1
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Horváth ZM, Kukuls K, Frolova AJ, Žogota M, Buczkowska EM, Pētersone L, Mohylyuk V. Effervescent Tablet Preparation by Twin-Screw Melt Granulation with Sorbitol as a Melt Binder. Pharmaceutics 2025; 17:676. [PMID: 40430966 PMCID: PMC12115153 DOI: 10.3390/pharmaceutics17050676] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/10/2025] [Revised: 05/12/2025] [Accepted: 05/16/2025] [Indexed: 05/29/2025] Open
Abstract
Methods: Effervescent granules containing citric acid and sodium bicarbonate were successfully prepared for the first time via TS-MG using a polyol (sorbitol) as a melt binder. Results: Processing parameters, specifically granulation temperature and screw speed, were systematically varied to investigate their influence. The granulation efficiency, inversely related to the wt.% of fines, decreased in the following order across the tested conditions (granulation temperature-screw speed; ℃-rpm): 95-6 > 100-5 > 90-5 > 100-7 > 90-7. Granulation temperature had a minimal impact on the bulk and tapped densities of the uncalibrated granules, whereas increased screw speed led to higher densities, associated with a reduced proportion of fines. The tensile strength of the resulting effervescent tablets increased with granulation temperature and was generally higher for tablets derived from granules with higher granulation efficiency. The residence time within the TS-MG barrel decreased with increasing temperature and screw speed. Notably, the greatest effect of granulation temperature on tensile strength occurred between 90 and 95 °C, particularly under longer residence times. The disintegration time of the tablets was shortest for the 90 °C and 5 rpm condition, corresponding to the lowest tensile strength, while tablets across formulations showed consistent homogeneity as indicated by similar pH values post-disintegration. Conclusions: These findings underscore sorbitol's suitability as a melt binder and highlight the interplay between TS-MG parameters and the physical characteristics of effervescent granules and tablets.
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Affiliation(s)
| | | | | | | | | | | | - Valentyn Mohylyuk
- Leading Research Group, Faculty of Pharmacy, Rīga Stradiņš University, 21 Konsula St., LV-1007 Riga, Latvia
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2
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Bachawala S, Lagare RB, Delaney AB, Nagy ZK, Reklaitis GV, Gonzalez M. Rational Function-Based Approach for Integrating Tableting Reduced-Order Models with Upstream Unit Operations: Dry Granulation Case Study. Pharmaceuticals (Basel) 2024; 17:1158. [PMID: 39338321 PMCID: PMC11434797 DOI: 10.3390/ph17091158] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/18/2024] [Revised: 08/22/2024] [Accepted: 08/23/2024] [Indexed: 09/30/2024] Open
Abstract
We present a systematic and automatic approach for integrating tableting reduced-order models with upstream unit operations. The approach not only identifies the upstream critical material attributes and process parameters that describe the coupling to the first order and, possibly, the second order, but it also selects the mathematical form of such coupling and estimates its parameters. Specifically, we propose that the coupling can be generally described by normalized bivariate rational functions. We demonstrate this approach for dry granulation, a unit operation commonly used to enhance the flowability of pharmaceutical powders by increasing granule size distribution, which, inevitably, negatively impacts tabletability by reducing the particle porosity and imparting plastic work. Granules of different densities and size distributions are made with a 10% w/w acetaminophen and 90% w/w microcrystalline cellulose formulation, and tablets with a wide range of relative densities are fabricated. This approach is based on product and process understanding, and, in turn, it is not only essential to enabling the end-to-end integration, control, and optimization of dry granulation and tableting processes, but it also offers insight into the granule properties that have a dominant effect on each of the four stages of powder compaction, namely die filling, compaction, unloading, and ejection.
