In Situ Monitoring of Polymorphic Transformations Using a Composite Sensor Array of Raman, NIR, and ATR-UV/vis Spectroscopy, FBRM, and PVM for an Intelligent Decision Support System

Development of a Digital Twin for the Prediction and Control of Supersaturation during Batch Cooling Crystallization

Fine chemicals produced via batch crystallization with properties dependent on the crystal size distribution require precise control of supersaturation, which drives the evolution of crystal size over time. Model predictive control (MPC) of supersaturation using a mechanistic model to represent the behavior of a crystallization process requires less experimental time and resources compared with fully empirical model-based control methods. Experimental characterization of the hexamine-ethanol crystallization system was performed in order to collect the parameters required to build a one-dimensional (1D) population balance model (PBM) in gPROMS FormulatedProducts software (Siemens-PSE Ltd.). Analysis of the metastable zone width (MSZW) and a series of seeded batch cooling crystallizations informed the suitable process conditions selected for supersaturation control experiments. The gPROMS model was integrated with the control software PharmaMV (Perceptive Engineering Ltd.) to create a digital twin of the crystallizer. Simulated batch crystallizations were used to train two statistical MPC blocks, allowing for in silico supersaturation control simulations to develop an effective control strategy. In the supersaturation set-point range of 0.012-0.036, the digital twin displayed excellent performance that would require minimal controller tuning to steady out any instabilities. The MPC strategy was implemented on a physical 500 mL crystallizer, with the simulated solution concentration replaced by in situ measurements from calibrated attenuated total reflection-Fourier transform infrared (ATR-FTIR) spectroscopy. Physical supersaturation control performance was slightly more unstable than the in silico tests, which is consistent with expected disturbances to the heat transfer, which were not specifically modeled in simulations. Overall, the level of supersaturation control in a real crystallizer was found to be accurate and precise enough to consider future adaptations to the MPC strategy for more advanced control objectives, such as the crystal size.

Challenges and Opportunities of Implementing Data Fusion in Process Analytical Technology—A Review

The release of the FDA’s guidance on Process Analytical Technology has motivated and supported the pharmaceutical industry to deliver consistent quality medicine by acquiring a deeper understanding of the product performance and process interplay. The technical opportunities to reach this high-level control have considerably evolved since 2004 due to the development of advanced analytical sensors and chemometric tools. However, their transfer to the highly regulated pharmaceutical sector has been limited. To this respect, data fusion strategies have been extensively applied in different sectors, such as food or chemical, to provide a more robust performance of the analytical platforms. This survey evaluates the challenges and opportunities of implementing data fusion within the PAT concept by identifying transfer opportunities from other sectors. Special attention is given to the data types available from pharmaceutical manufacturing and their compatibility with data fusion strategies. Furthermore, the integration into Pharma 4.0 is discussed.

Feedback Control of Crystal Size Distribution for Cooling Batch Crystallization Using Deep Learning-Based Image Analysis

The shape of the crystal size distribution directly determines the quality of crystal products. It is often assumed that distributional properties of crystal size conform to the Gaussian distribution or the log normal distribution. The mean and variance or relative crystal number are widely adopted to describe the crystal size distribution and taken as the control objectives. Therefore, the resulting control methods have difficulties in controlling the crystal size distribution with a general shape. In this article, a novel feedback control system of crystal size distribution based on image analysis is designed for the effective control of crystal size distribution with a general shape. First, a deep learning network-based image analysis method is adopted and implemented to extract the crystal size distribution. Second, the crystal size distribution is approximated by a radial basis function neural network. Consequently, a feedback controller is designed and the tracking control of the target crystal size distribution is finally realized. The results of crystallization experiments demonstrate the effectiveness of the proposed method.

Monitoring of Chemical Markers in Extraction of Traditional Medicinal Plants (Piper nigrum, Curcuma longa) Using In Situ ReactIR

BACKGROUND

The fingerprinting and quantification of marker compounds from medicinal plants is a domain of the herbal industry for quality/quantity control parameters.

