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Machine Learning for Process Monitoring and Control of Hot-Melt Extrusion: Current State of the Art and Future Directions. Pharmaceutics 2021; 13:pharmaceutics13091432. [PMID: 34575508 PMCID: PMC8466632 DOI: 10.3390/pharmaceutics13091432] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/25/2021] [Revised: 08/26/2021] [Accepted: 09/06/2021] [Indexed: 01/11/2023] Open
Abstract
In the last few decades, hot-melt extrusion (HME) has emerged as a rapidly growing technology in the pharmaceutical industry, due to its various advantages over other fabrication routes for drug delivery systems. After the introduction of the ‘quality by design’ (QbD) approach by the Food and Drug Administration (FDA), many research studies have focused on implementing process analytical technology (PAT), including near-infrared (NIR), Raman, and UV–Vis, coupled with various machine learning algorithms, to monitor and control the HME process in real time. This review gives a comprehensive overview of the application of machine learning algorithms for HME processes, with a focus on pharmaceutical HME applications. The main current challenges in the application of machine learning algorithms for pharmaceutical processes are discussed, with potential future directions for the industry.
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Bandari S, Nyavanandi D, Dumpa N, Repka MA. Coupling hot melt extrusion and fused deposition modeling: Critical properties for successful performance. Adv Drug Deliv Rev 2021; 172:52-63. [PMID: 33571550 DOI: 10.1016/j.addr.2021.02.006] [Citation(s) in RCA: 62] [Impact Index Per Article: 20.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/27/2020] [Revised: 01/14/2021] [Accepted: 02/04/2021] [Indexed: 01/19/2023]
Abstract
Interest in 3D printing for pharmaceutical applications has increased in recent years. Compared to other 3D printing techniques, hot melt extrusion (HME)-based fused deposition modeling (FDM) 3D printing has been the most extensively investigated for patient-focused dosage. HME technology can be coupled with FDM 3D printing as a continuous manufacturing process. However, the crucial pharmaceutical polymers, formulation and process parameters must be investigated to establish HME-coupled FDM 3D printing. These advancements will lead the way towards developing continuous drug delivery systems for personalized therapy. This brief overview classifies pharmaceutical additive manufacturing, Hot Melt Extrusion, and Fused Deposition Modeling 3D printing techniques with a focus on coupling HME and FDM 3D printing processes. It also provides insights on the critical material properties, process and equipment parameters and limitations of successful HME-coupled FDM systems.
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Affiliation(s)
- Suresh Bandari
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Dinesh Nyavanandi
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Nagireddy Dumpa
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677, USA; Pii Center for Pharmaceutical Technology, The University of Mississippi, University, MS 38677, USA.
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Queiroz ALP, Rodrigues M, Zeglinski J, Crean AM, Sarraguça MC, Vucen S. Determination of co-crystal phase purity by mid infrared spectroscopy and multiple curve resolution. Int J Pharm 2021; 595:120246. [PMID: 33482224 DOI: 10.1016/j.ijpharm.2021.120246] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/29/2020] [Revised: 12/17/2020] [Accepted: 12/18/2020] [Indexed: 11/29/2022]
Abstract
Multivariate Curve Resolution (MCR) was used to determine the phase purity of pharmaceutical co-crystals from mid infrared spectra. An in-silico coformer screening was used to choose one of ten potential coformers. This analysis used quantum chemistry simulation to predict which coformers are thermodynamically inclined to form cocrystals with the model drug, hydrochlorothiazide. The coformer chosen was nicotinamide. An experimental solvent screening by ultrasound assisted slurry co-crystallization was performed to evaluate the capacity of the method to determine phase purity. Afterwards, slurry and slow evaporation co-crystallizations were performed at 10, 25, and 40 °C using 7 solvent systems, and two levels of agitation for the evaporation co-crystallization (on and off). Mid infrared spectroscopy (MIRS) analysis of the products of these co-crystallizations was used to develop an MCR model to determine co-crystal phase purity. The MCR results were compared with a reference co-crystal. Experimental design (DoE) was used to investigate the effect of solvents, temperature, and agitation on the purity of co-crystals produced by slurry and evaporation co-crystallization. DoE revealed that evaporation co-crystallization with agitating at 65 rpm formed co-crystals with greater phase purity. The optimal temperature varied with the solvent used.
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Affiliation(s)
- Ana Luiza P Queiroz
- SSPC Pharmaceutical Research Centre, School of Pharmacy, University College Cork, Cork, Ireland; APC Ltd., Building 11, Cherrywood Business Park, Loughlinstown, Dublin D18 DH50, Ireland
| | - Marisa Rodrigues
- LAQV/REQUIMTE, Departamento de Ciências Químicas, Faculdade de Farmácia, Universidade do Porto, Rua Jorge Viterbo Ferreira, 228, 4050-313 Porto, Portugal
| | - Jacek Zeglinski
- APC Ltd., Building 11, Cherrywood Business Park, Loughlinstown, Dublin D18 DH50, Ireland
| | - Abina M Crean
- SSPC Pharmaceutical Research Centre, School of Pharmacy, University College Cork, Cork, Ireland
| | - Mafalda Cruz Sarraguça
- LAQV/REQUIMTE, Departamento de Ciências Químicas, Faculdade de Farmácia, Universidade do Porto, Rua Jorge Viterbo Ferreira, 228, 4050-313 Porto, Portugal.
| | - Sonja Vucen
- SSPC Pharmaceutical Research Centre, School of Pharmacy, University College Cork, Cork, Ireland
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Vo AQ, Kutz G, He H, Narala S, Bandari S, Repka MA. Continuous Manufacturing of Ketoprofen Delayed Release Pellets Using Melt Extrusion Technology: Application of QbD Design Space, Inline Near Infrared, and Inline Pellet Size Analysis. J Pharm Sci 2020; 109:3598-3607. [PMID: 32916139 PMCID: PMC7680423 DOI: 10.1016/j.xphs.2020.09.007] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/09/2020] [Revised: 08/27/2020] [Accepted: 09/03/2020] [Indexed: 11/27/2022]
Abstract
Delayed-release dosage forms are mainly manufactured as batch processes and include coated tablets, pellets, or particles with gastric resistant polymers. Authors propose a novel approach using the hot-melt extrusion technique to prepare delayed release dosage forms via a continuous manufacturing process, a new trend in the pharmaceutical industry. A full factorial design was employed to correlate input variables, including stearic acid (SA) content, drug content, and pellet size with drug release properties of the pellets. PLS fit method suitably elaborated the relationship between input and output variables with reasonably good fit and goodness of prediction. All three input factors influenced drug release in enzyme-free simulated gastric fluid (SGF) after 120 min; however, SA content did not significantly affect drug dissolution in the enzyme-free simulated intestinal fluid (SIF). An optimized formulation and design space were determined by overlaying multiple contours established from regression equations. The continuous manufacturing process was successfully monitored using inline near-infrared (NIR) and inline particle size analysis, with drug load and pellet size being well-controlled within the design space. The obtained pellets released less than 5% after 120 min in SGF and more than 85% and 95% after 30 min and 45 min, respectively, after switching to SIF.
