Rheological characterization of pharmaceutical powders using tap testing, shear cell and mercury porosimeter

Exploring conventional and emerging dehydration technologies for slurry/liquid food matrices and their impact on porosity of powders: A comprehensive review

The contribution of dehydration to the growing market of food powders from slurry/liquid matrices is inevitable. To overcome the challenges posed by conventional drying technologies, several innovative approaches have emerged. However, industrial implementation is limited due to insufficient information on the best-suited drying technologies for targeted products. Therefore, this review aimed to compare various conventional and emerging dehydration technologies (such as active freeze, supercritical, agitated thin-film, and vortex chamber drying) based on their fundamental principles, potential applications, and limitations. Additionally, this article reviewed the effects of drying technologies on porosity, which greatly influence the solubility, rehydration, and stability of powder. The comparison between different drying technologies enables informed decision-making in selecting the appropriate one. It was found that active freeze drying is effective in producing free-flowing powders, unlike conventional freeze drying. Vortex chamber drying could be considered a viable alternative to spray drying, requiring a compact chamber than the large tower needed for spray drying. Freeze-dried, spray freeze-dried, and foam mat-dried powders exhibit higher porosity than spray-dried ones, whereas supercritical drying produces nano-porous interconnected powders. Notably, several factors like glass transition temperature, drying technologies, particle aggregation, agglomeration, and sintering impact powder porosity. However, some binders, such as maltodextrin, sucrose, and lactose, could be applied in controlled agglomeration to enhance powder porosity. Further investigation on the effect of emerging technologies on powder properties and their commercial feasibility is required to discover their potential in liquid drying. Moreover, utilizing clean-label drying ingredients like dietary fibers, derived from agricultural waste, presents promising opportunities.

Selection of Silica Type and Amount for Flowability Enhancements via Dry Coating: Contact Mechanics Based Predictive Approach

PURPOSE

To investigate the effect of dry coating the amount and type of silica on powder flowability enhancement using a comprehensive set of 19 pharmaceutical powders having different sizes, surface roughness, morphology, and aspect ratios, as well as assess flow predictability via Bond number estimated using a mechanistic multi-asperity particle contact model.

METHOD

Particle size, shape, density, surface energy and area, SEM-based morphology, and FFC were assessed for all powders. Hydrophobic (R972P) or hydrophilic (A200) nano-silica were dry coated for each powder at 25%, 50%, and 100% surface area coverage (SAC). Flow predictability was assessed via particle size and Bond number.

RESULTS

Nearly maximal flow enhancement, one or more flow category, was observed for all powders at 50% SAC of either type of silica, equivalent to 1 wt% or less for both the hydrophobic R972P or hydrophilic A200, while R972P generally performed slightly better. Silica amount as SAC better helped understand the relative performance. The power-law relation between FFC and Bond number was observed.

CONCLUSION

Significant flow enhancements were achieved at 50% SAC, validating previous models. Most uncoated very cohesive powders improved by two flow categories, attaining easy flow. Flowability could not be predicted for both the uncoated and dry coated powders via particle size alone. Prediction was significantly better using Bond number computed via the mechanistic multi-asperity particle contact model accounting for the particle size, surface energy, roughness, and the amount and type of silica. The widely accepted 200 nm surface roughness was not valid for most pharmaceutical powders.

Control Strategy for Excipient Variability in the Quality by Design Approach Using Statistical Analysis and Predictive Model: Effect of Microcrystalline Cellulose Variability on Design Space

Although various quality by design (QbD) approaches have been used to establish a design space to obtain robust drug formulation and process parameters, the effect of excipient variability on the design space and drug product quality is unclear. In this study, the effect of microcrystalline cellulose (MCC) variability on drug product quality was examined using a design space for immediate-release tablets of amlodipine besylate. MCC variability was assessed by altering the manufacturer and grade. The formulation was developed by employing the QbD approach, which was optimized using a D-optimal mixture design. Using 36 different MCCs, the effect of MCC variability on the design space was assessed. The design space was shifted by different manufacturers and grades of MCC, which resulted in associations between the physicochemical properties of MCC and critical quality attributes (CQAs). The correlation between the physicochemical properties of MCCs and CQAs was assessed through a statistical analysis. A predictive model correlating the physicochemical properties of MCCs with dissolution was established using an artificial neural network (ANN). The ANN model accurately predicted dissolution with low absolute and relative errors. The present study described a comprehensive QbD approach, statistical analysis, and ANN to comprehend and manage the effect of excipient variability on the design space.