OBJECTIVE

The main objective of this study is the application of the in situ ReactIR technique for measuring the concentration of different components during the extraction process of different medicinal plants.

METHOD

In this study we have performed the extraction of two-marker compounds, viz. piperine from Piper nigrum and curcumin from Curcuma longa plants, using various solvents (dichloromethane and methanol). The progress of extraction was monitored using an in situ Fourier transform infrared (FTIR) probe instrument and an automated reactor.

RESULTS

In this communication, using the in situ ReactIR technique we developed a method which demonstrates the relative quantification of marker analytes, optimizes extraction time and type of solvents to be used for different analytes during the extraction process.

CONCLUSIONS

To the best of our knowledge, this is the first report of relative quantification and structural information of marker compounds during the process of extraction using in situ FTIR.

HIGHLIGHTS

The present study highlights the real-time monitoring, in situ quantification, and structural information of marker compounds during the process of extraction of medicinal plants using in situ FTIR.

Application of PAT-Based Feedback Control Approaches in Pharmaceutical Crystallization

Crystallization is one of the important unit operations for the separation and purification of solid products in the chemical, pharmaceutical, and pesticide industries, especially for realizing high-end, high-value solid products. The precise control of the solution crystallization process determines the polymorph, crystal shape, size, and size distribution of the crystal product, which is of great significance to improve product quality and production efficiency. In order to develop the crystallization process in a scientific method that is based on process parameters and data, process analysis technology (PAT) has become an important enabling platform. In this paper, we review the development of PAT in the field of crystallization in recent years. Based on the current research status of drug crystallization process control, the monitoring methods and control strategies of feedback control in the crystallization process were systematically summarized. The focus is on the application of model-free feedback control strategies based on the solution and solid information collected by various online monitoring equipment in product engineering, including improving particle size distribution, achieving polymorphic control, and improving purity. In this paper, the challenges of feedback control strategy in the crystallization process are also discussed, and the development trend of the feedback control strategy has been prospected.

Reactive crystallization: a review

Reactive crystallization is not new, but there has been recent growth in its use as a means of improving performance and sustainability of industrial processes.

Application of percolation threshold to disintegration and dissolution of ibuprofen tablets with different microcrystalline cellulose grades

The study presented was conducted to determine whether a percolation threshold value, previously determined for ibuprofen/microcrystalline cellulose (MCC) blends using percolation theory and compression data (Queiroz et al., 2019), could translate to tablet disintegration and dissolution data. The influence of MCC grade (air stream dried versus spray dried) on tablet disintegration and dissolution was also investigated. Complementary to conventional disintegration and dissolution testing, Raman imaging determined drug distribution within tablets, and in-line particle video microscopy (PVM) and focused-beam reflectance measurement (FBRM) monitored tablet disintegration. Tablets were prepared containing 0-30% w/w ibuprofen. Raman imaging confirmed the percolation threshold by quantifying the number and equivalent circular diameters of ibuprofen domains on tablet surfaces. Across the percolation threshold, a step change in dissolution behaviour occurred, and tablets containing air stream dried MCC showed slower disintegration rates compared to tablets containing spray dried MCC. Dissolution measurements confirmed experimentally a percolation threshold in agreement with that determined using percolation theory and compression data. An increase in drug domains, due to cluster formation, and less efficient tablet disintegration contributed to slower ibuprofen dissolution above the percolation threshold. Slower dissolution was measured for tablets containing air stream dried compared to spray dried MCC.

