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Continuous Twin Screw Granulation: A Review of Recent Progress and Opportunities in Formulation and Equipment Design. Pharmaceutics 2021; 13:pharmaceutics13050668. [PMID: 34066921 PMCID: PMC8148523 DOI: 10.3390/pharmaceutics13050668] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 04/30/2021] [Accepted: 05/02/2021] [Indexed: 11/16/2022] Open
Abstract
Continuous twin screw wet granulation is one of the key continuous manufacturing technologies that have gained significant interest in the pharmaceutical industry as well as in academia over the last ten years. Given its considerable advantages compared to wet granulation techniques operated in batch mode such as high shear granulation and fluid bed granulation, several equipment manufacturers have designed their own manufacturing setup. This has led to a steep increase in the research output in this field. However, most studies still focused on a single (often placebo) formulation, hence making it difficult to assess the general validity of the obtained results. Therefore, current review provides an overview of recent progress in the field of continuous twin screw wet granulation, with special focus on the importance of the formulation aspect and raw material properties. It gives practical guidance for novel and more experienced users of this technique and highlights some of the unmet needs that require further research.
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Berardi A, Bisharat L, Quodbach J, Abdel Rahim S, Perinelli DR, Cespi M. Advancing the understanding of the tablet disintegration phenomenon - An update on recent studies. Int J Pharm 2021; 598:120390. [PMID: 33607196 DOI: 10.1016/j.ijpharm.2021.120390] [Citation(s) in RCA: 27] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/24/2020] [Revised: 02/01/2021] [Accepted: 02/10/2021] [Indexed: 10/22/2022]
Abstract
Disintegration is the de-aggregation of particles within tablets upon exposure to aqueous fluids. Being an essential step in the bioavailability cascade, disintegration is a fundamental quality attribute of immediate release tablets. Although the disintegration phenomenon has been studied for over six decades, some gaps of knowledge and research questions still exist. Three reviews, published in 2015, 2016 and 2017, have discussed the literature relative to tablet disintegration and summarised the understanding of this topic. Yet, since then more studies have been published, adding to the established body of knowledge. This article guides a step forward towards the comprehension of disintegration by reviewing, concisely, the most recent scientific updates on this topic. Initially, we revisit the mechanisms of disintegration with relation to the three most used superdisintegrants, namely sodium starch glycolate, croscarmellose sodium and crospovidone. Then, the influence of formulation, storage, manufacturing and media conditions on disintegration is analysed. This is followed by an excursus on novel disintegrants. Finally, we highlight unanswered research questions and envision future research venues in the field.
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Affiliation(s)
- Alberto Berardi
- Department of Pharmaceutical Sciences and Pharmaceutics Faculty of Pharmacy, Applied Science Private University, Amman 11931, Jordan.
| | - Lorina Bisharat
- Department of Pharmaceutics and Pharmaceutical Technology, School of Pharmacy, The University of Jordan, Amman 11942, Jordan
| | - Julian Quodbach
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University Duesseldorf, Germany
| | - Safwan Abdel Rahim
- Department of Pharmaceutical Sciences and Pharmaceutics Faculty of Pharmacy, Applied Science Private University, Amman 11931, Jordan
| | - Diego R Perinelli
- School of Pharmacy, University of Camerino, 62032 Camerino, MC, Italy
| | - Marco Cespi
- School of Pharmacy, University of Camerino, 62032 Camerino, MC, Italy
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Portier C, Vigh T, Di Pretoro G, De Beer T, Vervaet C, Vanhoorne V. Continuous twin screw granulation: Impact of binder addition method and surfactants on granulation of a high-dosed, poorly soluble API. Int J Pharm 2020; 577:119068. [DOI: 10.1016/j.ijpharm.2020.119068] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/16/2019] [Revised: 01/14/2020] [Accepted: 01/17/2020] [Indexed: 10/25/2022]
