1
|
Desai PM, Bhugra C, Chowdhury A, Melkeri Y, Patel H, Lam S, Hayden T. Implementation of mechanistic modeling and global sensitivity analysis (GSA) for design, optimization, and scale-up of a roller compaction process. Int J Pharm 2024; 658:124201. [PMID: 38705250 DOI: 10.1016/j.ijpharm.2024.124201] [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: 01/19/2024] [Revised: 04/29/2024] [Accepted: 05/02/2024] [Indexed: 05/07/2024]
Abstract
The pharmaceutical industry has been shifting towards the application of mechanistic modeling to improve process robustness, enable scale-up, and reduce time to market. Modeling approaches have been well-developed for processes such as roller compaction, a continuous dry granulation process. Several mechanistic models/approaches have been documented with limited application to high drug-loaded formulations. In this study, the Johanson model was employed to optimize roller compaction processing and guide its scale-up for a high drug loaded formulation. The model was calibrated using a pilot-scale Minipactor and was validated for a commercial-scale Macropactor. Global sensitivity analysis (GSA) was implemented to determine the impact of process parameter variations (roll force, gap, speed) on a quality attribute [solid fraction (SF)]. The throughput method, which estimates SF values of ribbons using granule production rate, was also studied. The model predicted SF values for all 14 Macropactor batches within ± 0.04 SF. The throughput method estimated SF with ± 0.06 SF for 7 out of 11 batches. GSA confirmed that roll force had the largest impact on SF. This case study represents a process modeling approach to build quality into the products/processes and expands the use of mechanistic modeling during drug product development.
Collapse
Affiliation(s)
- Parind M Desai
- Drug Product Development, GSK R&D, Collegeville, PA, United States.
| | - Chandan Bhugra
- Drug Product Development, GSK R&D, Collegeville, PA, United States
| | - Ananya Chowdhury
- Process Automation, Siemens Digital Industries Inc., Parsippany, NJ, United States
| | - Yash Melkeri
- Drug Product Development, GSK R&D, Collegeville, PA, United States
| | - Hridayi Patel
- Drug Product Development, GSK R&D, Collegeville, PA, United States
| | - Stephanie Lam
- Drug Substance Development, GSK R&D, Collegeville, PA, United States
| | - Tamika Hayden
- Biologics & Device Manufacturing, GSK Global Supply Chain, Zebulon, NC, United States
| |
Collapse
|
2
|
Lück M, Klinken S, Kleinebudde P. Laser Triangulation Based In-Line Elastic Recovery Measurement for the Determination of Ribbon Solid Fraction in Roll Compaction. J Pharm Sci 2024; 113:1020-1028. [PMID: 37839611 DOI: 10.1016/j.xphs.2023.10.013] [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: 09/07/2023] [Revised: 10/09/2023] [Accepted: 10/09/2023] [Indexed: 10/17/2023]
Abstract
Process Analytical Technology (PAT) plays a crucial role in the design of today's manufacturing lines as continuous manufacturing becomes more important. Until now PAT tools to measure the ribbon solid fraction (SFribbon) in-line are not commonly used in roll compaction. The aim of this study was therefore to establish a new approach as PAT for in-line ribbon solid fraction determination. Different placebo formulations with different binders and one formulation containing active pharmaceutical ingredient were investigated using in-line laser triangulation measurement to detect the ribbon thickness after compaction. With this the ribbon elastic recovery was determined in-line (ERin-line) while the ribbons are attached to the roll surface. It was found that the ratio (ERratio) between the total elastic recovery and ERin-line is formulation specific and not influenced by any process parameters. This enables ERratio as prediction tool for SFribbon, if the solid fraction at gap (SFgap) width is known. SFgap was determined with ribbon mass flow measurement or based on the Midoux model, a simplified Johanson model, gaining two prediction models for SFribbon. Both models showed good agreement of the predicted SFribbon and the measured one.
