Effects of Environmental Temperature and Compression Energy on Polymorphic Transformation During Tabletting

Modulation of the powder properties of lamotrigine by crystal forms

The mechanical properties of powders determine the ease of manufacture and ultimately the quality of the oral solid dosage forms. Although poor mechanical properties of an active pharmaceutical ingredient (API) can be mitigated by using suitable excipients in a formulation, the effectiveness of that approach is limited for high dose drugs or multidrug tablets. In this context, improving the mechanical properties of the APIs through solid form optimisation is a good strategy to address such a challenge. This work explores the powder and tableting properties of various lamotrigine (LAM) solid forms with the aim to facilitate direct compression by overcoming the poor tabletability of LAM. The two drug-drug crystals of LAM with nicotinamide and valproic acid demonstrate superior flowability and tabletability over LAM. The improved powder properties are rationalised by structure analysis using energy framework, scanning electron microscopy, and Heckel analysis.

The solid state of rebamipide: preparation, characterization, and dissolution

Rebamipide is marketed as a peptic ulcer agent under the trade name Mucosta(R). The objective of this work was to investigate the existence of polymorphs and pseudopolymorphs of rebamipide. Two crystal forms of rebamipide were isolated by recrystallization and characterized by differential thermal analysis (DTA), thermogravimetric analysis (TG), powder X-ray diffractometry, infrared spectrometry, and nuclear magnetic resonance. The DTA curve of Form 1 showed one endothermic peak at 305.2 °C, and that of Form 2 showed one endothermic peak at 307.3 °C. The TG curve of Form 1 showed a single weight loss at 305.2 °C, which corresponded to melting. The TG curve of Form 2 also showed a single weight loss at 307.3 °C, which corresponded to melting. The melting point of Form 2 was higher than that of Form 1. In the dissolution studies in pH 6.8 buffer at 37 ± 0.5 °C, the two crystal forms showed no significant differences in dissolution. After 3 months of storage at 0, 52, and 95% RH, the two crystal forms were not transformed. After milling with a Specamill for 2 h, the two crystal forms were not transformed.

Vapor-induced phase transformations in docetaxel

Vapor-induced transformations of docetaxel anhydrous (form D(A)) under ambient conditions have been studied using methanol, ethanol, and water as the solvent media. The online vapor-induced transformations were monitored by powder X-ray diffractometry. New solid forms (solvates/hydrates/anhydrous) of docetaxel anhydrous were obtained in stoichiometric ratios which were characterized completely using powder X-ray diffraction, differential scanning calorimeter, thermogravimetric analysis, and spectroscopic ((13)C solid-state nuclear magnetic spectroscopy, solution (1)H NMR, and Fourier transform infrared) techniques. The new forms namely methanol solvate (D(M)), ethanol solvate (D(E)), monohydrate (D(MH)), trihydrate (D(TH)), and anhydrous (D(AN-I) and D(AN-II)) were identified through structural analysis.

Investigations on Solid–Solid Phase Transformation of 5-Methyl-2-[(4-Methyl-2-Nitrophenyl)Amino]-3- Thiophenecarbonitrile

Solid-solid transformation of 5-methyl-2-[(4-methyl-2-nitrophenyl)amino]-3-thiophenecarbonitrile from the dark-red to the red form was investigated. By controlled crystallization, the dark-red form was prepared and the crystals were sieved into fractions: coarse (>250 microm), medium (125-177 microm), and fine (<88 microm). The transformation rate order (fastest to slowest) of the different fractions is coarse > medium > fine. However, milling accelerates the transformation, that is, smaller particles generated by milling transforms faster. Furthermore, ethanol vapor annealing slows both the transformation of the coarse and medium fractions, especially the latter. Therefore, the mechanism of transformation is not directly related to the crystal-size and most likely related to the amount and activity of the defects in the crystals. The three-dimensional (3-D) Avrami-Erofe'ev model, know as "random nucleation and growth" model, fits the kinetics of coarse fraction best. Higher relative humidity accelerates the transformation dramatically even though the compound is highly-hydrophobic. With minimal hydrogen bonding interaction involved, it appears even small amounts of water can serve as a nucleation catalyst by binding to the crystal surface, especially at defect sites, thus increasing the molecular mobility of these sites, promoting the transformation to the second phase and thereby increasing the transformation rate.

Demonstration of a Shear-Based Solid-State Phase Transformation in a Small Molecular organic System: Chlorpropamide

Elucidation of the mechanisms for mechanically activated phase transformations of API are necessary for progress in materials and process understanding. The mechanically induced solid-state transformation between the A and C enantiotropes of the anti-diabetic drug chlorpropamide (C(10)H(13)ClN(2)O(3)S) was investigated. The structure of the high temperature stable phase (form C) was solved using powder X-ray data. Transmission powder X-ray diffraction (PXRD) and Raman spectroscopy were used for in situ quantification and analysis of the phase interconversion that occurs as a function of applied pressure during compaction. Each polymorph was observed to undergo a solid-state transition, which increased with pressure to a maximum extent that corresponded with the consolidation limit of the respective bulk powder. Neither form was observed to convert under hydrostatic pressure, suggesting a shear dependence for interconversion at compaction pressures. Examination of the two crystallographic structures indicated that both forms have a common slip system and preserved molecular positions. It is suggested that the transformation of either form is allowed when resolved shear stresses initiate deformation, causing lattice distortion, which allows the simultaneous reconformation of molecules.

