A Factorial Approach to High Dose Product Development by an Extrusion/Spheronization Process

Influence of the surface tension of wet massing liquid on the functionality of microcrystalline cellulose as pelletization aid

This study designed to investigate the impact of surface tension of moistening liquid on the functionality of MCC as pelletization aid. For this purpose, sodium dodecyl sulfate (SDS), poloxamer 188 (PL), di-potassium hydrogen phosphate (K₂HPO₄) and combinations thereof were incorporated into the powder blend comprised of MCC and dicalcium phosphate (DCP) at different levels. Physical mixture (PM) and co-processed composite (Cop) of MCC and sodium carboxymethyl cellulose (SCMC) replaced MCC as pelletization aids. The pellets prepared were characterized for their median diameter (D₅₀), particle size distribution (PSD), sphericity, porosity, tensile strength and disintegration. SDS induced a drop in the surface tension of water from 68.7 to 23.7 mN/m at 0.1% (w/w). In contrast, the surface tension values of PL and K₂HPO₄ solutions were 2.08- and 3.07-fold higher than that of SDS solutions, respectively. MCC based pellets obtained with SDS showed wider PSD and lower sphericity than those made with PL, K₂HPO₄ and their combinations. In addition, the PSD and porosity increased with rise of SDS concentration from 0.05 to 0.25% (w/w). It was thus inferred that a critical surface tension of moistening liquid was essential for functionality of MCC as pelletization aid but not for PM and Cop.

A Quality by Experimental Design Approach to Assess the Effect of Formulation and Process Variables on the Extrusion and Spheronization of Drug-Loaded Pellets Containing Polyplasdone® XL-10

Successful pellet production has been reported in literature with cross-linked poly(vinylpyrrolidone), Polyplasdone® XL-10 and INF-10. In the present study, a quality by experimental design approach was used to assess several formulation and process parameter effects on the characteristics of Polyplasdone® XL-10 pellets, including pellet size, shape, yield, usable yield, friability, and number of fines. The hypothesis is that design of experiments and appropriate data analysis allow optimization of the Polyplasdone product. High drug loading was achieved using caffeine, a moderately soluble drug to allow in vitro release studies. A five-factor, two-level, half-fractional factorial design (Resolution V) with center point batches allowed mathematical modeling of the influence of the factors and their two-factor interactions on five of the responses. The five factors were Polyplasdone® level in the powder blend, volume of water in the wet massing step, wet mixing time, spheronizer speed, and spheronization time. Each factor and/or its two-factor interaction with another factor influenced pellet characteristics. The behavior of these materials under various processing conditions and component levels during extrusion-spheronization have been assessed, discussed, and explained based on the results. Numerical optimization with a desirability of 0.974 was possible because curvature and lack of fit were not significant with any of the model equations. The values predicted by the optimization described well the observed responses. The hypothesis was thus supported.

Use of fine particle ethylcellulose as the diluent in the production of pellets by extrusion-spheronization

The effect of small ethylcellulose particle size on the manufacture and properties of pellets produced by extrusion-spheronization was investigated. A factorial design revealed the effects of microcrystalline cellulose (MCC), polyethylene oxide (PEO), water, and spheronization speed and time on pellet properties. Response surface modeling allowed optimization of the responses with expansion to a central composite design. Pellet yield, size, shape, friability and drug release profile were studied, along with surface and interior morphology. Pellets were spherical irrespective of the formulation and process variables and exhibited physical and mechanical characteristics appropriate for further processing. Yield in the 12/20 mesh cut was lower with FPEC than observed with coarse particle ethylcellulose (CPEC), but FPEC-containing pellets were more rugged and the PEO to obtain optimal pellets was lower for FPEC compared to CPEC. Immediate release products were obtained and ethylcellulose particle size was of no consequence to drug release. Observed responses for the optimized product agreed with predicted values, demonstrating the success of the optimization procedure. These results suggest that FPEC is a good diluent for extrusion-spheronization.