Collapse
Affiliation(s)
- Martin Lück
- Heinrich Heine University Duesseldorf, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstrasse 1, 40225 Duesseldorf, Germany
| | - Stefan Klinken
- Heinrich Heine University Duesseldorf, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstrasse 1, 40225 Duesseldorf, Germany
| | - Peter Kleinebudde
- Heinrich Heine University Duesseldorf, Institute of Pharmaceutics and Biopharmaceutics, Universitaetsstrasse 1, 40225 Duesseldorf, Germany.
| |
Collapse
|
3
|
Clarke J, Gamble JF, Jones JW, Tobyn M, Ingram A, Greenwood R. Determining the Impact of Roller Compaction Processing Conditions on Granulate and API Properties: Impact of Formulation API Load. AAPS PharmSciTech 2024; 25:24. [PMID: 38267745 DOI: 10.1208/s12249-024-02744-7] [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: 10/13/2023] [Accepted: 01/09/2024] [Indexed: 01/26/2024] Open
Abstract
Previous work demonstrated that roller compaction of a 40%w/w theophylline-loaded formulation resulted in granulate consisting of un-compacted fractions which were shown to constitute between 34 and 48%v/v of the granulate dependent on processing conditions. The active pharmaceutical ingredient (API) primary particle size within the un-compacted fraction was also shown to have undergone notable size reduction. The aim of the current work was to test the hypothesis that the observations may be more indicative of the relative compactability of the API due to the formulation being above the percolation threshold. This was done by assessing the impact of varied API loads in the formulation on the non-granulated fraction of the final granulate and the extent of attrition of API particles within the non-granulated fraction. The influence of processing conditions for all formulations was also investigated. The results verify that the observations, both of this study and the previous work, are not a consequence of exceeding the percolation threshold. The volume of un-compacted material within the granulate samples was observed to range between 34.7 and 65.5% depending on the API load and roll pressure, whilst the API attrition was equivalent across all conditions.
Collapse
Affiliation(s)
- James Clarke
- School of Chemical Engineering, University of Birmingham, Birmingham, B15 2TT, UK
| | - John F Gamble
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral, CH46 1QW, UK.
| | - John W Jones
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral, CH46 1QW, UK
| | - Mike Tobyn
- Bristol Myers Squibb, Reeds Lane, Moreton, Wirral, CH46 1QW, UK
| | - Andrew Ingram
- School of Chemical Engineering, University of Birmingham, Birmingham, B15 2TT, UK
| | - Richard Greenwood
- School of Chemical Engineering, University of Birmingham, Birmingham, B15 2TT, UK
| |
Collapse
|
4
|
Hassan L, Jensen R, Megarry A, Blaabjerg LI. Simulation of roller compaction by combination of a compaction simulator and oscillating mill - A material sparing approach. Int J Pharm 2023; 644:123281. [PMID: 37524254 DOI: 10.1016/j.ijpharm.2023.123281] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/15/2023] [Revised: 07/27/2023] [Accepted: 07/28/2023] [Indexed: 08/02/2023]
Abstract
This study investigates the feasibility of a compaction simulator and oscillating mill to mimic a roller compactor as a material sparing approach for process development. Microcrystalline cellulose and dicalcium phosphate dihydrate were selected to represent soft and hard materials, respectively. The relative density of ribbons and riblets was determined using a pycnometer and granules size distribution was determined by laser diffraction. Tablet tensile strength and relative density were determined using a hardness tester and pycnometer, respectively. This study showed that the relative density of riblets and ribbons were similar between 1 and 12 kN/cm, which indicates that the compaction simulator adequately mimics the compaction of the roller compactor using a Kp of 1. The size distribution of granules produced by the oscillating mill and roller compactor were similar, which indicates that the oscillating mill adequately mimics the roller compactor when using a similar gap and sieve design. Finally, the tablet tensile strength and relative density were similar independent of the applied granulation method and deformation behaviour of the material. In conclusion, the use of a compaction simulator and an oscillating mill in combination adequality mimics the roller compactor, which ultimately can save large amounts of material and time during process development.
