A novel approach to derive a compression parameter indicating effective particle deformability

Development of a PAT platform for the prediction of granule tableting properties

In this work, the feasibility of implementing a process analytical technology (PAT) platform consisting of Near Infrared Spectroscopy (NIR) and particle size distribution (PSD) analysis was evaluated for the prediction of granule downstream processability. A Design of Experiments-based calibration set was prepared using a fluid bed melt granulation process by varying the binder content, granulation time, and granulation temperature. The granule samples were characterized using PAT tools and a compaction simulator in the 100-500 kg load range. Comparing the systematic variability in NIR and PSD data, their complementarity was demonstrated by identifying joint and unique sources of variation. These particularities of the data explained some differences in the performance of individual models. Regarding the fusion of data sources, the input data structure for partial least squares (PLS) based models did not significantly impact the predictive performance, as the root mean squared error of prediction (RMSEP) values were similar. Comparing PLS and artificial neural network (ANN) models, it was observed that the ANNs systematically provided superior model performance. For example, the best tensile strength, ejection stress, and detachment stress prediction with ANN resulted in an RMSEP of 0.119, 0.256, and 0.293 as opposed to the 0.180, 0.395, and 0.430 RMSEPs of the PLS models, respectively. Finally, the robustness of the developed models was assessed.

Breakage Strength of Wood Sawdust Pellets: Measurements and Modelling

Wood pellets are an important source of renewable energy. Their mechanical strength is a crucial property. In this study, the tensile strength of pellets made from oak, pine, and birch sawdust with moisture contents of 8% and 20% compacted at 60 and 120 MPa was determined in a diametral compression test. The highest tensile strength was noted for oak and the lowest for birch pellets. For all materials, the tensile strength was the highest for a moisture content of 8% and 120 MPa. All pellets exhibited a ductile breakage mode characterised by a smooth and round stress–deformation relationship without any sudden drops. Discrete element method (DEM) simulations were performed to check for the possibility of numerical reproduction of pelletisation of the sawdust and then of the pellet deformation in the diametral compression test. The pellet breakage process was successfully simulated using the DEM implemented with the bonded particle model. The simulations reproduced the results of laboratory testing well and provided deeper insight into particle–particle bonding mechanisms. Cracks were initiated close to the centre of the pellet and, as the deformation progressed, they further developed in the direction of loading.

Mechanical properties of starch esters at particle and compact level - Comparisons and exploration of the applicability of Hiestand's equation to predict tablet strength

Hydrophobic starch esters have potential as tablet matrix formers in controlled drug delivery. The mechanical properties of native starch (SN), starch acetate (SA) and starch propionate (SP) were studied at particle and compact level. Particle microhardness and modulus of elasticity were evaluated by nanoindentation. Force-displacement data of compressed powder were analyzed using Heckel in conjunction with piecewise regression, Kuentz-Leuenberger, Kawakita and Adams models, and yield pressure parameters were derived. Starches were characterized for chemical structure by Raman spectroscopy, crystallinity from powder x-ray diffraction (PXRD) patterns and surface energy from apparent contact angle measurements. A-type starch reflections were absent in the PXRDs of esters indicating greater amorphicity. Consequently, the particle microhardness of starch esters decreased leading to greater deformation during compaction and lower values of yield pressure parameters. These parameters increased with microhardness and ranked the starches in the order: SP < SA < SN. Fitting the experimental data into Hiestand's bonding index equation, a linear correlation (R² = 0.902) was established between experimental and calculated tablet strength describing results of all starches, when Adams (τ_ο') yield pressure was used as the 'effective compression pressure' in the above equation.

Discrete Element Method Modelling of the Diametral Compression of Starch Agglomerates

Starch agglomerates are widely applied in the pharmaceutical, agricultural, and food industries. The formation of potato starch tablets and their diametral compression were simulated numerically and verified in a laboratory experiment to analyse the microscopic mechanisms of the compaction and the origins of their breakage strength. Discrete element method (DEM) simulations were performed using EDEM software. Samples comprised of 120,000 spherical particles with radii normally distributed in the range of 5–36 μm were compacted in a cylindrical die with a diameter of 2.5 cm. The linear elastic–plastic constitutive contact model with a parallel bonded-particle model (BPM) was used to model the diametral compression. DEM simulations indicated that the BPM, together with the linear elastic–plastic contact model, could describe the brittle, semi-brittle, or ductile breakage mode, depending on the ratio of the strength to Young’s modulus of the bond and the bond-to-contact elasticity ratio. Experiments confirmed the findings of the DEM simulations and indicated that potato starch (PS) agglomerates can behave as a brittle, semi-brittle, or ductile material, depending on the applied binder. The PS agglomerates without any additives behaved as a semi-brittle material. The addition of 5% of ground sugar resulted in the brittle breakage mode. The addition of 5% gluten resulted in the ductile breakage mode.

