1
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Wikström H, Martin de Juan L, Remmelgas J, Meier R, Altmeyer A, Emanuele D, Jormanainen M, Juppo A, Tajarobi P. Drying capacity of a continuous vibrated fluid bed dryer - Statistical and mechanistic model development. Int J Pharm 2023; 645:123368. [PMID: 37669728 DOI: 10.1016/j.ijpharm.2023.123368] [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: 05/16/2023] [Revised: 08/31/2023] [Accepted: 09/01/2023] [Indexed: 09/07/2023]
Abstract
The drying capacity of a continuous vibrated fluid bed dryer was studied using a DoE by varying microcrystalline cellulose content in the formulation, water amount in the twin-screw granulation, inlet air temperature, air flow rate and the acceleration of the horizontal fluid-bed. Temperature and humidity profiles were measured along the dryer using wireless sensors. For the parameter space explored in this study, acceleration was the most influential process parameter of the dryer regarding the resulting granule moisture content. An empirical model was developed that allowed for fast and accurate moisture content prediction that could be incorporated into an enhanced control strategy. In addition, a mechanistic model was formulated that allow for prediction of temperature and moisture profiles, and most importantly the moisture content of the granules inside the dryer. The mechanistic model can be integrated to other unit operation models to provide overall understanding of an integrated continuous process line. The mechanistic model also makes it possible to define the equipment design requirements (e.g., length of the dryer) to meet the specific needs in terms of drying capacity, temperature and moisture profile.
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Affiliation(s)
- Håkan Wikström
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
| | - Luis Martin de Juan
- Oral Product Development, Pharmaceutical Technology & Development, AstraZeneca, Gothenburg, Sweden
| | | | - Robin Meier
- L.B. Bohle Maschinen und Verfahren GmbH, Ennigerloh, Germany
| | | | - Daniel Emanuele
- L.B. Bohle Maschinen und Verfahren GmbH, Ennigerloh, Germany
| | - Miika Jormanainen
- Division of Pharmaceutical Chemistry and Technology, University of Helsinki, Finland
| | - Anne Juppo
- Division of Pharmaceutical Chemistry and Technology, University of Helsinki, Finland
| | - Pirjo Tajarobi
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden.
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2
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Zhao J, Tian G, Qu H. Pharmaceutical Application of Process Understanding and Optimization Techniques: A Review on the Continuous Twin-Screw Wet Granulation. Biomedicines 2023; 11:1923. [PMID: 37509561 PMCID: PMC10377609 DOI: 10.3390/biomedicines11071923] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2023] [Revised: 06/15/2023] [Accepted: 07/05/2023] [Indexed: 07/30/2023] Open
Abstract
Twin-screw wet granulation (TSWG) is a method of continuous pharmaceutical manufacturing and a potential alternative method to batch granulation processes. It has attracted more and more interest nowadays due to its high efficiency, robustness, and applications. To improve both the product quality and process efficiency, the process understanding is critical. This article reviews the recent work in process understanding and optimization for TSWG. Various aspects of the progress in TSWG like process model construction, process monitoring method development, and the strategy of process control for TSWG have been thoroughly analyzed and discussed. The process modeling technique including the empirical model, the mechanistic model, and the hybrid model in the TSWG process are presented to increase the knowledge of the granulation process, and the influence of process parameters involved in granulation process on granule properties by experimental study are highlighted. The study analyzed several process monitoring tools and the associated technologies used to monitor granule attributes. In addition, control strategies based on process analytical technology (PAT) are presented as a reference to enhance product quality and ensure the applicability and capability of continuous manufacturing (CM) processes. Furthermore, this article aims to review the current research progress in an effort to make recommendations for further research in process understanding and development of TSWG.
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Affiliation(s)
- Jie Zhao
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| | - Geng Tian
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
| | - Haibin Qu
- Pharmaceutical Informatics Institute, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China
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3
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Chavez PF, Stauffer F, Eeckman F, Bostijn N, Didion D, Schaefer C, Yang H, El Aalamat Y, Lories X, Warman M, Mathieu B, Mantanus J. Control strategy definition for a drug product continuous wet granulation process: Industrial case study. Int J Pharm 2022; 624:121970. [PMID: 35781027 DOI: 10.1016/j.ijpharm.2022.121970] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/02/2022] [Revised: 06/22/2022] [Accepted: 06/27/2022] [Indexed: 11/28/2022]
Abstract
This paper describes the specific control strategy of the commercial manufacturing process of an immediate release tablet formulation based on continuous twin-screw wet granulation. This control strategy has been defined by a multidisciplinary team using an enhanced approach, in alignment with the quality by design principles. During process development, experiments have been performed according to multivariate designs first to identify critical material attributes and critical process parameters and then, to define process conditions generating a product having the required quality. Hence, controls have been applied on critical quality attributes and on related critical process parameters and critical material attributes. Due to the specificity of the process that combines batch and continuous unit operations, a specific control strategy has been designed to ensure intermediate and end product quality. Therefore, controls including soft sensor model and in process controls have been developed to continuously monitor granules residual moisture content, assay and dissolution as granules and tablets critical attributes. In addition, process analytical technology implementation enabled increased process understanding and provided support for the development of the control strategy. This study is therefore considered as a real industrial case study of control strategy definition and implementation for an intended commercial continuous manufacturing process.