Process Monitoring of Antisolvent Based Crystallization in Low Conductivity Solutions Using Electrical Impedance Spectroscopy and 2-D Electrical Resistance Tomography

Industrial process monitoring is an important field of research where different chemical processes are monitored and controlled. In this work, electrical impedance spectroscopy (EIS) was used to analyze antisolvent based crystallization of sucrose solutions. The impedance and phase spectra were recorded for four known sucrose concentrations in water, and for each case, four predetermined amounts of ethanol were added. As a result, sixteen different solutions involving sucrose solutions of different concentrations and ethanol to water ratios were analyzed. Significant differences were observed in the magnitude and phase spectra of the solutions in the frequency range of 50 kHz to 300 kHz. The experimentally obtained data from the EIS were converted into frequency response models. Three continuous-time transfer function models of the first-order, second-order, and a second-order with a zero were estimated and compared. In addition, a 2-D electrical resistance tomography (ERT) system with a low conductivity sensor unit was designed and tested with demineralized water, tap water and industrial food grade saturated sucrose solution. Non-conducting phantom and sugar crystals were observed within the saturated sucrose solution using the Bayesian reconstruction algorithm. These demonstrations have the potential to be developed into a multi-frequency ERT systems for monitoring the distribution of the crystals in the reactor. The EIS modality can be a complementary process analytical technology (PAT) tool indicating supersaturation status and provide quality assurance.

An automated modular assembly line for drugs in a miniaturized plant

We report here a fully automated, end-to-end, integrated continuous manufacturing process for a small-molecule generic medication with built-in quality assurance. The entire process fits into a box of 30.7 m2 modular footprint and a total residence time of less than 30 h, with a throughput up to 40.3 × 106 tablets per year.

Continuous reactive crystallization of an API in PFR-CSTR cascade with in-line PATs

The influence of PFR on crystal size distribution, reaction and crystallization yields, and supersaturation level was investigated.

Thermodynamics and molecular mechanism of the formation of the cocrystals of p-hydroxybenzoic acid and glutaric acid

The thermodynamics and molecular mechanism of the formation of a new cocrystal of p-hydroxybenzoic acid and glutaric acid were investigated.

Vibrational Spectroscopy for Cocrystals Screening. A Comparative Study

A recurrent problem faced by the pharmaceutical industry when formulating drug products concerns poorly soluble drugs, which, despite having desirable pharmacological activity, present limited bioavailability. Cocrystallization is growing up as a possible approach to tackle this problem. Cocrystals are crystalline materials comprising at least two components, solid at room temperature, and held together by non-covalent bonds. The increasing interest in these compounds is steadily demanding faster, simpler, and more reliable methods for the task of screening new cocrystals. This work aims at comparing the performance of three vibrational spectroscopy techniques (mid infrared, near infrared, and Raman spectroscopy) for cocrystals screening. Presented results are based on hydrochlorothiazide, a poorly soluble drug belonging to class IV of the Biopharmaceutical Classification System. The implemented cocrystal screening procedure tested six coformers (all considered safe for human administration) added according to a drug:coformer ratio of 1:1 and 1:2 and seven solvents with different polarity. The screening method chosen was based on slurry cocrystallization performed by sonication (ultrasound assisted) in a 96-well plate. Results show that all evaluated vibrational spectroscopy techniques provided important information regarding cocrystal formation, including information on the groups involved in the cocrystallization and purity, and can be used for the screening task.

Smart systems for determination of drug's solubility

The solubility of drugs is a crucial physicochemical property in the drug discovery or development process and for improving the bioavailability of drugs. There are various methods for evaluating the solubility of drugs including manual measurement methods, mathematical methods, and smart methods. Manual measurement and mathematical methods have some defects which make the smart systems more reliable and important in this field. In this review, various instruments used for the solubility determination, along with the smart systems, have been discussed. Mechanism and applications of each method have been elaborated in detail. Moreover, unique characteristics as well as some limitations of discussed methods are also described.

