Pharmaceutical Film Coating Catalog for Spectral Domain Optical Coherence Tomography

Extending the Use of Optical Coherence Tomography to Scattering Coatings Containing Pigments

Coating thickness is a critical quality attribute of many coated tablets. Functional coatings ensure correct drug release kinetics or protection from light, while non-functional coatings are generally applied for cosmetic reasons. Traditionally, coating thickness is assessed indirectly via offline methods, such as weight gain or diameter growth. In the past decade, several methods, including optical coherence tomography (OCT) and Raman spectroscopy, have emerged to perform in-line measurements of various subclasses of coating formulations. However, there are some obstacles. For example, when using OCT, a major challenge is scattering pigments, such as titanium dioxide and iron oxide, which make the interface between the coating and the tablet core difficult to detect. This work explores novel OCT image evaluation techniques using unsupervised machine learning to compute image metrics. Certain image metrics of highly scattering coatings are correlated with the tablet thickness, and hence indirectly with the coating thickness. The method was demonstrated using a titanium dioxide rich coating formulation. The results are expected to be applicable to other scattering coatings and will significantly broaden the applicability of OCT to at-line and in-line coating thickness measurements of a much larger class of coating formulations.

The Use of Novel, Rapid Analytical Tools in the Assessment of the Stability of Tablets—A Pilot Analysis of Expired and Unexpired Tablets Containing Nifuroxazide

In the analysis of finished pharmaceutical products, numerous innovative analytical techniques are often used, i.e., Raman spectroscopy, scanning electron microscopy, computer microtomography, directional hemispherical reflectance, and hyperspectral analyses. These techniques allow for the identification of changes in solid phases. Many advantages over other techniques can be attributed to these techniques, e.g., they are rapid, non-destructive, and comprehensive. They allow for the identification of changes occurring in solid phases. However, the above-mentioned methods are still not standard procedures in pharmaceutical research. The present study aimed to assess the possible usefulness of total directional hemispherical reflectance (THR), hyperspectral imaging, and computer microtomography to evaluate the stability of tablets containing nifuroxazide during storage. In the study, expired and unexpired coating tablets containing nifuroxazide (n = 10 each) were analyzed. In addition, four unexpired tablets were stored at 40°C over 3 months (stressed tablets). Reflectance was determined with seven wavelength bands from 335 nm to 2500 nm using an SOC-410 Directional Hemispherical Reflectometer (Surface Optics Corporation, San Diego, CA, USA). A Specim IQ hyperspectral camera (Spectral Imaging Ltd., Oulu, Finland) was used with a wavelength range of 400–1030 nm. Tablets were also scanned using X-ray microtomography (Phoenix vǀtomeǀx, GE Sensing & Inspection Technologies GmbH, Wunstorf, Germany). The results indicated that total reflectance was lower in expired tablets than in unexpired tablets in all spectral bands, except for 700–1100 nm and 1700–2500 nm. In turn, the stressed tablets showed higher THR values than expired tablets in all spectral bands, except for 1000–1700 nm. In addition, hyperspectral analysis of the homogeneity of the tablets, as well as X-ray microtomographic analysis of tablet density and coating thickness, indicated that these parameters differed significantly between the analyzed tablets.

Research progress on the application of spectral imaging technology in pharmaceutical tablet analysis

Tablet as a traditional dosage form in pharmacy has the advantages of accurate dosage, ideal dissolution and bioavailability, convenient to carry and transport. The most concerned tablet quality attributes include active pharmaceutical ingredient (API) contents and polymorphic forms, components distribution, hardness, density, coating state, dissolution behavior, etc., which greatly affect the bioavailability and consistency of tablet final products. In the pharmaceutical industry, there are usually industry standard methods to analyze the tablet quality attributes. However, these methods are generally time-consuming and laborious, and lack a comprehensive understanding of the properties of tablets, such as spatial information. In recent years, spectral imaging technology makes up for the shortcomings of traditional tablet analysis methods because it provides non-contact and rich information in time and space. As a promising technology to replace the traditional tablet analysis methods, it has attracted more and more attention. The present paper briefly describes a series of spectral imaging techniques and their applications in tablet analysis. Finally, the possible application prospect of this technology and the deficiencies that need to be improved were also prospected.

Nondestructive in situ monitoring of pea seeds germination using optical coherence tomography

Seed germination and uniform plant stand in the field are the most critical crop growth stages determining the final yield. Pea (Pisum sativum L.) seeds production is often hampered due to the seed dormancy caused by the hard seed coat. Such effect is mainly attributed to poor or uneven germination and unsynchronised seedling emergence. Understanding the time course of water intake and several critical germination indicators can reveal many features of seed germination such as rate and uniformity. This paper used optical coherence tomography (OCT), a noninvasive and cross-sectional imaging technique, to monitor the inner structural changes throughout the germination process. A sequence of cross-sectional OCT images of pea (P. sativum L.) seeds, together with additional microscopic optical images, was recorded continuously and in situ for over 40 h. OCT and microscopic images revealed the changes in the internal structure and the external shape of the pea seeds during germination, respectively. It was found that the cross-sectional OCT images helped to identify the critical indicators distinguishing the different phases of germination pea seeds. Therefore, the presented OCT approach offers a fast and nondestructive way to precisely measure the structural indicators in different germination phases.

