Evaluation of coat uniformity and taste-masking efficiency of irregular-shaped drug particles coated in a modified tangential spray fluidized bed processor

Exploring the Potential of Artificial Intelligence as a Facilitating Tool for Formulation Development in Fluidized Bed Processor: a Comprehensive Review

This in-depth study looks into how artificial intelligence (AI) could be used to make formulation development easier in fluidized bed processes (FBP). FBP is complex and involves numerous variables, making optimization challenging. Various AI techniques have addressed this challenge, including machine learning, neural networks, genetic algorithms, and fuzzy logic. By integrating AI with experimental design, process modeling, and optimization strategies, intelligent systems for FBP can be developed. The advantages of AI in this context include improved process understanding, reduced time and cost, enhanced product quality, and robust formulation optimization. However, data availability, model interpretability, and regulatory compliance challenges must be addressed. Case studies demonstrate successful applications of AI in decision-making, process outcome prediction, and scale-up. AI can improve efficiency, quality, and cost-effectiveness in significant ways. Still, it is important to think carefully about data quality, how easy it is to understand, and how to follow the rules. Future research should focus on fully harnessing the potential of AI to advance formulation development in FBP.

Development of taste masking microcapsules containing azithromycin by fluid bed coating for powder for suspension and in vivo evaluation

This research aims to develop bitter taste masking microcapsules containing azithromycin by a simpler and familiar method, fluid-bed coating technology, in comparison with Zithromax®. Cores of microcapsules, azithromycin microparticles, were prepared by fluid-bed granulation, then taste-masking polymer was covered on by fluid-bed coating technique. Eudragit L100, Eudragit RL100, ethyl cellulose in single and combined with Eudragit L100, Eudragit E100 were used as taste-masking polymers. The obtained microcapsules were characterized by taste masking ability, in-vitro release, SEM, coating thickness and coating efficiency. Combination of ethyl cellulose and Eudragit E100 (3:1) in coating thickness of 45.13 ± 2.12% w/w prevent azithromycin release from microcapsules below bitter taste threshold (1.78 ± 1.17 μg/ml). Bioavailability of powders containing azithromycin microcapsules and pH modulators (50mg Na₃PO₄ and 35mg Mg(OH)₂) was not significantly different from the reference product (Zithromax®, Pfizer) in the rabbit model (p > 0.05). These results support the possibility of developing a generic product containing azithromycin.

Charge Reduction Assisted Production of Diminutive Fluid Bed Granules for High Drug Load Minitablets

Micronized drug powders are generally unsuitable as tableting feed to produce minitablets due to their cohesivity and poor flow. The silicification of fine paracetamol powder (PCM_F) with an optimal concentration range of fumed silica (fSi) [0.7 - 0.9 %, w/w] reduced the net negative charge of PCM_F and improved powder flow. The optimal fSi concentration range suitable was established through the measurement of charge and flowability of the silicified powders. Silicification of PCM_F by physical mix did not satisfactorily overcome the cohesive forces between the PCM_F crystals and improve powder flow sufficiently such that it will feed consistently into the smaller die orifices during tableting. Using a specialized fluid bed system with swirling air and side spray, controlled granulation of silicified PCM_F packed and agglomerated the interlocking-prone needle shaped PCM_F crystals into diminutive granules that are more spherical and free flowing. With optimized fSi concentration (≈ 0.8 %, w/w) and granulation process parameters, high drug load diminutive granules (D₅₀≃ 90 μm) were successfully prepared from PCM_F as starter seeds (D₅₀≃ 30 μm). Minitablets prepared from the diminutive granules had low weight variation, and were mechanically strong with disintegration time of less than 30 s. This study demonstrated the feasibility of producing high drug load minitablets from a cohesive, electrostatic-prone fine drug powder.