Collapse
Affiliation(s)
- Layla Hassan
- Novo Nordisk A/S, Novo Nordisk Park 2, 2760 Maaloev, Denmark
| | - René Jensen
- Novo Nordisk A/S, Novo Nordisk Park 2, 2760 Maaloev, Denmark
| | - Andrew Megarry
- Novo Nordisk A/S, Novo Nordisk Park 2, 2760 Maaloev, Denmark
| | | |
Collapse
|
5
|
Awasthi S, Gopireddy SR, Kako D, Tanabe S, Nakagawa H, Miyajima M, Profitlich T, Scherließ R, Urbanetz NA. Combined DEM and Johanson model for ribbon density prediction in a roller compactor. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118296] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/05/2023]
|
6
|
Modelling of the Fine-Grained Materials Briquetting Process in a Roller Press with the Discrete Element Method. MATERIALS 2022; 15:ma15144901. [PMID: 35888372 PMCID: PMC9317880 DOI: 10.3390/ma15144901] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/10/2022] [Revised: 07/06/2022] [Accepted: 07/12/2022] [Indexed: 11/17/2022]
Abstract
By using the Altair® EDEM™ software, which implements the discrete element method, modelling and further study of the processes occurring in the roller press’s deformation area were carried out. It was shown that the discrete element method makes it possible to accurately describe the phenomena occurring in the area of roller press deformation compared with the finite element method. Models of material compaction in a roller press are developed using calcium hydroxide (slaked lime) and copper ore concentrate. The developed model makes it possible to determine the process’s energy parameters and the material’s compaction characteristics, taking into account the characteristics of its constituent particles. It was shown that discrete element modelling could be used effectively to create roller presses that provide rational characteristics of the briquetting process, taking into account the properties of the material being briquetted and the operating modes of the equipment. The results of the studies provided the basis for the applicability of the development of the discrete element method for describing the phenomena occurring in roller presses and accelerating the design of press equipment and briquetting technological processes.
Collapse
|
7
|
Vasudevan KV, Pu YE, Amini H, Guarino C, Agrawal A, Akseli I. Using a Model-based Material Sparing Approach for Formulation and Process Development of a Roller Compacted Drug Product. Pharm Res 2022; 39:2083-2093. [PMID: 35218443 DOI: 10.1007/s11095-022-03192-3] [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: 09/21/2021] [Accepted: 02/07/2022] [Indexed: 11/28/2022]
Abstract
The present work details a material sparing approach that combines material profiling with Instron uniaxial die-punch tester and use of a roller compaction mathematical model to guide both formulation and process development of a roller-compacted drug product. True density, compression profiling, and frictional properties of the pre-blend powders are used as inputs for the predictive roller compaction model, while flow properties, particle size distribution, and assay uniformity of roller compaction granules are used to select formulation composition and ribbon solid fraction. Using less than 10 g of a model drug compound for material profiling, roller compacted blend in capsule formulations with appropriate excipient ratios were developed at both 1.4% and 14.4% drug loadings. Subsequently, scale-up batches were successfully manufactured based on the roller compaction process parameters obtained from predictive modeling. The measured solid fractions of roller compaction ribbon samples from the scale-up batches were in good agreement with the target solid fraction of the modeling. This approach demonstrated considerable advantages through savings in both materials and number of batches in the development of a roller-compacted drug product, which is of particular value at early development stages when drug substance is often limited and timelines are aggressive.