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Affiliation(s)
- Sunidhi Bachawala
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Rexonni B Lagare
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Abigail B Delaney
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Zoltan K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA
- Ray W. Herrick Laboratories, Purdue University, West Lafayette, IN 47907, USA
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3
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Köster C, Kleinebudde P. Evaluation of binders in twin-screw wet granulation - Optimization of tabletability. Int J Pharm 2024; 659:124290. [PMID: 38821435 DOI: 10.1016/j.ijpharm.2024.124290] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/02/2024] [Revised: 05/27/2024] [Accepted: 05/28/2024] [Indexed: 06/02/2024]
Abstract
The influence of hydroxypropyl cellulose type (HPC-SSL SFP, HPC-SSL), concentration (2 %, 3.5 %, 5 %) and filler (lactose, calcium hydrogen phosphate (DCP)/microcrystalline cellulose (MCC)) on twin-screw wet granulation and subsequent tableting was studied. The aim was to identify the formulation of the highest tabletability which still fulfills the requirements of the disintegration. Lactose combined with 5 % binder enabled a higher tabletability and a faster disintegration than DCP/MCC. It was found that tabletability of lactose formulations can be increased by higher binder concentration and higher compression pressure while tabletability of DCP/MCC formulations can be only increased by higher compression pressure. It was observed that batches containing DCP/MCC failed the disintegration test, if the highest binder concentration and the highest compression pressure were used. To ensure a fast disintegration, the compression pressure or at least the binder concentration had to be low. Changing the disintegrant and its localization improved the DCP/MCC formulation, resulting in faster disintegration than lactose tablets. However, it also resulted in a lower tabletability. In this study best tablets were achieved with 3.5 % or 5 % binder and lactose as filler. These tablets presented the highest tabletability but still disintegrated in less than 500 s.
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Affiliation(s)
- Claudia Köster
- Institute of Pharmaceutics and Biopharmaceutics, Faculty of Mathematics and Natural Sciences, Heinrich Heine University, Universitätsstr. 1, 40225 Düsseldorf, Germany.
| | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Faculty of Mathematics and Natural Sciences, Heinrich Heine University, Universitätsstr. 1, 40225 Düsseldorf, Germany.
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4
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Su J, Zhang K, Qi F, Cao J, Miao Y, Zhang Z, Qiao Y, Xu B. A tabletability change classification system in supporting the tablet formulation design via the roll compaction and dry granulation process. Int J Pharm X 2023; 6:100204. [PMID: 37560487 PMCID: PMC10407897 DOI: 10.1016/j.ijpx.2023.100204] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/24/2023] [Revised: 07/26/2023] [Accepted: 07/27/2023] [Indexed: 08/11/2023] Open
Abstract
In this paper, the material library approach was used to uncover the pattern of tabletability change and related risk for tablet formulation design under the roll compaction and dry granulation (RCDG) process. 31 materials were fully characterized using 18 physical parameters and 9 compression behavior classification system (CBCS) parameters. Then, each material was dry granulated and sieved into small granules (125-250 μm) and large granules (630-850 μm), respectively. The compression behavior of granules was characterized by the CBCS descriptors, and were compared with that of ungranulated powders. The relative change of tabletability (CoTr) index was used to establish the tabletability change classification system (TCCS), and all materials were classified into three types, i.e. loss of tabletability (LoT, Type I), unchanged tabletability (Type II) and increase of tabletability (Type III). Results showed that approximately 65% of materials presented LoT, and as the granules size increased, 84% of the materials exhibited LoT. A risk decision tree was innovatively proposed by joint application of the CBCS tabletability categories and the TCCS tabletability change types. It was found that the LoT posed little risk to the tensile strength of the final tablet, when Category 1 or 2A materials, or Category 2B materials with Type II or Type III change of tabletability were used. Formulation risk happened to Category 2C or 3 materials, or Category 2B materials with Type I change of tabletability, particularly when high proportions of these materials were involved in tablet formulation. In addition, the risk assessment results were verified in the material property design space developed from a latent variable model in prediction of tablet tensile strength. Overall, results suggested that a combinational use of CBCS and TCCS could aid the decision making in selecting materials for tablet formulation design via RCDG.