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Affiliation(s)
- Anh Q Vo
- School of Pharmacy, University of Mississippi, University, MS 38677, USA; Department of Physical Chemistry and Physics, Hanoi University of Pharmacy, Hanoi, Vietnam
| | - Gerd Kutz
- OWL University of Applied Sciences and Arts, Pharmaceutical Engineering, Lemgo, Germany
| | - Herman He
- Thermo Fisher Scientific, Tewksbury, MA 01876, USA
| | - Sagar Narala
- School of Pharmacy, University of Mississippi, University, MS 38677, USA
| | - Suresh Bandari
- School of Pharmacy, University of Mississippi, University, MS 38677, USA
| | - Michael A Repka
- School of Pharmacy, University of Mississippi, University, MS 38677, USA; Pii Center for Pharmaceutical Technology, The University of Mississippi, University, MS 38677, USA.
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Deshkar S, Rathi M, Zambad S, Gandhi K. Hot Melt Extrusion and its Application in 3D Printing of Pharmaceuticals. Curr Drug Deliv 2020; 18:387-407. [PMID: 33176646 DOI: 10.2174/1567201817999201110193655] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/22/2020] [Revised: 09/10/2020] [Accepted: 09/29/2020] [Indexed: 11/22/2022]
Abstract
Hot Melt Extrusion (HME) is a continuous pharmaceutical manufacturing process that has been extensively investigated for solubility improvement and taste masking of active pharmaceutical ingredients. Recently, it is being explored for its application in 3D printing. 3D printing of pharmaceuticals allows flexibility of dosage form design, customization of dosage form for personalized therapy and the possibility of complex designs with the inclusion of multiple actives in a single unit dosage form. Fused Deposition Modeling (FDM) is a 3D printing technique with a variety of applications in pharmaceutical dosage form development. FDM process requires a polymer filament as the starting material that can be obtained by hot melt extrusion. Recent reports suggest enormous applications of a combination of hot melt extrusion and FDM technology in 3D printing of pharmaceuticals and need to be investigated further. This review in detail describes the HME process, along with its application in 3D printing. The review also summarizes the published reports on the application of HME coupled with 3D printing technology in drug delivery.
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Affiliation(s)
- Sanjeevani Deshkar
- Department of Pharmaceutics, Dr. D.Y. Patil Institute of Pharamceutical Sciences and Research, Pune, Maharashtra 411018, India
| | - Mrunali Rathi
- Department of Pharmaceutics, Dr. D.Y. Patil Institute of Pharamceutical Sciences and Research, Pune, Maharashtra 411018, India
| | - Shital Zambad
- ThinCR Technologies India Pvt Ltd, Rahatani, Pune, Maharashtra 411017, India
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De-risking excipient particle size distribution variability with automated robust mixing: Integrating quality by design and process analytical technology. Eur J Pharm Biopharm 2020; 157:9-24. [PMID: 33022392 DOI: 10.1016/j.ejpb.2020.09.014] [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: 07/25/2020] [Revised: 09/14/2020] [Accepted: 09/22/2020] [Indexed: 11/21/2022]
Abstract
BACKGROUND Particle size distribution (PSD) variability in excipients affects mixing. In response, manufacturers rely on raw material control and rigidly defined process parameters to achieve quality. However, this status quo is costly; and diverges from regulatory exceptions for process robustness. Although robustness improves cost and material usage efficiency, it remains under-adopted. METHOD To address this gap, a robust batch mixing operation that mitigated the impact of PSD variability was evaluated, with blends comprising chlorpheniramine, microcrystalline cellulose and lactose. PSD of lactose was varied to simulate commercially-relevant variability. Due to PSD-induced rheological variations, the blends had different optimal mixing speeds. For the automation study, near infrared (NIR) spectroscopy; process optimization and endpoint detection algorithms; and control hardware were integrated within a cluster of software environments. NIR spectroscopy was employed for in-line PSD characterization and blend monitoring, to modulate mixing speed and detect endpoint (feedforward and feedback control). RESULTS NIR spectroscopy rapidly detected PSD variations by the 6th-9th rotations, to activate feedforward control, which mitigated the effect of PSD variability and reduced the mixing time by 13-34%. Endpoints were correctly detected. PSD variations and blend homogeneity were accurately predicted (relative standard error of prediction ≤ 2%). CONCLUSION The automated robust mixing operation was successful. Pertinently, NIR spectrometer can be adopted for multimodal sensing. Its applicability for production-driven characterization of raw materials in batch and continuous pharmaceutical processing should be further explored. Lastly, this study laid the groundwork for end-to-end implementation of process analytical technology in robust batch processing.
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Detsi A, Kavetsou E, Kostopoulou I, Pitterou I, Pontillo ARN, Tzani A, Christodoulou P, Siliachli A, Zoumpoulakis P. Nanosystems for the Encapsulation of Natural Products: The Case of Chitosan Biopolymer as a Matrix. Pharmaceutics 2020; 12:E669. [PMID: 32708823 PMCID: PMC7407519 DOI: 10.3390/pharmaceutics12070669] [Citation(s) in RCA: 54] [Impact Index Per Article: 13.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/29/2020] [Revised: 06/24/2020] [Accepted: 06/25/2020] [Indexed: 12/12/2022] Open
Abstract
Chitosan is a cationic natural polysaccharide, which has emerged as an increasingly interesting biomaterialover the past few years. It constitutes a novel perspective in drug delivery systems and nanocarriers' formulations due to its beneficial properties, including biocompatibility, biodegradability and low toxicity. The potentiality of chemical or enzymatic modifications of the biopolymer, as well as its complementary use with other polymers, further attract the scientific community, offering improved and combined properties in the final materials. As a result, chitosan has been extensively used as a matrix for the encapsulation of several valuable compounds. In this review article, the advantageous character of chitosan as a matrix for nanosystemsis presented, focusing on the encapsulation of natural products. A five-year literature review is attempted covering the use of chitosan and modified chitosan as matrices and coatings for the encapsulation of natural extracts, essential oils or pure naturally occurring bioactive compounds are discussed.
