Enabling direct compression tablet formulation of celecoxib by simultaneously eliminating punch sticking, improving manufacturability, and enhancing dissolution through co-processing with a mesoporous carrier

Advancements in the Application of Numerical Simulation During Tablet Compaction

Background: Numerical simulation is a technique that utilizes electronic computers to combine concepts of the discrete element method (DEM), finite element method (FEM), computational fluid dynamics (CFD), etc., and express simulated behaviors utilizing numerical computations and images. Compaction is the main process of tablet manufacturing; most of the current studies have focused on macroscopic compaction and tablet characterization, while the internal stress state and microstructure changes as a result of the compaction process are not well understood. Therefore, an in-depth understanding of the flow and compaction behavior of pharmaceutical powders is essential for the analysis and control of the compaction process. Methods: Current research shows that compaction is shifting from macroscopic behavior toward internal microscopic behavior using numerical simulation technology. Results: This review focuses on the application of various numerical simulation technologies during compaction and the contact model, or the constitutive equation commonly used in numerical simulation. In addition, the difficulties of numerical simulation technology in calibrating powder parameters and the limitations of the current research are also discussed. Conclusions: Numerical simulation research in medicine and other fields will continue to flourish as numerical simulation technology advances, attracting more and more researchers using it effectively.

Regulatory Considerations for Stability Studies of Co-Processed Active Pharmaceutical Ingredient

A co-processed active pharmaceutical ingredient (CP API) is the combination of an active pharmaceutical ingredient (API) with non-active component(s). This technology has been demonstrated to offer numerous benefits, including but not limited to improved API properties and stability. The infrastructure requirements are such that the manufacture of a CP API is typically best suited for an API facility. CP API has been regulated as either an API or as a drug product intermediate (DPI). This variability in the designation has led to ambiguities on the regulatory CMC expectations in the CP API including the stability of CP API and CP API containing products which, in turn has hampered the broader application of this technology in the pharmaceutical industry. This difference in designation also resulted in challenges to the lifecycle management of the regulatory documentation for the CMC information of the CP API.This white paper represents the proposals for the regulatory requirements on stability studies related to CP API and to drug product containing CP API by the CP API Working Group (WG) of the International Consortium for Innovation and Quality in Pharmaceutical Development (IQ). Additionally, considerations and the WG's recommendations on the stability studies of CP API from different manufacturing sites or processes and post-approval changes for product containing CP API are described.

Uncovering the mechanism of Tenofovir amibufenamide fumarate punch sticking by combining direct compression experiment and computational simulation

Punch sticking during tablet manufacturing is a prevalent issue for many active pharmaceutical ingredients (APIs) encountered by the pharmaceutical industry. Tenofovir amibufenamide fumarate (TMF), a heavyweight drug for the treatment of hepatitis B, was selected as a model drug due to its tendency to punch sticking during tablet compression. In this study, the cause of sticking was explored by investigating crystal habits, excipients and structure characteristics. The difference in sticking of three crystal habits can be visually represented through direct compression experiments on powdered samples and analysis of crystal surfaces. The excipients play a direct role in decreasing the probability of sticking, and the extent of sticking can be assessed by measuring the tensile strength of the tablet. Additionally, the plasticity index was utilized to theoretically analyze the potential enhancements of four excipients. These experimental results indicate that the block-shaped crystals have superior ability of anti-sticking and that suitable excipients can significantly improve the sticking situation of TMF. Ultimately, the phenomenon of punch sticking was additionally examined through computational calculations, focusing on the mechanical characteristics of TMF molecules and intermolecular interactions. The strategy of combining experiments and simulation calculations has broader significance for the study of drug production.

A Commentary on Co-Processed API as a Promising Approach to Improve Sustainability for the Pharmaceutical Industry

Pharmaceutical products represent a meaningful target for sustainability improvement and emissions reduction. It is proposed here that rethinking the standard, and often linear, approach to the synthesis of Active Pharmaceutical Ingredients (API) and subsequent formulation and drug product processing will deliver transformational sustainability opportunities. The greatest potential arguably involves API that have challenging physico-chemical properties. These can require the addition of excipients that can significantly exceed the weight of the API in the final dosage unit, require multiple manufacturing steps to achieve materials amenable to delivering final dosage units, and need highly protective packaging for final product stability. Co-processed API are defined as materials generated via addition of non-covalently bonded, non-active components during drug substance manufacturing steps, differing from salts, solvates and co-crystals. They are an impactful example of provocative re-thinking of historical regulatory and quality precedents, blurring drug substance and drug product operations, with sustainability opportunities. Successful examples utilizing co-processed API can modify properties with use of less excipient, while simultaneously reducing processing requirements by delivering material amenable to continuous manufacturing. There are also opportunities for co-processed API to reduce the need for highly protective packaging. This commentary will detail the array of sustainability impacts that can be delivered, inclusive of business, regulatory, and quality considerations, with discussion on potential routes to more comprehensively commercialize co-processed API technologies.

Worsened punch sticking by external lubrication with magnesium stearate

External lubrication of tooling with magnesium stearate (MgSt) is a common strategy to eliminate punch sticking when compressing powders with a high sticking propensity, such as many pure active pharmaceutical ingredients (APIs). We found that it actually led to aggravated punch sticking at low compaction pressures. This counterintuitive phenomenon was explained based on interplay of forces among the punch tip, MgSt, and API. The explanation is supported by the observed effects of pressure and mechanical properties of APIs on this phenomenon.