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Affiliation(s)
- Junhui Su
- Department of Chinese Medicine Informatics, Beijing University of Chinese Medicine, Beijing 100029, PR China
- Beijing Key Laboratory of Chinese Medicine Manufacturing Process Control and Quality Evaluation, Beijing 100029, PR China
| | - Kunfeng Zhang
- Department of Chinese Medicine Informatics, Beijing University of Chinese Medicine, Beijing 100029, PR China
| | - Feiyu Qi
- Department of Chinese Medicine Informatics, Beijing University of Chinese Medicine, Beijing 100029, PR China
| | - Junjie Cao
- Department of Chinese Medicine Informatics, Beijing University of Chinese Medicine, Beijing 100029, PR China
| | - Yuhua Miao
- The International Department, No. 8 Middle School of Beijing, Beijing 100045, PR China
| | - Zhiqiang Zhang
- Beijing Tcmages Pharmceutical Co. LTD, Beijing 101301, PR China
| | - Yanjiang Qiao
- Department of Chinese Medicine Informatics, Beijing University of Chinese Medicine, Beijing 100029, PR China
- Beijing Key Laboratory of Chinese Medicine Manufacturing Process Control and Quality Evaluation, Beijing 100029, PR China
| | - Bing Xu
- Department of Chinese Medicine Informatics, Beijing University of Chinese Medicine, Beijing 100029, PR China
- Beijing Key Laboratory of Chinese Medicine Manufacturing Process Control and Quality Evaluation, Beijing 100029, PR China
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5
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Vijayakumar J, Goudarzi NM, Eeckhaut G, Schrijnemakers K, Cnudde V, Boone MN. Characterization of Pharmaceutical Tablets by X-ray Tomography. Pharmaceuticals (Basel) 2023; 16:ph16050733. [PMID: 37242516 DOI: 10.3390/ph16050733] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/02/2023] [Revised: 05/07/2023] [Accepted: 05/08/2023] [Indexed: 05/28/2023] Open
Abstract
Solid dosage forms such as tablets are extensively used in drug administration for their simplicity and large-scale manufacturing capabilities. High-resolution X-ray tomography is one of the most valuable non-destructive techniques to investigate the internal structure of the tablets for drug product development as well as for a cost effective production process. In this work, we review the recent developments in high-resolution X-ray microtomography and its application towards different tablet characterizations. The increased availability of powerful laboratory instrumentation, as well as the advent of high brilliance and coherent 3rd generation synchrotron light sources, combined with advanced data processing techniques, are driving the application of X-ray microtomography forward as an indispensable tool in the pharmaceutical industry.
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Affiliation(s)
- Jaianth Vijayakumar
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86/N3, 9000 Gent, Belgium
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, 9000 Gent, Belgium
| | - Niloofar Moazami Goudarzi
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86/N3, 9000 Gent, Belgium
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, 9000 Gent, Belgium
| | - Guy Eeckhaut
- Janssen Pharmaceutica, Turnhoutseweg 30, 2340 Beerse, Belgium
| | | | - Veerle Cnudde
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86/N3, 9000 Gent, Belgium
- Pore-Scale Processes in Geomaterials Research (PProGRess), Department of Geology, Ghent University, Krijgslaan 281/S8, 9000 Gent, Belgium
- Environmental Hydrogeology, Department of Earth Sciences, Faculty of Geosciences, Utrecht University, Princetonlaan 8A, 3584 CD Utrecht, The Netherlands
| | - Matthieu N Boone
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86/N3, 9000 Gent, Belgium
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, 9000 Gent, Belgium
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6
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Peeters M, Alejandra Barrera Jimenez A, Matsunami K, Stauffer F, Nopens I, De Beer T. Evaluation of the influence of material properties and process parameters on granule porosity in twin-screw wet granulation. Int J Pharm 2023; 641:123010. [PMID: 37169104 DOI: 10.1016/j.ijpharm.2023.123010] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/08/2023] [Revised: 04/26/2023] [Accepted: 04/27/2023] [Indexed: 05/13/2023]
Abstract
In recent years, continuous twin-screw wet granulation (TSWG) is gaining increasing interest from the pharmaceutical industry. Despite the many publications on TSWG, only a limited number of studies focused on granule porosity, which was found to be an important granule property affecting the final tablet quality attributes, e.g. dissolution. In current study, the granule porosity along the length of the twin-screw granulator (TSG) barrel was evaluated. An experimental set-up was used allowing the collection of granules at the different TSG compartments. The effect of active pharmaceutical ingredient (API) properties on granule porosity was evaluated by using six formulations with a fixed composition but containing APIs with different physical-chemical properties. Furthermore, the importance of TSWG process parameters liquid-to-solid (L/S) ratio, mass feed rate and screw speed for the granule porosity was evaluated. Several water-related properties as well as particle size, density and flow properties of the API were found to have an important effect on granule porosity. While the L/S ratio was confirmed to be the dictating TSWG process parameter, granulator screw speed was also found to be an important process variable affecting granule porosity. This study obtained crucial information on the effect of material properties and process parameters on granule porosity (and granule formation) which can be used to accelerate TSWG process and formulation development.
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Affiliation(s)
- Michiel Peeters
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Ana Alejandra Barrera Jimenez
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure Links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Kensaku Matsunami
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium; BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure Links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Fanny Stauffer
- Product Design & Performance, UCB, Ottergemsesteenweg 460, Braine l'Alleud 1420, Belgium
| | - Ingmar Nopens
- BIOMATH, Department of Data Analysis and Mathematical Modelling, Ghent University, Coupure Links 653, Ghent 9000, Oost-Vlaanderen, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Oost-Vlaanderen, Belgium.
