1
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Benque B, Orefice L, Forgber T, Habeler M, Schmid B, Remmelgas J, Khinast J. Improvement of a pharmaceutical powder mixing process in a tote blender via DEM simulations. Int J Pharm 2024; 658:124224. [PMID: 38740105 DOI: 10.1016/j.ijpharm.2024.124224] [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: 03/05/2024] [Revised: 04/30/2024] [Accepted: 05/10/2024] [Indexed: 05/16/2024]
Abstract
An industrial-scale pharmaceutical powder blending process was studied via discrete element method (DEM) simulations. A DEM model of two active pharmaceutical ingredient (API) components and a combined excipient component was calibrated by matching the simulated response in a dynamic angle of repose tester to the experimentally observed response. A simulation of the 25-minute bin blending process predicted inhomogeneous API distributions along the rotation axis of the blending container. These concentration differences were confirmed experimentally in a production-scale mixing trial using high-performance liquid chromatography analysis of samples from various locations in the bin. Several strategies to improve the blend homogeneity were then studied using DEM simulations. Reversing the direction of rotation of the blender every minute was found to negligibly improve the blending performance. Introducing a baffle into the lid at a 45° angle to the rotation axis sped up the axial mixing and resulted in a better final blend uniformity. Alternatively, rotating the blending container 90° around the vertical axis five minutes prior to the process end was predicted to reduce axial segregation tendencies.
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Affiliation(s)
- Benedict Benque
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.
| | - Luca Orefice
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Thomas Forgber
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | | | - Beate Schmid
- Sandoz GmbH, Biochemiestrasse 10, 6250 Kundl, Austria
| | - Johan Remmelgas
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria; Institute of Process and Particle Engineering, TU Graz, Inffeldgasse 13, 8010 Graz, Austria
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2
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Waněk A, Menarini L, Giatti F, Kubelka T, Consoli F, Funaro C, Stasiak P, Štěpánek F. Manufacturing process transfer to a 30 kg/h continuous direct compression line with real-time composition monitoring. Int J Pharm 2024; 656:124100. [PMID: 38609059 DOI: 10.1016/j.ijpharm.2024.124100] [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: 12/30/2023] [Revised: 04/06/2024] [Accepted: 04/07/2024] [Indexed: 04/14/2024]
Abstract
Transferring an existing marketed pharmaceutical product from batch to continuous manufacturing (CM) without changes in regulatory registration is a challenging task in the pharmaceutical industry. Continuous manufacturing can provide an increased production rate and better equipment utilisation while retaining key quality attributes of the final product. Continuous manufacturing necessitates the monitoring of critical quality attributes in real time by appropriate process analytical tools such as near infra-red (NIR) probes. The present work reports a successful transfer of an existing drug product from batch to continuous manufacturing process without changing the formulation. A key step was continuous powder blending, whose design and operating parameters including weir type, agitation rate, dynamic hold-up and residence time were systematically investigated with respect to process repeatability. A NIR-based multivariate data model for in-line composition monitoring has been developed and validated against an existing quality control method for measuring tablet content uniformity. A continuous manufacturing long-run with a throughput of 30 kg/h (approx. 128,000 tablets per hour), uninterrupted for 320 min, has been performed to test and validate the multivariate data model as well as the batch to continuous process transfer. The final disintegration and dissolution properties of tablets manufactured by the continuous process were found to be equivalent to those manufactured by the original batch process.
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Affiliation(s)
- Adam Waněk
- Zentiva, k.s., U Kabelovny 130, Prague 10, Czech Republic; Department of Chemical Engineering, University of Chemistry and Technology, Prague, Technická 5, Prague 6, Czech Republic
| | | | | | - Tomáš Kubelka
- Zentiva, k.s., U Kabelovny 130, Prague 10, Czech Republic
| | | | | | - Pawel Stasiak
- Zentiva, k.s., U Kabelovny 130, Prague 10, Czech Republic
| | - František Štěpánek
- Department of Chemical Engineering, University of Chemistry and Technology, Prague, Technická 5, Prague 6, Czech Republic.