Starch flow behavior alone and under different glidants action using the shear cell method

The objective of this work was to analyze the flow behavior of a commonly used filler (pregelatinised starch) and the effect of two of the most used lubricants (talc and colloidal silicon dioxide). The studies were carried out according to the conventional methods (Angle of Repose, Bulk and Tapped densities and from these the Compressibility Index) and shear cell methods (Brookfield Powder Flow Tester apparatus) described in European Pharmacopeia (Ph. Eur.). The results showed some surprising and unexpected values for the flow behavior of this filler under influence of the methods and the used glidants. Regarding pure starch and mixtures containing talc, the flow behavior was similar between them and the Flow Index (ff_c) values varied between 1.8 and 4 (very cohesive and cohesive) as consolidation stress (σ₁) increased. In this case, the glidant effect was not observed. However, for the mixtures of starch with colloidal silicon dioxide this effect was observed providing Flow Index (ff_c) values between 2.6 and 8.9 (cohesive and easy-flowing) as consolidation stress (σ₁) increased. Other parameters that are also used to characterize flow properties, more specifically, within silos, chutes and hoppers, such as effective angle of internal friction (φe), effective angle of wall friction (φx), critical arching and critical rathole values, provided similar information. Based in the obtained results from all tests it can be said that the talc did not induce improvement on the starch flow behavior in the used conditions in opposition to the effect produced by colloidal silicon dioxide.HighlightsExample 1. A good flowability of powders is needed in order to be compressed/filled;Example 2. The overcome the poor flow it is usual to use glidants;Example 3. CSD improved the pregelatinised starch (Starch 1500®) flow;Example 4. Talc do not have relevant effect in the pregelatinised starch (Starch 1500®) flow;Example 5. Powder FlowTester method showed more complete and consistent results.

Hydrophobic and raw glass beads flow behavior under different processing conditions

Controlling the powder flow by the surface properties of the particles as well as understanding their flowability under different processing dynamics are amongst the major challenges of the powder industry. Indeed, handling large quantities needs powders with good flowability, adequate compressibility and few electrostatic charges. We have performed a chemical treatment in order to obtain hydrophobic glass bead and its bulk behavior has been compared with raw glass bead. We characterized flow properties under different processing conditions. Both powders presented similar flow behavior in the free fall measurement, however hydrophobic glass bead showed lower flow behavior under flow with rotating drum. Also, hydrophobic glass bead presented negative and raw glass bead almost zero electrostatic charges.

Bioavailability Improvement of Carbamazepine via Oral Administration of Modified-Release Amorphous Solid Dispersions in Rats

The purpose of this study was to improve the bioavailability of carbamazepine (CBZ), a poorly water-soluble antiepileptic drug, via modified-release amorphous solid dispersions (mr-ASD) by a thin film freezing (TFF) process. Three types of CBZ-mr-ASD with immediate-, delayed-, and controlled-release properties were successfully prepared with HPMC E3 (hydrophilic), L100-55 (enteric), and cellulose acetate (CA, lipophilic), defined as CBZ-ir-ASD, CBZ-dr-ASD, and CBZ-cr-ASD, respectively. A dry granulation method was used to prepare CBZ-mr-ASD capsule formulations. Various characterization techniques were applied to evaluate the physicochemical properties of CBZ-mr-ASD and the related capsules. The drug remained in an amorphous state when encapsulated within CBZ-mr-ASD, and the capsule formulation progress did not affect the performance of the dispersions. In dissolution tests, the preparations and the corresponding dosage forms similarly showed typical immediate-, delayed-, and controlled-release properties depending on the solubility of the polymers. Moreover, single-dose 24 h pharmacokinetic studies in rats indicated that CBZ-mr-ASD significantly enhanced the oral absorption of CBZ compared to that of crude CBZ. Increased oral absorption of CBZ was observed, especially in the CBZ-dr-ASD formulation, which showed a better pharmacokinetic profile than that of crude CBZ with 2.63- and 3.17-fold improved bioavailability of the drug and its main active metabolite carbamazepine 10,11-epoxide (CBZ-E).

