Effect of compression speeds on the compaction properties of a 1:1 paracetamol-microcrystalline cellulose mixture prepared by single compression and by combinations of pre-compression and main-compression

A modified mechanistic approach for predicting ribbon solid fraction at different roller compaction speeds

This research investigates the modeling of the pharmaceutical roller compaction process, focusing on the application of the Johanson model and the impact of varying roll speeds from 1 to 15 RPM on predictive accuracy of ribbon solid fraction. The classical Johanson's model was integrated with a dwell time parameter leading to an expression of a floating correction factor as a function of roll speed. Through systematic analysis of the effect of different roll speeds on the solid fraction of ribbons composed of microcrystalline cellulose, lactose, and their blends, corrective adjustment to the Johanson model was found to depend on both roll speed and formulation composition. Interestingly, the correction factor demonstrated excellent correlation with the blend's mechanical properties, namely yield stress (Py) and elastic modulus (E0), representative of the deformability of the powder. Validated by a multicomponent drug formulation with ±0.4-1.3 % differences, the findings underscore the utility of this modified mechanistic approach for precise prediction of ribbon solid fraction when Py or E0 is known for a given blend. Hence, this work advances the field by offering early insights for more accurate and controllable roller compaction operations during late-stage pharmaceutical manufacturing.

Continuous measurement of die wall pressure in a rotary tablet machine

In the pharmaceutical industry, tablets are manufactured using rotary tableting machines. Recently, die wall pressure in a single-punch press was measured to understand the compaction mechanism and predict tableting failure. However, die wall pressure measurements in rotary tableting machines have not been studied. Two challenges exist in measuring die wall pressure in these machines, viz. (i) lack of space inside the machine to set up the measurement equipment and (ii) difficulty in installing wired measurement hardware because the die rotates with the rotary plate. This study aimed to continuously measure die wall pressure in a rotary tableting machine and investigate the effect of high compression speed on die wall pressure. Die wall pressure at tableting speeds of up to 140 mm/s was successfully determined using a wireless telemeter. Residual die wall pressure for plastic materials was strongly dependent on the tableting speed, although the tableting speed affected the maximum die wall pressure minimally. This novel measurement technique can be used to study the effect of tableting speed on die wall pressure, which can be applied in solving the problems of capping and lamination during tablet production.

Systematic approach to elucidate compaction behavior of acyclovir using a compaction simulator

In this research, various approaches were attempted with a compaction simulator to investigate the unidentified compaction behavior of acyclovir, a model compound. Various indicators for the compaction behavior of acyclovir were obtained and compared with those of three commonly used excipients with relatively well-known compaction behavior. From two frequently used powder compaction models, the Heckel and Walker models, curvature of plot, yield stress, D₀, SRS value, and W value were acquired. In addition, compression and elastic energies were obtained during the loading and unloading phases, respectively. The ratio of the two energies was also utilized. To characterize the mechanical properties of materials during bond formation, the radial tensile strength of powder compacts was measured. For all evaluations, the effects of compaction rate and lubrication were studied simultaneously. We found that primary particles of acyclovir were compacted mainly by plastic flow, with high viscoelasticity and low particle interactions. Their bond formation was highly sensitive to strain rate and lubrication. This study showed the potential application of a compaction simulator to elucidate the compaction behavior of a material of interest.

Predicting tablet tensile strength with a model derived from the gravitation-based high-velocity compaction analysis data

In the present study, a model was developed to estimate tablet tensile strength utilizing the gravitation-based high-velocity (G-HVC) method introduced earlier. Three different formulations consisting of microcrystalline cellulose (MCC), dicalcium phosphate dihydrate (DCP), hydroxypropyl methylcellulose (HPMC), theophylline and magnesium stearate were prepared. The formulations were granulated using fluid bed granulation and the granules were compacted with the G-HVC method and an eccentric tableting machine. Compaction energy values defined from G-HVC data predicted tensile strength of the tablets surprisingly well. It was also shown, that fluid bed granulation improved the compaction energy intake of the granules in comparison to respective physical mixtures. In addition, general mechanical properties and elastic recovery were also examined for all samples. In this study it was finally concluded, that the data obtained by the method was of practical relevance in pharmaceutical formulation development.

Preparation and characterization of multi-component tablets containing co-amorphous salts: Combining multimodal non-linear optical imaging with established analytical methods

Co-amorphous mixtures have rarely been formulated as oral dosage forms, even though they have been shown to stabilize amorphous drugs in the solid state and enhance the dissolution properties of poorly soluble drugs. In the present study we formulated tablets consisting of either spray dried co-amorphous ibuprofen-arginine or indomethacin-arginine, mannitol or xylitol and polyvinylpyrrolidone K30 (PVP). Experimental design was used for the selection of tablet compositions, and the effect of tablet composition on tablet characteristics was modelled. Multimodal non-linear imaging, including coherent anti-Stokes Raman scattering (CARS) and sum frequency/second harmonic generation (SFG/SHG) microscopies, as well as scanning electron microscopy, X-ray diffractometry and Fourier-transform infrared spectroscopy were utilized to characterize the tablets. The tablets possessed sufficient strength, but modelling produced no clear evidence about the compaction characteristics of co-amorphous salts. However, co-amorphous drug-arginine mixtures resulted in enhanced dissolution behaviour, and the PVP in the tableting mixture stabilized the supersaturation. The co-amorphous mixtures were physically stable during compaction, but the excipient selection affected the long term stability of the ibuprofen-arginine mixture. CARS and SFG/SHG proved feasible techniques in imaging the component distribution on the tablet surfaces, but possibly due to the limited imaging area, recrystallization detected with x-ray diffraction was not detected.