Polymorphic Transformation of Indomethacin Under High Pressures**The previous affiliation when this study was done, Organic Synthesis Research Laboratory, Sumitomo Chemical Co., Ltd. 3-1-98, Kasugade-naka, Konohana-ku, Osaka 554-8558, Japan

To study the effect of pressure on polymorphic transformation, intact powder, and ethanol slurry of alpha, gamma, and amorphous forms of indomethacin (IMC) were compressed under high pressures. A quantifying method for the percentages of these three constituents in sample powder was established. Using this method, analysis of compressed samples revealed that alpha form, which is difficult to prepare in stable form under atmospheric pressure, was easily obtained in stable form from the ethanol slurry of the amorphous IMC, which does not include any specific crystalline forms. In the ethanol slurry of gamma form, transformation to alpha form was observed: a reciprocal phenomenon under atmospheric pressure. These results can be rationally explained as follows: alpha form is more easily crystallized than gamma form in the ethanol solution, the more closely-packed crystal structure of alpha form is thermodynamically predominant over gamma form under high pressure, and pressure-induced amorphization occurs. This study indicates that crystallization experiments from the slurry of amorphous samples under various pressures can be useful in screening polymorphic or other solid states.

Effect of milling and compression on the solid-state Maillard reaction

The effects of milling and compression on the solid-state Maillard reaction between metoclopramide hydrochloride and lactose were investigated. Anhydrous metoclopramide hydrochloride was milled for various times, and then mixed with amorphous lactose. The mixtures were stored at 105 degrees C and 0% RH. The reactivity of metoclopramide hydrochloride towards the Maillard reaction increased with milling time, as the result of increased surface area, formation of amorphous content, and creation of defects. Metoclopramide hydrochloride anhydrate and lactose were mixed and the mixtures were compressed into tablets under pressure varied from 70 to 350 MPa. Both tablets and mixtures were stored at 105 degrees C and 0% RH for 9 days. For all three types of lactose used, spray-dried anhydrous lactose, spray-dried lactose monohydrate, and amorphous lactose, tablets exhibited higher reaction rate toward the Maillard reaction than the powder mixtures. Tablets containing metoclopramide hydrochloride and amorphous lactose prepared at higher pressure showed higher reaction rates than those prepared at lower pressure. This is due to increased contact between reactants and an increased amount of water retained in the tablets.

“Soft Tableting”: A New Concept to Tablet Pressure Sensitive Materials

The aim of this study was to confirm the hypothesis that tableting using excipients with greater elastic deformation results in improved performance of pressure-sensitive drugs relative to the excipients with low elastic deformation. Tableting with highly elastic deforming excipients and the resultant minimization of the process damage is referred to in this article as "soft tableting." Carrageenans, chitosans, and polyethylene oxides were tested as potentially useful tableting excipients. alpha-Amylase, amorphous indomethacin, theophylline monohydrate, and enteric-coated pellets were used as models for pressure-sensitive materials. Three-dimensional modeling of the tableting data and elastic recovery of the tablets were the tools for mechanical characterization. The crushing force of the tablets was analyzed. Inactivation of alpha-amylase was determined by using the starch iodine reaction method. Pseudopolymorphic and polymorphic changes were analyzed using Fourier transform (FT) Raman spectroscopy. The effects of pressure on the integrity of the pellets were tested by release studies and scanning electron microscopy. The process of tablet formation was characterized for potentially useful tableting excipients. The results were compared with the results of traditional excipients as microcrystalline cellulose (MCC), dicalcium phosphate dihydrate, and hydroxypropyl methylcellulose (HPMC). A ranking order for soft tableting was deduced from the mechanical properties. The tableting excipients were ranked according to their general plasticity (GP): GP(carrageenans)<GP(chitosans)<GP(MCC)<GP(HPMC)<GP(polyethylene oxides). This theoretical order of suitability has been experimentally proven to be valid for the pressure-sensitive materials. In conclusion, the new concept for soft tableting is valid.