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Dun J, Osei-Yeboah F, Boulas P, Lin Y, Sun CC. A systematic evaluation of dual functionality of sodium lauryl sulfate as a tablet lubricant and wetting enhancer. Int J Pharm 2018; 552:139-147. [DOI: 10.1016/j.ijpharm.2018.09.056] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/27/2018] [Revised: 09/18/2018] [Accepted: 09/22/2018] [Indexed: 12/01/2022]
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Leane M, Pitt K, Reynolds GK, Dawson N, Ziegler I, Szepes A, Crean AM, Dall Agnol R, The Manufacturing Classification System McS Working Group. Manufacturing classification system in the real world: factors influencing manufacturing process choices for filed commercial oral solid dosage formulations, case studies from industry and considerations for continuous processing. Pharm Dev Technol 2018; 23:964-977. [PMID: 30320539 DOI: 10.1080/10837450.2018.1534863] [Citation(s) in RCA: 50] [Impact Index Per Article: 8.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
Abstract
Following the first Manufacturing Classification System (MCS) paper, the team conducted surveys to establish which active pharmaceutical ingredient (API) properties were important when selecting or modifying materials to enable an efficient and robust pharmaceutical manufacturing process. The most commonly identified factors were (1) API particle size: small particle sizes are known to increase risk of processing issues; (2) Drug loading in the formulation: high drug loadings allow less opportunity to mitigate poor API properties through the use of excipients. The next step was to establish linkages with process decisions by identifying publicly-available proxies for these important parameters: dose (in place of drug loading) and BCS class (in place of particle size). Poorly-soluble API were seen as more likely to have controlled (smaller) particle size than more highly soluble API. Analysis of 435 regulatory filings revealed that higher doses and more poorly-soluble API was associated with more complex processing routes. Replacing the proxy factors with the original parameters should give the opportunity to demonstrate stronger trends. This assumption was tested by accessing a dataset relating to commercial tablet products. This showed that, for dry processes, a larger particle size was associated with higher achievable drug loading as determined by percolation threshold.
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Affiliation(s)
- Michael Leane
- a Drug Product Science & Technology (DPST), Bristol-Myers Squibb , Moreton , UK
| | - Kendal Pitt
- b Global Manufacturing and Supply, GlaxoSmithKline , Ware , UK
| | | | - Neil Dawson
- d Global Research and Development, Pfizer , Sandwich , UK
| | - Iris Ziegler
- e Corden Pharma International GmbH , Plankstadt , Germany
| | - Aniko Szepes
- f Research and Development Division, F. Hoffmann-La Roche AG , Basel , Switzerland
| | - Abina M Crean
- g Pharmaceutical Manufacturing Technology Centre, School of Pharmacy , University College Cork - National University of Ireland , Cork , Ireland.,h Synthesis and Solid State Pharmaceutical Centre, School of Pharmacy , University College Cork - National University of Ireland , Cork , Ireland
| | - Rafaela Dall Agnol
- i Curso de Farmácia, Centro de Ciências Biológicas e da Saúde , Universidade de Caxias do Sul , Caxias do Sul , Brazil
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Sun WJ, Rantanen J, Sun CC. Ribbon density and milling parameters that determine fines fraction in a dry granulation. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.07.009] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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Zhao J, Koo O, Pan D, Wu Y, Morkhade D, Rana S, Saha P, Marin A. The Impact of Disintegrant Type, Surfactant, and API Properties on the Processability and Performance of Roller Compacted Formulations of Acetaminophen and Aspirin. AAPS JOURNAL 2017; 19:1387-1395. [DOI: 10.1208/s12248-017-0104-6] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/23/2017] [Accepted: 05/26/2017] [Indexed: 11/30/2022]
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Influence of particle properties on powder bulk behaviour and processability. Int J Pharm 2017; 518:138-154. [DOI: 10.1016/j.ijpharm.2016.12.045] [Citation(s) in RCA: 49] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/12/2016] [Revised: 12/16/2016] [Accepted: 12/19/2016] [Indexed: 11/18/2022]