The Evaluation of Formulations for the Preparation of Pellets with High Drug Loading by Extrusion/Spheronization

A capillary rheometer was used to evaluate rheological properties and the fluid mobility of mixtures with a high drug loading (80%) of three model drugs (ibuprofen, lactose, and ascorbic acid) when extruded. These drugs have a range of solubility in water, with 20% microcrystalline cellulose (MCC) as the spheronization aid, and water, pH 2.0, and pH 10.0 buffer as the binder liquid. The results were compared with the ability of the systems to form spherical pellets by the process of extrusion/spheronization. It was found possible to produce round pellets with a narrow size distribution by the process of extrusion/spheronization for formulations containing 80% of either lactose or ascorbic acid with MCC as the spheronization aid. It was not, however, possible to form pellets containing the same level of ibuprofen. This appears to be associated with the high level of fluid mobility observed when the wet masses were extruded in a ram extruder. A range of rheological characteristics in terms of shear stress, die entry pressure, angles of convergence, extensional flow, and elasticity were determined, but the variations in the values of these, which were observed, did not give an indication of the ability of the wet mass to form spherical pellets when subjected to the spheronization process. This could be associated with the fact that the selection of the conditions necessary to provide a valid quantification of the extrusion process did not truly represent the stability of the systems in terms of the mobility of the fluid when the wet mass was processed. The formulation of a wet mass with limited fluid mobility appears to be the first priority of formulations used in extrusion/spheronization.

Formulation Design of a Highly Hygroscopic Drug (Pyridostigmine Bromide) for its Hygroscopic Character Improvement and Investigation of In Vitro/In Vivo Dissolution Properties

Pyridostigmine bromide (PB) sustained-release (SR) pellets were developed by extrusion-spheronization and fluid-bed methods using Taguchi experimental and 2(3) full factorial design. In vitro studies, the 2(3) full factorial design was utilized to search for the optimal SR pellets with specific release rate at different time intervals (release percent of 2, 6, 12, and 24 hr were 6.24, 33.48, 75.18, and 95.26%, respectively) which followed a zero-order mechanism (n=0.93). The results of moisture absorption by Karl Fischer has shown the optimum SR pellets at 25 degrees C/60% RH, 30 degrees C/65% RH, and 40 degrees C/75% RH chambers from 1 hr-4 weeks, attributing that the moisture absorption was not significantly increased. In the in vivo study, the results of the bioavailability data showed the Tmax (from 0.65+/-0.082 hr-4.82+/-2.12 hr) and AUC0-30 hr (from 734.88+/-230.68 ng/mL.hr-1454.86+/-319.28 ng/mL.hr) were prolonged and increased, as well as Cmax (from 251.87+/-27.51 ng/mL-115.08+/-14.87 ng/mL) was decreased for optimum SR-PB pellets when compared with commercial immediate-release (IR) tablets. Furthermore, a good linear regression relationship (r=0.9943) was observed between the fraction dissolution and fraction absorption for the optimum SR pellets. In this study, the formulation design not only improved the hygroscopic character of PB but also achieved the SR effect.

Evaluation of the Performance of a New Continuous Spheronizer

This study aims to evaluate the performance of a new continuous spheronizer with multiple concentric chambers. The characteristics of the pellets produced in the different chambers (moisture content, mechanical strength, density, sphericity, size, release of a drug) were compared by multivariate analysis of variance (MANOVA), when different times of spheronization and chambers were considered. The statistical analysis has shown that both the diameter of the chambers and the time of spheronization affected the properties of the pellets, and, thus, they must be considered when the spheronizer is used. To minimize these effects all the forming pellets should be processed in all chambers for a defined period of time.