Nucleation in food colloids

Nucleation in food colloids has been studied in detail using ultrasound spectroscopy. Our data show that classical nucleation theory (CNT) remains a sound basis from which to understand nucleation in food colloids and analogous model systems using n-alkanes. Various interpretations and modifications of CNT are discussed with regard to their relevance to food colloids. Much of the evidence presented is based on the ultrasound velocity spectrometry measurements which has many advantages for the study of nucleating systems compared to light scattering and NMR due to its sensitivity at low solid contents and its ability to measure true solid contents in the nucleation and early crystal growth stages. Ultrasound attenuation spectroscopy also responds to critical fluctuations in the induction region. We show, however, that a periodic pressure fluctuation such as a quasi-continuous (as opposed to a pulse comprising only a few pressure cycles) ultrasound field can alter the nucleation process, even at very low acoustic intensity. Thus care must be taken when using ultrasound techniques that the measurements do not alter the studied processes. Quasi-continuous ultrasound fields may enhance or suppress nucleation and the criteria to determine such effects are derived. The conclusions of this paper are relevant to colloidal systems in foods, pharmaceuticals, agro-chemicals, cosmetics, and personal products.

Detection of contaminants in water supply: A review on state-of-the-art monitoring technologies and their applications

Water monitoring technologies are widely used for contaminants detection in wide variety of water ecology applications such as water treatment plant and water distribution system. A tremendous amount of research has been conducted over the past decades to develop robust and efficient techniques of contaminants detection with minimum operating cost and energy. Recent developments in spectroscopic techniques and biosensor approach have improved the detection sensitivities, quantitatively and qualitatively. The availability of in-situ measurements and multiple detection analyses has expanded the water monitoring applications in various advanced techniques including successful establishment in hand-held sensing devices which improves portability in real-time basis for the detection of contaminant, such as microorganisms, pesticides, heavy metal ions, inorganic and organic components. This paper intends to review the developments in water quality monitoring technologies for the detection of biological and chemical contaminants in accordance with instrumental limitations. Particularly, this review focuses on the most recently developed techniques for water contaminant detection applications. Several recommendations and prospective views on the developments in water quality assessments will also be included.

Development of an automated multi-stage continuous reactive crystallization system with in-line PATs for high viscosity process

Lower E-factor was obtained in an automated multi-stage continuous reactive-crystallization system.

Preparation, crystal structure and solution-mediated phase transformation of a novel solid-state form of CL-20

The crystal structure, thermodynamic phase diagram, and polymorphic transformation behaviors of CL-20 acetonitrile solvate are systematically investigated.

Application of feedback control and in situ milling to improve particle size and shape in the crystallization of a slow growing needle-like active pharmaceutical ingredient

Control of crystal size and shape is crucially important for crystallization process development in the pharmaceutical industries. In general crystals of large size and low aspect ratio are desired for improved downstream manufacturability. It can be extremely challenging to design crystallization processes that achieve these targets for active pharmaceutical ingredients (APIs) that have very slow growth kinetics and needle-like morphology. In this work, a batch cooling crystallization process for a GlaxoSmithKline patented API, which is characterized by very slow growth rate and needle morphology, was studied and improved using process analytical technology (PAT) based feedback control techniques and in situ immersion milling. Four specific approaches were investigated: Supersaturation control (SSC), direct nucleation control (DNC), sequential milling-DNC, and simultaneous milling-DNC. This is the first time that immersion wet milling is combined with feedback control in a batch crystallization process. All four approaches were found to improve crystal size and/or shape compared to simple unseeded or seeded linear cooling crystallizations. DNC provided higher quality crystals than SSC, and sequential and simultanesou milling-DNC approaches could reduce particle 2D aspect ratio without generating too much fines. In addition, an ultra-performance liquid chromatography (UPLC) system was used online as a novel PAT tool in the crystallization study.