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Affiliation(s)
| | - Fanny Stauffer
- Product Design & Performance, UCB, Braine l'Alleud, Belgium
| | | | - Nils Bostijn
- Product Design & Performance, UCB, Braine l'Alleud, Belgium
| | - David Didion
- Analytical Sciences for Pharmaceuticals, UCB, Braine l'Alleud, Belgium
| | - Cédric Schaefer
- Analytical Sciences for Pharmaceuticals, UCB, Braine l'Alleud, Belgium
| | - Hong Yang
- CoE Analytics, Knowledge Management & Documentation, UCB, Braine l'Alleud, Belgium
| | - Yousef El Aalamat
- CoE Analytics, Knowledge Management & Documentation, UCB, Braine l'Alleud, Belgium
| | - Xavier Lories
- CoE Analytics, Knowledge Management & Documentation, UCB, Braine l'Alleud, Belgium
| | - Martin Warman
- Martin Warman Consultancy Ltd, Chestfield, Kent CT5 3LY, UK
| | - Benoit Mathieu
- Analytical Sciences for Pharmaceuticals, UCB, Braine l'Alleud, Belgium
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4
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Junnila A, Wikström H, Megarry A, Gholami A, Papathanasiou F, Blomberg A, Ketolainen J, Tajarobi P. Faster to First-time-in-Human: Prediction of the liquid solid ratio for continuous wet granulation. Eur J Pharm Sci 2022; 172:106151. [PMID: 35217210 DOI: 10.1016/j.ejps.2022.106151] [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: 10/22/2021] [Revised: 01/21/2022] [Accepted: 02/21/2022] [Indexed: 11/03/2022]
Abstract
In early development, when active pharmaceutical ingredient (API) is in short supply, it would be beneficial to reduce the number of experiments by predicting a suitable L/S ratio before starting the product development. The aim of the study was to decrease development time and the amount of API needed for the process development of high drug load formulations for continuous twin-screw wet granulation (TSWG). Mixer torque rheometry was used as a pre-formulation tool to predict the suitable L/S ratios for granulation experiments. Three different values that were based on the MTR curves, were determined and assessed for their ability to predict the suitable L/S ratio for TSWG. Three APIs (allopurinol, paracetamol and metformin HCl) were used as model substances in high drug load formulations containing 60% drug substance. The MCC-mannitol ratio was varied to assess the optimal composition for the high-dose formulations. The API solubility affected the mixer torque rheometer (MTR) curves and the optimum L/S ratio for TSWG. The highly soluble metformin needed a much lower L/S ratio compared with allopurinol and paracetamol. A design space was determined for each API based on granule flowability and tablet tensile strength. The flowability of the granules and tensile strength of the tablets improved with an increasing L/S ratio. The MCC-mannitol filler ratio had a significant effect on tabletability for paracetamol and metformin, and these APIs having poor compaction properties needed higher MCC ratios to achieve the 2 MPa limit. The MCC-mannitol ratio had no effect on the granule flow properties. Instead, API properties had the largest influence on both granule flow properties and tensile strength. Based on this study, both the L/S ratio and MCC-mannitol ratio are crucial in controlling the critical quality attributes in high drug load formulations processed by TSWG. The optimum flow and tablet mechanical properties were achieved when using 75:25 MCC-mannitol ratio. Both start of the slope and 2/3 of the L/S ratio at the maximum torque in MTR provided a solid guideline to aim for in a TSWG experiment.
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Affiliation(s)
- Atte Junnila
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, Kuopio, Finland
| | - Håkan Wikström
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca Gothenburg, 431 83 Mölndal, Sweden
| | - Andrew Megarry
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca Gothenburg, 431 83 Mölndal, Sweden
| | - Aida Gholami
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca Gothenburg, 431 83 Mölndal, Sweden
| | - Foteini Papathanasiou
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca Gothenburg, 431 83 Mölndal, Sweden
| | - Andreas Blomberg
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca Gothenburg, 431 83 Mölndal, Sweden
| | - Jarkko Ketolainen
- School of Pharmacy, Faculty of Health Sciences, University of Eastern Finland, Kuopio, Finland
| | - Pirjo Tajarobi
- Early Product Development and Manufacturing, Pharmaceutical Sciences, BioPharmaceuticals R&D, AstraZeneca Gothenburg, 431 83 Mölndal, Sweden.