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Affiliation(s)
- Anastasia Detsi
- Department of Chemical Sciences, Laboratory of Organic Chemistry, School of Chemical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou Campus, 15780 Athens, Greece; (E.K.); (I.K.); (I.P.); (A.R.N.P.); (A.T.)
| | - Eleni Kavetsou
- Department of Chemical Sciences, Laboratory of Organic Chemistry, School of Chemical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou Campus, 15780 Athens, Greece; (E.K.); (I.K.); (I.P.); (A.R.N.P.); (A.T.)
| | - Ioanna Kostopoulou
- Department of Chemical Sciences, Laboratory of Organic Chemistry, School of Chemical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou Campus, 15780 Athens, Greece; (E.K.); (I.K.); (I.P.); (A.R.N.P.); (A.T.)
| | - Ioanna Pitterou
- Department of Chemical Sciences, Laboratory of Organic Chemistry, School of Chemical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou Campus, 15780 Athens, Greece; (E.K.); (I.K.); (I.P.); (A.R.N.P.); (A.T.)
| | - Antonella Rozaria Nefeli Pontillo
- Department of Chemical Sciences, Laboratory of Organic Chemistry, School of Chemical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou Campus, 15780 Athens, Greece; (E.K.); (I.K.); (I.P.); (A.R.N.P.); (A.T.)
| | - Andromachi Tzani
- Department of Chemical Sciences, Laboratory of Organic Chemistry, School of Chemical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou Campus, 15780 Athens, Greece; (E.K.); (I.K.); (I.P.); (A.R.N.P.); (A.T.)
| | - Paris Christodoulou
- Institute of Chemical Biology, National Hellenic Research Foundation, Vassileos Constantinou Ave. 48, 116 35 Athens, Greece; (P.C.); (A.S.)
| | - Aristeia Siliachli
- Institute of Chemical Biology, National Hellenic Research Foundation, Vassileos Constantinou Ave. 48, 116 35 Athens, Greece; (P.C.); (A.S.)
- Department of Biochemistry and Biotechnology, University of Thessaly, Viopolis, 41500 Larissa, Greece
| | - Panagiotis Zoumpoulakis
- Institute of Chemical Biology, National Hellenic Research Foundation, Vassileos Constantinou Ave. 48, 116 35 Athens, Greece; (P.C.); (A.S.)
- Department of Food Science and Technology, Universisty of West Attica, Ag. Spyridonos Str., Egaleo, 12243 Athens, Greece
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Scheibelhofer O, Kruisz J, Rehrl J, Faulhammer E, Witschnigg A, Khinast JG. LIF or dye: Comparison of different tracing methods for granular solids. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.03.033] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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Feidl F, Vogg S, Wolf M, Podobnik M, Ruggeri C, Ulmer N, Wälchli R, Souquet J, Broly H, Butté A, Morbidelli M. Process‐wide control and automation of an integrated continuous manufacturing platform for antibodies. Biotechnol Bioeng 2020; 117:1367-1380. [DOI: 10.1002/bit.27296] [Citation(s) in RCA: 51] [Impact Index Per Article: 12.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/19/2019] [Accepted: 02/03/2020] [Indexed: 12/17/2022]
Affiliation(s)
- Fabian Feidl
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Sebastian Vogg
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Moritz Wolf
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Matevz Podobnik
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Caterina Ruggeri
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Nicole Ulmer
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Ruben Wälchli
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Jonathan Souquet
- Merck Serono S.A. Biotech Process Sciences Corsier‐sur‐Vevey Switzerland
| | - Hervé Broly
- Merck Serono S.A. Biotech Process Sciences Corsier‐sur‐Vevey Switzerland
| | - Alessandro Butté
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
| | - Massimo Morbidelli
- Institute for Chemical and BioengineeringDepartment of Chemistry and Applied BiosciencesZurich Switzerland
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Development and Validation of an In-Line API Quantification Method Using AQbD Principles Based on UV-Vis Spectroscopy to Monitor and Optimise Continuous Hot Melt Extrusion Process. Pharmaceutics 2020; 12:pharmaceutics12020150. [PMID: 32059445 PMCID: PMC7076712 DOI: 10.3390/pharmaceutics12020150] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/13/2019] [Revised: 02/10/2020] [Accepted: 02/10/2020] [Indexed: 01/16/2023] Open
Abstract
A key principle of developing a new medicine is that quality should be built in, with a thorough understanding of the product and the manufacturing process supported by appropriate process controls. Quality by design principles that have been established for the development of drug products/substances can equally be applied to the development of analytical procedures. This paper presents the development and validation of a quantitative method to predict the concentration of piroxicam in Kollidon® VA 64 during hot melt extrusion using analytical quality by design principles. An analytical target profile was established for the piroxicam content and a novel in-line analytical procedure was developed using predictive models based on UV-Vis absorbance spectra collected during hot melt extrusion. Risks that impact the ability of the analytical procedure to measure piroxicam consistently were assessed using failure mode and effect analysis. The critical analytical attributes measured were colour (L* lightness, b* yellow to blue colour parameters—in-process critical quality attributes) that are linked to the ability to measure the API content and transmittance. The method validation was based on the accuracy profile strategy and ICH Q2(R1) validation criteria. The accuracy profile obtained with two validation sets showed that the 95% β-expectation tolerance limits for all piroxicam concentration levels analysed were within the combined trueness and precision acceptance limits set at ±5%. The method robustness was tested by evaluating the effects of screw speed (150–250 rpm) and feed rate (5–9 g/min) on piroxicam content around 15% w/w. In-line UV-Vis spectroscopy was shown to be a robust and practical PAT tool for monitoring the piroxicam content, a critical quality attribute in a pharmaceutical HME process.
