Effects of process variables on the size, shape, and surface characteristics of microcrystalline cellulose beads prepared in a centrifugal granulator

Preparation and evaluation of highly drug-loaded fine globular granules using a multi-functional rotor processor

The manufacture of highly drug-loaded fine globular granules eventually applied for orally disintegrating tablets has been investigated using a unique multi-functional rotor processor with acetaminophen, which was used as a model drug substance. Experimental design and statistical analysis were used to evaluate potential relationships between three key operating parameters (i.e., the binder flow rate, atomization pressure and rotating speed) and a series of associated micromeritics (i.e., granule mean size, proportion of fine particles (106-212 µm), flowability, roundness and water content). The results of multiple linear regression analysis revealed several trends, including (1) the binder flow rate and atomization pressure had significant positive and negative effects on the granule mean size value, Carr's flowability index, granular roundness and water content, respectively; (2) the proportion of fine particles was positively affected by the product of interaction between the binder flow rate and atomization pressure; and (3) the granular roundness was negatively and positively affected by the product of interactions between the binder flow rate and the atomization pressure, and the binder flow rate and rotating speed, respectively. The results of this study led to the identification of optimal operating conditions for the preparation of granules, and could therefore be used to provide important information for the development of processes for the manufacture of highly drug-loaded fine globular granules.

Comparison of film-coated retarded release pellets manufactured by layering technique or by bed rotor pelletization

In order to investigate the influence of coatings for controlled active pharmaceutical ingredient (API) release, two types of pellets were used. Microcrystalline pellets were coated with a model API using the Wurster fluidized bed technique in laboratory scale (layered Cellets). Another type of pellets consisting of microcrystalline cellulose and model API was manufactured by fluidized bed rotor pelletization (matrix pellets (MP)). Both kinds of pellets were coated in a Wurster fluidized bed process with a polymer mixture of ethylcellulose to achieve retarded API release. With layered Cellets and an increased thickness of the ethylcellulose layer, the lag-time was increased and the release rate was decreased. In the case of MP, retardation was less pronounced probable due to inhomogeneous polymer film formation as a result of the porous particle surface. To reduce the surface roughness, the MP were coated with polyvinylpyrrolidone (PVP) as an intermediate smoothing layer, in a first trial step by step. In a second trial, pelletization and the coating steps were performed in an uninterrupted process. Intermediate PVP coating improved the ethylcellulose film formation and led to a more pronounced retardation of API release. The uninterrupted process of matrix pellet manufacturing and coating results in a product with only low retarded release.

Microscopic image analysis techniques for the morphological characterization of pharmaceutical particles: Influence of the software, and the factor algorithms used in the shape factor estimation

The present report highlights the difficulties of particle shape characterizations of multiparticulate systems obtained using different image analysis techniques. The report describes and discusses a number of shape factors that are widely used in pharmaceutical research. Using photographs of 16 pellets of different shapes, obtained by extrusion-spheronization, we investigated how shape factor estimates vary depending on method of calculation, and among different software packages. The results obtained indicate that the algorithms used (both for estimation of basic dimensions such as perimeter and maximum diameter, and for estimation of shape factors on the basis of these basic dimensions) have marked influences on the shape factor values obtained. These findings suggest that care is required when comparing results obtained using different image analysis programs.

Optimization and scale-up of a fluid bed tangential spray rotogranulation process

The production of pellets in the pharmaceutical industry generally involves multi-step processing: (1) mixing, (2) wet granulation, (3) spheronization and (4) drying. While extrusion-spheronization processes have been popular because of their simplicity, fluid-bed rotogranulation (FBRG) is now being considered as an alternative, since it offers the advantages of combining the different steps into one processing unit, thus reducing processing time and material handling. This work aimed at the development of a FBRG process for the production of pellets in a 4.5-l Glatt GCPG1 tangential spray rotoprocessor and its optimization using factorial design. The factors considered were: (1) rotor disc velocity, (2) gap air pressure, (3) air flow rate, (4) binder spray rate and (5) atomization pressure. The pellets were characterized for their physical properties by measuring size distribution, roundness and flow properties. The results indicated that: pellet mean particle size is negatively affected by air flow rate and rotor plate speed, while binder spray rate has a positive effect on size; pellet flow properties are enhanced by operating with increased air flow rate and worsened with increased binder spray rate. Multiple regression analysis enabled the identification of an optimal operating window for production of acceptable pellets. Scale-up of these operating conditions was tested in a 30-l Glatt GPCG15 FBRG.