Collapse
Affiliation(s)
- Kalyan V Vasudevan
- Drug Product Development, Pharmaceutical Science & Technology, Bristol Myers Squibb, Summit, NJ, USA.
| | - Yu Elaine Pu
- Drug Product Development, Pharmaceutical Science & Technology, Bristol Myers Squibb, Summit, NJ, USA
| | - Hossein Amini
- Engineering Technology, Bristol Myers Squibb, Summit, NJ, USA
| | | | - Anjali Agrawal
- Drug Product Development, Pharmaceutical Science & Technology, Bristol Myers Squibb, Summit, NJ, USA
| | - Ilgaz Akseli
- Engineering Technology, Bristol Myers Squibb, Summit, NJ, USA
| |
Collapse
|
8
|
Relationship between powder properties and uniformity of ribbon property using feeding guider designs with thermography (PAT) in roller compaction. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117134] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
|
9
|
Kleinebudde P. Improving Process Understanding in Roll Compaction. J Pharm Sci 2021; 111:552-558. [PMID: 34562447 DOI: 10.1016/j.xphs.2021.09.024] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/13/2021] [Revised: 09/17/2021] [Accepted: 09/17/2021] [Indexed: 11/26/2022]
Abstract
Roll compaction/ dry granulation is gaining importance. Numerous papers have been published and many attempts to model the process are available in the meantime. Johanson published a model in 1965, which is the basis for many further modifications until today. The aim of the paper is to improve process understanding in roll compaction, which can be used to setup a roll compaction process, to design a scale-up strategy or to help in process transfer between different types of roll compactors. Based on some assumptions, simple considerations help to estimate a required densification factor and to visualize the relations between roll diameter, gap width and nip angle. Two recently published papers based on simplified Johansen models are used to visualize the relations between specific compaction force and the maximal pressure experienced by the material. The influence of roll diameter, gap width and compressibility constant are discussed. This helps to estimate, if a scale-up or process transfer is reasonable. The recently introduced dimensionless Midoux-number can also be used to design scale-up or process transfer of roll compaction without knowledge about the maximal pressure. Exploring the simple concepts can help to improve process understanding even without a background in engineering.
Collapse
Affiliation(s)
- Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University Duesseldorf, Universitaetsstrasse 1, 40225 Duesseldorf, Germany.
| |
Collapse
|
10
|
Lim SH, Kim SI, Song JS, Kim KH. A study on the pelletizing condition for roll compaction of powdered radioactive wastes. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.01.068] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
|
11
|
Clarke J, Gamble JF, Jones JW, Tobyn M, Dawson N, Davies C, Ingram A, Greenwood R. Determining the Impact of Roller Compaction Processing Conditions on Granule and API Properties. AAPS PharmSciTech 2020; 21:218. [PMID: 32743765 DOI: 10.1208/s12249-020-01773-2] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/09/2020] [Accepted: 07/22/2020] [Indexed: 01/08/2023] Open
Abstract
The attrition of drug particles during the process of dry granulation, which may (or may not) be incorporated into granules, could be an important factor in determining the subsequent performance of that granulation, including key factors such as sticking to punches and bio-performance of the dosage form. It has previously been demonstrated that such attrition occurs in one common dry granulation process train; however, the fate of these comminuted particles in granules was not determined. An understanding of the phenomena of attrition and incorporation into granule will improve our ability to understand the performance of granulated systems, ultimately leading to an improvement in our ability to optimize and model the process. Unique feeding mechanisms, geometry, and milling systems of roller compaction equipment mean that attrition could be more or less substantial for any given equipment train. In this work, we examined attrition of API particles and their incorporation into granule in an equipment train from Gerteis, a commonly used equipment train for dry granulation. The results demonstrate that comminuted drug particles can exist free in post-milling blends of roller compaction equipment trains. This information can help better understand the performance of the granulations, and be incorporated into mechanistic models to optimize such processes.