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7
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Elsergany RN, Vreeman G, Calvin Sun C. An approach for predicting the true density of powders based on in-die compression data. Int J Pharm 2023; 637:122875. [PMID: 36948478 DOI: 10.1016/j.ijpharm.2023.122875] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/20/2023] [Revised: 03/14/2023] [Accepted: 03/17/2023] [Indexed: 03/24/2023]
Abstract
Helium pycnometry, a commonly used technique for measuring the true density of powders, is sensitive to the release of volatiles during measurement. This can lead to over-estimated true density, and as such, an accurate method for determining the true density of powders containing volatile components is needed. Here, a method based on in-die compression data obtained with a compaction simulator was assessed. Specifically, the stress transmission coefficient (STC), measured using an instrumented die, was used to predict the in-die Heckel mean yield pressure (Py). A true density was derived by repeatedly performing a Heckel analysis using iteratively estimated true density values until the predicted Py value from the measured STC value is obtained from in-die density - pressure data. This novel method was validated using a set of water-free powders. Using crystalline hydrates, we further showed that the calculated true densities were closer to values calculated from crystal structure than those from helium pycnometry. Hence, this method may be used for determining the true density of powders from their STC values.
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Affiliation(s)
- Ramy N Elsergany
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, Minneapolis, MN 55455, USA
| | - Gerrit Vreeman
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, Minneapolis, MN 55455, USA
| | - Changquan Calvin Sun
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, Minneapolis, MN 55455, USA.
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8
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Janssen PH, Jaspers M, Meier R, Roelofs TP, Dickhoff BH. The effect of excipient particle size on the reduction of compactibility after roller compaction. Int J Pharm X 2022; 4:100117. [PMID: 35496756 PMCID: PMC9043665 DOI: 10.1016/j.ijpx.2022.100117] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/26/2022] [Revised: 04/06/2022] [Accepted: 04/12/2022] [Indexed: 12/02/2022] Open
Abstract
Developing a robust roller compaction process can be challenging, due to the diversity in process parameters and material properties of the components in a formulation. A major challenge in dry granulation is the reduction of tablet strength as a result of re-compaction of the materials. The aim of this study is to investigate the impact of excipient type and particle size distribution on tablet tensile strength after roller compaction. Lactose monohydrate, anhydrous lactose and microcrystalline cellulose with different particle sizes are roller compacted at varying specific compaction forces. Granules obtained are compressed into tablets to evaluate the reduction in tablet strength upon increasing the specific compaction force. The impact of particle size of the starting material is shown to be vastly different for the three types of excipients investigated, due to the differences in mechanical deformation mechanisms. The presence of rough surfaces and a high degree of fragmentation for anhydrous lactose appears to be beneficial for compaction and re-compaction process. Additionally, the particle size of anhydrous lactose hardly affects the tensile strength of tablets, which can be beneficial for the robustness of a roller compaction process. The impact of particle size on the re-compactibility differs per excipient type. Re-compactibility is classified and quantified for different excipients. Rough surfaces and a high degree of fragmentation are beneficial for re-compaction. The particle size of anhydrous lactose hardly affects the re-compactibility.
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Affiliation(s)
- Pauline H.M. Janssen
- DFE Pharma, Klever Strasse 187, 47568 Goch, Germany
- University of Groningen, Department of Pharmaceutical Technology and Biopharmacy, Antonius Deusinglaan 1, 9713, AV, Groningen, the Netherlands
- Corresponding author at: DFE Pharma, Klever Strasse 187, 47568 Goch, Germany.
| | | | - Robin Meier
- L.B. Bohle Maschinen und Verfahren GmbH, Industriestrasse 18, 59320 Ennigerloh, Germany
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9
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Mareczek L, Riehl C, Harms M, Reichl S. Understanding the Multidimensional Effects of Polymorphism, Particle Size and Processing for D-Mannitol Powders. Pharmaceutics 2022; 14:pharmaceutics14102128. [PMID: 36297563 PMCID: PMC9611586 DOI: 10.3390/pharmaceutics14102128] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/21/2022] [Revised: 10/03/2022] [Accepted: 10/04/2022] [Indexed: 11/05/2022] Open
Abstract
The relevance of the polymorphic form, particle size, and processing of mannitol for the mechanical properties of solid oral dosage forms was examined. Thus, particle and powder properties of spray granulated β D-mannitol, β D-mannitol, and δ D-mannitol were assessed in this study with regards to their manufacturability. D-mannitol is a commonly used excipient in pharmaceutical formulations, especially in oral solid dosage forms, and can be crystallized as three polymorphic forms, of which β is the thermodynamically most stable form and δ is a kinetically stabilized polymorph. A systematic analysis of the powders as starting materials and their respective roller compacted granules is presented to elucidate the multidimensional effects of powder and granules characteristics such as polymorphic form, particle size, and preprocessing on the resulting tablets’ mechanical properties. In direct compression and after roller compaction, δ polymorph displayed superior tableting properties over β mannitol, but was outperformed by spray granulated β mannitol. This could be primarily correlated to the higher specific surface area, leading to higher bonding area and more interparticle bonds within the tablet. Hence, it was shown that surface characteristics and preprocessing can prevail over the impact of polymorphism on manufacturability for oral solid dosage forms.
