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Patil H, Vemula SK, Narala S, Lakkala P, Munnangi SR, Narala N, Jara MO, Williams RO, Terefe H, Repka MA. Hot-Melt Extrusion: from Theory to Application in Pharmaceutical Formulation-Where Are We Now? AAPS PharmSciTech 2024; 25:37. [PMID: 38355916 DOI: 10.1208/s12249-024-02749-2] [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: 11/20/2023] [Accepted: 01/19/2024] [Indexed: 02/16/2024] Open
Abstract
Hot-melt extrusion (HME) is a globally recognized, robust, effective technology that enhances the bioavailability of poorly soluble active pharmaceutical ingredients and offers an efficient continuous manufacturing process. The twin-screw extruder (TSE) offers an extremely resourceful customizable mixer that is used for continuous compounding and granulation by using different combinations of conveying elements, kneading elements (forward and reverse configuration), and distributive mixing elements. TSE is thus efficiently utilized for dry, wet, or melt granulation not only to manufacture dosage forms such as tablets, capsules, or granule-filled sachets, but also for designing novel formulations such as dry powder inhalers, drying units for granules, nanoextrusion, 3D printing, complexation, and amorphous solid dispersions. Over the past decades, combined academic and pharmaceutical industry collaborations have driven novel innovations for HME technology, which has resulted in a substantial increase in published articles and patents. This article summarizes the challenges and models for executing HME scale-up. Additionally, it covers the benefits of continuous manufacturing, process analytical technology (PAT) considerations, and regulatory requirements. In summary, this well-designed review builds upon our earlier publication, probing deeper into the potential of twin-screw extruders (TSE) for various new applications.
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Affiliation(s)
- Hemlata Patil
- Department of Product Development, Catalent Pharma Solutions, 14 Schoolhouse Road, Somerset, New Jersey, 08873, USA
| | - Sateesh Kumar Vemula
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
- Department of Pharmaceutics, School of Pharmaceutical Sciences, Lovely Professional University, Phagwara, Punjab, 144001, India
| | - Sagar Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Preethi Lakkala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Siva Ram Munnangi
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Nagarjuna Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Miguel O Jara
- Molecular Pharmaceutics and Drug Delivery Division, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, Austin, Texas, 78712, USA
| | - Robert O Williams
- Molecular Pharmaceutics and Drug Delivery Division, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, Austin, Texas, 78712, USA
| | - Hibreniguss Terefe
- Department of Product Development, Catalent Pharma Solutions, 14 Schoolhouse Road, Somerset, New Jersey, 08873, USA
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA.
- Pii Center for Pharmaceutical Technology, The University of Mississippi, University, Oxford, Mississippi, 38677, USA.
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Steady-state modeling of a new continuous API dryer: Reduced-order model and investigation of dryer performance. Int J Pharm 2023; 635:122701. [PMID: 36773730 DOI: 10.1016/j.ijpharm.2023.122701] [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: 02/07/2022] [Revised: 02/01/2023] [Accepted: 02/04/2023] [Indexed: 02/11/2023]
Abstract
In the present study, a reduced-order model is proposed to analyze a novel continuous dryer with an application in the pharmaceutical industry. The model was validated using process data from ibuprofen drying test runs, and the results were in good agreement with the experimental data. The test substance was an ibuprofen paste with an initial LOD of up to 30 w%. The simulations showed that the contact heat transfer coefficient can be correlated with the degree of wetness. Furthermore, a set of simulations was performed to analyze the influence of input parameters on the dryer's performance: i) the inlet air flow rate and ii) the inlet air temperature. The simulation results demonstrated that a variation in the inlet air temperature significantly affects the air temperature profile, while the inlet air flow rate has a minor effect. Besides, it was also established that the inlet solid LoD has the most considerable effect on the product quality (e.g., final solid moisture content). The results showed a deviation of less than 10% for the product LoD and the product temperature in most cases.