Effects of Morphology on the Bulk Density of Instant Whole Milk Powder

The chemical and physical properties of instant whole milk powder (IWMP), such as morphology, protein content, and particle size, can affect its functionality and performance. Bulk density, which directly determines the packing cost and transportation cost of milk powder, is one of the most important functional properties of IWMP, and it is mainly affected by physical properties, e.g., morphology and particle size. This work quantified the relationship between morphology and bulk density of IWMP and developed a predictive model of bulk density for IWMP. To obtain milk powder samples with different particle size fractions, IWMP samples of four different brands were sieved into three different particle size range groups, before using the simplex-centroid design (SCD) method to remix the milk powder samples. The bulk densities of these remixed milk powder samples were then measured by tap testing, and the particles' shape factors were extracted by light microscopy and image processing. The number of variables was decreased by principal component analysis and partial least squares models and artificial neural network models were built to predict the bulk density of IWMP. It was found that different brands of IWMP have different morphology, and the bulk density trends versus the shape factor changes were similar for the different particle size range groups. Finally, prediction models for bulk density were developed by using the shape factors and particle size range fractions of the IWMP samples. The good results of these models proved that predicting the bulk density of IWMP by using shape factors and particle size range fractions is achievable and could be used as a model for online model-based process monitoring.

Lactose monohydrate flow characterization using shear cell method

The flow properties of pharmaceutical powders have a great importance in the manufacturing of solid dosage forms. In order to ensure the performance in the production line this parameter must be determined. There are several methods described in European Pharmacopeia that are used to measure these properties. Some of them were used in this study and the results obtained from conventional methods (Conv) and shear cell using the powder flow tester (PFT) showed differences that were more evident in fractions with smaller particle size (F < 63) and for bulk powder (F_Total). The various powder behaviors showed to be related with the size of the particles. An increase of the ff_c (Flow Index) was observed with the increase of the particle size. It was also found for the different fractions that the ff_c always increases with increasing major principal consolidation stress (σ₁). This study shown to be predictive because it also allowed the behavior profiles of other LactMN fractions to be known by interpolation of the median size (Dv50) or σ₁ values ranged between the studied intervals. Furthermore, it was also observed that ff_c of the F_Total was similar to the F < 63, showing the same behavior under σ₁. The occurrence of caking was not observed.

On the mechanism of colloidal silica action to improve flow properties of pharmaceutical excipients

The mechanism of colloidal silica action to improve flow properties of pharmaceutical powders is known to be based on inter-particle force disruption by silica particles adhered to the particle surface. In the present article, the kinetic aspects of this action are investigated, focusing on non-spherical particles of different size. Blends comprising microcrystalline cellulose or calcium hydrogen phosphate dihydrate and colloidal silica were examined using powder rheometer. The blends were formulated to represent effects of particle size, surface texture, colloidal silica loading, and mixing time. Pre-conditioning, shear testing, compressibility, and flow energy measurements were used to monitor flow properties. Components and blends were analyzed using particle size analysis and scanning electron microscopy (SEM), using energy dispersive spectroscopy (EDS) and back-scattered electron (BSE) detection to determine surface particle arrangement. All studied parameters were found to have substantial effects on flow properties of powder blends. Those effects were explained by identifying key steps of colloidal silica action, which were found to proceed at substantially different rates, causing the flow properties change over time being dependent on the blend formulation and the component properties.

Characterisation of pore structures of pharmaceutical tablets: A review

Traditionally, the development of a new solid dosage form is formulation-driven and less focus is put on the design of a specific microstructure for the drug delivery system. However, the compaction process particularly impacts the microstructure, or more precisely, the pore architecture in a pharmaceutical tablet. Besides the formulation, the pore structure is a major contributor to the overall performance of oral solid dosage forms as it directly affects the liquid uptake rate, which is the very first step of the dissolution process. In future, additive manufacturing is a potential game changer to design the inner structures and realise a tailor-made pore structure. In pharmaceutical development the pore structure is most commonly only described by the total porosity of the tablet matrix. Yet it is of great importance to consider other parameters to fully resolve the interplay between microstructure and dosage form performance. Specifically, tortuosity, connectivity, as well as pore shape, size and orientation all impact the flow paths and play an important role in describing the fluid flow in a pharmaceutical tablet. This review presents the key properties of the pore structures in solid dosage forms and it discusses how to measure these properties. In particular, the principles, advantages and limitations of helium pycnometry, mercury porosimetry, terahertz time-domain spectroscopy, nuclear magnetic resonance and X-ray computed microtomography are discussed.

