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Sohail Arshad M, Zafar S, Yousef B, Alyassin Y, Ali R, AlAsiri A, Chang MW, Ahmad Z, Ali Elkordy A, Faheem A, Pitt K. A review of emerging technologies enabling improved solid oral dosage form manufacturing and processing. Adv Drug Deliv Rev 2021; 178:113840. [PMID: 34147533 DOI: 10.1016/j.addr.2021.113840] [Citation(s) in RCA: 27] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2021] [Revised: 06/08/2021] [Accepted: 06/14/2021] [Indexed: 12/20/2022]
Abstract
Tablets are the most widely utilized solid oral dosage forms because of the advantages of self-administration, stability, ease of handling, transportation, and good patient compliance. Over time, extensive advances have been made in tableting technology. This review aims to provide an insight about the advances in tablet excipients, manufacturing, analytical techniques and deployment of Quality by Design (QbD). Various excipients offering novel functionalities such as solubility enhancement, super-disintegration, taste masking and drug release modifications have been developed. Furthermore, co-processed multifunctional ready-to-use excipients, particularly for tablet dosage forms, have benefitted manufacturing with shorter processing times. Advances in granulation methods, including moist, thermal adhesion, steam, melt, freeze, foam, reverse wet and pneumatic dry granulation, have been proposed to improve product and process performance. Furthermore, methods for particle engineering including hot melt extrusion, extrusion-spheronization, injection molding, spray drying / congealing, co-precipitation and nanotechnology-based approaches have been employed to produce robust tablet formulations. A wide range of tableting technologies including rapidly disintegrating, matrix, tablet-in-tablet, tablet-in-capsule, multilayer tablets and multiparticulate systems have been developed to achieve customized formulation performance. In addition to conventional invasive characterization methods, novel techniques based on laser, tomography, fluorescence, spectroscopy and acoustic approaches have been developed to assess the physical-mechanical attributes of tablet formulations in a non- or minimally invasive manner. Conventional UV-Visible spectroscopy method has been improved (e.g. fiber-optic probes and UV imaging-based approaches) to efficiently record the dissolution profile of tablet formulations. Numerous modifications in tableting presses have also been made to aid machine product changeover, cleaning, and enhance efficiency and productivity. Various process analytical technologies have been employed to track the formulation properties and critical process parameters. These advances will contribute to a strategy for robust tablet dosage forms with excellent performance attributes.
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Affiliation(s)
| | - Saman Zafar
- Faculty of Pharmacy, Bahauddin Zakariya University, Multan, Pakistan
| | - Bushra Yousef
- Leicester School of Pharmacy, De Montfort University, Leicester, United Kingdom
| | - Yasmine Alyassin
- Leicester School of Pharmacy, De Montfort University, Leicester, United Kingdom
| | - Radeyah Ali
- Leicester School of Pharmacy, De Montfort University, Leicester, United Kingdom
| | - Ali AlAsiri
- Leicester School of Pharmacy, De Montfort University, Leicester, United Kingdom; Pharmacy College, Pharmaceutics Department, Najran University, Najran, Saudi Arabia
| | - Ming-Wei Chang
- Nanotechnology and Integrated Bioengineering Centre, University of Ulster, Jordanstown Campus, Newtownabbey BT37 0QB, Northern Ireland, United Kingdom
| | - Zeeshan Ahmad
- Leicester School of Pharmacy, De Montfort University, Leicester, United Kingdom
| | - Amal Ali Elkordy
- School of Pharmacy and Pharmaceutical Sciences, Faculty of Health Sciences and Wellbeing,University of Sunderland, Sunderland, United Kingdom
| | - Ahmed Faheem
- School of Pharmacy and Pharmaceutical Sciences, Faculty of Health Sciences and Wellbeing,University of Sunderland, Sunderland, United Kingdom; Faculty of Pharmacy, University of Tanta, Tanta, Egypt
| | - Kendal Pitt
- Manufacturing, Science & Technology, Pharma Supply Chain, GlaxoSmithKline, Ware, United Kingdom.
