Uniaxial Compaction Modelled using the Properties of Single Crystals

Understanding the roles of compaction pressure and crystal hardness on powder tabletability through bonding area - Bonding strength interplay

Bonding area (BA) and bonding strength (BS) interplay dictates tensile strength of a tablet and, hence, tabletability. Using a series of alkali halides with mechanical properties spanning more than one order of magnitude, the role of compaction pressure and mechanical properties on tabletability is systematically investigated and explained using the BA-BS interplay. Results reveal that BA dominates the BA-BS interplay at low pressures, where more plastic powders attain higher tensile strength due to larger BA. In contrast, BS dominates the interplay at high pressures, when difference in BA between powders is minimized. Under the typical compaction pressures of 100-300 MPa, tablet tensile strength is the highest for materials with intermediate hardness, or plasticity, due to an optimal BA-BS interplay.

How can single particle compression and nanoindentation contribute to the understanding of pharmaceutical powder compression?

The deformation behaviour of a powder and, thus, of the individual particles is a crucial parameter in powder compaction and affects powder compressibility and compactibility. The classical approach for the characterization of the deformation behaviour is the performance of powder compression experiments combined with the application of mathematical models, such as the Heckel-Model, for the derivation of characteristic compression parameters. However, the correlation of these parameters with the deformation behaviour is physically often not well understood. Single particle compression and nanoindentation enables the in-depth investigation of the deformation behaviour of particulate materials. In this study, single particle compression experiments were performed for the characterization of the deformation behaviour of common pharmaceutical excipients and active pharmaceutical ingredients (APIs) with various, irregular particle morphologies of industrial relevance and the findings are compared with the results from powder compression. The technique was found useful for the characterization and clarification of the qualitative deformation behaviour. However, the derivation of a quantitative functional relationship between single particle deformation behavior and powder compression is limited. Nanoindentation was performed as complementary technique for the characterization of the micromechanical behavior of the APIs. A linear relationship between median indentation hardness and material densification strength as characteristic parameter derived by in-die powder compression analysis is found.

Structural heterogeneity of pharmaceutical compacts probed by micro-indentation

Indentation has been used for several decades to conveniently assess the hardness and modulus of various compacts. However, this measurement is dependent on the size of the indentation area from a few nanometers to several millimeters, which is determined by the maximum indentation force (MIF). Micro-indentation often loses its ability to give an accurate representation of the hardness due to its relatively small micron-size indentation area compared with the dimensions of the structural inhomogeneity of compacts. This study used a different approach to micro-indentation by examining whether this method can probe the inhomogeneity of compacts with varying MIF. Two typical pharmaceutical excipients, one brittle and one ductile, were used as model compacts. The representative hardness and modulus values were available when the MIF was >1000 mN. Changes in the standard deviation of the indentation hardness reflected the structural inhomogeneity of the compacts, which was found to increase with decreasing MIF to below 800 mN in the case of the microcrystalline cellulose compacts. The information on the structural inhomogeneity obtained by micro-indentation appears to be consistent with the observations from microscopy investigations. Anisotropy and other related structural information could be readily obtained by probing the two different surfaces of compacts with changing MIF, one parallel and the other perpendicular to the compaction pressure direction.

Evaluation of the compaction of sulfathiazole polymorphs

The aim of this study was to relate the tableting performance assessed by an instrumented tableting machine to the mechanical properties measured by nanoindentation. Three different polymorphic forms of sulfathiazole were prepared by recrystallization, and the density and X-ray powder diffraction patterns were measured and compared with theoretical density and simulated powder patterns, respectively. Tablets were prepared using a series of applied pressures, and the results were subjected to energy analysis, three dimensional (3D) modeling, and the traditional Heckel analysis. With these approaches, form I was found to be consistently the most brittle material, but the subtle differences between forms II and III were only revealed by 3D modeling. The rank order of the crushing force was found to be I is congruent to II < III. From nanoindentation, form III was found to be much harder than forms I and II, and III also had a much higher Young's modulus. The energy calculations of the nanoindentation curves showed that form III was distinct from forms I and II, which is consistent with the presence of slip planes that are only present in form III. However, in this system, there was little correspondence between the macroscopic and microscopic measurements, and thus particle-particle interactions may to be of paramount importance.

Pressure susceptibility of polymer tablets as a critical property: a modified Heckel equation

The pressure susceptibility (chip), which is defined as the decrease of porosity (epsilon) under pressure was investigated. Of special interest are compacts obtained at very low pressures, because of the transition between the state of a powder and the state of a tablet. This range was found to be critical in respect to a diverging pressure susceptibility. Above a critical porosity (epsilonc) or below the corresponding relative density (rhoc), no pressure susceptibility can be defined, because of no rigid structure exists. To take this into account, a simple function was proposed for the pressure susceptibility: chip approximately 1/(epsilonc - epsilon). This proposal leads to a new porosity vs pressure relationship. The new model was compared to the Heckel equation that involves a constant pressure susceptibility. Various polymers were tested from "out of die" measurements, and the new relationship was found superior to the Heckel equation. As a conclusion, the pressure susceptibility exhibits a curvature that can be called critical at low relative densities. Consequently, a better understanding evolves as to why the Heckel equation is not valid at low pressures. The new model has proven to be adequate for polymer tablets but, so far it is not clear whether other substances exhibit the same performance. Especially tableting materials exhibiting brittle fracture will be of interest considering their importance in compaction technology.

Mechanical properties of powders for compaction and tableting: an overview

This review provides an insight into mechanical properties that are critical to understanding powder processing for tableting. Various parameters that reflect these basic fundamental properties of powder and their evaluation by different techniques are described. Some recent examples in which these techniques are used in drug substance selection, formulation optimization or scale-up are also provided.

Mechanical properties of compacts and particles that control tableting success

The use and limitations of linear-elasticity equations for describing mechanical properties of compacts is discussed; the limitations occur because compacts are porous, viscoelastic, nonhomogeneous, Mohr bodies. Awareness of these properties permits meaningful comparisons to be made. Ignoring limitations may result in unjustified conclusions. Special care during measuring mechanical properties of compacts is required. The mechanical criteria for a successful formulation are good flowability for powders and adequate strength without fracture for compacts. Interparticle attraction is spontaneous but particle contact numbers and size are limited by mechanical preclusion. Plastic deformation and fracture mechanics are controlling mechanisms with the magnitude of elastic constants having little effect on the successful processing. General compaction characteristics can be appraised by using combinations of properties, e.g., specific tableting indices.