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Exploring the Complexity of Processing-Induced Dehydration during Hot Melt Extrusion Using In-Line Raman Spectroscopy. Pharmaceutics 2020; 12:pharmaceutics12020116. [PMID: 32024085 PMCID: PMC7076463 DOI: 10.3390/pharmaceutics12020116] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/08/2019] [Revised: 01/16/2020] [Accepted: 01/17/2020] [Indexed: 11/21/2022] Open
Abstract
The specific aim in this study was to understand the effect of critical process parameters on the solid form composition of model drug compounds during hot melt extrusion using in-line Raman spectroscopy combined with Multivariate Curve Resolution-Alternating Least Squares (MCR-ALS) modeling for semi-quantitative kinetic profiling. It was observed that the hydrate and anhydrate solid forms of two model drugs in the melts of nitrofurantoin (NF):polyethylene oxide (PEO) and piroxicam (PRX):PEO could be resolved from a MCR-ALS model without an external calibration dataset. Based on this model, the influence of two critical process parameters (shear and temperature) on the solid form composition could be evaluated in a real-time mode and the kinetics of complex transformation pathways could be explored. Additionally, the dehydration pathways of NF monohydrate and PRX monohydrate in molten PEO could be derived. It can be concluded that dehydration of both hydrates in PEO occurs via competing mechanisms—a solution-mediated transformation pathway and a solid–solid transformation, and that the balance between these mechanisms is determined by the combined effect of both temperature and shear. Another important observation was that the water released from these hydrate compounds has a detectable effect on the rheological characteristics of this mixture.
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Process monitoring and fault detection on a hot-melt extrusion process using in-line Raman spectroscopy and a hybrid soft sensor. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2019.03.019] [Citation(s) in RCA: 17] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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13
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Design space determination and process optimization in at-scale continuous twin screw wet granulation. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2019.03.026] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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14
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Su Q, Bommireddy Y, Shah Y, Ganesh S, Moreno M, Liu J, Gonzalez M, Yazdanpanah N, O’Connor T, Reklaitis GV, Nagy ZK. Data reconciliation in the Quality-by-Design (QbD) implementation of pharmaceutical continuous tablet manufacturing. Int J Pharm 2019; 563:259-272. [PMID: 30951859 PMCID: PMC9976296 DOI: 10.1016/j.ijpharm.2019.04.003] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/01/2019] [Revised: 03/25/2019] [Accepted: 04/02/2019] [Indexed: 11/25/2022]
Abstract
Data provided by in situ sensors is always affected by some level of impreciseness as well as uncertainty in the measurements due to process operation disturbance or material property variance. In-process data precision and reliability should be considered when implementing active product quality control and real-time process decision making in pharmaceutical continuous manufacturing. Data reconciliation is an important strategy to address such imperfections effectively, and to exploit the data redundancy and data correlation based on process understanding. In this study, a correlation between tablet weight and main compression force in a rotary tablet press was characterized by the classical Kawakita equation. A load cell, situated at the exit of the tablet press chute, was also designed to measure the tablet production rate as well as the tablet weight. A novel data reconciliation strategy was proposed to reconcile the tablet weight measurement subject to the correlation between tablet weight and main compression force, in such, the imperfect tablet weight measurement can be reconciled with the much more precise main compression force measurement. Special features of the Welsch robust estimator to reject the measurement gross errors and the Kawakita model parameter estimation to monitor the material property variance were also discussed. The proposed data reconciliation strategy was first evaluated with process control open-loop and closed-loop experimental data and then integrated into the process control system in a continuous tablet manufacturing line. Specifically, the real-time reconciled tablet weight measurements were independently verified with an at-line Sotax Auto Test 4 tablet weight measurements every five minutes. Promising and reliable performance of the reconciled tablet weight measurement was demonstrated in achieving process automation and quality control of tablet weight in pilot production runs.
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Affiliation(s)
- Qinglin Su
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States.
| | - Yasasvi Bommireddy
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Yash Shah
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Mariana Moreno
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Jianfeng Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States,Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
| | - Nima Yazdanpanah
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Thomas O’Connor
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, MD 20993, United States
| | - Gintaras V. Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States,Corresponding authors. (Q. Su), (Z.K. Nagy)
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Kallakunta VR, Sarabu S, Bandari S, Tiwari R, Patil H, Repka MA. An update on the contribution of hot-melt extrusion technology to novel drug delivery in the twenty-first century: part I. Expert Opin Drug Deliv 2019; 16:539-550. [PMID: 31007090 PMCID: PMC6791722 DOI: 10.1080/17425247.2019.1609448] [Citation(s) in RCA: 36] [Impact Index Per Article: 7.2] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/05/2019] [Accepted: 04/16/2019] [Indexed: 10/27/2022]
Abstract
INTRODUCTION Currently, hot melt extrusion (HME) is a promising technology in the pharmaceutical industry, as evidenced by its application to manufacture various FDA-approved commercial products in the market. HME is extensively researched for enhancing the solubility and bioavailability of poor water-soluble drugs, taste masking, and modifying release in drug delivery systems. Additionally, its other novel opportunities or pharmaceutical applications, and capability for continuous manufacturing are being investigated. This efficient, industrially scalable, solvent-free, continuous process can be easily automated and coupled with other novel platforms for continuous manufacturing of pharmaceutical products. AREAS COVERED This review focuses on updates on solubility enhancement of poorly water-soluble drugs and process analytical tools such as UV/visible spectrophotometry; near-infrared spectroscopy; Raman spectroscopy; and rheometry for continuous manufacturing, with a special emphasis on fused deposition modeling 3D printing. EXPERT OPINION The strengths, weakness, opportunities, threats (SWOT) and availability of commercial products confirmed wide HME applicability in pharmaceutical research. Increased interest in continuous manufacturing processes makes HME a promising strategy for this application. However, there is a need for extensive research using process analytical tools to establish HME as a dependable continuous manufacturing process.