Shear strength of pharmaceutical tablets: Theoretical considerations, evaluation and relation with the capping tendency of biconvex tablets

Capping is a major industrial issue during pharmaceutical powder compression, especially in the case of biconvex tablets. Several articles proposed that capping was in fact a failure in shear. Shear strength should thus be interesting to study the capping tendency of a formulation. In this work, the ratio between the shear strength and the tensile strength obtained by diametral compression was first studied from a theoretical point of view considering different failure criteria. Then, a shear test usually performed on bilayer tablets was adapted to monolayer tablets. The shear strength obtained for 5 products, 2 of them having a known capping tendency, were compared with the strengths obtained during diametral compression test and uniaxial compression test. The results indicated that, for the formulations with a capping tendency, the ratio between the shear strength and diametral compression strength was lower than for the other products. Considering the mechanism of capping, the weakness in shear of these formulations explained their capping tendency. This was also linked with the mechanical anisotropy of the same formulations which was shown in the literature. In the cases studied in this article, the fundamental reason for the capping tendency was the anisotropic strength of the tablets.

Physical characterization of whole and skim dried milk powders

The lack of updated knowledge about the physical properties of milk powders aimed us to evaluate selected physical properties (water activity, particle size, density, flowability, solubility and colour) of eleven skim and whole milk powders produced in Europe. These physical properties are crucial both for the management of milk powder during the final steps of the drying process, and for their use as food ingredients. In general, except for the values of water activity, the physical properties of skim and whole milk powders are very different. Particle sizes of the spray-dried skim milk powders, measured as volume and surface mean diameter were significantly lower than that of the whole milk powders, while the roller dried sample showed the largest particle size. For all the samples the size distribution was quite narrow, with a span value less than 2. The loose density of skim milk powders was significantly higher than whole milk powders (541.36 vs 449.75 kg/m³). Flowability, measured by Hausner ratio and Carr's index indicators, ranged from passable to poor when evaluated according to pharmaceutical criteria. The insolubility index of the spray-dried skim and whole milk powders, measured as weight of the sediment (from 0.5 to 34.8 mg), allowed a good discrimination of the samples. Colour analysis underlined the relevant contribution of fat content and particle size, resulted in higher lightness (L*) for skim milk powder than whole milk powder, which, on the other hand, showed higher yellowness (b*) and lower greenness (-a*). In conclusion a detailed knowledge of functional properties of milk powders may allow the dairy to tailor the products to the user and help the food processor to perform a targeted choice according to the intended use.

To Evaluate the Effect of Solvents and Different Relative Humidity Conditions on Thermal and Rheological Properties of Microcrystalline Cellulose 101 Using METHOCEL™ E15LV as a Binder

The solvent used for preparing the binder solution in wet granulation can affect the granulation end point and also impact the thermal, rheological, and flow properties of the granules. The present study investigates the effect of solvents and percentage relative humidity (RH) on the granules of microcrystalline cellulose (MCC) with hydroxypropyl methyl cellulose (HPMC) as the binder. MCC was granulated using 2.5% w/w binder solution in water and ethanol/water mixture (80:20 v/v). Prepared granules were dried until constant percentage loss on drying, sieved, and further analyzed. Dried granules were exposed to different percentage RH for 48 h at room temperature. Powder rheometer was used for the rheological and flow characterization, while thermal effusivity and differential scanning calorimeter were used for thermal analysis. The thermal effusivity values for the wet granules showed a sharp increase beginning 50% w/w binder solution in both cases, which reflected the over-wetting of granules. Ethanol/water solvent batches showed greater resistance to flow as compared to the water solvent batches in the wet granule stage, while the reverse was true for the dried granule stage, as evident from the basic flowability energy values. Although the solvents used affected the equilibration kinetics of moisture content, the RH-exposed granules remained unaffected in their flow properties in both cases. This study indicates that the solvents play a vital role on the rheology and flow properties of MCC granules, while the different RH conditions have little or no effect on them for the above combination of solvent and binder.

Development of a solidified self-microemulsifying drug delivery system (S-SMEDDS) for atorvastatin calcium with improved dissolution and bioavailability