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3
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Jones-Salkey O, Nicusan AL, Windows-Yule CRK, Ingram A, Werner D, Clifford S, Reynolds GK. Application of Positron Emission Particle Tracking (PEPT) for the evaluation of powder behaviour in an incline linear blender for Continuous Direct Compression (CDC). Int J Pharm 2023; 645:123361. [PMID: 37673280 DOI: 10.1016/j.ijpharm.2023.123361] [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: 05/01/2023] [Revised: 08/11/2023] [Accepted: 08/31/2023] [Indexed: 09/08/2023]
Abstract
Positron Emission Particle Tracking (PEPT) is a non-invasive measurement technique which offers the ability to track the motion of individual particles with high temporal and spatial resolution, and thus build up an understanding of the bulk behaviour of a system from its microscopic (particle level) dynamics. Using this measurement technique, we have developed a series of novel metrics to better understand the behaviours of powders during the steady-state operation of a continuous blender system. Results are presented concerning the response of particle motion to processing parameters (mixing blade configuration and RPM), quantifying the motion in terms of predicted mixing performance. It was found that both increasing rpm and increasing hold-up mass (by selecting fewer transport blades and more mixing blades) provided improved mixing conditions. Interestingly, under specific conditions, there is evidence of convection-like mixing occurring at the interface of the transport and mixing region. This suggests the existence of a potential 'folding region' whereby powder is transported up the barrel (and away from the powder bulk bed) before being reconstituted back into the bulk mass. The results also provide valuable experimental data for the development, calibration and validation of future Discrete Element Method (DEM) simulations.
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Affiliation(s)
- O Jones-Salkey
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK.
| | - A L Nicusan
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - C R K Windows-Yule
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - A Ingram
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - D Werner
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - S Clifford
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
| | - G K Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
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4
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Parametric Analysis of a Double Shaft, Batch-Type Paddle Mixer Using the Discrete Element Method (DEM). Processes (Basel) 2023. [DOI: 10.3390/pr11030738] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/06/2023] Open
Abstract
To improve the understanding of the mixing performance of double shaft, batch-type paddle mixers, the discrete element method (DEM) in combination with a Plackett–Burman design of experiments simulation plan is used to identify factor significance on the system’s mixing performance. Effects of several factors, including three material properties (particle size, particle density and composition), three operational conditions (initial filling pattern, fill level and impeller rotational speed) and three geometric parameters (paddle size, paddle angle and paddle number), were quantitatively investigated using the relative standard deviation (RSD). Four key performance indicators (KPIs), namely the mixing quality, mixing time, average mixing power and energy required to reach a steady state, were defined to evaluate the performance of the double paddle mixer. The results show that the material property effects are not as significant as those of the operational conditions and geometric parameters. In particular, the geometric parameters were observed to significantly influence the energy consumption, while not affecting the mixing quality and mixing time, showing their potential towards designing more sustainable mixers. Furthermore, the analysis of granular temperature revealed that the centre area between the two paddles has a high diffusivity, which can be correlated to the mixing time.
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5
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Effect of the Mixer Design Parameters on the Performance of a Twin Paddle Blender: A DEM Study. Processes (Basel) 2023. [DOI: 10.3390/pr11030733] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/06/2023] Open
Abstract
The design parameters of a mixing system have a major impact on the quality of the final product. Therefore, identifying the optimum parameters of mixing systems is highly relevant to various industrial processes dealing with particulate flows. However, the studies on the influences of the mixer’s design features are still insufficient. In this study, the Discrete Element Method (DEM) is used to examine the impact of paddle angle, width, and gap on the mixing performance of a twin paddle blender. The mixing performance and particle flow are assessed using the relative standard deviation (RSD) mixing index, velocity field, diffusivity coefficient, granular temperature, the force acting on particles, and the mixer’s power consumption. The mixing performance is highest for a paddle angle of 0° at the cost of the highest forces acting on particles. The paddle width is indicated as a critical factor for achieving better mixing quality. In contrast, the powder mixing efficiency and the mixer’s power consumption are not significantly affected by the paddle gap. The results regarding the power consumption denote that the mixer using the paddle angle of 60° has the minimum power consumption. Moreover, increasing the paddle width results in the enhancement of the mixer’s power consumption.