The evaluation of modified microcrystalline cellulose for the preparation of pellets with high drug loading by extrusion/spheronization

The performance of microcrystalline cellulose (MCC) which had been modified by the inclusion of various levels of sodium carboxymethylcellulose (SCMC) in the wet cake prior to drying, in terms of their ability to form pellets by a standardised extrusion/spheronization process has been assessed. Initial screening of the ability of the modified MCCs to form pellets with an 80% level of lactose as a model drug identified two potential products containing 6 or 8% of SCMC (B 6 and B 8). These two products were compared with a standard grade of MCC (Avicel PH101) in terms of their ability to produce pellets with 80% of model drugs of low (ibuprofen), intermediate (lactose) and high (ascorbic acid) water solubility when subjected to a standardised extrusion/spheronization process. Also assessed was their ability to retain water with applied pressure using a pressure membrane technique and their ability to restrict water migration during extrusion with a ram extruder. The two new types of MCC (B 6 and B 8) were able to form good quality pellets with all three model drugs, whereas Avicel PH101 could not form pellets with this high level of ibuprofen. This improved performance was related to the ability of the new types of MCC to hold higher levels of water within their structure and restrict the migration of water in the wet mass when subjected to pressure applied during the process of preparing the pellets. There is evidence to show that the two new types of MCC can function over a wider range of water contents than Avicel PH101 and that they have an improved performance if the extrusion process is rapid and if, after incorporation of the water into the powder, the sample is stored for some time before extrusion.

Development of 400 µm Pellets by Extrusion‐Spheronization Application with Gelucire 50/02 to Produce a “Sprinkle” Form

The aim of this study was to develop monodimensional, spherical particles of 400 microm by extrusion-spheronization. An Alexanderwerk GA65 cylinder extruder with two counter-rotating rollers associated with a Caleva model 15 spheronizer were used. The study was made with an auxiliary substance of fatty consistency and with amphiphilic properties: Gelucire 50/02. The plasticity of the mass can be deduced using a piston extruder. Pellet quality can be determined by particle-size analysis and shape estimation by microscopy. Modifications to the cylinders and the extruder itself are required for feasibility studies of extruded materials of 400 microm. The horizontal plate of the spheronizer had to be adapted to take into account the small size of the extruded materials. For the chosen auxiliary substance, Gelucire 50/02, the formulation of the wet mass to be extruded and the conditions required to obtain this mass were defined. The results show the feasibility of 400 microm pellets with Gelucire 50/02. At least 90% of the pellets have a particle size of between 250 microm and 500 microm and particle shape is acceptable. In this form the dose can be adapted to individual patients. After proving the feasibility of 400 microm spheroids of Gelucire 50/02, the association of a drug with it was considered.

Small-scale characterization of wet powder masses suitable for extrusion-spheronization

The method of compresso-rheology with an Instron 5567 was used for flow assessment of wet powder mass in order to improve its formulation. In our experiments, the method was efficient for selection of the excipient (Avicel CL611) able to improve the extrusion behavior of the high-dose wet powder mass. The method also allowed the determination of the minima and maxima of the wetting agent volume necessary to identify the correct moisture content for extrusion (20%). The results were not discriminative for the choice of the Avicel CL611 amount in the formulae even if an average amount necessary to improve extrudability of the active ingredient could have been estimated at about 10%. Nevertheless, this method appeared to be a rapid and easy small-scale method for studying wet powder mass, cause only a few grams of solids are required, this rheometer should prove useful in formulation research.

Comparison between a twin-screw extruder and a rotary ring die press. Part II: influence of process variables

The influence of different processing steps on pellet quality was investigated: granulation/extrusion and spheronization. Pellets were produced at two levels of water content on two different types of extruders: a twin screw extruder and a rotary ring die press. In order to control the spheronization process each extrudate was rounded in two spheronizers using two radial velocities, respectively. Pellet shape and size were selected to describe the pellet quality. Under constant spheronization conditions the extrudates behaved dissimilar on the two spheronizers. This could be attributed to the geometry of the friction plates. The spheronizer with the rougher surface applied more mechanical energy to the extrudate and wet pellets which reduced the water content necessary for the formation of good pellets. Eliminating the influence of the spheronization process, high differences were observed in the quality of the extrudates produced by the two extruders. This confirmed the results from the first part of this study. Due to the crystallite-gel-model the different extruder types apply different mechanical stress on the extrudate which affect the network structure of the microcrystalline cellulose gel. The twin-screw extruder produced a more delicate network with a lower water movement. This led to a shift of the optimal moisture content towards higher values. Compared with spheronization, process changes in the granulation/extrusion process were more critical.