Surface Treatment of Indomethacin Agglomerates with Eudragit

Indomethacin is a widely used anti-inflammatory drug with serious side-effects. This drug was used as a model drug for the coating of agglomerates with a permeable film (Eudragit NE). The agglomeration of the crystals increased the flowability of the bulk crystals. The coating further improved the flowability, and also the uniformity of the mass of the filled capsules. The coating film also influenced the wetting of the samples. The coating decreased the surface free energy and therefore reduced the adhesion forces between both the dry and the wet particles. The modification of the flow properties and the even capsule filling can be explained by this phenomenon. Since coating film does not dissolve in the artificial gastric juice, the dissolution test was performed only in the artificial intestinal juice. The dissolution of indomethacin from the coated sample was changed significantly. Accordingly, coating of the crystals can be performed in order to protect the mucosa of the gastrointestinal tract or to promote the preparation of solid dosage form.

Factorial design in the spheronization of ibuprofen microparticulates using the rotor disk fluid-bed technology

The aim of this study was to statistically evaluate the effects of some formulation and process variables in the spheronization of microparticulates of ibuprofen using the rotor disk fluid-bed technology and water as binder. Preliminary studies revealed that presence of surfactant, plate material type, and nature and content of binder influenced the process and quality of the spheronized material. A 2 x 2 x 3 full factorial randomized experiment was designed, demonstrating the influence of these factors on properties such as percent yield, particle size distribution, densities, ibuprofen release, moisture content, etc., as well as their interactions in the experimental response. A response known as the usable fraction was created representing microparticulates of 250 to 850 microm sizes (mesh size 20-60). The reproducibility of the spheronization process was assessed by blocking the experiments with the experiments within the blocks randomly replicated. The main effects included two binder levels (X1), two surfactant levels (X2), and a three-level plate type (X3) in which 2 two-level factors were collapsed into a single three-level factor. The results from the statistical analysis (general linear model, JMP 4) showed that the variables studied had a significant influence on most of the response variables evaluated (p < 0.05), with the binder level proving to be the most significant of the three. There was also significant interaction (p<0.05) between binder level and plate type with the drug content, friability, sphericity, loss on drying (LOD), and usable fraction response variables, and between the binder and the surfactant levels with the drug content, Q20, true density, geometric mean diameter, LOD, and usable fraction responses. High levels of surfactant and binder increased the sphere size, while low levels decreased it. Significant (p < 0.05) interaction was also observed between the plate type and surfactant level with the drug content, geometric mean diameter, and more or less with Q20 and bulk density response variables. Blocking of the experiments had no significant effect on the process and product characteristics analyzed, indicating the reproducibility of the process.

Film coating as a method to enhance the preparation of tablets from dimenhydrinate crystals

Crystals of dimenhydrinate as a model drug were used for crystal coating, a method that can be applied to increase the flowability of a material and facilitate the tablet making. An increase in particle size was observed during the film coating. The change in shape of the coated particles was also examined. Some physicochemical parameters changed during coating, e.g. the surface free energy parameters and the wetting of the samples. The amount of coating material (and therefore the coating time) influenced several parameters (the shape of the particles, the flow properties and surface free energy parameters, compressibility and compactibility). Several parameters of prepared tablet (porosity, breaking hardness) were examined. Accordingly, coating of the crystals can be performed in order to enhance the handling of a material with insufficient properties for tablet making.