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Madarász L, Köte Á, Hambalkó B, Csorba K, Kovács V, Lengyel L, Marosi G, Farkas A, Nagy ZK, Domokos A. In-line particle size measurement based on image analysis in a fully continuous granule manufacturing line for rapid process understanding and development. Int J Pharm 2022; 612:121280. [PMID: 34774695 DOI: 10.1016/j.ijpharm.2021.121280] [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: 08/31/2021] [Revised: 10/27/2021] [Accepted: 11/06/2021] [Indexed: 12/01/2022]
Abstract
The present paper serves as a demonstration how an in-line PAT tool can be used for rapid and efficient process development in a fully continuous powder to granule line consisting of an interconnected twin-screw wet granulator, vibrational fluid bed dryer, and a regranulating mill. A new method was investigated for the periodic in-line particle size measurement of high mass flow materials to obtain real-time particle size data of the regranulated product. The system utilises a vibratory feeder with periodically altered feeding intensity in order to temporarily reduce the mass flow of the material passing in front of the camera. This results in the drastic reduction of particle overlapping in the images, making image analysis a viable tool for the in-line particle size measurement of high mass-flow materials. To evaluate the performance of the imaging system, the effect of several milling settings and the liquid-to-solid ratio was investigated on the product's particle size in the span of a few hours. The particle sizes measured with the in-line system were in accordance with the expected trends as well as with the results of the off-line reference particle size measurements. Based on the results, the in-line imaging system can serve as a PAT tool to obtain valuable real-time information for rapid process development or quality assurance.
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Affiliation(s)
- Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Ákos Köte
- Department of Automation and Applied Informatics, Budapest University of Technology and Economics, H-1117, Budapest Magyar Tudósok körútja 2 QB-207, Hungary
| | - Bence Hambalkó
- Department of Automation and Applied Informatics, Budapest University of Technology and Economics, H-1117, Budapest Magyar Tudósok körútja 2 QB-207, Hungary
| | - Kristóf Csorba
- Department of Automation and Applied Informatics, Budapest University of Technology and Economics, H-1117, Budapest Magyar Tudósok körútja 2 QB-207, Hungary
| | - Viktor Kovács
- Department of Automation and Applied Informatics, Budapest University of Technology and Economics, H-1117, Budapest Magyar Tudósok körútja 2 QB-207, Hungary
| | - László Lengyel
- Department of Automation and Applied Informatics, Budapest University of Technology and Economics, H-1117, Budapest Magyar Tudósok körútja 2 QB-207, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Zsombor Kristóf Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111 Budapest, Műegyetem rakpart 3, Hungary.
| | - András Domokos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, H-1111 Budapest, Műegyetem rakpart 3, Hungary
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Domokos A, Pusztai É, Madarász L, Nagy B, Gyürkés M, Farkas A, Fülöp G, Casian T, Szilágyi B, Nagy ZK. Combination of PAT and mechanistic modeling tools in a fully continuous powder to granule line: Rapid and deep process understanding. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.04.059] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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7
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Continuous Twin Screw Granulation: A Review of Recent Progress and Opportunities in Formulation and Equipment Design. Pharmaceutics 2021; 13:pharmaceutics13050668. [PMID: 34066921 PMCID: PMC8148523 DOI: 10.3390/pharmaceutics13050668] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 04/30/2021] [Accepted: 05/02/2021] [Indexed: 11/16/2022] Open
Abstract
Continuous twin screw wet granulation is one of the key continuous manufacturing technologies that have gained significant interest in the pharmaceutical industry as well as in academia over the last ten years. Given its considerable advantages compared to wet granulation techniques operated in batch mode such as high shear granulation and fluid bed granulation, several equipment manufacturers have designed their own manufacturing setup. This has led to a steep increase in the research output in this field. However, most studies still focused on a single (often placebo) formulation, hence making it difficult to assess the general validity of the obtained results. Therefore, current review provides an overview of recent progress in the field of continuous twin screw wet granulation, with special focus on the importance of the formulation aspect and raw material properties. It gives practical guidance for novel and more experienced users of this technique and highlights some of the unmet needs that require further research.
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Ishimoto H, Kano M, Sugiyama H, Takeuchi H, Terada K, Aoyama A, Shoda T, Demizu Y, Shimamura J, Yokoyama R, Miyamoto Y, Hasegawa K, Serizawa M, Unosawa K, Osaki K, Asai N, Matsuda Y. Approach to Establishment of Control Strategy for Oral Solid Dosage Forms Using Continuous Manufacturing. Chem Pharm Bull (Tokyo) 2021; 69:211-217. [PMID: 33298636 DOI: 10.1248/cpb.c20-00824] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Abstract
As a result of the research activities of the Japan Agency for Medical Research and Development (AMED), this document aims to show an approach to establishing control strategy for continuous manufacturing of oral solid dosage forms. The methods of drug development, technology transfer, process control, and quality control used in the current commercial batch manufacturing would be effective also in continuous manufacturing, while there are differences in the process development using continuous manufacturing and batch manufacturing. This document introduces an example of the way of thinking for establishing a control strategy for continuous manufacturing processes.