Optimization of aqueous-based film coating of tablets performed by a side-vented pan-coating system

The purpose of this research was to characterize the aqueous-based hydroxypropylmethylcellulose (HPMC) film coating of tablets utilizing a laboratory-scale side-vented pan-coating apparatus (Thai coater). The process and apparatus parameters of potential importance with respect to the final film quality were evaluated by using fractional factorial design (2(6-2)IV) and the process was optimized using response surface methodology (central composite design). Rotating speed of the pan was identified as a major parameter with respect to film thickness (weight increase; p < 0.05) and breaking strength (p < 0.05) of the aqueous HPMC film-coated tablets. Increasing the rotating speed from 5 rpm to 10 rpm resulted in a mean relative change of -43.9% and 2.4% of film thickness (weight increase) and breaking strength, respectively. As expected, inlet air temperature significantly affected the moisture content of the final film-coated tablets (p < 0.01) and the film thickness (weight increase; p < 0.05), but the effects on the other responses studied were minimal or negligible. Pneumatic spraying pressure and position of the spray gun (excluding angle of the gun) did not affect the responses studied. The process parameters relevant to a side-vented pan-coating process can be identified (by fractional factorial design) and, consequently, optimized (by central composite design) by using the factorial design approach.

Effect of common classes of excipients on extrusion-spheronization

Different classes of excipients with potential for use in the design of novel pelletized formulations manufactured by extrusion-spheronization were examined using factorial experiments. Among the various silicates examined in a model mix with microcrystalline cellulose and lactose wetted with water, kaolin, talc and Veegum F provided improved plasticity for the formation of spherical pellets. Weak bases such sodium bicarbonate and weak acids such as fumaric acid also aided spheronization. Whereas waxy materials such as hydrogenated castor oil and Precirol ATO5, and wetting agent such as sodium lauryl sulphate improved sphericity, these excipients reduced pellet yield by favouring agglomeration. Other materials promoting unwanted formation of over-size pellets were bentonite, citric acid and tartaric acid. The inclusion of Bentone 27, various hydroxide and carbonate bases, and fumaric acid favoured fines production. Collectively the results showed that within classes of excipients, it was not possible to predict the effect of different materials on pellet yield and sphericity. However, Carr's index and Hausner ratio calculated from density determinations correlated well with sphericity measured by image analysis.

Drug solubility effects on predicting optimum conditions for extrusion and spheronization of pellets

This paper explores the utility of aqueous solubility of structurally similar drugs in predicting optimum conditions for extrusion and spheronization of pellets using response surface methodology. Pharmacologically active xanthine derivatives exhibiting widely varying aqueous solubility were used to determine optimum conditions for pelletization. The amount of water added to the formulation, wet mixing time, and spheronizing time were explored in a series of central composite experimental designs to exhaustively explore and mathematically model the response surfaces for each drug. Using a marketed microcrystalline cellulose excipient, optimum extrusion and spheronization conditions for less soluble drugs required more water, a longer wet mixing time, and prolonged spheronizing times. Results were similar when a new microcrystalline cellulose was substituted, except that more water was required. When comparing results for different drugs, a strong linear relationship was observed between the aqueous solubility of the drug and the water content required for optimum pellet production. The water content range over which quality pellets could be produced was much broader for poorly soluble drugs. Aqueous solubility of the active component appears to be a good predictor for the water requirements for optimum extrusion and spheronization of pellets for pharmaceutical applications.