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Kondo H, Toyota H, Kamiya T, Yamashita K, Hakomori T, Imoto J, Kimura SI, Iwao Y, Itai S. Effect of the External Lubrication Method for a Rotary Tablet Press on the Adhesion of the Film Coating Layer. Chem Pharm Bull (Tokyo) 2017; 65:848-853. [DOI: 10.1248/cpb.c17-00376] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
Affiliation(s)
- Hisami Kondo
- Pharmaceutical Research and Technology Laboratories, Astellas Pharma Inc
- Department of Pharmaceutical Engineering, School of Pharmaceutical Sciences, University of Shizuoka
| | - Hiroyasu Toyota
- Pharmaceutical Research and Technology Laboratories, Astellas Pharma Inc
| | - Takayuki Kamiya
- Pharmaceutical Research and Technology Laboratories, Astellas Pharma Inc
| | - Kazunari Yamashita
- Pharmaceutical Research and Technology Laboratories, Astellas Pharma Inc
| | - Tadashi Hakomori
- Pharmaceutical Research and Technology Laboratories, Astellas Pharma Inc
| | - Junko Imoto
- CMC Analytical Group, Astellas Analytical Science Laboratories Inc
| | - Shin-ichiro Kimura
- Department of Pharmaceutical Engineering, School of Pharmaceutical Sciences, University of Shizuoka
| | - Yasunori Iwao
- Department of Pharmaceutical Engineering, School of Pharmaceutical Sciences, University of Shizuoka
| | - Shigeru Itai
- Department of Pharmaceutical Engineering, School of Pharmaceutical Sciences, University of Shizuoka
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Pandey P, Levins C, Pafiakis S, Zacour B, Bindra DS, Trinh J, Buckley D, Gour S, Sharif S, Stamato H. Enhancing tablet disintegration characteristics of a highly water-soluble high-drug-loading formulation by granulation process. Pharm Dev Technol 2016; 23:587-595. [PMID: 27879156 DOI: 10.1080/10837450.2016.1264416] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
Abstract
The objective of this study was to improve the disintegration and dissolution characteristics of a highly water-soluble tablet matrix by altering the manufacturing process. A high disintegration time along with high dependence of the disintegration time on tablet hardness was observed for a high drug loading (70% w/w) API when formulated using a high-shear wet granulation (HSWG) process. Keeping the formulation composition mostly constant, a fluid-bed granulation (FBG) process was explored as an alternate granulation method using a 2(4-1) fractional factorial design with two center points. FBG batches (10 batches) were manufactured using varying disingtegrant amount, spray rate, inlet temperature (T) and atomization air pressure. The resultant final blend particle size was affected significantly by spray rate (p = .0009), inlet T (p = .0062), atomization air pressure (p = .0134) and the interaction effect between inlet T*spray rate (p = .0241). The compactibility of the final blend was affected significantly by disintegrant amount (p < .0001), atomization air pressure (p = .0013) and spray rate (p = .05). It was observed that the fluid-bed batches gave significantly lower disintegration times than the HSWG batches, and mercury intrusion porosimetry data revealed that this was caused by the higher internal pore structure of tablets manufactured using the FBG batches.
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Affiliation(s)
- Preetanshu Pandey
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Christopher Levins
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Steve Pafiakis
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Brian Zacour
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Dilbir S Bindra
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Jade Trinh
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - David Buckley
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Shruti Gour
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Shasad Sharif
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Howard Stamato
- a Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
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Kristó K, Kovács O, Kelemen A, Lajkó F, Klivényi G, Jancsik B, Pintye-Hódi K, Regdon G. Process analytical technology (PAT) approach to the formulation of thermosensitive protein-loaded pellets: Multi-point monitoring of temperature in a high-shear pelletization. Eur J Pharm Sci 2016; 95:62-71. [DOI: 10.1016/j.ejps.2016.08.051] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/15/2016] [Revised: 08/25/2016] [Accepted: 08/26/2016] [Indexed: 10/21/2022]
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