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Affiliation(s)
- Hayato Ishimoto
- Formulation Research, Pharmaceutical Science & Technology Core Function Unit, Medicine Development Center, Eisai Co., Ltd
| | - Manabu Kano
- Department of Systems Science, Kyoto University
| | | | - Hirofumi Takeuchi
- Advanced Pharmaceutical Process Engineering, Gifu Pharmaceutical University
| | | | - Atsushi Aoyama
- Office of New Drug III, Pharmaceuticals and Medical Devices Agency
| | - Takuji Shoda
- Division of Organic Chemistry, National Institute of Health Sciences
| | - Yosuke Demizu
- Division of Organic Chemistry, National Institute of Health Sciences
| | - Jinen Shimamura
- Pharmaceutical Research Dept. Research & Development Headquarters, TAKATA Pharmaceutical Co., Ltd
| | - Reiji Yokoyama
- CMC R&D Division, Shionogi Co., Ltd., Formulation R&D Laboratory
| | - Yuji Miyamoto
- Formulation Research & Pharmaceutical Process Group, CMC R&D Center, Kyowa Kirin Co., Ltd
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9
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Comparison between twin-screw and high-shear granulation - The effect of filler and active pharmaceutical ingredient on the granule and tablet properties. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.08.030] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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10
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Megarry A, Taylor A, Gholami A, Wikström H, Tajarobi P. Twin-screw granulation and high-shear granulation: The influence of mannitol grade on granule and tablet properties. Int J Pharm 2020; 590:119890. [PMID: 32946976 DOI: 10.1016/j.ijpharm.2020.119890] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/24/2020] [Revised: 09/05/2020] [Accepted: 09/14/2020] [Indexed: 01/27/2023]
Abstract
Granule structure has a key influence on tablet critical quality attributes. The ability to control this structure through excipient choice is an important part of formulation development. Mannitol is a popular diluent and the choice of input grade has been shown to impact granule properties. Allopurinol formulations containing two grades of mannitol (Pearlitol 160C and 200SD) were prepared by wet-granulation (twin-screw and high-shear) at different liquid/solid ratios (0.3 and 0.6 g/g). The particle and bulk properties were characterised by a range of techniques and linked to flow performance and tablet tensile strength during compression on a rotary tablet press. During granulation, 200SD underwent a polymorphic transition from a mixture of α and β to predominantly β. This transition was accompanied by a morphology change. Mannitol needles were formed, giving more porous granules with a higher specific surface area, which led to poorer flow properties but higher tablet tensile strength. This study concludes that understanding the effect of mannitol grade is a crucial part of formulation selection.
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Affiliation(s)
- Andrew Megarry
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden.
| | - Agnes Taylor
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
| | - Aida Gholami
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
| | - Håkan Wikström
- Oral Product Development, Pharmaceutical Technology and Development, Operations & IT, AstraZeneca, Gothenburg, Sweden
| | - Pirjo Tajarobi
- Early Product Development and Manufacture, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Gothenburg, Sweden
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Pawar P, Clancy D, Gorringe L, Barlow S, Hesketh A, Elkes R. Development and Scale-Up of Diversion Strategy for Twin Screw Granulation in Continuous Manufacturing. J Pharm Sci 2020; 109:3439-3450. [PMID: 32798502 DOI: 10.1016/j.xphs.2020.08.004] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2020] [Revised: 07/07/2020] [Accepted: 08/07/2020] [Indexed: 11/28/2022]
Abstract
Successful implementation of Continuous Manufacturing technology requires real time product quality monitoring that can result into rejection strategies for material manufactured outside process control limits. In a twin screw granulation process, parameters like water content, powder feed rate, and granulator screw speed can influence granule quality. Deviations in any of these parameters from the set-point may affect granule quality. Having a sound diversion strategy in place can help divert these implicated granules to waste. Residence time distribution experiments were conducted on a 16-mm Thermo Fisher twin screw granulator (TSG) for a range of process parameters, and the data was modelled to predict the needed diversion time as a function of process parameters. Scale-up from the 16-mm to 24-mm granulator was evaluated and data was found to scale based on mass per unit volume of granulator (channel fill), thus enabling 16-mm data to scale to 24-mm. The diversion strategy proposed is based on utilizing a wash out curve derived from residence time distribution to quantify the maximum concentration of implicated material that could be present in the next downstream unit operation(s) (e.g. a fluid bed dryer) and ensuring it is less than a suitable threshold to prevent product quality impact.
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