Collapse
|
12
|
Model-Based Scale-Up Methodologies for Pharmaceutical Granulation. Pharmaceutics 2020; 12:pharmaceutics12050453. [PMID: 32423051 PMCID: PMC7284585 DOI: 10.3390/pharmaceutics12050453] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2020] [Revised: 05/09/2020] [Accepted: 05/11/2020] [Indexed: 12/13/2022] Open
Abstract
In the pharmaceutical industry, it is a major challenge to maintain consistent quality of drug products when the batch scale of a process is changed from a laboratory scale to a pilot or commercial scale. Generally, a pharmaceutical manufacturing process involves various unit operations, such as blending, granulation, milling, tableting and coating and the process parameters of a unit operation have significant effects on the quality of the drug product. Depending on the change in batch scale, various process parameters should be strategically controlled to ensure consistent quality attributes of a drug product. In particular, the granulation may be significantly influenced by scale variation as a result of changes in various process parameters and equipment geometry. In this study, model-based scale-up methodologies for pharmaceutical granulation are presented, along with data from various related reports. The first is an engineering-based modeling method that uses dimensionless numbers based on process similarity. The second is a process analytical technology-based modeling method that maintains the desired quality attributes through flexible adjustment of process parameters by monitoring the quality attributes of process products in real time. The third is a physics-based modeling method that involves a process simulation that understands and predicts drug quality through calculation of the behavior of the process using physics related to the process. The applications of these three scale-up methods are summarized according to granulation mechanisms, such as wet granulation and dry granulation. This review shows that these model-based scale-up methodologies provide a systematic process strategy that can ensure the quality of drug products in the pharmaceutical industry.
Collapse
|
13
|
Moroney KM, Cronin P, Adeleye OA, Schaller BE, Howard MA, Castro-Dominguez B, Ramachandran R, Walker GM. An evaluation of the Johanson model for roller compaction process development for a high dose API. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.02.058] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
|
14
|
Kalaria DR, Parker K, Reynolds GK, Laru J. An industrial approach towards solid dosage development for first-in-human studies: Application of predictive science and lean principles. Drug Discov Today 2020; 25:505-518. [DOI: 10.1016/j.drudis.2019.12.012] [Citation(s) in RCA: 16] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/30/2019] [Revised: 12/16/2019] [Accepted: 12/30/2019] [Indexed: 01/24/2023]
|
15
|
Muliadi AR, Banda A, Mao C. Recent Progress in Roll Compaction Process Development for Pharmaceutical Solid Dosage Form Manufacture. CONTINUOUS PHARMACEUTICAL PROCESSING 2020. [DOI: 10.1007/978-3-030-41524-2_7] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/13/2023]
|
16
|
Reddy JP, Phanse R, Nesarikar V. Parameter estimation for roller compaction process using an instrumented vector TF mini roller compactor. Pharm Dev Technol 2019; 24:1250-1257. [PMID: 31437082 DOI: 10.1080/10837450.2019.1658775] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
Abstract
Using instrumented roll technology, statistical models relating process parameters such as hydraulic pressure, roll speed and screw speed of Vector TF mini roller compactor to ribbon normal stress and density were developed for placebo blends. Normal stress was found to be directly proportional to hydraulic pressure, roll speed and inversely to screw to roll speed ratio. A power-law relationship between ribbon density and normal stress was observed for placebo blends. Models developed for placebo were found to predict ribbon densities of active blends with good accuracy. Standard optimization of roller compaction process parameters involves the investment of a large amount of time and active ingredient. These models can, therefore, be utilized to predict starting instrument settings required to generate a ribbon of desired solid fraction during early-stage development where material availability & time is limited.
Collapse
Affiliation(s)
- Jay Poorna Reddy
- Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Rahul Phanse
- Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| | - Vishwas Nesarikar
- Drug Product Science and Technology, Bristol-Myers Squibb , New Brunswick , NJ , USA
| |
Collapse
|
17
|
Toson P, Lopes DG, Paus R, Kumar A, Geens J, Stibale S, Quodbach J, Kleinebudde P, Hsiao WK, Khinast J. Model-based approach to the design of pharmaceutical roller-compaction processes. INTERNATIONAL JOURNAL OF PHARMACEUTICS-X 2019; 1:100005. [PMID: 31517270 PMCID: PMC6733294 DOI: 10.1016/j.ijpx.2019.100005] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/02/2018] [Revised: 12/18/2018] [Accepted: 12/29/2018] [Indexed: 11/29/2022]
Abstract
This work presents a new model based approach to process design and scale-up within the same equipment of a roller compaction process. The prediction of the operating space is not performed fully in-silico, but uses low-throughput experiments as input. This low-throughput data is utilized in an iterative calibration routine to describe the behavior of the powder in the roller compactor and improves the predictive quality of the mechanistic models at low and high-throughput. The model has been validated with an experimental design of experiments of two ibuprofen formulations. The predicted sweet spots in the operating space are in good agreement with the experimental results.