Atypical compaction behaviour of disordered lactose explained by a shift in type of compact fracture pattern

The objective was to investigate tabletability and compactibility for compacts of a series of α-lactose monohydrate powders with different degree of disorder. Regarding the tabletability, the powders of high degree of disorder displayed similar behaviour that deviated markedly from the behaviour of the crystalline powders and the milled powder of modest degree of disorder. The Ryshkewitch-Duckworth equation, describing compactibility, was nearly linear for the crystalline powders, while for the disordered powders the model failed to describe the relationships, i.e. the disordered powders were characterised by a plateau in the Ryshkewitch-Duckworth plots over a relatively wide range of compact porosities. It was concluded that the difference in compaction behaviour of the milled particles compared to the crystalline powders was primarily explained by the increased particle plasticity of the disordered particles. The plateau in the Ryshkewitch-Duckworth plots obtained for the disordered powders was explained by a change in the fracture behaviour of the compacts, from an around grain to an across grain fracture pattern. This implied that the disordered particles can be described as a type of core-shell particles with an amorphous shell and a defective crystalline core.

A compression behavior classification system of pharmaceutical powders for accelerating direct compression tablet formulation design

In this paper, a compression behavior classification system (CBCS) for direct compression (DC) pharmaceutical powders is presented. Seven descriptors from a series of compression models for powder compressibility, compactibility and tabletability analysis were included in the CBCS. A new tabletability index d was proposed to differentiate three categories of tensile strength (TS) vs. pressure relationships, and its physical meaning was explained thoroughly. 130 materials containing diverse pharmaceutical excipients and natural product powders (NPPs) were fully characterized and were compiled into an in-house developed material library, in which 70 materials with potential DC applications were used to justify the effectiveness of the CBCS. Principle component analysis (PCA) was used to uncover the latent structure of compression variables. Moreover, partial least squares (PLS) regression models are established in prediction of both tablet TS and solid fraction (SF) based on the raw materials' physical characteristics, the compression behavior indices and the compression force. The obtained scores and loadings are used to group the materials and the compression variables, respectively. Different categories of tabletability for DC powders were clearly clustered along two orthogonal directions pointing to the index d and the compression force. Finally, a multi-objective design space was identified under the latent variable space, summarizing the operationally possible region for both material properties and compression pressure required in DC tablet formulation design.

Consolidation trend design based on Young's modulus of clarithromycin single crystals

The key aim of this study was to determine single mechanical properties of clarithromycin polymorphic forms in order to select some of them as more suitable for the tableting process. For this purpose, AFM single-point nanoindentation was used. The Young's moduli of clarithromycin polymorphs were substantially different, which was consistent with the structural variations in their packing motifs. The presence of the adjacent layers, which can easily slide over each other due to the low energy barrier (the lowest Young's modulus was 0.25 GPa) resulted in better bulk compressibility (the highest Heckel coefficient) of clarithromycin Form I. We also addressed the importance of tip geometry screening because the stress during the force mode often results in tip apex fracture. Even the initial manufacture of the diamond-coated tips can result in defects such as double-apex tips.

Use of Compaction Energetics for Understanding Particle Deformation Mechanism

A primary goal of the current work was to examine the potential use of compaction energetics as a tool to predict particle deformation mechanism. Three deformation models, namely, those developed by Heckel, Walker, and Gurnham, were first used to evaluate the deformation mechanisms of 11 commonly used excipients. To complement the information gained from the deformation models, the mechanical energy used in tablet formation was then examined. It has been found that the sum of the work in the compression and decompression phases (plastic work) is a relatively good indicator of a material's plasticity. Conclusions based on this indicator regarding deformation mechanism for the different diluents used were in good agreement with those obtained from the different deformation models studied.

Quantification of the compactibility of pharmaceutical powders

The purpose of this study is to investigate and to quantify the compactibility of pharmaceutical powders by a simple linear relationship between the diametral compressive strength of tablets and the applied compaction pressure. The mechanical strength of the tablets is characterized as the crushing force normalized with the dimension of the tablet and termed the specific crushing strength, SCS. The proposed model: SCS=Cp*P+b estimates the slope of the regression line Cp as a dimensionless compactibility parameter and is reported with the corresponding standard deviation SCp. The linear region of the compactibility profile is selected using the 95% predictability limits bordering the regression line. Eleven different materials were tested and acceptable fits to the linear model were observed in all cases. The ability of the model to discriminate between the investigated materials is excellent, in cases where the difference may be difficult to show a simple t-test is used as an inference tool. No difference was found between lactose tablets of different masses (500 and 1000 mg). A relationship between the compactibility parameter and the compressibility characterized by the Walker coefficient is demonstrated.

Particle size distribution and evolution in tablet structure during and after compaction

The objective of this study was to investigate the effect of the distribution in size of free-flowing particles for the evolution in tablet structure and tablet strength. For sucrose and sodium chloride, three powders of different size distributions were prepared by mixing predetermined quantities of particle size fractions. For paracetamol, three batches with varying particle size distributions were prepared by crystallisation. The powders were formed into tablets. Tablet porosity and tensile strength were determined directly after compaction and after short-term storage at two different relative humidities. Tablets were also formed after admixture of a lubricant (magnesium stearate) and the tablet tensile strength was determined. For the test materials used in this study, the spread in particle size had no influence on the evolution in tablet porosity and tensile strength during compression. However, the spread in particle size had a significant and complex influence on the short-term post-compaction increase in tablet tensile strength. The effect of the spread was related to the instability mechanism and the presence of lubricant. It is concluded that the distribution in size of free-flowing particles is not critical for the tablet porosity but may give significant effects on tablet tensile strength due to a post-compaction reaction.