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Affiliation(s)
- Venkata Raman Kallakunta
- Department of Pharmaceutics and Drug Delivery, The University of Mississippi, University, MS 38677
| | - Sandeep Sarabu
- Department of Pharmaceutics and Drug Delivery, The University of Mississippi, University, MS 38677
| | - Suresh Bandari
- Department of Pharmaceutics and Drug Delivery, The University of Mississippi, University, MS 38677
| | - Roshan Tiwari
- Department of Pharmaceutics and Drug Delivery, The University of Mississippi, University, MS 38677
| | - Hemlata Patil
- Department of Pharmaceutics and Drug Delivery, The University of Mississippi, University, MS 38677
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, The University of Mississippi, University, MS 38677
- Pii Center for Pharmaceutical Technology, The University of Mississippi, University, MS 38677
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Karttunen AP, Hörmann TR, De Leersnyder F, Ketolainen J, De Beer T, Hsiao WK, Korhonen O. Measurement of residence time distributions and material tracking on three continuous manufacturing lines. Int J Pharm 2019; 563:184-197. [DOI: 10.1016/j.ijpharm.2019.03.058] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/11/2018] [Revised: 03/21/2019] [Accepted: 03/27/2019] [Indexed: 10/27/2022]
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17
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Nagy B, Farkas A, Borbás E, Vass P, Nagy ZK, Marosi G. Raman Spectroscopy for Process Analytical Technologies of Pharmaceutical Secondary Manufacturing. AAPS PharmSciTech 2018; 20:1. [PMID: 30560395 DOI: 10.1208/s12249-018-1201-2] [Citation(s) in RCA: 59] [Impact Index Per Article: 9.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/01/2018] [Accepted: 10/01/2018] [Indexed: 01/03/2023] Open
Abstract
As the process analytical technology (PAT) mindset is progressively introduced and adopted by the pharmaceutical companies, there is an increasing demand for effective and versatile real-time analyzers to address the quality assurance challenges of drug manufacturing. In the last decades, Raman spectroscopy has emerged as one of the most promising tools for non-destructive and fast characterization of the pharmaceutical processes. This review summarizes the achieved results of the real-time application of Raman spectroscopy in the field of the secondary manufacturing of pharmaceutical solid dosage forms, covering the most common secondary process steps of a tablet production line. In addition, the feasibility of Raman spectroscopy for real-time control is critically reviewed, and challenges and possible approaches to moving from real-time monitoring to process analytically controlled technologies (PACT) are discussed.
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18
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Vo AQ, He H, Zhang J, Martin S, Chen R, Repka MA. Application of FT-NIR Analysis for In-line and Real-Time Monitoring of Pharmaceutical Hot Melt Extrusion: a Technical Note. AAPS PharmSciTech 2018; 19:3425-3429. [PMID: 29948985 DOI: 10.1208/s12249-018-1091-3] [Citation(s) in RCA: 23] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/01/2018] [Accepted: 05/29/2018] [Indexed: 11/30/2022] Open
Abstract
Continuous manufacturing, a gaining interest paradigm in the pharmaceutical industry, requires in-process monitoring of critical process parameters to ensure product consistency. This study demonstrated the application of Fourier transform near-infrared (FT-NIR) spectroscopy in conjunction with chemometrics modeling for in-line hot melt extrusion process monitoring. The obtained results suggested that inline FT-NIR analysis, along with a tailored NIR reflector, is a viable process analytical tool to monitor active pharmaceutical ingredient concentration as well as processing parameters.
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Censi R, Gigliobianco MR, Casadidio C, Di Martino P. Hot Melt Extrusion: Highlighting Physicochemical Factors to Be Investigated While Designing and Optimizing a Hot Melt Extrusion Process. Pharmaceutics 2018; 10:E89. [PMID: 29997332 PMCID: PMC6160992 DOI: 10.3390/pharmaceutics10030089] [Citation(s) in RCA: 75] [Impact Index Per Article: 12.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/07/2018] [Revised: 06/22/2018] [Accepted: 07/09/2018] [Indexed: 12/15/2022] Open
Abstract
Hot-melt extrusion (HME) is a well-accepted and extensively studied method for preparing numerous types of drug delivery systems and dosage forms. It offers several advantages: no solvents are required, it is easy to scale up and employ on the industrial level, and, in particular, it offers the possibility of improving drug bioavailability. HME involves the mixing of a drug with one or more excipients, in general polymers and even plasticizers, which can melt, often forming a solid dispersion of the drug in the polymer. The molten mass is extruded and cooled, giving rise to a solid material with designed properties. This process, which can be realized using different kinds of special equipment, may involve modifications in the drug physicochemical properties, such as chemical, thermal and mechanical characteristics thus affecting the drug physicochemical stability and bioavailability. During process optimization, the evaluation of the drug solid state and stability is thus of paramount importance to guarantee stable drug properties for the duration of the drug product shelf life. This manuscript reviews the most important physicochemical factors that should be investigated while designing and optimizing a hot melt extrusion process, and by extension, during the different pre-formulation, formulation and process, and post-formulation phases. It offers a comprehensive evaluation of the chemical and thermal stability of extrudates, the solid physical state of extrudates, possible drug-polymer interactions, the miscibility/solubility of the drug-polymer system, the rheological properties of extrudates, the physicomechanical properties of films produced by hot melt extrusion, and drug particle dissolution from extrudates. It draws upon the last ten years of research, extending inquiry as broadly as possible.
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Affiliation(s)
- Roberta Censi
- School of Pharmacy, University of Camerino, Via S. Agostino, 62032 Camerino, Italy.
| | | | - Cristina Casadidio
- School of Pharmacy, University of Camerino, Via S. Agostino, 62032 Camerino, Italy.
| | - Piera Di Martino
- School of Pharmacy, University of Camerino, Via S. Agostino, 62032 Camerino, Italy.
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Rodrigues M, Baptista B, Lopes JA, Sarraguça MC. Pharmaceutical cocrystallization techniques. Advances and challenges. Int J Pharm 2018; 547:404-420. [PMID: 29890258 DOI: 10.1016/j.ijpharm.2018.06.024] [Citation(s) in RCA: 63] [Impact Index Per Article: 10.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/19/2018] [Revised: 06/06/2018] [Accepted: 06/07/2018] [Indexed: 12/11/2022]
Abstract
Cocrystals are homogenous (single-phase) crystalline structures composed by two or more components in a definite stoichiometric ratio bonded together by noncovalent bonds. Pharmaceutical industry has been showing interest in cocrystals due to their ability to improve active pharmaceutical ingredients (API's) properties, such as solubility, dissolution, bioavailability, stability and processability. The necessity for high-throughput screening methods and methods capable of producing cocrystals in an industrial scale still hinders the use of cocrystals by the pharmaceutical industry. The aim of this review is to present an extensive overview of the cocrystallization methods, focusing in the specificities of each technique, its advantages and disadvantages. The review is divided into solvent-based and solvent-free methods. The most appropriate methods to the different stages of cocrystals manufacture, from the screening phase to industrial production are identified. The use of continuous and scalable methods in cocrystal production as well as the implementation of quality-by-design and process analytical technology concepts are also addressed.