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Affiliation(s)
- Lena Mareczek
- Institute of Pharmaceutical Technology and Biopharmaceutics, Technische Universität Braunschweig, 38106 Braunschweig, Germany
- Department of Pharmaceutical Technologies, Merck KGaA, 64293 Darmstadt, Germany
| | - Carolin Riehl
- Department of Pharmaceutical Technologies, Merck KGaA, 64293 Darmstadt, Germany
| | - Meike Harms
- Department of Pharmaceutical Technologies, Merck KGaA, 64293 Darmstadt, Germany
| | - Stephan Reichl
- Institute of Pharmaceutical Technology and Biopharmaceutics, Technische Universität Braunschweig, 38106 Braunschweig, Germany
- Correspondence:
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10
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Jaspers M, Roelofs TP, Janssen PH, Meier R, Dickhoff BH. A novel approach to minimize loss of compactibility in a dry granulation process using superdisintegrants. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117773] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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11
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Deciphering the role of granule deformation and fragmentation for the tableting performance of some dry granulated powders. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117794] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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12
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Tofiq M, Nordström J, Persson AS, Alderborn G. Effect of excipient properties and blend ratio on the compression properties of dry granulated particles prepared from microcrystalline cellulose and lactose. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117207] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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13
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Lillotte TD, Bebernik P, Keck J, Bommer M, Schröder D, Wagner KG. Laser triangulation as a fast and reliable method for determining ribbon solid fraction; focus on accuracy, precision, and measurement time. Int J Pharm 2021; 610:121241. [PMID: 34748811 DOI: 10.1016/j.ijpharm.2021.121241] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2021] [Revised: 10/25/2021] [Accepted: 10/25/2021] [Indexed: 11/24/2022]
Abstract
Roller compaction and dry granulation represent well-established unit operations in the pharmaceutical industry. The ribbon solid fraction is classified as a critical quality attribute, that directly impacts final product quality and performance. The development and evaluation of novel methods measuring ribbon solid fraction represent a subject of current research, since novel analyses strategies need to be established for at-, on-, or in-line process monitoring to overcome limitations of end product testing and to set the course for continuous manufacturing. In this study, a novel analytical device, using the principle of laser triangulation, was investigated to asses its potential being used as at-line process analytical technology tool during a roller compaction process. To this end, the laser triangulation device was compared with X-ray micro-computed tomography and powder based volume displacement measurement techniques using different statistical evaluation methods. Special focus was given to accuracy, precision, and total measurement time. The laser triangulation device was confirmed as highly accurate and precise, enabling the shortest total measurement time compared to the other methods. The findings of this study support the idea of implementing the laser triangulation device as a novel at-line process analytical technology tool into a roller compaction process.
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Affiliation(s)
- Tim D Lillotte
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany
| | - Paul Bebernik
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany
| | - Johanna Keck
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Str. 65, 88397 Biberach an der Riß, Germany
| | - Moritz Bommer
- CMO-SYS GmbH, Karl-Ehmann-Str. 46, 73037 Göppingen, Germany
| | - Daniela Schröder
- Boehringer Ingelheim Pharma GmbH & Co. KG, Birkendorfer Str. 65, 88397 Biberach an der Riß, Germany
| | - Karl G Wagner
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany.