Collapse
Affiliation(s)
- Peter Toson
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Diogo G Lopes
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Raphael Paus
- Discovery, Product Development and Supply, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Ashish Kumar
- Discovery, Product Development and Supply, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Jeroen Geens
- Discovery, Product Development and Supply, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Sandy Stibale
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstraße 1, 40225 Düsseldorf, Germany
| | - Julian Quodbach
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstraße 1, 40225 Düsseldorf, Germany
| | - Peter Kleinebudde
- Institute of Pharmaceutics and Biopharmaceutics, Heinrich Heine University, Universitätsstraße 1, 40225 Düsseldorf, Germany
| | - Wen-Kai Hsiao
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.,Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13, 8010 Graz, Austria
| |
Collapse
|
18
|
Haeffler G, Schmidt L, Lakio S, Reynolds G, Ödman J, Tajarobi P. A systematic study of the impact of changes of roller compactor equipment on granule and tablet properties. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.09.002] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
|
19
|
Pishnamazi M, Casilagan S, Clancy C, Shirazian S, Iqbal J, Egan D, Edlin C, Croker DM, Walker GM, Collins MN. Microcrystalline cellulose, lactose and lignin blends: Process mapping of dry granulation via roll compaction. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.07.003] [Citation(s) in RCA: 46] [Impact Index Per Article: 9.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
|
20
|
Omar CS, Al-Asady RB, Salman AD. Roller compaction: Improving the homogeneity of ribbon properties along the roller width. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.10.018] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
|
21
|
|
22
|
Martinetz M, Karttunen AP, Sacher S, Wahl P, Ketolainen J, Khinast J, Korhonen O. RTD-based material tracking in a fully-continuous dry granulation tableting line. Int J Pharm 2018; 547:469-479. [DOI: 10.1016/j.ijpharm.2018.06.011] [Citation(s) in RCA: 36] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2018] [Revised: 05/30/2018] [Accepted: 06/04/2018] [Indexed: 11/28/2022]
|
23
|
Bano G, Facco P, Bezzo F, Barolo M. Probabilistic Design space determination in pharmaceutical product development: A Bayesian/latent variable approach. AIChE J 2018. [DOI: 10.1002/aic.16133] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Gabriele Bano
- CAPE‐Lab—Computer‐Aided Process Engineering Laboratory, Dept. of Industrial EngineeringUniversity of Padova35131 Padova PD Italy
| | - Pierantonio Facco
- CAPE‐Lab—Computer‐Aided Process Engineering Laboratory, Dept. of Industrial EngineeringUniversity of Padova35131 Padova PD Italy
| | - Fabrizio Bezzo
- CAPE‐Lab—Computer‐Aided Process Engineering Laboratory, Dept. of Industrial EngineeringUniversity of Padova35131 Padova PD Italy
| | - Massimiliano Barolo
- CAPE‐Lab—Computer‐Aided Process Engineering Laboratory, Dept. of Industrial EngineeringUniversity of Padova35131 Padova PD Italy
| |
Collapse
|
24
|
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: 0.2] [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.