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6
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Nadeem H, Subramaniam S, Nere NK, Heindel TJ. A particle scale mixing measurement method using a generalized nearest neighbor mixing index. ADV POWDER TECHNOL 2023. [DOI: 10.1016/j.apt.2022.103933] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/07/2023]
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7
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Advanced image analytics to study powder mixing in a novel laboratory scale agitated filter dryer. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118273] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/22/2023]
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8
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Jaspers M, Kulkarni SS, Tegel F, Roelofs TP, de Wit MT, Janssen PH, Meir B, Weinekötter R, Dickhoff BH. Batch versus continuous blending of binary and ternary pharmaceutical powder mixtures. Int J Pharm X 2022; 4:100111. [PMID: 35028558 PMCID: PMC8739470 DOI: 10.1016/j.ijpx.2021.100111] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2021] [Revised: 12/15/2021] [Accepted: 12/30/2021] [Indexed: 12/03/2022] Open
Abstract
The material properties of excipients and active pharmaceutical ingredients (API's) are important parameters that affect blend uniformity of pharmaceutical powder formulations. With the current shift from batch to continuous manufacturing in the pharmaceutical industry, blending of excipients and API is converted to a continuous process. The relation between material properties and blend homogeneity, however, is generally based on batch-wise blending trials. Limited information is available on how material properties affect blending performance in a continuous process. Here, blending of API and excipients is studied in both a batch and a continuous process. Homogeneity of the resulting mixtures is analyzed, which reveals that the impact of material properties is very different in a continuous process. Where parameters such as particle size, density and flowability have significant impact on blending performance in a traditional batch process, continuous blending is more robust resulting in uniform blends for a large variety of blend compositions. Continuous mixing improves blend uniformity of pharmaceutical powder mixtures. Blend uniformity is highly dependent on excipient properties in a batch process. Continuous mixing is more robust, with little impact of material properties. Powder bulk density strongly affects blend homogeneity in a batch process. Blending of low API dosages is more challenging in a continuous process.
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9
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Zheng C, Li L, Nitert BJ, Govender N, Chamberlain T, Zhang L, Wu CY. Investigation of granular dynamics in a continuous blender using the GPU-enhanced discrete element method. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117968] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/31/2022]
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10
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Hu L, Zhu H, Hua J. DEM study on effects of particle size and grinding media properties on energy transitions in a horizontal agitator. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103604] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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11
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Tan Y, Dahlenburg M, Fottner J, Kessler S. Influencing factors of the mixing performance of a near-nozzle continuous mixer for 3D concrete printing: An analysis based on spatial Lacey mixing index (SLMI). POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117414] [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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12
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Jadidi B, Ebrahimi M, Ein-Mozaffari F, Lohi A. A comprehensive review of the application of DEM in the investigation of batch solid mixers. REV CHEM ENG 2022. [DOI: 10.1515/revce-2021-0049] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
Abstract
Abstract
Powder mixing is a vital operation in a wide range of industries, such as food, pharmaceutical, and cosmetics. Despite the common use of mixing systems in various industries, often due to the complex nature of mixing systems, the effects of operating and design parameters on the mixers’ performance and final blend are not fully known, and therefore optimal parameters are selected through experience or trial and error. Experimental and numerical techniques have been widely used to analyze mixing systems and to gain a detailed understanding of mixing processes. The limitations associated with experimental techniques, however, have made discrete element method (DEM) a valuable complementary tool to obtain comprehensive particle level information about mixing systems. In the present study, the fundamentals of solid-solid mixing, segregation, and characteristics of different types of batch solid mixers are briefly reviewed. Previously published papers related to the application of DEM in studying mixing quality and assessing the influence of operating and design parameters on the mixing performance of various batch mixing systems are summarized in detail. The challenges with regards to the DEM simulation of mixing systems, the available solutions to address those challenges and our recommendations for future simulations of solid mixing are also presented and discussed.
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Affiliation(s)
- Behrooz Jadidi
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
| | - Mohammadreza Ebrahimi
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
| | - Farhad Ein-Mozaffari
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
| | - Ali Lohi
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
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13
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Nagawkar BR, Kotrike VP, Passalacqua A, Subramaniam S. An index to characterize gas‐solid and solid‐solid mixing from average volume fraction fields. AIChE J 2022. [DOI: 10.1002/aic.17639] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
- Barlev R. Nagawkar
- Department of Mechanical Engineering Iowa State University, Black Engineering Building Ames Iowa USA
- Center for Multiphase Flow Research and Education (CoMFRE) Iowa State University Ames Iowa USA
| | - Venkata P. Kotrike
- Department of Mechanical Engineering Iowa State University, Black Engineering Building Ames Iowa USA
- Center for Multiphase Flow Research and Education (CoMFRE) Iowa State University Ames Iowa USA
| | - Alberto Passalacqua
