A Nondestructive Technique to Determine the Rate of Oxygen Permeation into Solid Dosage Forms

Optimization of Critical Quality Attributes in Tablet Film Coating and Design Space Determination Using Pilot-Scale Experimental Data

In this study, the novel high-speed tablet film coating process in the continuous manufacturing was investigated. The influence of key process variables (inlet air flow rate, inlet air temperature, and suspension spray rate) were investigated using a Box-Behnken experimental design method. Statistical regression models were developed to predict the outlet air temperature and relative humidity, the coating efficiency, the tablet moisture content, and coating uniformity. The effects of the three key process variables were comprehensively investigated based on mathematical analysis, contour plots, and interaction plots. The results indicate that all the process responses are affected by changing the inlet air flow rate, temperature, and suspension spray rate. A design space (DS) in terms of failure probability was determined based on specifications for tablet moisture content (< 3.5%) and coating uniformity (tablet weight standard deviation < 4 mg for tablet weight of 200 mg) using Monte Carlo simulations. Independent experiments were carried out and successfully validated the robustness and accuracy of the determined DS for the investigated tablet film coating process. All the data were generated using an industrial pilot-scale novel high-speed tablet coating unit from a continuous manufacturing line. The work facilitates the quality by design implementation of continuous pharmaceutical manufacturing.

Novel Technique for Coating of Fine Particles Using Fluidized Bed and Aerosol Atomizer

Fine particles are widely used in many industrial fields, and there are many techniques applied for these particles, like electroplating, and chemical and physical vapor deposition. However, in the food and pharmaceutical industries, most coating processes conducted with fluidized bed use core particles with a diameter larger than 200 μm, otherwise agglomerates are formed. This study contributes to the development of a new coating process for fine particles with diameters of around 50 μm. The innovation lies in the combined use of a Wurster fluidized bed and a novel aerosol atomizer. The feasibility of the operation is based on the application of the aerosol atomizer, which generates droplets smaller than 1 μm in diameter. A series of experiments with different coating solutions and glass beads in a 150 mm fluidized bed fed with droplet aerosol supplied from the cone chamber bottom is presented. The quality of the coating product is analyzed by scanning electron microscopy and CAMSIZER®. In this way, the influence of different conditions and core material properties on the product quality were determined. Experimental results showed the coating layer quality getting worse as coating solution viscosity became lower, meanwhile moderate process temperature was found to enhance coating layer formation and quality of that. It was also observed that lower aerosol feed rates help improve the yield of the process.

A Thermodynamic Balance Model for Liquid Film Drying Kinetics of a Tablet Film Coating and Drying Process

A tablet film coating and drying process was assessed by an experimentally validated thermodynamic balance model. Mass conservation equations were derived for the process air and the aqueous coating solution. Thermodynamic behavior of the solution was described by evaporation at the tablet surface and penetration into the tablet. Energy balance equations including heat loss to the atmosphere were coupled to the mass conservation equation. Experimental data using the ConsiGma™ coater (GEA, Belgium) were used for both parameter estimation and model validation. The results showed the proposed model can investigate primitive outlet variables and further internal variables representing evaporation and penetration. A sensitivity analysis revealed that evaporation depended more on the input parameters while penetration hinges on the tablet properties, particularly on the tablet volume affecting the tablet porosity.

Development of a PAT tool for monitoring the Wurster coater performance

Real-time process analytical technology (PAT) is proposed as an effective approach for monitoring the performance of a Wurster coater. The coater was used for coating of 0.78 mm pharmaceutical pellets. The coating solution consisted of Hydroxypropyl methylcellulose/Poly ethylene glycol. During the coating process, small amounts of pellets (∼2 g) were sampled at 10 min. intervals and the pressure fluctuations were recorded at the same time. The signals were analyzed using the wavelet transform (WT) and decomposed into different sub-signals. Principal component analysis (PCA) was employed to the energies of these sub-signals, whose outliers were eliminated using the Mahalanobis distance method. The reference coating thickness data were obtained via spectrophotometry during the coating process. The partial least squares (PLS) regression was incorporated with the PCA for the development of a model for prediction of the coating thickness. The PLS regression revealed that the pressure fluctuations can be used to evaluate the thickness with a good precision. This study demonstrated the applicability of pressure fluctuations for the prediction of the coating thickness. This method can be regarded as a new robust, fast and non-intrusive PAT approach for monitoring the coating process which can be easily used by engineers and practitioners.

Enhancing the Dissolution Stability of Hard Gelatin Capsules Using Activated Carbon as a Packaging Component

Hard gelatin capsule (HGC) shells are widely used to encapsulate drugs for oral delivery but are vulnerable to gelatin cross-linking, which can lead to slower and more variable in vitro dissolution rates. Adding proteolytic enzymes to the dissolution medium can attenuate these problems, but this complicates dissolution testing and is only permitted by some regulatory authorities. Here, we expand the scope of our previous work to demonstrate that canisters containing activated carbon (AC) or polymeric films embedded with AC particles can be used as packaging components to attenuate gelatin cross-linking and improve the dissolution stability of hard gelatin-encapsulated products under accelerated International Council for Harmonisation conditions. We packaged acetaminophen and diphenhydramine HCl HGCs with or without AC canisters in induction-sealed high-density polyethylene bottles and with or without AC films in stoppered glass vials and stored these samples at 50°C/75% relative humidity through 3 months and at 40°C/75% relative humidity for 6 months. Samples packaged with AC canisters or AC films dissolved more rapidly than samples packaged without AC when differences were observed. These results demonstrate that different sources and formats of AC can enhance the dissolution stability of HGCs packaged in bottles and other potential packaging systems such as blister cards.