Visualising liquid transport through coated pharmaceutical tablets using Terahertz pulsed imaging

Dissolution of pharmaceutical tablets is a complex process, especially for coated tablets where layered structures form an additional barrier for liquid transport into the porous tablet matrix. A better understanding of the role of the coating structure in the mass transport processes that govern drug release, starting with the wetting of the coating layer by the dissolution medium, can benefit the formulation design and optimisation of the production. For this study, terahertz pulsed imaging was used to investigate how dissolution medium can penetrate coated tablets. In order to focus on the fundamental process, the model system for this proof-of-principle study consisted of tablet cores made from pure microcrystalline cellulose compacted to a defined porosity coated with Opadry II, a PVA-based immediate release coating blend. The coating was applied to a single side of flat-faced tablets using vacuum compression moulding. It was possible to resolve the hydration of the coating layer and the subsequent liquid ingress into the dry tablet core. The analysis revealed a discontinuity in density at the interface between coating and core, where coating polymer could enter the pore space at the immediate surface of the tablet cores during the coating process. This structure affected the liquid transport of the dissolution medium into the core. We found evidence for the formation of a gel layer upon hydration of the coating polymer. The porosity of the tablet core impacted the quality of coating and thus affected its dissolution performance (r =  0.6932 for the effective liquid penetration rate RP_eff and the core porosity). This study established a methodology and can facilitate a more in-depth understanding of the role of coating on tablet dissolution.

Ascertain a minimum coating thickness for acid protection of enteric coatings by means of optical coherence tomography

Enteric coatings are designed to protect active pharmaceutical ingredients (APIs) against untimely release in the stomach. Acid protection of such coatings depends on the coating layer thickness and integrity, which must be determined in an accurate and reliable way to ensure the final product's desired performance. Our work addresses the use of optical coherence tomography (OCT) for characterizing the coating thickness and variability of an enteric-coated drug product and linking them to resistance against gastric fluid. In this study, three batches of enteric-coated tablets drawn during the manufacturing process were investigated. An industrial OCT system was used to establish the coating thickness variability of single tablets (intra-tablet), all tablets in a batch (inter-tablet) and between the batches (inter-batch). Based on the large amount of OCT data, we calculated a critical coating thickness for the investigated film coating, which was found to be 27.4 µm. The corresponding distribution has a mean coating thickness of 44.3 µm ± 7.8 µm. The final coated product has a final mean coating thickness of 63.4 µm ± 8.7 µm, guaranteeing that all tablets meet the quality criterion (i.e., acid protection). Based on the measured thickness distributions, already known distribution functions were considered and an additional, new function was proposed for characterizing the coating thickness distributions in the early stages of industrial coating processes. The proposed approach can be transferred to in-line monitoring of the tablet coating processes, which could drastically improve the production efficiency by ultimately allowing real-time release testing (RTRT).

Melanins as Sustainable Resources for Advanced Biotechnological Applications

Melanins are a class of biopolymers that are widespread in nature and have diverse origins, chemical compositions, and functions. Their chemical, electrical, optical, and paramagnetic properties offer opportunities for applications in materials science, particularly for medical and technical uses. This review focuses on the application of analytical techniques to study melanins in multidisciplinary contexts with a view to their use as sustainable resources for advanced biotechnological applications, and how these may facilitate the achievement of the United Nations Sustainable Development Goals.

Feasibility of In-line monitoring of critical coating quality attributes via OCT: Thickness, variability, film homogeneity and roughness

The feasibility of Optical Coherence Tomography (OCT) for in-line monitoring of pharmaceutical film coating processes has recently been demonstrated. OCT enables real-time acquisition of high-resolution cross-sectional images of coating layers and computation of coating thickness. In addition, coating quality attributes can be computed based on in-line data. This study assesses the in-line applicability of OCT to various coating functionalities and formulations. Several types of commercial film-coated tablets containing the most common ingredients were investigated. To that end, the tablets were placed into a miniaturized perforated drum. An in-line OCT system was used to monitor the tablet bed. This set-up resembles the final stage of an industrial pan coating process. All investigated coatings were measured, and the coating thickness, homogeneity and roughness were computed. The rotation rate was varied in a range comparable to large-scale coating operations, and no influence on the outcome was observed. The results indicate that OCT can be used to determine end-point and establish in-process control for a wide range of coating formulations. The real-time computation of coating homogeneity and roughness can support process optimization and formulation development.