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DUAN CS, CAI WS, SHAO XG. Multivariate Optical Computing and Next-generation Spectrometer. CHINESE JOURNAL OF ANALYTICAL CHEMISTRY 2021. [DOI: 10.1016/s1872-2040(21)60093-2] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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Model-Based Scale-Up Methodologies for Pharmaceutical Granulation. Pharmaceutics 2020; 12:pharmaceutics12050453. [PMID: 32423051 PMCID: PMC7284585 DOI: 10.3390/pharmaceutics12050453] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2020] [Revised: 05/09/2020] [Accepted: 05/11/2020] [Indexed: 12/13/2022] Open
Abstract
In the pharmaceutical industry, it is a major challenge to maintain consistent quality of drug products when the batch scale of a process is changed from a laboratory scale to a pilot or commercial scale. Generally, a pharmaceutical manufacturing process involves various unit operations, such as blending, granulation, milling, tableting and coating and the process parameters of a unit operation have significant effects on the quality of the drug product. Depending on the change in batch scale, various process parameters should be strategically controlled to ensure consistent quality attributes of a drug product. In particular, the granulation may be significantly influenced by scale variation as a result of changes in various process parameters and equipment geometry. In this study, model-based scale-up methodologies for pharmaceutical granulation are presented, along with data from various related reports. The first is an engineering-based modeling method that uses dimensionless numbers based on process similarity. The second is a process analytical technology-based modeling method that maintains the desired quality attributes through flexible adjustment of process parameters by monitoring the quality attributes of process products in real time. The third is a physics-based modeling method that involves a process simulation that understands and predicts drug quality through calculation of the behavior of the process using physics related to the process. The applications of these three scale-up methods are summarized according to granulation mechanisms, such as wet granulation and dry granulation. This review shows that these model-based scale-up methodologies provide a systematic process strategy that can ensure the quality of drug products in the pharmaceutical industry.
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Henriques J, Cardoso C, Vitorino C. On demand for new process analytical technologies applied to injectable drug products. Eur J Pharm Sci 2019; 137:104975. [PMID: 31252050 DOI: 10.1016/j.ejps.2019.104975] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/05/2019] [Revised: 06/07/2019] [Accepted: 06/25/2019] [Indexed: 11/19/2022]
Abstract
Currently, in the pharmaceutical manufacturing process of injectable drug products, quality is still assessed under a quality-by-test system, wherein the product quality is evaluated at fixed manufacturing steps and in the end product. The introduction of the quality by design (QbD) approach, supported on process analytical technologies (PAT) is changing this paradigm. Efficiently understanding the process parameters and material attributes and how they affect the quality profile of the final product is increasingly a real need. In this context, all manufacturing steps should be ideally monitored as they are carried out, following the evolution of quality throughout the entire process. The PAT application to injectable drug products is still in its infancy since several constraints are raised mainly due to the solvent influence. This mini-review aims at identifying PAT potentially suitable for injectable analysis and foster their adoption by the pharmaceutical industries in their industrial processes, paving the way to enhanced quality and efficient processes.
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Affiliation(s)
- João Henriques
- Faculty of Pharmacy, University of Coimbra, Pólo das Ciências da Saúde, Azinhaga de Santa Comba, 3000-548 Coimbra, Portugal; Coimbra Chemistry Centre, Department of Chemistry, University of Coimbra, Coimbra, Portugal
| | - Catarina Cardoso
- Laboratórios Basi, Parque Industrial Manuel Lourenço Ferreira, lote 15, 3450-232 Mortágua, Portugal
| | - Carla Vitorino
- Faculty of Pharmacy, University of Coimbra, Pólo das Ciências da Saúde, Azinhaga de Santa Comba, 3000-548 Coimbra, Portugal; Coimbra Chemistry Centre, Department of Chemistry, University of Coimbra, Coimbra, Portugal; Center for Neurosciences and Cell Biology (CNC), University of Coimbra, Rua Larga, Faculty of Medicine, Pólo I, 1st floor, 3004-504 Coimbra, Portugal.