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14
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Lillotte TD, Joester M, Frindt B, Berghaus A, Lammens RF, Wagner KG. UV-VIS spectra as potential process analytical technology (PAT) for measuring the density of compressed materials: Evaluation of the CIELAB color space. Int J Pharm 2021; 603:120668. [PMID: 33945854 DOI: 10.1016/j.ijpharm.2021.120668] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/17/2021] [Revised: 04/23/2021] [Accepted: 04/28/2021] [Indexed: 11/29/2022]
Abstract
Measurement methods for determining the density of compressed materials, being a critical quality attribute, provide an important parameter for successful processing. In this study, a novel approach was developed for determining the density of compacts using ultraviolet-visible spectrophotometry. The assumption within this context was that a change in density affects the corresponding color information of the compact. From the obtained spectra of the visible range, the color information of the compact was calculated which turned out to be directly proportional to the density of the compact. In comparison, the obtained spectra were analyzed using partial least square regression. The results of this study showed that both methods could be used predicting the density of a compact from the corresponding visible spectrum at identical accuracy. In contrast to the partial least square regression, the correlation of the color information as a direct output parameter of the spectrophotometer with the density required no excessive data pre-processing. Subsequently, the easier and faster data processing of the color information over the partial least square regression, conceives using this novel approach as potential process analytical technology tool for implementation into a compression process e.g., tableting or roller compaction.
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Affiliation(s)
- Tim D Lillotte
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany
| | - Maike Joester
- ColVisTec AG, Max-Planck-Str. 3, 12489 Berlin - Adlershof, Germany
| | - Benjamin Frindt
- Solids Development Consult GmbH, Peter-Joseph-Lenné-Str. 11, 51377 Leverkusen, Germany
| | - Andreas Berghaus
- ColVisTec AG, Max-Planck-Str. 3, 12489 Berlin - Adlershof, Germany
| | - Robert F Lammens
- Solids Development Consult GmbH, Peter-Joseph-Lenné-Str. 11, 51377 Leverkusen, Germany
| | - Karl G Wagner
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, Gerhard-Domagk-Straße 3, 53121 Bonn, Germany.
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15
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Lillotte TD, Bebernik P, Wagner KG. A novel approach to determine the granule density of milled ribbons using multi-stage air classification combined with dynamic image analysis. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2020.12.023] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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16
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17
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Comparison between twin-screw and high-shear granulation - The effect of filler and active pharmaceutical ingredient on the granule and tablet properties. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.08.030] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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18
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Hwang KM, Kim SY, Nguyen TT, Cho CH, Park ES. Use of roller compaction and fines recycling process in the preparation of erlotinib hydrochloride tablets. Eur J Pharm Sci 2019; 131:99-110. [PMID: 30716380 DOI: 10.1016/j.ejps.2019.01.036] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/01/2018] [Revised: 12/29/2018] [Accepted: 01/30/2019] [Indexed: 12/28/2022]
Abstract
This study focuses on improving the manufacturing process for a generic immediate-release tablet containing erlotinib hydrochloride by adding a fines recycling process during roller compaction. Due to the large fraction of small-sized API particles, the starting powder mixture was inconsistently fed into the roller compactor. Consequently, poorly flowing granules with a high ratio of fines were produced. A fines recycling step was, therefore, added to the existing roller compaction process to minimize the risks caused by the poor granule flow. A laboratory scale roller compactor and a tablet simulator were used to prepare granules at various process conditions. The effect of dry granulation parameters on size distribution, API distribution, powder flow, compaction properties, and dissolution profile was evaluated. The granule batch after fines recycling had markedly improved size distribution and flowability while maintaining acceptable tablet tensile strength and rapid dissolution profile. The application of the fines recycling process at commercial scale resulted in reliable dissolution performance and batch-to-batch consistency, which were further confirmed by bioequivalence to the reference product. Understanding how granule properties are impacted by the fines recycling process may enable fine-tuning of the dry granulation process for optimal product quality.
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Affiliation(s)
- Kyu-Mok Hwang
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Sang-Yeop Kim
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea; Boryung Pharmaceutical Co., Ltd., Ansan 15425, Republic of Korea
| | - Thi-Tram Nguyen
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Cheol-Hee Cho
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea
| | - Eun-Seok Park
- School of Pharmacy, Sungkyunkwan University, Suwon 16419, Republic of Korea.
