Controlling in situ crystallization of pharmaceutical particles within the spray dryer

Concept, design, and measurement methodology of a highly dynamic thin film dryer for experimental in situ drying manipulation

This paper describes the technical setup and validation of a thin film drying device in which the conditions such as air temperature, relative humidity, and velocity can be controlled in the range of 20-200 °C, 0-1.5 m s^-1, and vapor mass flows up to 1200 g min^-1. For the first time, it is possible to perform in situ manipulation of the drying kinetic in a highly dynamic manner. The setup allows for a precise online determination of drying and rehydration kinetics; the recording of relevant process parameters such as air humidity, air and surface temperature; and the monitoring of optically observable material properties. The concept for rapid real-time changes in drying conditions is explained, and the constructive details are elucidated. Highly precise gravimetry by a proposed measurement methodology and simultaneously avoiding condensation during rapid parameter changes is accomplished. This is achieved by the combination of minimized thermal inertia of the system, air conditioning via carrier gas-free evaporation, and a highly responsive active insulation. The influence on the drying kinetics by temperature, humidity, and air velocity is shown with experiments on aqueous maltose solution, and the experimental precision is validated. The validation showed a high grade of accuracy regarding gravimetric determination with a maximum observed mass difference of 0.21% referring to the dried product. The dynamics of the setup under in situ changes in drying conditions is exemplified by further experiments. In addition, the presented setup for the first time enables the real time manipulation and observation of kinetically coupled processes such as crystallization behavior, morphology formation, or material degradation during drying. Therefore, it has important practical value for the development of efficient and energy-saving drying methods and products with specific, tailor-made properties.

Application of a Microreactor to Pharmaceutical Manufacturing: Preparation of Amorphous Curcumin Nanoparticles and Controlling the Crystallinity of Curcumin Nanoparticles by Ultrasonic Treatment

Amorphous nanoparticles of curcumin (ANC) with primary particle sizes of 50 to 100 nm were prepared using a forced thin film reactor (FTFR). An ethanolic solution of curcumin and polyvinylpyrrolidone was mixed with purified water in an FTFR to precipitate the curcumin nanoparticles. In order to obtain amorphous particles, the solvent used and the operation conditions of FTFR such as the rotation speed of the disk and the flow rate of solutions were adjusted. According to powder X-ray diffraction (XRD) analysis and Fourier transform infrared spectroscopy (FT-IR), amorphous curcumin nanoparticles were obtained. To control the crystallinity, ultrasonic treatment was carried out on ANC suspended in water or hexane to which a polymer or a surfactant was added to prevent the growth of the particles. Transmission electron microscopy, XRD, and FT-IR analyses indicated that the treatment enabled the transformation of ANC to crystalline form 1 (a fundamental curcumin structure) and then to crystalline form 2 or crystalline form 3 without any change in the size of the primary particles. These findings suggest the possibility of preparing solid particles with a desired particle size and crystallinity.

Scale-up of pharmaceutical spray drying using scale-up rules: A review

Spray drying is one of the widely used manufacturing processes in pharmaceutical industry. While there are voluminous experimental studies pertaining to the impact of various process-formulation parameters on the quality attributes of spray dried powders such as particle size, morphology, density, and crystallinity, there is scant information available in the literature regarding process scale-up. Here, we first analyze salient features of scale-up attempts in literature. Then, spray drying process is analyzed considering the fundamental physical transformations involved, i.e., atomization, drying, and gas-solid separation. Each transformation is scrutinized from a scale-up perspective with non-dimensional parameters & multi-scale analysis, and comprehensively discussed in engineering context. Successful scale-up entails similar key response variables from each transformation across various scales. These variables are identified as droplet size distribution, outlet temperature, relative humidity, separator pressure loss coefficient, and collection efficiency. Instead of trial-and-error-based approaches, this review paper advocates the use of mechanistic models and scale-up rules for establishing design spaces for the process variables involved in each transformation of spray drying. While presenting a roadmap for process development and scale-up, the paper demonstrates how to bridge the current gap in spray drying scale-up via a rational understanding of the fundamental transformations.

Aerosol processing: a wind of innovation in the field of advanced heterogeneous catalysts

Aerosol processing technologies represent a major route of innovation in the mushrooming field of heterogeneous catalysts preparation.