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Khan M, Reza MQ, Salhan AK, Sirdeshmukh SP. Acoustic resonance spectroscopy based simple system for spectral characterization and classification of materials. JOURNAL OF INTELLIGENT & FUZZY SYSTEMS 2019. [DOI: 10.3233/jifs-169994] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Affiliation(s)
- Munna Khan
- Department of Electrical Engineering, Faculty of Engineering and Technology, Jamia Millia Islamia, Delhi, India
| | - Md Qaiser Reza
- Department of Electrical Engineering, Faculty of Engineering and Technology, Jamia Millia Islamia, Delhi, India
| | | | - Shaila P.S.M.A. Sirdeshmukh
- Department of Electrical Engineering, Faculty of Engineering and Technology, Jamia Millia Islamia, Delhi, India
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Emerging technologies for the non-invasive characterization of physical-mechanical properties of tablets. Int J Pharm 2017; 532:299-312. [DOI: 10.1016/j.ijpharm.2017.09.009] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/16/2017] [Revised: 08/31/2017] [Accepted: 09/04/2017] [Indexed: 11/22/2022]
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Laske S, Paudel A, Scheibelhofer O, Sacher S, Hoermann T, Khinast J, Kelly A, Rantannen J, Korhonen O, Stauffer F, De Leersnyder F, De Beer T, Mantanus J, Chavez PF, Thoorens B, Ghiotti P, Schubert M, Tajarobi P, Haeffler G, Lakio S, Fransson M, Sparen A, Abrahmsen-Alami S, Folestad S, Funke A, Backx I, Kavsek B, Kjell F, Michaelis M, Page T, Palmer J, Schaepman A, Sekulic S, Hammond S, Braun B, Colegrove B. A Review of PAT Strategies in Secondary Solid Oral Dosage Manufacturing of Small Molecules. J Pharm Sci 2017; 106:667-712. [DOI: 10.1016/j.xphs.2016.11.011] [Citation(s) in RCA: 56] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/22/2016] [Revised: 10/14/2016] [Accepted: 11/08/2016] [Indexed: 12/14/2022]
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Stelzer T, Wong SY, Chen J, Myerson AS. Evaluation of PAT Methods for Potential Application in Small-Scale, Multipurpose Pharmaceutical Manufacturing Platforms. Org Process Res Dev 2016. [DOI: 10.1021/acs.oprd.6b00129] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/20/2023]
Affiliation(s)
- Torsten Stelzer
- Department of Chemical Engineering, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139, United States
| | - Shin Yee Wong
- Department of Chemical Engineering, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139, United States
| | - Jie Chen
- Department of Chemical Engineering, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139, United States
| | - Allan S. Myerson
- Department of Chemical Engineering, Massachusetts Institute of Technology, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139, United States
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Shah IG, Ely KJ, Stagner WC. Effect of Tapped Density, Compacted Density, and Drug Concentration on Light-Induced Fluorescence Response as a Process Analytical Tool. J Pharm Sci 2015; 104:1732-40. [DOI: 10.1002/jps.24386] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2014] [Accepted: 01/21/2015] [Indexed: 11/06/2022]
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Stephens JD, Kowalczyk BR, Hancock BC, Kaul G, Cetinkaya C. Ultrasonic real-time in-die monitoring of the tablet compaction process—A proof of concept study. Int J Pharm 2013; 442:20-6. [DOI: 10.1016/j.ijpharm.2012.09.014] [Citation(s) in RCA: 9] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2012] [Revised: 09/07/2012] [Accepted: 09/08/2012] [Indexed: 10/27/2022]
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Stephens J, Lakshmaiah M, Kowalczyk B, Hancock B, Cetinkaya C. Wireless transmission of ultrasonic waveforms for monitoring drug tablet properties and defects. Int J Pharm 2013; 442:35-41. [DOI: 10.1016/j.ijpharm.2012.08.050] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/06/2012] [Revised: 08/29/2012] [Accepted: 08/29/2012] [Indexed: 11/15/2022]
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Process analytical technology (PAT) for biopharmaceutical products. Anal Bioanal Chem 2010; 398:137-54. [DOI: 10.1007/s00216-010-3781-x] [Citation(s) in RCA: 227] [Impact Index Per Article: 16.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/26/2010] [Revised: 04/20/2010] [Accepted: 04/23/2010] [Indexed: 11/27/2022]
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Integrated Sensing and Processing—Acoustic Resonance Spectrometry (ISP-ARS) in Differentiating d-Tagatose and Other Toll Manufactured Drugs. J Pharm Innov 2008. [DOI: 10.1007/s12247-008-9038-y] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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Medendorp JP, Fackler JA, Douglas CC, Lodder RA. Integrated Sensing and Processing Acoustic Resonance Spectrometry (ISP-ARS) for Sample Classification. J Pharm Innov 2007. [DOI: 10.1007/s12247-007-9014-y] [Citation(s) in RCA: 11] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
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