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19
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Grote S, Osthues H, Schaeffer F, Kleinebudde P. The influence of isomalt particle morphology on tabletability after roll compaction/dry granulation. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.01.077] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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20
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Wiedey R, Kleinebudde P. Potentials and limitations of thermography as an in-line tool for determining ribbon solid fraction. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.03.047] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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21
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22
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Kallakunta VR, Patil H, Tiwari R, Ye X, Upadhye S, Vladyka RS, Sarabu S, Kim DW, Bandari S, Repka MA. Exploratory studies in heat-assisted continuous twin-screw dry granulation: A novel alternative technique to conventional dry granulation. Int J Pharm 2018; 555:380-393. [PMID: 30458256 DOI: 10.1016/j.ijpharm.2018.11.045] [Citation(s) in RCA: 19] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/11/2018] [Revised: 11/13/2018] [Accepted: 11/16/2018] [Indexed: 11/16/2022]
Abstract
Dry granulation is the preferred technique for solvent-sensitive products, especially drugs with stability problems such as hydrolysis. Twin-screw granulation is a continuous granulation technique, offering a potential alternative to conventional dry granulation techniques such as roller compaction. The major advantage of twin-screw granulation is the ability to adjust process parameters of dry granulation without compromising the compression properties. This study was aimed to perform exploratory studies of heat-assisted continuous twin-screw dry granulation process to formulate sustained release tablets for APIs with different melting points: theophylline, acetaminophen and lidocaine hydrochloride hydrate. Granulation feasibility was studied with different binders (e.g. Klucel™ EF, Kollidon® VA64), sustained release agents (e.g. Klucel™ MF, Eudragit® RSPO) and diluents at various drug loads. The processing conditions were below the melting point or glass transition temperature of the formulation ingredients. After successful granulation, DSC and XRD studies revealed the crystalline nature of the granules and FTIR studies showed no interaction of the API with the excipients. The granules were compressed into sustained release tablets without any compressibility issues. The tablets were stable after testing for 6 months at 25 °C/60% RH. This novel continuous dry granulation technique may offer an excellent alternative to conventional dry granulation techniques.
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Affiliation(s)
- Venkata Raman Kallakunta
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States
| | - Hemlata Patil
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States
| | - Roshan Tiwari
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States
| | - Xingyou Ye
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States
| | - Sampada Upadhye
- Catalent Pharma Solutions, 14 School House Road, Somerset, NJ 08873, USA
| | - Ronald S Vladyka
- Catalent Pharma Solutions, 14 School House Road, Somerset, NJ 08873, USA
| | - Sandeep Sarabu
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States
| | - Dong Wuk Kim
- College of Pharmacy, Kyungpook National University, Daegu 41566, South Korea
| | - Suresh Bandari
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, MS 38677, United States; Pii Center for Pharmaceutical Technology, University of Mississippi, MS 38677, USA.
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23
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Infrared thermography — A new approach for in-line density measurement of ribbons produced from roll compaction. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2017.01.052] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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24
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Zhou M, Wang Y, Wu F, Shen L, Lin X, Feng Y. Development on porous particles of Pueraria lobatae Radix for improving its compactibility and dissolution. RSC Adv 2018; 8:24250-24260. [PMID: 35539169 PMCID: PMC9082050 DOI: 10.1039/c8ra04125c] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/15/2018] [Accepted: 06/21/2018] [Indexed: 11/21/2022] Open
Abstract
Herein, we report a study on the influence of particles having different porosities on tablet performance. The ethanol extract of Pueraria lobatae Radix (EPL) was chosen as the model drug. A series of porous EPL particles were prepared by co-spray drying EPL with different amounts of ammonium bicarbonate (NH4HCO3), and their powder properties (particle morphology, particle size, porosity, flowability, bulk density, and tap density) and tablet properties (tensile strength, E sp, yield pressure, dissolution, etc.) were comparatively investigated. The results showed that there were significant differences in the fundamental and functional properties of the spray-dried and parent EPLs. First, the irregular and dense primary EPL particles were transformed into loose, hollow, and spheroidal particles via co-spray drying with NH4HCO3. Second, compared to parent EPL, porous EPLs showed a significant improvement (1.80-7.03 times) in compactibility. Third, the dissolution rates of porous EPLs were similar, and all were more than twice as fast as that of parent EPL. The increased porosity, on the one hand, led to the increase in interparticle and intraparticle bonding forces during tableting and, on the other hand, facilitated water intrusion into tablets for disintegration and dissolution. Porous particle design is therefore promising, especially for drugs with both poor compactibility and dissolution.