- Department of Mechanical Engineering Iowa State University, Black Engineering Building Ames Iowa USA
- Center for Multiphase Flow Research and Education (CoMFRE) Iowa State University Ames Iowa USA
| | - Shankar Subramaniam
- Department of Mechanical Engineering Iowa State University, Black Engineering Building Ames Iowa USA
- Center for Multiphase Flow Research and Education (CoMFRE) Iowa State University Ames Iowa USA
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14
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Wang S, Wu K, Yu J, Zhang H. Design optimization and scale-up characteristics of a double-helical ribbon reactor for biomass catalytic pyrolysis. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117192] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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15
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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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16
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Jadidi B, Ebrahimi M, Ein-Mozaffari F, Lohi A. Mixing performance analysis of non-cohesive particles in a double paddle blender using DEM and experiments. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117122] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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17
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Kamesh R, Vaddagani S, Sumana C, Rani KY, Gopireddy SR, Urbanetz NA. Six-directional sampling method and mean mixing indices for solids blending performance analysis of DEM simulations. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.117051] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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18
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Li B, Gui N, Wu H, Yang X, Tu J, Jiang S. Effects of the 3-D wall structures on the flow and mixing characteristics of pebbles in pebble beds in HTR-10. ANN NUCL ENERGY 2021. [DOI: 10.1016/j.anucene.2021.108607] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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19
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Jakubowska E, Ciepluch N. Blend Segregation in Tablets Manufacturing and Its Effect on Drug Content Uniformity-A Review. Pharmaceutics 2021; 13:pharmaceutics13111909. [PMID: 34834324 PMCID: PMC8620778 DOI: 10.3390/pharmaceutics13111909] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/18/2021] [Revised: 11/02/2021] [Accepted: 11/08/2021] [Indexed: 11/26/2022] Open
Abstract
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.
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Affiliation(s)
- Emilia Jakubowska
- Chair and Department of Pharmaceutical Technology, Faculty of Pharmacy, Poznan University of Medical Sciences, 6 Grunwaldzka Street, 60-780 Poznan, Poland
- Correspondence:
| | - Natalia Ciepluch
- Department of Medical Rescue, Chair of Emergency Medicine, Faculty of Health Sciences, Poznan University of Medical Sciences, 7 Rokietnicka Street, 60-806 Poznan, Poland;
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20
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Zhao L, Gu H, Ye M, Wang Q. Mixing uniformity of particles in a double barrel with differential velocity based on the discrete element method. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.08.009] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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21
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Xi K, Guo Q, Boyce CM, Lu Y. Contact-Based Method to Evaluate Mixing in Multicomponent Experiments and Simulations. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c03015] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Kenan Xi
- State Key Laboratory of Multiphase Flow in Power Engineering, Xi’an Jiaotong University, Xi’an 710049, Shaanxi, China
- Department of Chemical Engineering, Columbia University, New York, New York 10027, United States
| | - Qiang Guo
- Department of Chemical Engineering, Columbia University, New York, New York 10027, United States
| | - Christopher M. Boyce
- Department of Chemical Engineering, Columbia University, New York, New York 10027, United States
| | - Youjun Lu
- State Key Laboratory of Multiphase Flow in Power Engineering, Xi’an Jiaotong University, Xi’an 710049, Shaanxi, China
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22
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Kottlan A, Glasser BJ, Khinast JG. Vibratory mixing of pharmaceutical powders on a single-tablet-scale. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.04.040] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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23
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Hybrid multi-zonal compartment modeling for continuous powder blending processes. Int J Pharm 2021; 602:120643. [PMID: 33901598 DOI: 10.1016/j.ijpharm.2021.120643] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/10/2021] [Revised: 04/03/2021] [Accepted: 04/21/2021] [Indexed: 02/02/2023]
Abstract
To modernize drug manufacturing, the pharmaceutical industry has been moving towards implementing emerging technologies to enhance manufacturing robustness and process reliability for production of regulation compliant drug products. Although different science and risk based technologies, like Quality-by-Design, have been used to illustrate their potential, there still exist some underlying obstacles. Specifically, for the production of oral solid drug products, an in-depth process understanding, and predictive modeling of powder mixing in continuous powder blenders is one such major obstacle and originates from the current limitations of the experimental and modeling approaches. Though first principle based discrete element modeling (DEM) approach can address the above issues, it can get very computationally intensive which limits its applications for predictive modeling. In the proposed work, we aim to address this limitation using a multi-zonal compartment modeling approach, which is constructed from DEM. The approach provides a computationally efficient and mechanistically informed hybrid model. The application of the proposed approach is first demonstrated for a periodic section of the blender, followed by its extension for the entire continuous powder blender and the obtained model predictions are validated. The proposed approach provides an overall assessment of powder mixing along axial and radial directions, which is an important requirement for the quantification of blend uniformity. Given the low computational cost, the developed model can further be integrated within the predictive flowsheet model of the manufacturing line.
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