Collapse
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
| |
Collapse
|
25
|
Omar CS, Hounslow MJ, Salman AD. Implementation of an online thermal imaging to study the effect of process parameters of roller compactor. Drug Deliv Transl Res 2018; 8:1604-1614. [PMID: 29441467 PMCID: PMC6280803 DOI: 10.1007/s13346-018-0493-9] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Abstract
During roller compaction, not only the properties of the primary powder affect the product quality but also the process parameters. Any change in the process parameters during roller compaction will result in changing the properties of the ribbon. In this study, the temperature of the ribbon during production was monitored online using a thermal camera. The information from the thermal camera was used to explain the differences in ribbon properties at varying process parameters. Lactose powder was used as a primary powder, and ribbons were produced at different process parameters. The surface temperature of the ribbon during production was found to increase with increasing both the gap between the two rollers and the roller speed. This was attributed to the screw feeder speed, which increased to feed additional powder as required to adjust to the change in process parameters. Increasing the roller gap resulted in wider ribbons and decreased the percentage of fines in the product, which was a signature of better powder distribution across the roller width. The results were also supported by the uniform temperature distribution recorded across the ribbon width. It was found that increasing the roller speed during roller compaction decreased the width of the ribbon while increasing the percentage of fines in the product. The feeder screw speed was found to have a similar effect as the roller gap.
Collapse
Affiliation(s)
- Chalak S Omar
- Department of Chemical and Biological Engineering, University of Sheffield, Mappin Street, Sheffield, S1 3JD, UK
| | - Michael J Hounslow
- Department of Chemical and Biological Engineering, University of Sheffield, Mappin Street, Sheffield, S1 3JD, UK
| | - Agba D Salman
- Department of Chemical and Biological Engineering, University of Sheffield, Mappin Street, Sheffield, S1 3JD, UK.
| |
Collapse
|
26
|
|
27
|
Uncertainty back-propagation in PLS model inversion for design space determination in pharmaceutical product development. Comput Chem Eng 2017. [DOI: 10.1016/j.compchemeng.2017.02.038] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
|
28
|
Sajjia M, Shirazian S, Kelly CB, Albadarin AB, Walker G. ANN Analysis of a Roller Compaction Process in the Pharmaceutical Industry. Chem Eng Technol 2016. [DOI: 10.1002/ceat.201600229] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Mustafa Sajjia
- University of Limerick, Castletroy; Pharmaceutical Manufacturing Technology Centre, Analog Devices Building; Bernal Institute; Limerick Ireland
- University of Limerick, Castletroy; Synthesis and Solid State Pharmaceutical Centre, Analog Devices Building, Bernal Institute; Limerick Ireland
| | - Saeed Shirazian
- University of Limerick, Castletroy; Synthesis and Solid State Pharmaceutical Centre, Analog Devices Building, Bernal Institute; Limerick Ireland
| | - Catherine B. Kelly
- University of Limerick, Castletroy; Synthesis and Solid State Pharmaceutical Centre, Analog Devices Building, Bernal Institute; Limerick Ireland
| | - Ahmad B. Albadarin
- University of Limerick, Castletroy; Synthesis and Solid State Pharmaceutical Centre, Analog Devices Building, Bernal Institute; Limerick Ireland
| | - Gavin Walker
- University of Limerick, Castletroy; Pharmaceutical Manufacturing Technology Centre, Analog Devices Building; Bernal Institute; Limerick Ireland
- University of Limerick, Castletroy; Synthesis and Solid State Pharmaceutical Centre, Analog Devices Building, Bernal Institute; Limerick Ireland
| |
Collapse
|
29
|
Sajjia M, Albadarin AB, Walker G. Statistical analysis of industrial-scale roller compactor ‘Freund TF-MINI model’. Int J Pharm 2016; 513:453-463. [DOI: 10.1016/j.ijpharm.2016.09.052] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/22/2016] [Revised: 09/15/2016] [Accepted: 09/16/2016] [Indexed: 10/21/2022]
|
30
|
Mazor A, Perez-Gandarillas L, de Ryck A, Michrafy A. Effect of roll compactor sealing system designs: A finite element analysis. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2015.11.039] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
|