To improve the dissolution and oral bioavailability (BA) of atorvastatin calcium (ATV), we previously introduced an optimized self-microemulsifying drug delivery system (SMEDDS) using Capmul(®) MCM (oil), Tween(®) 20 (surfactant), and tetraglycol (cosurfactant). In this study, various solid carriers were employed to develop a solidified SMEDDS (S-SMEDDS): mannitol (M) and lactose (L) as water-soluble carriers, and Sylysia(®) 350 (S) and Aerosil(®) 200 (A) as water-insoluble carriers. Maximum solidifying capacities (SCmax) of water-insoluble carriers were significantly greater than those of water-soluble carriers were. The resultant powders were free flowing with an angle of repose <40° and Carr's index 5-20%, regardless of the solid carrier types. S-SMEDDS with mannitol (S(M)-SMEDDS) or lactose (S(L)-SMEDDS) had a smaller droplet size and greater dissolution than S-SMEDDS with Sylysia(®) 350 (S(S)-SMEDDS) or Aerosil(®) 200 (S(A)-SMEDDS). Following oral administration of various formulations to rats at a dose equivalent to 25mg/kg of ATV, plasma drug levels were measured by LC-MS/MS. The relative BAs (RBAs) of SMEDDS, S(M)-SMEDDS, and S(S)-SMEDDS were 345%, 216%, and 160%, respectively, compared to that of ATV suspension. Additionally, at a reduced dose of ATV equivalent to 5mg/kg, the RBAs of S(M)-SMEDDS and S(S)-SMEDDS compared to that of SMEDDS were 101% and 65%, respectively. These results suggest that S(M)-SEMDDS offers great potential for the development of solid dosage forms with improved oral absorption of drugs with poor water solubility.

Advanced three dimensional characterization of silica-based ultraporous materials

Whatever the field of application in building, transportation, packaging, etc., the energy losses must be reduced. In this context, the development of superinsulating materials is mandatory. Ultra-porous silica aerogels are good candidates.

Rapid characterization of tanshinone extract powder by near infrared spectroscopy

Chemical and physical quality attributes of herbal extract powders play an important role in the research and development of Chinese medicine preparations. The active pharmaceutical ingredients have a direct impact on the herbal extract's efficacy, while the physical properties of raw material affect the pharmaceutical manufacturing process and the final products' quality. In this study, tanshinone extract powders from Salvia miltiorrhiza which are widely used for the treatment of cardiovascular diseases in the clinic are taken as the research object. Both the chemical information and physical information of tanshinone extract powders are analyzed by near infrared (NIR) spectroscopy. The partial least squares (PLS) and least square support vector machine (LS-SVM) models are investigated to build the relationship between NIR spectra and reference values. PLS models performed well for the content of crytotanshinone, tanshinone IIA, the moisture, and average median particle size, while, for specific surface area and tapped density, the LS-SVM models performed better than the PLS models. Results demonstrated NIR to be a valid and fast process analytical technology tool to simultaneously determine multiple quality attributes of herbal extract powders and indicated that there existed some nonlinear relationship between NIR spectra and physical quality attributes.

Analogous viscosity equations of granular powders based on Eyring's rate process theory and free volume concept

Granular powders can be successfully treated with kinetic theory and statistical mechanics, though the granular powders are athermal systems and the conventional environmental temperature is too weak to drive particles to move.

Predictive and correlative techniques for the design, optimisation and manufacture of solid dosage forms

There is much interest in predicting the properties of pharmaceutical dosage forms from the properties of the raw materials they contain. Achieving this with reasonable accuracy would aid the faster development and manufacture of dosage forms. A variety of approaches to prediction or correlation of properties are reviewed. These approaches have variable accuracy, with no single technique yet able to provide an accurate prediction of the overall properties of the dosage form. However, there have been some successes in predicting trends within a formulation series based on the physicochemical and mechanical properties of raw materials, predicting process scale-up through mechanical characterisation of materials and predicting product characteristics by process monitoring. Advances in information technology have increased predictive capability and accuracy by facilitating the analysis of complex multivariate data, mapping formulation characteristics and capturing past knowledge and experience.

Application of powder rheometer to determine powder flow properties and lubrication efficiency of pharmaceutical particulate systems

The objective of this study was to understand the behavior of particulate systems under different conditions of shear dynamics before and after granulation and to investigate the efficiency of powder lubrication. Three drug powders, metronidazole, colloidal bismuth citrate, and tetracycline hydrochloride, were chosen as model drugs representing noncohesive and cohesive powder systems. Each powder was individually granulated with microcrystalline cellulose and 5%PVP as a binder. One portion from each granulation was lubricated with different levels of magnesium stearate for 5 minutes. The powder characterization was performed on the plain powders, nonlubricated and lubricated granules using powder rheometer equipped with a helical blade rotating and moving under experimentally fixed set of parameters. The profiles of interaction during the force-distance measurements indicate that powder compresses, expands, and shears many times in a test cycle. Test profiles also clearly reveal existence of significant differences between cohesive and noncohesive powders. In all cases lubrication normalized the overall interactive nature of the powder by reducing peaks and valleys as observed from the profiles and reduced the frictional effect. The developed methods are easy to perform and will allow formulation scientists to better understand powder behavior and help in predicting potential impact of processing factors on particulate systems.