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Affiliation(s)
- MiaoMiao Zhou
- College of Chinese Materia Medica, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322197 +86 21 51322197
- Engineering Research Center of Modern Preparation Technology of TCM of Ministry of Education, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322429 +86 21 51322429
| | - YouJie Wang
- Engineering Research Center of Modern Preparation Technology of TCM of Ministry of Education, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322429 +86 21 51322429
| | - Fei Wu
- College of Chinese Materia Medica, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322197 +86 21 51322197
- Engineering Research Center of Modern Preparation Technology of TCM of Ministry of Education, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322429 +86 21 51322429
| | - Lan Shen
- College of Chinese Materia Medica, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322197 +86 21 51322197
| | - Xiao Lin
- College of Chinese Materia Medica, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322197 +86 21 51322197
| | - Yi Feng
- Engineering Research Center of Modern Preparation Technology of TCM of Ministry of Education, Shanghai University of Traditional Chinese Medicine Shanghai 201203 PR China +86 21 51322429 +86 21 51322429
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25
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Grote S, Kleinebudde P. Impact of functionalized particle structure on roll compaction/dry granulation and tableting of calcium carbonate. Int J Pharm 2018; 544:235-241. [DOI: 10.1016/j.ijpharm.2018.04.044] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/28/2018] [Revised: 04/10/2018] [Accepted: 04/20/2018] [Indexed: 11/28/2022]
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26
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Grote S, Kleinebudde P. Roll Compaction/Dry Granulation of Dibasic Calcium Phosphate Anhydrous—Does the Morphology of the Raw Material Influence the Tabletability of Dry Granules? J Pharm Sci 2018; 107:1104-1111. [DOI: 10.1016/j.xphs.2017.12.003] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/03/2017] [Revised: 12/01/2017] [Accepted: 12/06/2017] [Indexed: 11/16/2022]
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27
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Csordas K, Wiedey R, Kleinebudde P. Impact of roll compaction design, process parameters, and material deformation behaviour on ribbon relative density. Drug Dev Ind Pharm 2018; 44:1295-1306. [PMID: 29484952 DOI: 10.1080/03639045.2018.1446444] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
Abstract
Ribbons from microcrystalline cellulose (MCC), mannitol, and their 50:50% mixture were produced using the roll compactors AlexanderWerk BT120, Hosokawa Alpine Pharmapaktor C250, L.B. Bohle BRC 25, and Gerteis Mini-Pactor in the frame of multilevel full factorial experimental plans. The specific compaction force (SCF)/hydraulic pressure (HP), gap width (GW), roll speed, and fraction of MCC were analyzed as quantitative factors, whereas the roll surface and sealing system were examined as qualitative factors. Ribbon relative density was investigated as response of the models. The SCF/HP is found to be the most significant factor in each model. A significant inverse effect of the GW is obtained in the models of AlexanderWerk BT120, Pharmapaktor C250, and BRC 25 roll compactors, using smooth rolls. The principle of the establishment of a conversion factor (cf) is introduced based on the obtained data sets of AlexanderWerk BT120 and Mini-Pactor. This can facilitate the transfer of a roll compaction process between different types of roll compactors.
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Affiliation(s)
- Kitti Csordas
- a Institute of Pharmaceutics and Biopharmaceutics , Heinrich Heine University , Duesseldorf , Germany
| | - Raphael Wiedey
- a Institute of Pharmaceutics and Biopharmaceutics , Heinrich Heine University , Duesseldorf , Germany
| | - Peter Kleinebudde
- a Institute of Pharmaceutics and Biopharmaceutics , Heinrich Heine University , Duesseldorf , Germany
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28
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Affiliation(s)
- Raphael Wiedey
- Heinrich Heine University; Institute of Pharmaceutics and Biopharmaceutics; Universitätsstraße 1 40225 Dusseldorf Germany
| | - Peter Kleinebudde
- Heinrich Heine University; Institute of Pharmaceutics and Biopharmaceutics; Universitätsstraße 1 40225 Dusseldorf Germany
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29
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Sun CC, Kleinebudde P. Mini review: Mechanisms to the loss of tabletability by dry granulation. Eur J Pharm Biopharm 2016; 106:9-14. [DOI: 10.1016/j.ejpb.2016.04.003] [Citation(s) in RCA: 68] [Impact Index Per Article: 7.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/13/2015] [Revised: 03/31/2016] [Accepted: 04/05/2016] [Indexed: 11/30/2022]
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30
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Microstructure of Tablet—Pharmaceutical Significance, Assessment, and Engineering. Pharm Res 2016; 34:918-928. [DOI: 10.1007/s11095-016-1989-y] [Citation(s) in RCA: 38] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2016] [Accepted: 06/28/2016] [Indexed: 10/21/2022]
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31
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Multimodal approach to characterization of hydrophilic matrices manufactured by wet and dry granulation or direct compression methods. Int J Pharm 2016; 499:263-270. [DOI: 10.1016/j.ijpharm.2015.12.067] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/01/2015] [Accepted: 12/27/2015] [Indexed: 11/24/2022]
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