensured improved processability and dissolution. CONCLUSION Agglomeration, an overlooked material-sparing measure for powder cohesiveness, was a key indicator of powder processability and dissolution. The significant agglomerate reduction was possible via dry coating with either silica type at adequate surface area coverage. Reduced agglomeration after dry coating also countered the adverse impact of increased surface hydrophobicity on dissolution.
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Affiliation(s)
- Sangah Kim
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, New Jersey, 07102, USA
| | - Mirna Cheikhali
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, New Jersey, 07102, USA
| | - Rajesh N Davé
- New Jersey Center for Engineered Particulates, New Jersey Institute of Technology, Newark, New Jersey, 07102, USA.
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Davé R, Kim S, Kunnath K, Tripathi S. A concise treatise on model-based enhancements of cohesive powder properties via dry particle coating. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103836] [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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Maharjan R, Jeong SH. Application of different models to evaluate the key factors of fluidized bed layering granulation and their influence on granule characteristics. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117737] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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A Continuous Conical-Mill Operation for Dry Coating of Pharmaceutical Powders: The Role of Processing Time. Processes (Basel) 2022. [DOI: 10.3390/pr10030540] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/25/2023] Open
Abstract
Over the last decade, the conical mill has emerged as a potential piece of equipment to use for continuous dry coating pharmaceutical powders. In this work, silicon dioxide was used as a guest particle on two excipients, fast flow lactose (FFL) and grade PH200 microcrystalline cellulose (MCC), for dry coating by a conical mill with a modified screen that permitted batch and continuous mode operation. Samples were pre-processed in a V-blender. SEM images, particle size distribution, and EDS mapping were used to characterise the treated powders. Pre-processed samples showed some discrete coating of the host particle. After batch processing, the samples were covered with a complete coating. When processed at high impeller speed, coating of FFL was a mix of A200P and FFL fines generated by attrition. Continuous mode processed samples, which had a lower processing time, were coated discretely and showed a better coating than the pre-processed samples. Increasing guest/host mass ratio with FFL host particle had a positive impact on the quality of the coating. These results help to build the case that the processing time of the conical mill is a key parameter to the success of the conical mill as dry coating equipment in the pharmaceutical industry.
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Jagadeeswari V, Sahoo A. An overview on dry powder coating in advancement to electrostatic dry powder coating used in pharmaceutical industry. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117214] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
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Design-of-experiment approach to quantify the effect of nano-sized silica on tableting properties of microcrystalline cellulose to facilitate direct compression tableting of binary blend containing a low-dose drug. J Drug Deliv Sci Technol 2022. [DOI: 10.1016/j.jddst.2022.103127] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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Zheng K, Kunnath K, Davé RN. DEM
Simulation of Binary Blend Mixing of Cohesive Particles in a High Intensity Vibration System. AIChE J 2022. [DOI: 10.1002/aic.17603] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Kai Zheng
- Chemical and Materials Engineering Department New Jersey Institute of Technology Newark New Jersey USA
| | - Kuriakose Kunnath
- Chemical and Materials Engineering Department New Jersey Institute of Technology Newark New Jersey USA
| | - Rajesh N. Davé
- Chemical and Materials Engineering Department New Jersey Institute of Technology Newark New Jersey USA
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Tanaka R, Osotprasit S, Peerapattana J, Ashizawa K, Hattori Y, Otsuka M. Complete Cocrystal Formation during Resonant Acoustic Wet Granulation: Effect of Granulation Liquids. Pharmaceutics 2021; 13:pharmaceutics13010056. [PMID: 33406659 PMCID: PMC7823328 DOI: 10.3390/pharmaceutics13010056] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/08/2020] [Revised: 12/23/2020] [Accepted: 12/29/2020] [Indexed: 11/30/2022] Open
Abstract
The manufacturing of solid pharmaceutical dosage forms composed of cocrystals requires numerous processes during which there is risk of dissociation into parent molecules. Resonant acoustic wet granulation (RAG) was devised in an effort to complete theophylline–citric acid (THPCIT) cocrystal formation during the granulation process, thereby reducing the number of operations. In addition, the influence of granulation liquid was investigated. A mixture of anhydrous THP (drug), anhydrous CIT (coformer), and hydroxypropyl cellulose (granulating agent) was processed by RAG with water or ethanol as a granulation liquid. The purposes were to (i) form granules using RAG as a breakthrough method; (ii) accomplish the cocrystallization during the integrated unit operation; and (iii) characterize the final solid product (i.e., tablet). The RAG procedure achieved complete cocrystal formation (>99%) and adequately sized granules (d50: >250 μm). The granulation using water (GW) facilitated formation of cocrystal hydrate which were then transformed into anhydrous cocrystal after drying, while the granulation using ethanol (GE) resulted in the formation of anhydrous cocrystal before and after drying. The dissolution of the highly dense GW tablet, which was compressed from granules including fine powder due to the dehydration, was slower than that of the GE tablet.
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Affiliation(s)
- Ryoma Tanaka
- Graduate School of Pharmaceutical Sciences, Musashino University, 1-1-20 Shin-machi, Nishi-Tokyo, Tokyo 202-8585, Japan; (R.T.); (Y.H.)
| | - Supisara Osotprasit
- Center for Research and Development of Herbal Health Products, Faculty of Pharmaceutical Sciences, Khon Kaen University, Khon Kaen 40002, Thailand; (S.O.); (J.P.)
| | - Jomjai Peerapattana
- Center for Research and Development of Herbal Health Products, Faculty of Pharmaceutical Sciences, Khon Kaen University, Khon Kaen 40002, Thailand; (S.O.); (J.P.)
| | - Kazuhide Ashizawa
- Research Institute of Pharmaceutical Sciences, Musashino University, 1-1-20 Shin-machi, Nishi-Tokyo, Tokyo 202-8585, Japan;
| | - Yusuke Hattori
- Graduate School of Pharmaceutical Sciences, Musashino University, 1-1-20 Shin-machi, Nishi-Tokyo, Tokyo 202-8585, Japan; (R.T.); (Y.H.)
- Research Institute of Pharmaceutical Sciences, Musashino University, 1-1-20 Shin-machi, Nishi-Tokyo, Tokyo 202-8585, Japan;
| | - Makoto Otsuka
- Graduate School of Pharmaceutical Sciences, Musashino University, 1-1-20 Shin-machi, Nishi-Tokyo, Tokyo 202-8585, Japan; (R.T.); (Y.H.)
- Research Institute of Pharmaceutical Sciences, Musashino University, 1-1-20 Shin-machi, Nishi-Tokyo, Tokyo 202-8585, Japan;
- Correspondence: ; Tel./Fax: +81-42-468-8658
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Moisture barrier films for herbal medicines fabricated by electrostatic dry coating with ultrafine powders. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.03.023] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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