Simultaneous optical coherence tomography and Scheimpflug imaging using the same incident light

For any single anterior chamber cross-sectional (tomographic) imaging method, there is a practical compromise between image size and image resolution. In order to obtain large field-of-view cross-sectional images of the whole anterior chamber and high-resolution cross-sectional images of the fine corneal layers, measurements by multiple devices are currently required. This paper presents a novel raster scanning tomographic imaging device that acquires simultaneous large field-of-view Scheimpflug (12.5 mm image depth, 50 μm axial resolution in air) and high-resolution spectral domain optical coherence tomography (SD-OCT) (2 mm image depth, 3.7μm axial resolution in air) using the same illuminating photons. For the novel raster scanning 3D Scheimpflug imaging, a tunable lens system together with numerical methods for correcting refraction distortion were used. To demonstrate the capability of simultaneous measurement of both fine corneal layers and whole anterior chambers topology, ex vivo measurements on 12 porcine and 12 bovine eyes were carried out. There is a reasonable agreement in the overall central corneal thicknesses (CCT) obtained from the simultaneous SD-OCT and Scheimpflug measurements. In addition, because the same infrared light beam was used to illuminate the sample, both OCT and Scheimpflug images were taken at the exact same location of a sample simultaneously in a single measurement. This provides a unique method for measuring both the thickness and the refractive index of a sample.

Deep convolutional neural networks: Outperforming established algorithms in the evaluation of industrial optical coherence tomography (OCT) images of pharmaceutical coatings

This paper presents a novel evaluation approach for optical coherence tomography (OCT) image analysis of pharmaceutical solid dosage forms based on deep convolutional neural networks (CNNs). As a proof of concept, CNNs were applied to image data from both, in- and at-line OCT implementations, monitoring film-coated tablets as well as single- and multi-layered pellets. CNN results were compared against results from established algorithms based on ellipse-fitting, as well as to human-annotated ground truth data. Performance benchmarks used include, efficiency (computation speed), sensitivity (number of detections from a defined test set) and accuracy (deviation from the reference method). The results were validated by comparing the output of several algorithms to data manually annotated by human experts and microscopy images of cross-sectional cuts of the same dosage forms as a reference method. In order to guarantee comparability for all results, the algorithms were executed on the same hardware. Since modern OCT systems must operate under real-time conditions in order to be implemented in-line into manufacturing lines, the necessary steps are discussed on how to achieve this goal without sacrificing the algorithmic performance and how to tailor a deep CNN to cope with the high amount of image noise and alterations in object appearance. The developed deep learning approach outperforms static algorithms currently available in pharma applications with respect to performance benchmarks, and represents the next level in real time evaluation of challenging industrial OCT image data.

Review of Terahertz Pulsed Imaging for Pharmaceutical Film Coating Analysis

Terahertz pulsed imaging (TPI) was introduced approximately fifteen years ago and has attracted a lot of interest in the pharmaceutical industry as a fast, non-destructive modality for quantifying film coatings on pharmaceutical dosage forms. In this topical review, we look back at the use of TPI for analysing pharmaceutical film coatings, highlighting the main contributions made and outlining the key challenges ahead.

Differentiating Generic versus Branded Pharmaceutical Tablets Using Ultra-High-Resolution Optical Coherence Tomography

Optical coherence tomography (OCT) has recently been demonstrated as a powerful tool to image through pharmaceutical film coatings. Majority of the existing systems can, however, resolve film coatings for thickness greater than 10 µm. Here we report on an ultra-high-resolution (UHR) OCT system, with 1 µm axial and 1.6 µm lateral resolutions, which can resolve thin coatings at approximately 4 µm. We further demonstrate a novel application of the system for differentiating generic and branded suppliers of paracetamol tablets.

A Review of the Applications of OCT for Analysing Pharmaceutical Film Coatings

Optical coherence tomography (OCT) has recently attracted a lot of interest in the pharmaceutical manufacturing industry as a fast, contactless and non-destructive modality for quantifying thin film coatings on pharmaceutical dosage forms, which cannot be resolved easily with other techniques. In this topical review, we present an overview of the research that has been performed to date, highlighting key differences between systems and outlining major challenges ahead.

A Scale-up Approach for Film Coating Process Based on Surface Roughness as the Critical Quality Attribute

Scale-up approaches for film coating process have been established for each type of film coating equipment from thermodynamic and mechanical analyses for several decades. The objective of the present study was to establish a versatile scale-up approach for film coating process applicable to commercial production that is based on critical quality attribute (CQA) using the Quality by Design (QbD) approach and is independent of the equipment used. Experiments on a pilot scale using the Design of Experiment (DoE) approach were performed to find a suitable CQA from surface roughness, contact angle, color difference, and coating film properties by terahertz spectroscopy. Surface roughness was determined to be a suitable CQA from a quantitative appearance evaluation. When surface roughness was fixed as the CQA, the water content of the film-coated tablets was determined to be the critical material attribute (CMA), a parameter that does not depend on scale or equipment. Finally, to verify the scale-up approach determined from the pilot scale, experiments on a commercial scale were performed. The good correlation between the surface roughness (CQA) and the water content (CMA) identified at the pilot scale was also retained at the commercial scale, indicating that our proposed method should be useful as a scale-up approach for film coating process.