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Ren A, Koleng JJ, Costello M, Spahn JE, Smyth HDC, Zhang F. Twin-Screw Continuous Mixing Can Produce Dry Powder Inhalation Mixtures for Pulmonary Delivery. J Pharm Sci 2023; 112:272-281. [PMID: 36228755 DOI: 10.1016/j.xphs.2022.10.007] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/09/2022] [Revised: 10/05/2022] [Accepted: 10/05/2022] [Indexed: 12/23/2022]
Abstract
The feasibility of twin-screw corotating extruder as a continuous process mixer to prepare dry powder inhalation (DPI) powders was investigated. Interactive mixtures of 1% micronized budesonide, 0.3% magnesium stearate and 98.7% alpha-lactose monohydrate were manufactured using a Leistritz Nano-16 extruder at various processing conditions. One set of GFM (grooved mixing) elements were included in the screw profile to provide distributive mixing of conveyed powders with the goal of resulting in a homogeneous mixture. Residence time in the twin-screw mixer was modelled to quantify mixing efficiency. Comparative powders were also prepared using either low or high-shear batch mixing to compare the effect of mixing methods on the properties of the budesonide dry powder inhalation formulation. Twin screw mixing results in homogeneous mixtures with aerosol performance comparable to that of high-shear batch mixing. Scanning electron microscopy confirmed that twin screw mixing produces particles with morphology like that of low and high-shear batch mixing. X-ray diffraction (XRD) analysis verified that there was no form change of the drug due to twin-screw processing. Statistical regression was used to probe the relationship between twin screw mixing process parameters such as screw speed and feed rate and aerosol performance. The twin screw mixing process was found to be robust, as no significant differences in aerosol performance were found for various processing parameters.
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Affiliation(s)
- Angela Ren
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - John J Koleng
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Mark Costello
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Jamie E Spahn
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Hugh D C Smyth
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Ave, Austin TX, 78712, USA.
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Haser A, Kittikunakorn N, Dippold E, DiNunzio JC, Blincoe W. Continuous Twin-Screw wet granulation process with In-Barrel drying and NIR setup for Real-Time Moisture Monitoring. Int J Pharm 2022; 630:122377. [PMID: 36368607 DOI: 10.1016/j.ijpharm.2022.122377] [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: 09/05/2022] [Revised: 10/27/2022] [Accepted: 11/03/2022] [Indexed: 11/11/2022]
Abstract
The purpose of this study was to evaluate if wet granule formation and drying could take place in a single operation by utilizing in-barrel drying. The drying kinetics of the formulation were studied in order to select appropriate processing parameters and assess feasibility with short residence times in the extruder. The 18-mm extruder was operated in a 40:1 L:D ratio with 8 zones. The first two zones were used for material feeding and wet granule formation and the remaining zones were used for drying at elevated temperature. The impact of screw configuration as well as screw speed, feed rate, and residence time were all studied to optimize the drying process. Due to limitations of temperature and residence time, vacuum was added to enable sufficient drying. In-line NIR spectroscopy was incorporated into the twin-screw wet granulation (TSWG) process to monitor the moisture content of wet granules in real-time. The set-up was optimized and a predictive model was developed for future experiments. This study demonstrated the success of this technique on a pilot-scale (18-mm) extruder for the first time. Granules were formed and dried to a target loss on drying (LOD) of less than 2 % at moderate temperatures (100 °C - 110 °C) with one single operation. Streamlining wet granulation and drying into one unit operation can have a profound impact on pharmaceutical manufacturing reducing time, footprint, and environmental exposure due to reduced product transfers.
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Affiliation(s)
- Abbe Haser
- Oral Formulation Sciences and Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA.
| | - Nada Kittikunakorn
- Oral Formulation Sciences and Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
| | - Erin Dippold
- Process Commercialization Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
| | - James C DiNunzio
- Oral Formulation Sciences and Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
| | - William Blincoe
- Process Analytical Technology, Merck & Co., Inc., 126 E. Lincoln Ave, Rahway, NJ 07065, USA
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Gyürkés M, Madarász L, Záhonyi P, Köte Á, Nagy B, Pataki H, Nagy ZK, Domokos A, Farkas A. Soft sensor for content prediction in an integrated continuous pharmaceutical formulation line based on the residence time distribution of unit operations. Int J Pharm 2022; 624:121950. [PMID: 35753540 DOI: 10.1016/j.ijpharm.2022.121950] [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: 03/31/2022] [Revised: 06/14/2022] [Accepted: 06/20/2022] [Indexed: 12/01/2022]
Abstract
In this study, a concentration predicting soft sensor was achieved based on the Residence Time Distribution (RTD) of an integrated, three-step pharmaceutical formulation line. The RTD was investigated with color-based tracer experiments using image analysis. Twin-screw wet granulation (TSWG) was directly coupled with a horizontal fluid bed dryer and an oscillating mill. Based on integrated measurement, we proved that it is also possible to couple the unit operations in silico. Three surrogate tracers were produced with a coloring agent to investigate the separated unit operations and the solid and liquid inputs of the TSWG. The soft sensor's prediction was compared to validating experiments of a 0.05 mg/g (15% of the nominal) concentration change with High-Performance Liquid Chromatography (HPLC) reference measurements of the active ingredient proving the adequacy of the soft sensor (RMSE < 4%).