Modeling of Transmitted X-ray Intensity Variation with Sample Thickness and Solid Fraction in Glycine Compacts

The previous paper in this series introduced an X-ray diffraction quantitation method for the polymorphic content in tablets made of pure components. Before the method could be transferred, further studies were required to explain the commonly observed X-ray intensity variation in analyzing compacts. The literature typically attributes the variation to partial amorphization under compression and/or to preferred orientation, without much viable explanation or compelling evidence. In this study, changes in intensity in compacts analyzed in transmission geometry were found to be primarily a function of sample thickness and solid fraction. A theoretical model was developed to describe the X-ray powder diffraction (XRPD) intensity as a function of solid fraction, mass absorption coefficient, and thickness. The model was tested on two sets of glycine compacts: one with varying thickness at constant solid fraction, and the other with various solid fractions at a given thickness. The results show that the model predicts the XRPD intensity at any given sample thickness and solid fraction. With this model, the intensity variation of compacts made under different compression conditions can be normalized, making the method transferable to various tablet geometries and facilitating the analysis over expected ranges of formulation and process variation.

Solid-state analysis of the active pharmaceutical ingredient in drug products

The solid form of a drug substance is important when developing a new chemical entity. The crystalline form used in development is significant based on possible manufacturability, solubility, bioavailability and stability differences between the solid forms. Regulatory issues require that the form present in a solid dosage form or liquids containing undissolved drug substance be identified. Drug product samples can be analyzed by a variety of techniques to determine the crystal form present or changes that occur during the manufacture of a drug product. The form present will affect development, regulatory and intellectual property issues.

Quantitative determination of polymorphic composition in intact compacts by parallel-beam X-ray powder diffractometry

This paper details the development of a method using parallel-beam X-ray powder diffractometry as a novel means of determining polymorphic composition in intact compacts. Two polymorphic systems, chlorpropamide and glycine, were selected. The polymorphic components were weighed, mixed, and compressed using a Carver press with 3/8-in. concave tooling. The compacts were then analyzed using parallel-beam X-ray powder diffractometry in transmission geometry. The data were processed using the profile-fitting module in the Shimadzu XRD-6000 software V 4.1 (for NT 4.0/98). The integrated intensity ratio of a selected peak for each crystal form was used for quantitation of each polymorph. Excellent linear correlation was observed for both polymorphic systems. The convex shape of the compact surface had no effect on the XRD patterns. Since parallel-beam X-ray diffractometry is not sensitive to the shape of the sample surface, it provides a simple method for quantifying polymorphs in intact compacts. Further work to extend this to formulated tablets is ongoing. The relatively larger variation in one of the peaks in the chlorpropamide study was found to be consistent with the computational analysis of the slip behavior of the stable polymorph. This method provides the first reported non-invasive X-ray diffraction pattern quantitation of crystal forms in intact compacts.

Effects of mechanical processing on phase composition

One factor that must be considered during drug development process is that various types of pharmaceutical manufacturing can alter the physical characteristics of the drug entity. These effects become particularly important during scale-up of processing operations, because new and unanticipated results can become manifest in systems of insufficient characterization. Any transformed drug substance or altered dosage form could exhibit an altered solubility or dissolution rate that might produce an undesirable bioavailability profile. Some of the more interesting mechanical manipulations that have the potential to yield problems include particle size reduction and compression, and such investigations are the focus of this minireview.

The use of solution calorimetry with micellar solvent systems for the detection of polymorphism

The presence of multiple polymorphic forms in seven batches of raw material of a model compound having poor wettability properties (cimetidine) was studied by solution calorimetry. Due to the large number of polymorphic forms described in the literature ('Gazz. Chim. Ital., 109 (1979) 535'; 'J. Pharm. Sci., 73 (1983) 1436'; 'J. Pharm. Biomed. Anal., 3 (1985) 303') and its poor wettability characteristics, cimetidine was chosen as a model compound to illustrate the possible use of solution calorimetry in the detection of polymorphism using surfactant systems as solvents for dissolution. Due to the closeness of the melting points of the different polymorphic forms of cimetidine, DSC was not the best investigational tool. As initially suspected, the measurement of enthalpy of solution values in water of the cimetidine batches was not possible. However, the use of sodium dodecyl sulfate (SDS) and polysorbate 20 (Tween 20(R)) at concentrations above their respective cmc values permitted the detection of significant differences in enthalpy of solution among several batches. The presence of different polymorphic forms was confirmed by microscopy, X-ray powder diffractometry, and Fourier transform infrared spectroscopy.

Theoretical approaches to physical transformations of active pharmaceutical ingredients during manufacturing processes

Processing-induced transformations (PITs) during pharmaceutical manufacturing are well known but difficult to predict and often difficult to control. This review of the concepts of transformations is couched in terms of the issues associated with identifying rate-controlling events from the materials side and the processing side. Specifically, the approach is reconciling the characteristic time scale of the structural change(s) in the material with the time scale of the processing-induced stress. This is definitely a model (or rather a melding of a group of existing theories) in development. This overview is a 'snapshot' of the authors' attempts to identify the categories of existing theories needed to encompass all of the relevant events for each possible PIT. The ultimate goal is to establish a framework of concepts and theories for consideration, discussion, and modeling of PITs as well as to locate much of the relevant literature in the framework.