Process analytical approaches for the coil-to-globule transition of poly(N-isopropylacrylamide) in a concentrated aqueous suspension

The coil-to-globule transition of poly(N-isopropylacrylamide) (PNIPAM) microgel particles suspended in water has been investigated in situ as a function of heating and cooling rate with four optical process analytical technologies (PAT), sensitive to structural changes of the polymer. Photon Density Wave (PDW) spectroscopy, Focused Beam Reflectance Measurements (FBRM), turbidity measurements, and Particle Vision Microscope (PVM) measurements are found to be powerful tools for the monitoring of the temperature-dependent transition of such thermo-responsive polymers. These in-line technologies allow for monitoring of either the reduced scattering coefficient and the absorption coefficient, the chord length distribution, the reflected intensities, or the relative backscatter index via in-process imaging, respectively. Varying heating and cooling rates result in rate-dependent lower critical solution temperatures (LCST), with different impact of cooling and heating. Particularly, the data obtained by PDW spectroscopy can be used to estimate the thermodynamic transition temperature of PNIPAM for infinitesimal heating or cooling rates. In addition, an inverse hysteresis and a reversible building of micrometer-sized agglomerates are observed for the PNIPAM transition process.

Raman spectroscopy as a process analytical technology for pharmaceutical manufacturing and bioprocessing

Adoption of Quality by Design (QbD) principles, regulatory support of QbD, process analytical technology (PAT), and continuous manufacturing are major factors effecting new approaches to pharmaceutical manufacturing and bioprocessing. In this review, we highlight new technology developments, data analysis models, and applications of Raman spectroscopy, which have expanded the scope of Raman spectroscopy as a process analytical technology. Emerging technologies such as transmission and enhanced reflection Raman, and new approaches to using available technologies, expand the scope of Raman spectroscopy in pharmaceutical manufacturing, and now Raman spectroscopy is successfully integrated into real-time release testing, continuous manufacturing, and statistical process control. Since the last major review of Raman as a pharmaceutical PAT in 2010, many new Raman applications in bioprocessing have emerged. Exciting reports of in situ Raman spectroscopy in bioprocesses complement a growing scientific field of biological and biomedical Raman spectroscopy. Raman spectroscopy has made a positive impact as a process analytical and control tool for pharmaceutical manufacturing and bioprocessing, with demonstrated scientific and financial benefits throughout a product’s lifecycle.

Real-time monitoring of the mechanism of ibuprofen-cationic dextran crystanule formation using crystallization process informatics system (CryPRINS)

One step aqueous melt-crystallization and in situ granulation was utilized to produce ibuprofen-cationic dextran [diethylaminoethyl dextran (Ddex)] conjugate crystanules without the use of surfactants or organic solvents. This study investigates the mechanism of in situ granulation-induced crystanule formation using ibuprofen (Ibu) and Ddex. Laboratory scale batch aqueous crystallization system containing in situ monitoring probes for particle vision measurement (PVM), UV-vis measurement and focused beam reflectance measurements (FBRM) was adapted using pre-defined formulation and process parameters. Pure ibuprofen showed nucleation domain between 25 and 64°C, producing minicrystals with onset of melting at 76°C and enthalpy of fusion (ΔH) of 26.22kJ/mol. On the other hand Ibu-Ddex crystanules showed heterogeneous nucleation which produced spherical core-shell structure. PVM images suggest that internalization of ibuprofen in Ddex corona occurred during the melting phase (before nucleation) which inhibited crystal growth inside the Ddex corona. The remarkable decrease in ΔH of the crystanules from 26.22 to 11.96kJ/mol and the presence of broad overlapping DSC thermogram suggests formation of ibuprofen-Ddex complex and crystalline-amorphous transformation. However Raman and FTIR spectra did not show any significant chemical interaction between ibuprofen and Ddex. A significant increase in dissolution efficiency from 45 to 81% within 24h and reduced burst release provide evidence for potential application of crystanules in controlled drug delivery systems. It was evident that in situ granulation of ibuprofen inhibited the aqueous crystallization process. It was concluded that in situ granulation-aqueous crystallization technique is a novel unit operation with potential application in continuous pharmaceutical processing.