Use of Activated Carbon in Packaging to Attenuate Formaldehyde-Induced and Formic Acid-Induced Degradation and Reduce Gelatin Cross-Linking in Solid Dosage Forms

Formaldehyde and formic acid are reactive impurities found in commonly used excipients and can be responsible for limiting drug product shelf-life. Described here is the use of activated carbon in drug product packaging to attenuate formaldehyde-induced and formic acid-induced drug degradation in tablets and cross-linking in hard gelatin capsules. Several pharmaceutical products with known or potential vulnerabilities to formaldehyde-induced or formic acid-induced degradation or gelatin cross-linking were subjected to accelerated stability challenges in the presence and absence of activated carbon. The effects of time and storage conditions were determined. For all of the products studied, activated carbon attenuated drug degradation or gelatin cross-linking. This novel use of activated carbon in pharmaceutical packaging may be useful for enhancing the chemical stability of drug products or the dissolution stability of gelatin-containing dosage forms and may allow for the 1) extension of a drug product's shelf-life when the limiting attribute is a degradation product induced by a reactive impurity, 2) marketing of a drug product in hotter and more humid climatic zones than currently supported without the use of activated carbon, and 3) enhanced dissolution stability of products that are vulnerable to gelatin cross-linking.

Influence of process parameters on tablet bed microenvironmental factors during pan coating

Recent studies have shown the importance of monitoring microenvironmental conditions (temperature, relative humidity) experienced by the tablet bed during a pan coating process, thereby necessitating the need to understand how various process parameters influence these microenvironmental conditions. The process parameters studied in this work include exhaust air temperature, spray rate, inlet airflow rate, gun-to-bed distance, coating suspension percent solids, and atomization and pattern air pressure. Each of these process parameters was found to have an impact on the tablet bed relative humidity (RH), as measured using PyroButton data logging devices. A higher tablet bed RH was obtained with an increase in spray rate and atomization air pressure and with a decrease in exhaust air temperature, inlet airflow rate, gun-to-bed distance, suspension percent solids, and pattern air pressure. Based on this work, it can be concluded that the tablet bed thermodynamic conditions are a cumulative effect of the various process conditions. A strong correlation between the tablet bed RH and the frequency of tablet coating defect (logo bridging) was established, with increasing RH resulting in a higher percent of logo bridging events.

Effect of formulation conditions on hypromellose performance properties in films used for capsules and tablet coatings

This study investigated the effects of polymer dispersion and hydration conditions on hypromellose (HPMC) film properties, such as strength, oxygen permeability, water vapor transmission, clarity, and haze. The focus of the study was to build a better understanding of the impact that changes to HPMC dispersion and hydration conditions have on performance properties of the resulting films. This understanding could potentially lead to more flexible formulation guidelines for formulators. Films of HPMC 2906 (USP) were produced from aqueous solutions prepared using various formulation conditions. Results showed that tensile properties and oxygen permeability were not significantly affected by the variables used. The differences observed in water vapor transmission are unlikely to affect practical application of the material. However, the differences observed in clarity and haze at 50°C hydration temperature could affect the appearance of a capsule or coated tablet. Several methods were used to determine whether loss of optical properties was due to surface phenomena or bulk defects within a film. Results indicated that the cloudy appearance was primarily due to surface roughness. Based on this information, there is some flexibility in formulation conditions; however, hydration temperatures greater than 25°C are not recommended.

A novel imaging technique to investigate the influence of atomization air pressure on film-tablet interfacial thickness

A novel X-ray photoelectron spectroscopic (XPS) technique combined with principal component analysis of spectra-to-image datasets was employed to study the effects of atomization air pressure used during the coating process on film-tablet interfacial thickness. Placebo tablet cores were prepared and coated with Eudragit RL 30 D. Atomization air pressure was varied from 10 to 20 psi, whereas all other processing parameters were held constant. Higher air pressures generally produced thinner interfaces, although the interfacial region was not uniform across the tablet surface and was dependent on the sampling location. These results demonstrate the suitability of this XPS technique to study the coating-tablet interface. Moreover, the variability in the interfacial thickness illustrates the need to further study such systems.

Characterization of coating systems

Polymeric film coatings have been applied to solid substrates for decorative, protective, and functional purposes. Irrespective of the reasons for coating, certain properties of the polymer films may be determined as a method to evaluate coating formulations, substrate variables, and processing conditions. This article describes experimental techniques to assess various properties of both free and applied films, including water vapor and oxygen permeability, as well as thermal, mechanical, and adhesive characteristics. Methods to investigate interfacial interactions are also presented.

A rapid technique to evaluate the oxidative stability of a model drug

The objective of the current study was to investigate the oxidative induction time (OIT) as a measurement of the stability of an oxygen-sensitive model drug. The OIT was determined by differential scanning calorimetry and represents the time required for oxidative decomposition to occur at a given temperature. Samples were heated to a specific temperature under a nitrogen blanket then held isothermal while exposed to oxygen. The experiment proceeded until oxidative degradation of the sample was apparent from the real-time heat flow graphs. Variables investigated in this study included different lots and suppliers of a model drug as well as the addition of antioxidants. Results demonstrated that the stability of the drug was dependent on the supplier. All antioxidants investigated in this study improved oxygen stability of the model compound, as evidenced by a longer OIT. Butylated hydroxyanisole (BHA) was found to better stabilize the drug than butylated hydroxytoluene at equivalent concentrations. The combination of ascorbic acid and BHA provided the greatest protection against oxidation of the model compound. The results of this study demonstrate the usefulness of OIT to investigate the oxygen stability of pharmaceutical compounds.