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Affiliation(s)
- Marisa Rodrigues
- LAQV/REQUIMTE, Departamento de Ciências Químicas, Faculdade de Farmácia, Universidade do Porto, Rua Jorge Viterbo Ferreira, 228, 4050-313 Porto, Portugal
| | - Bárbara Baptista
- Research Institute for Medicines (iMed.Lisboa), Faculdade de Farmácia, Universidade de Lisboa, Av. Prof. Gama Pinto, 1649-003 Lisboa, Portugal
| | - João Almeida Lopes
- Research Institute for Medicines (iMed.Lisboa), Faculdade de Farmácia, Universidade de Lisboa, Av. Prof. Gama Pinto, 1649-003 Lisboa, Portugal
| | - Mafalda Cruz Sarraguça
- LAQV/REQUIMTE, Departamento de Ciências Químicas, Faculdade de Farmácia, Universidade do Porto, Rua Jorge Viterbo Ferreira, 228, 4050-313 Porto, Portugal.
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21
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Scheiblauer J, Scheiner S, Joksch M, Kavsek B. Fermentation of Saccharomyces cerevisiae - Combining kinetic modeling and optimization techniques points out avenues to effective process design. J Theor Biol 2018; 453:125-135. [PMID: 29778649 DOI: 10.1016/j.jtbi.2018.05.016] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/26/2017] [Revised: 04/20/2018] [Accepted: 05/15/2018] [Indexed: 11/29/2022]
Abstract
A combined experimental/theoretical approach is presented, for improving the predictability of Saccharomyces cerevisiae fermentations. In particular, a mathematical model was developed explicitly taking into account the main mechanisms of the fermentation process, allowing for continuous computation of key process variables, including the biomass concentration and the respiratory quotient (RQ). For model calibration and experimental validation, batch and fed-batch fermentations were carried out. Comparison of the model-predicted biomass concentrations and RQ developments with the corresponding experimentally recorded values shows a remarkably good agreement for both batch and fed-batch processes, confirming the adequacy of the model. Furthermore, sensitivity studies were performed, in order to identify model parameters whose variations have significant effects on the model predictions: our model responds with significant sensitivity to the variations of only six parameters. These studies provide a valuable basis for model reduction, as also demonstrated in this paper. Finally, optimization-based parametric studies demonstrate how our model can be utilized for improving the efficiency of Saccharomyces cerevisiae fermentations.
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Affiliation(s)
| | - Stefan Scheiner
- Institute for Mechanics of Materials and Structures, Vienna University of Technology, Karlsplatz 13/202, Vienna A-1040, Austria.
| | - Martin Joksch
- Siemens AG, Corporate Technology, Siemensstraße 90, Vienna A-1210, Austria
| | - Barbara Kavsek
- Siemens AG, Corporate Technology, Siemensstraße 90, Vienna A-1210, Austria
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Rehrl J, Karttunen AP, Nicolaï N, Hörmann T, Horn M, Korhonen O, Nopens I, De Beer T, Khinast JG. Control of three different continuous pharmaceutical manufacturing processes: Use of soft sensors. Int J Pharm 2018; 543:60-72. [DOI: 10.1016/j.ijpharm.2018.03.027] [Citation(s) in RCA: 49] [Impact Index Per Article: 8.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2017] [Revised: 02/26/2018] [Accepted: 03/14/2018] [Indexed: 11/30/2022]
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Espinell JRH, López-Mejías V, Stelzer T. Revealing Polymorphic Phase Transformations in Polymer-Based Hot Melt Extrusion Processes. CRYSTAL GROWTH & DESIGN 2018; 18:1995-2002. [PMID: 31889927 PMCID: PMC6936767 DOI: 10.1021/acs.cgd.7b01374] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/10/2023]
Abstract
The inadvertent occurrence of polymorphic phase transformations in active pharmaceutical ingredients (APIs) during hot melt extrusion (HME) processes has been claimed to limit the application of this technique. Hence, the control of polymorphism would need to be addressed if there is any prospect of HME to be successfully implemented as an alternative solid dosage formulation strategy in integrated, continuous end-to-end pharmaceutical manufacturing settings. This work demonstrates that flufenamic acid (FFA), one of the most polymorphic APIs known, thus far, can be processed using temperature-simulated HME with polyethylene glycol (PEG) as polymeric carrier. At temperatures above the transition point of FFA forms III and I (42 °C), the induction time of the polymorphic phase transformation is longer than the average reported residence time in conventional HME processes (5 min). Moreover, it was demonstrated that thorough understanding of the thermodynamic and kinetic design space for the PEG-FFA system leads to polymorphic control in the produced crystalline solid dispersions. Ultimately, this investigation helps to gain fundamental understanding of the processing needs of crystalline solid dispersions, which will lead to the broader application of HME as a continuous manufacturing strategy for drug products containing APIs prone to polymorphism, representing about 80% of all APIs.