Differences in fundamental and functional properties of HPMC co-processed fillers prepared by fluid-bed coating and spray drying

This study aimed to develop novel co-processed tablet fillers based on the principle of particle engineering for direct compaction and to compare the characteristics of co-processed products obtained by fluid-bed coating and co-spray drying, respectively. Water-soluble mannitol and water-insoluble calcium carbonate were selected as representative fillers for this study. Hydroxypropyl methylcellulose (HPMC), serving as a surface property modifier, was distributed on the surface of primary filler particles via the two co-processing methods. Both fundamental and functional properties of the products were comparatively investigated. The results showed that functional properties of the fillers, like flowability, compactibility, and drug-loading capacity, were effectively improved by both co-processing methods. However, fluid-bed coating showed greater advantages over co-spray drying in some aspects, which was mainly attributed to the remarkable differences in some fundamental properties of co-processed powders, like particle size, surface topology, and particle structure. For example, the more irregular surface and porous structure induced by fluid-bed coating could contribute to better compaction properties and lower lubricant sensitivity due to the increasing contact area and mechanical interlocking between particles under pressure. More effective surface distribution of HPMC during fluid-bed coating was also a contributor. In addition, such a porous agglomerate structure could also reduce the separation of drug and excipients after mixing, resulting in the improvement in drug loading capacity and tablet uniformity. In summary, fluid-bed coating appears to be more promising for co-processing than spray drying in some aspects, and co-processed excipients produced by it have a great prospect for further investigations and development.

High Pressure Compression-Molding of α-Cellulose and Effects of Operating Conditions

Commercial α-cellulose was compression-molded to produce 1A dog-bone specimens under various operating conditions without any additive. The resulting agromaterials exhibited a smooth, plastic-like surface, and constituted a suitable target as replacement for plastic materials. Tensile and three-points bending tests were conducted according to ISO standards related to the evaluation of plastic materials. The specimens had strengths comparable to classical petroleum-based thermoplastics. They also exhibited high moduli, which is characteristic of brittle materials. A higher temperature and higher pressure rate produced specimens with higher mechanical properties while low moisture content produced weaker specimens. Generally, the strong specimen had higher specific gravity and lower moisture content. However, some parameters did not follow the general trend e.g., thinner specimen showed much higher Young's Modulus, although their specific gravity and moisture content remained similar to control, revealing a marked skin-effect which was confirmed by SEM observations.

Effect of Particle Size and Compression Force on Compaction Behavior and Derived Mathematical Parameters of Compressibility

PURPOSE

To analyze the influence of inherent densification and deformation properties of paracetamol on the mathematical parameters derived from Heckel, Walker, Kawakita, and Adams equations and to correlate these with single particle nominal fracture strength and bulk compression parameters using confined compression on a fully instrumented rotary tablet press.

MATERIALS AND METHODS

Force-displacement data were captured during in-die compression for four different particle size fractions (150-250, 300-450, 500-650, and 700-1,000 microm) of paracetamol each at compression force of 5.2, 8.6, and 17.3 kN. Nominal single particle fracture strength was obtained by micro tensile testing.

RESULTS

Apparent mean yield pressure (Py) from Heckel analysis was significantly affected by the applied pressure, and was influenced by elastic energy and Young's modulus. The single particle fracture strength correlated to parameters obtained from Heckel, Walker, Kawakita, and Adams equations. Results obtained from bulk compression and single particle measurements were consistent with, and polynomially related to Py, Kawakita (1/b), and Adams parameter (tau0').

CONCLUSIONS

Values of Py, 1/b, and tau0' obtained from Heckel, Kawakita, and Adams equations, respectively, can be interpreted as a measure of single particle nominal fracture strength during confined compression loading. Walker and Adams parameters were less affected, than Heckel and Kawakita parameters, by the applied pressure.

Influence of particle size and shape on flowability and compactibility of binary mixtures of paracetamol and microcrystalline cellulose

The influence of the size and shape of paracetamol particles on the flow and compression behavior of blends (1:1) of microcrystalline cellulose (MCC) was investigated. The effect of paracetamol particle shape was investigated by using two differently prepared samples, micronized and novel engineered Solution Atomization and Xstallization by Sonication (SAXS) particles, which exhibited similar particle size ranges (2-6 microm). The results were compared to data obtained for an untreated paracetamol sample. The blends containing SAXS particles exhibited increased bulk and tapped density and improved flow, compared to the blend containing micronized particles. This may reflect differences in shape since the SAXS particles exhibited spherical morphology. The compressibility of the blend containing untreated paracetamol was greater than blends containing the SAXS and micronized materials, which may reflect the different drug particle sizes and shapes. However, blends containing the needle-shaped particles of pure untreated sample, exhibited poor compactibility after storage at 10% RH. It was found that increasing the moisture content in the blends by storage at 44% RH resulted in an increase in the compactibility of the samples containing untreated and SAXS paracetamol with the blends containing micronized paracetamol being relatively unaffected. In general, tablets prepared from blends containing smaller particles of paracetamol exhibited significantly greater compactibility compared to tablets prepared containing the larger particle sized untreated paracetamol. The use of small, spherical drug particles may result in improvements in the bulk density, densification and compactibility of blends of paracetamol and microcrystalline cellulose.