Building Process Understanding of Fluid Bed Taste Mask Coating of Microspheres

Taste is routinely cited as one of the major contributing factors that negatively influence pediatric patient compliance. A promising solution is coated microsphere systems, which provide doses of active pharmaceutical ingredients (API) subdivided into a plurality of small dosage units. In this work, the microspheres were coated with Kollicoat® Smartseal, a reverse enteric polymer, which acts to minimize or prevent the release of API in the neutral pH of the oral cavity, which results in a masking effect of the unpleasant taste of the API. A screening of seven key variables in a Wurster coating process was evaluated by D-optimal design and by analysis of variance. The percentage of API released at pH 6.2 was used as a surrogate method for the taste-masking performance evaluation of Kollicoat® Smartseal. The seven studied variables were: product bed temperature, inlet airflow, atomizing air pressure, spray rate (process parameters), coating level, plasticizer level, solids in coating suspension (material attributes), and curing. Results show that coating level, plasticizer level, product bed temperature, and spray rate are the critical process parameters and reinforce the importance of curing to reduce the overall variability within the batch by promoting complete film formation. The link between material attributes, process parameters, and quality attributes were demonstrated to allow a better understanding of the parameters that affect the API release profile at neutral pH (in vitro) while not injuring release at acidic pH (in vitro). It was demonstrated that not only thickness but also coating morphology have an impact on the dissolution in 50 mM potassium phosphate buffer, pH 6.2.

Development and Palatability Assessment of Norvir® (Ritonavir) 100 mg Powder for Pediatric Population

Norvir^® (ritonavir) is a Biopharmaceutical Classification System Class IV compound with poor solubility in water (~5 µg/mL) and limited oral bioavailability. Early stage development efforts were focused on an oral solution (OS) which provided reasonable bioavailability but exhibited taste-masking challenges and required the use of solvents with potential pediatric toxicity. Norvir^® oral powder, 100 mg (NOP) was developed to replace OS. The objective of this study is to provide an overview of the development of NOP and palatability assessment strategy. Palatability of NOP was assessed using the flavor profile method: (1) As an aqueous suspension dose/response and (2) evaluation with foods. The dose/response sensory analysis indicated that NOP has strong intensity bitterness and burnt aromatics (3 on the 0–3 flavor profile scale) at the clinical dose (100 mg/10 mL) and the recognition threshold was determined to be 0.3 mg/10 mL. To improve palatability, 100 mg/10 mL NOP aqueous suspension was evaluated with foods. Consuming foods high in fat and/or sugar content after NOP administration successfully reduced bitterness to a 1.5 intensity. In summary, NOP provides dose flexibility, enhanced stability, eliminated solvents, and maintains consistent bioavailability, with reduced bitterness and improved palatability via administration with common food products.

Application of the Modified Tangential Spray-Fluidized Bed to Produce Nonpareils from Primary Crystals

Coating of fine primary drug particles by a fluidized bed processor has been reported to be potentially challenging. This work aimed to develop a spray layering process to produce nonpareils by a side spray fluid bed with swirling air flow. The first part examined the effects of various parameters for producing lactose nonpareils by using Box-Behnken design. The factors considered were atomizing air pressure, spray rate, and fluidizing air temperature. This was followed by an in-depth investigation on the effects of inlet airflow rate, air temperature, and spray rate on properties of the product, in addition to process optimization. The results indicated a negative correlation between atomizing air pressure and D₉₀ (particle size at 90th percentile in the cumulative undersize plot) as well as span (size distribution). Temperature had a positive correlation with D₉₀ and span while spray rate affected span. Both atomizing air pressure and temperature correlated negatively with span. It was also found that spray rate negatively affected roundness at different coat weight gain levels across the study design space. Inlet airflow rate was found to correlate negatively with roundness at 15%, w/w coat weight gain. The mean useful yield of the optimized runs was about 91%. In the second part of this study, the metformin hydrochloride crystals as starter seeds were converted into nearly spherical shaped spheroids with 1:1 crystals to coat weight deposition over a processing time of about 3.5 h. The processor studied shows promise for direct spheronization of crystals into spherical seeds.