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Affiliation(s)
- José R. Hernández Espinell
- Department of Chemistry, University of Puerto Rico, Río Piedras Campus, San Juan, Puerto Rico 00931, United States
- Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, Puerto Rico 00926, United States
| | - Vilmalí López-Mejías
- Department of Chemistry, University of Puerto Rico, Río Piedras Campus, San Juan, Puerto Rico 00931, United States
- Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, Puerto Rico 00926, United States
| | - Torsten Stelzer
- Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, Puerto Rico 00926, United States
- Department of Pharmaceutical Sciences, University of Puerto Rico, Medical Sciences Campus, San Juan, Puerto Rico 00936, United States
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Nicolaï N, De Leersnyder F, Copot D, Stock M, Ionescu CM, Gernaey KV, Nopens I, De Beer T. Liquid‐to‐solid ratio control as an advanced process control solution for continuous twin‐screw wet granulation. AIChE J 2018. [DOI: 10.1002/aic.16161] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/16/2023]
Affiliation(s)
- Niels Nicolaï
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
- Dept. of Data Analysis and Mathematical Modelling, BIOMATH, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Fien De Leersnyder
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
| | - Dana Copot
- Dept. of Electrical Energy, Metals, Mechanical Constructions and Systems, Research Group on Dynamical Systems and ControlGhent University, Technologiepark 914Zwijnaarde 9052 Belgium
| | - Michiel Stock
- Dept. of Data Analysis and Mathematical Modelling, KERMIT, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Clara M. Ionescu
- Dept. of Electrical Energy, Metals, Mechanical Constructions and Systems, Research Group on Dynamical Systems and ControlGhent University, Technologiepark 914Zwijnaarde 9052 Belgium
| | - Krist V. Gernaey
- Dept. of Chemical and Biochemical Engineering, CAPEC‐PROCESS Research CenterTechnical University of Denmark, Building 229Kgs. Lyngby 2800 Denmark
| | - Ingmar Nopens
- Dept. of Data Analysis and Mathematical Modelling, BIOMATH, Faculty of Bioscience EngineeringGhent University, Coupure Links 653Ghent 9000 Belgium
| | - Thomas De Beer
- Dept. of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Laboratory of Pharmaceutical Process Analytical Technology (LPPAT)Ghent University, Ottergemsesteenweg 460Ghent 9000 Belgium
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25
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Process analytical technology in continuous manufacturing of a commercial pharmaceutical product. Int J Pharm 2018; 538:167-178. [DOI: 10.1016/j.ijpharm.2018.01.003] [Citation(s) in RCA: 73] [Impact Index Per Article: 12.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2017] [Revised: 12/17/2017] [Accepted: 01/01/2018] [Indexed: 11/18/2022]
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Ross SA, Lamprou DA, Douroumis D. Engineering and manufacturing of pharmaceutical co-crystals: a review of solvent-free manufacturing technologies. Chem Commun (Camb) 2018; 52:8772-86. [PMID: 27302311 DOI: 10.1039/c6cc01289b] [Citation(s) in RCA: 65] [Impact Index Per Article: 10.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/19/2022]
Abstract
Design and synthesis of pharmaceutical cocrystals have received great interest in recent years. Cocrystallization of drug substances offers a tremendous opportunity for the development of new drug products with superior physical and pharmacological properties such as solubility, stability, hydroscopicity, dissolution rates and bioavailability. It is now possible to engineer and develop cocrystals via 'green chemistry' and environmentally friendly approaches such as solid-state synthesis in the absence of organic solvents. In addition, significant efforts have been directed towards computational screening, cocrystal manufacturing in a continuous manner and real-time monitoring for quality purposes by using various analytical tools. Pharmaceutical cocrystals are not fully exploited yet and there is a lot of ground to cover before they can be successfully utilized as medical products.
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Affiliation(s)
- S A Ross
- Faculty of Engineering and Science, University of Greenwich, Medway Campus, Chatham Maritime, Kent ME4 4TB, UK.
| | - D A Lamprou
- Strathclyde Institute of Pharmacy and Biomedical Science (SIPBS)s, University of Strathclyde, 161 Cathedral Street, Glasgow G4 0RE, UK. and EPSRC Centre for Innovative Manufacturing in Continuous Manufacturing and Crystallisation (CMAC), University of Strathclyde, Technology and Innovation Centre, 99 George Street, Glasgow, G1 1 RD, UK
| | - D Douroumis
- Faculty of Engineering and Science, University of Greenwich, Medway Campus, Chatham Maritime, Kent ME4 4TB, UK.
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Naidu VR, Deshpande RS, Syed MR, Deoghare P, Singh D, Wakte PS. PAT-Based Control of Fluid Bed Coating Process Using NIR Spectroscopy to Monitor the Cellulose Coating on Pharmaceutical Pellets. AAPS PharmSciTech 2017; 18:2045-2054. [PMID: 27995464 DOI: 10.1208/s12249-016-0680-2] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/03/2016] [Accepted: 11/20/2016] [Indexed: 11/30/2022] Open
Abstract
Current endeavor was aimed towards monitoring percent weight build-up during functional coating process on drug-layered pellets. Near-infrared (NIR) spectroscopy is an emerging process analytical technology (PAT) tool which was employed here within quality by design (QbD) framework. Samples were withdrawn after spraying every 15-Kg cellulosic coating material during Wurster coating process of drug-loaded pellets. NIR spectra of these samples were acquired using cup spinner assembly of Thermoscientific Antaris II, followed by multivariate analysis using partial least squares (PLS) calibration model. PLS model was built by selecting various absorption regions of NIR spectra for Ethyl cellulose, drug and correlating the absorption values with actual percent weight build up determined by HPLC. The spectral regions of 8971.04 to 8250.77 cm-1, 7515.24 to 7108.33 cm-1, and 5257.00 to 5098.87 cm-1 were found to be specific to cellulose, where as the spectral region of 6004.45 to 5844.14 cm-1was found to be specific to drug. The final model gave superb correlation co-efficient value of 0.9994 for calibration and 0.9984 for validation with low root mean square of error (RMSE) values of 0.147 for calibration and 0.371 for validation using 6 factors. The developed correlation between the NIR spectra and cellulose content is useful in precise at-line prediction of functional coat value and can be used for monitoring the Wurster coating process.
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Laske S, Paudel A, Scheibelhofer O, Sacher S, Hoermann T, Khinast J, Kelly A, Rantannen J, Korhonen O, Stauffer F, De Leersnyder F, De Beer T, Mantanus J, Chavez PF, Thoorens B, Ghiotti P, Schubert M, Tajarobi P, Haeffler G, Lakio S, Fransson M, Sparen A, Abrahmsen-Alami S, Folestad S, Funke A, Backx I, Kavsek B, Kjell F, Michaelis M, Page T, Palmer J, Schaepman A, Sekulic S, Hammond S, Braun B, Colegrove B. A Review of PAT Strategies in Secondary Solid Oral Dosage Manufacturing of Small Molecules. J Pharm Sci 2017; 106:667-712. [DOI: 10.1016/j.xphs.2016.11.011] [Citation(s) in RCA: 56] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/22/2016] [Revised: 10/14/2016] [Accepted: 11/08/2016] [Indexed: 12/14/2022]
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Pajander J, Rensonnet A, Hietala S, Rantanen J, Baldursdottir S. The evaluation of physical properties of injection molded systems based on poly(ethylene oxide) (PEO). Int J Pharm 2017; 518:203-212. [DOI: 10.1016/j.ijpharm.2016.12.050] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/05/2016] [Revised: 12/06/2016] [Accepted: 12/21/2016] [Indexed: 10/20/2022]
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Naidu VR, Deshpande RS, Syed MR, Wakte PS. Real-time imaging as an emerging process analytical technology tool for monitoring of fluid bed coating process. Pharm Dev Technol 2017; 23:596-601. [PMID: 28121263 DOI: 10.1080/10837450.2017.1287730] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
Abstract
A direct imaging system (EyeconTM) was used as a Process Analytical Technology (PAT) tool to monitor fluid bed coating process. EyeconTM generated real-time onscreen images, particle size and shape information of two identically manufactured laboratory-scale batches. EyeconTM has accuracy of measuring the particle size increase of ±1 μm on particles in the size range of 50-3000 μm. EyeconTM captured data every 2 s during the entire process. The moving average of D90 particle size values recorded by EyeconTM were calculated for every 30 min to calculate the radial coating thickness of coated particles. After the completion of coating process, the radial coating thickness was found to be 11.3 and 9.11 μm, with a standard deviation of ±0.68 and 1.8 μm for Batch 1 and Batch 2, respectively. The coating thickness was also correlated with percent weight build-up by gel permeation chromatography (GPC) and dissolution. GPC indicated weight build-up of 10.6% and 9.27% for Batch 1 and Batch 2, respectively. In conclusion, weight build-up of 10% can also be correlated with 10 ± 2 μm increase in the coating thickness of pellets, indicating the potential applicability of real-time imaging as an endpoint determination tool for fluid bed coating process.