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Affiliation(s)
- Martin Gyürkés
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Petra Záhonyi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Ákos Köte
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Zsombor Kristóf Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - András Domokos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
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Spahn JE, Hefnawy A, Smyth HDC, Zhang F. Development of a novel method for the continuous blending of carrier-based dry powders for inhalation using a co-rotating twin-screw extruder. Int J Pharm 2022; 623:121914. [PMID: 35716975 DOI: 10.1016/j.ijpharm.2022.121914] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/04/2022] [Revised: 06/10/2022] [Accepted: 06/11/2022] [Indexed: 11/27/2022]
Abstract
Twin-screw extruders are useful in tuning certain product characteristics due to the ability to greatly modify screw profiles as well as operating parameters. However, their use has not yet been applied to dry powder inhalation. In this study the feasibility of using a twin-screw extruder to blend dry powders for inhalation was assessed. Micronized rifampicin (1%) was used as a model drug with lactose carrier (median size ∼ 44 µm) and 0.4% magnesium stearate as a multi-functional ternary agent. Blend performance was compared with low shear (Turbula®) batch mixing. Similar blend uniformity and aerosol performance was observed, indicating the twin-screw extruder successfully functions as a mixer for dry powders for inhalation. The ability to utilize the twin-screw extruder as a continuous mixer leads to new opportunities in the continuous manufacturing of powders for inhalation.
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Affiliation(s)
- Jamie E Spahn
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, A1920 Austin, TX 78712, USA.
| | - Amr Hefnawy
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, A1920 Austin, TX 78712, USA
| | - Hugh D C Smyth
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, A1920 Austin, TX 78712, USA
| | - Feng Zhang
- Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, A1920 Austin, TX 78712, USA.
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Steenweg C, Seifert AI, Böttger N, Wohlgemuth K. Process Intensification Enabling Continuous Manufacturing Processes Using Modular Continuous Vacuum Screw Filter. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00294] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Claas Steenweg
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
| | - Astrid Ina Seifert
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
| | - Nils Böttger
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
| | - Kerstin Wohlgemuth
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
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Zettl M, Aigner I, Mannschott T, van der Wel P, Schröttner H, Khinast J, Krumme M. Characterization of a Novel Drying Technology for Continuous Processing of Cohesive Materials: An Ibuprofen Case Study. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00413] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Manuel Zettl
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | - Isabella Aigner
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | | | | | - Hartmuth Schröttner
- Graz University of Technology, Institute for Electron Microscopy and Nanoanalysis, 8010 Graz, Austria
- Austrian Centre for Electron Microscopy and Nanoanalysis (FELMI-ZFE), 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
- Graz University of Technology, Institute for Process and Particle Engineering, 8010 Graz, Austria
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Steenweg C, Seifert AI, Schembecker G, Wohlgemuth K. Characterization of a Modular Continuous Vacuum Screw Filter for Small-Scale Solid–Liquid Separation of Suspensions. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00550] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
Affiliation(s)
- Claas Steenweg
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
| | - Astrid Ina Seifert
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
| | - Gerhard Schembecker
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
| | - Kerstin Wohlgemuth
- Department of Biochemical and Chemical Engineering, Laboratory of Plant and Process Design, TU Dortmund University, D-44227 Dortmund, Germany
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Zettl M, Kreimer M, Aigner I, Mannschott T, van der Wel P, Khinast J, Krumme M. Runtime Maximization of Continuous Precipitation in an Ultrasonic Process Chamber. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.9b00311] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Manuel Zettl
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | - Manuel Kreimer
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | - Isabella Aigner
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
| | | | - Peter van der Wel
- Hosokawa Micron B.V., Gildenstraat 26, 7005 BL Doetinchem, The Netherlands
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering (RCPE) GmbH, 8010 Graz, Austria
- Institute for Process and Particle Engineering, Graz University of Technology, 8010 Graz, Austria
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