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Affiliation(s)
- Venkata Ramana Naidu
- a Pharma Research Department , Wockhardt Research Centre , Aurangabad , Maharashtra , India
| | - Rucha S Deshpande
- a Pharma Research Department , Wockhardt Research Centre , Aurangabad , Maharashtra , India
| | - Moinuddin R Syed
- a Pharma Research Department , Wockhardt Research Centre , Aurangabad , Maharashtra , India
| | - Pravin S Wakte
- b Department of Chemical Technology , Dr. Babasaheb Ambedkar Marathwada University , Aurangabad , Maharashtra , India
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Rehrl J, Kruisz J, Sacher S, Khinast J, Horn M. Optimized continuous pharmaceutical manufacturing via model-predictive control. Int J Pharm 2016; 510:100-15. [DOI: 10.1016/j.ijpharm.2016.06.024] [Citation(s) in RCA: 29] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/29/2016] [Revised: 05/25/2016] [Accepted: 06/07/2016] [Indexed: 10/21/2022]
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Llusa M, Mohr S, Baumgartner R, Paudel A, Koscher G, Khinast J. Continuous low-dose feeding of highly active pharmaceutical ingredients in hot-melt extrusion. Drug Dev Ind Pharm 2016; 42:1360-4. [DOI: 10.3109/03639045.2015.1135938] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022]
Affiliation(s)
- Marcos Llusa
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Stefan Mohr
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | | | - Amrit Paudel
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Gerold Koscher
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
- Institute for Particle and Process Engineering, Graz University of Technology, Graz, Austria
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35
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Rantanen J, Khinast J. The Future of Pharmaceutical Manufacturing Sciences. J Pharm Sci 2015; 104:3612-3638. [PMID: 26280993 PMCID: PMC4973848 DOI: 10.1002/jps.24594] [Citation(s) in RCA: 204] [Impact Index Per Article: 22.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/06/2014] [Revised: 06/26/2015] [Accepted: 06/29/2015] [Indexed: 12/13/2022]
Abstract
The entire pharmaceutical sector is in an urgent need of both innovative technological solutions and fundamental scientific work, enabling the production of highly engineered drug products. Commercial-scale manufacturing of complex drug delivery systems (DDSs) using the existing technologies is challenging. This review covers important elements of manufacturing sciences, beginning with risk management strategies and design of experiments (DoE) techniques. Experimental techniques should, where possible, be supported by computational approaches. With that regard, state-of-art mechanistic process modeling techniques are described in detail. Implementation of materials science tools paves the way to molecular-based processing of future DDSs. A snapshot of some of the existing tools is presented. Additionally, general engineering principles are discussed covering process measurement and process control solutions. Last part of the review addresses future manufacturing solutions, covering continuous processing and, specifically, hot-melt processing and printing-based technologies. Finally, challenges related to implementing these technologies as a part of future health care systems are discussed.
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Affiliation(s)
- Jukka Rantanen
- Department of Pharmacy, Faculty of Health and Medical Sciences, University of Copenhagen, Denmark.
| | - Johannes Khinast
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, Austria; Research Center Pharmaceutical Engineering, Graz, Austria.
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36
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Lee SL, O’Connor TF, Yang X, Cruz CN, Chatterjee S, Madurawe RD, Moore CMV, Yu LX, Woodcock J. Modernizing Pharmaceutical Manufacturing: from Batch to Continuous Production. J Pharm Innov 2015. [DOI: 10.1007/s12247-015-9215-8] [Citation(s) in RCA: 484] [Impact Index Per Article: 53.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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37
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Stanković M, Frijlink HW, Hinrichs WLJ. Polymeric formulations for drug release prepared by hot melt extrusion: application and characterization. Drug Discov Today 2015; 20:812-23. [PMID: 25660507 DOI: 10.1016/j.drudis.2015.01.012] [Citation(s) in RCA: 86] [Impact Index Per Article: 9.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/21/2014] [Revised: 01/08/2015] [Accepted: 01/27/2015] [Indexed: 12/15/2022]
Abstract
Over the past few decades hot melt extrusion (HME) has emerged as a powerful processing technology for the production of pharmaceutical solid dosage forms in which an active pharmaceutical ingredient (API) is dispersed into polymer matrices. It has been shown that formulations using HME can provide time-controlled, sustained and targeted drug delivery, and improved bioavailability of poorly soluble drugs. In this review, the basic principles of the HME process are described together with an overview of some of the most common biodegradable and nonbiodegradable polymers used for the preparation of different formulations using this method. Further, the applications of HME in drug delivery and analytical techniques employed to characterize HME products are addressed.
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Affiliation(s)
- Milica Stanković
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, A. Deusinglaan 1, 9713 AV Groningen, The Netherlands; Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, A-8010, Graz, Austria.
| | - Henderik W Frijlink
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, A. Deusinglaan 1, 9713 AV Groningen, The Netherlands
| | - Wouter L J Hinrichs
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, A. Deusinglaan 1, 9713 AV Groningen, The Netherlands
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38
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Predicting final product properties of melt extruded solid dispersions from process parameters using Raman spectrometry. J Pharm Biomed Anal 2014; 98:166-77. [DOI: 10.1016/j.jpba.2014.05.025] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/22/2014] [Revised: 05/12/2014] [Accepted: 05/16/2014] [Indexed: 11/18/2022]
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