Wet granulation in rotary processor and fluid bed: comparison of granule and tablet properties

On demand for new process analytical technologies applied to injectable drug products

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.

Process analytical techniques for hot-melt extrusion and their application to amorphous solid dispersions

Newly developed active pharmaceutical ingredients (APIs) are often poorly soluble in water. As a result the bioavailability of the API in the human body is reduced. One approach to overcome this restriction is the formulation of amorphous solid dispersions (ASDs), e.g., by hot-melt extrusion (HME). Thus, the poorly soluble crystalline form of the API is transferred into a more soluble amorphous form. To reach this aim in HME, the APIs are embedded in a polymer matrix. The resulting amorphous solid dispersions may contain small amounts of residual crystallinity and have the tendency to recrystallize. For the controlled release of the API in the final drug product the amount of crystallinity has to be known. This review assesses the available analytical methods that have been recently used for the characterization of ASDs and the quantification of crystalline API content. Well-established techniques like near- and mid-infrared spectroscopy (NIR and MIR, respectively), Raman spectroscopy, and emerging ones like UV/VIS, terahertz, and ultrasonic spectroscopy are considered in detail. Furthermore, their advantages and limitations are discussed with regard to general practical applicability as process analytical technology (PAT) tools in industrial manufacturing. The review focuses on spectroscopic methods which have been proven as most suitable for in-line and on-line process analytics. Further aspects are spectroscopic techniques that have been or could be integrated into an extruder.

Mathematical models for the acoustic response of a solids-loaded encapsulated bubble

A method of active acoustic resonance interference spectroscopy is introduced for estimation of bubble properties. A modified form of Rayleigh-Plesset equation for forced oscillation of either a single free bubble or elastic shell encapsulated microbubble with attached solids loading is solved by the regular perturbation method for steady oscillatory solutions as a result of small amplitude acoustic excitation by a point sinusoidal oscillator. A model for the total pressure field at an acoustic receiver in an incompressible liquid is then solved by the regular perturbation method. Closed-form analytical solutions are found for pressure power at the acoustic receiver as a function of the excitation frequency and strength; the properties of the bubble, liquid, and encapsulating shell; and the geometry of the active monitoring system. The receiver pressure power exhibits a maximum due to bubble resonance and a minimum due to destructive interference between source and bubble response pressure fields at higher excitation frequencies. The inverse problem is solved to derive unique closed-form analytical estimators for bubble equilibrium size, attached solids mass loading, and encapsulating layer dilatational viscosity as a function of the frequencies of the fundamental resonance maximum, interference minimum, second harmonic maximum total average acoustic power, monitoring system, and phase properties.

Analytical technologies for real-time drug dissolution and precipitation testing on a small scale

Objectives

This review focuses on real-time analytics of drug dissolution and precipitation testing on a comparatively small scale.

Key findings

Miniaturisation of test equipment is an important trend in pharmaceutics, and several small-scale experiments have been reported for drug dissolution and precipitation testing. Such tests typically employ analytics in real-time. Fibre optic ultraviolet (UV) analytics has become a well-established method in this field. Novel imaging techniques are emerging that use visible or UV light; also promising is Fourier transform infrared imaging based on attenuated total reflection. More information than just a rate constant is obtained from these methods. The early phase of a dissolution process can be assessed and drug precipitation may eventually be observed. Some real-time techniques are particularly well suited to studying drug precipitation during formulation dispersion; for example, turbidity, focused beam reflectance measurement and Raman spectroscopy.

Summary

Small-scale dissolution tests equipped with real-time analytics have become important to screen drug candidates as well as to study prototype formulations in early development. Future approaches are likely to combine different analytical techniques including imaging. Miniaturisation started with mini-vessels or small vials and future assays of dissolution research will probably more often reach the level of parallel well plates and microfluidic channels.

Comparison of high-resolution ultrasonic resonator technology and Raman spectroscopy as novel process analytical tools for drug quantification in self-emulsifying drug delivery systems

Self-emulsifying drug delivery systems (SEDDS) are complex mixtures in which drug quantification can become a challenging task. Thus, a general need exists for novel analytical methods and a particular interest lies in techniques with the potential for process monitoring. This article compares Raman spectroscopy with high-resolution ultrasonic resonator technology (URT) for drug quantification in SEDDS. The model drugs fenofibrate, indomethacin, and probucol were quantitatively assayed in different self-emulsifying formulations. We measured ultrasound velocity and attenuation in the bulk formulation containing drug at different concentrations. The formulations were also studied by Raman spectroscopy. We used both, an in-line immersion probe for the bulk formulation and a multi-fiber sensor for measuring through hard-gelatin capsules that were filled with SEDDS. Each method was assessed by calculating the relative standard error of prediction (RSEP) as well as the limit of quantification (LOQ) and the mean recovery. Raman spectroscopy led to excellent calibration models for the bulk formulation as well as the capsules. The RSEP depended on the SEDDS type with values of 1.5-3.8%, while LOQ was between 0.04 and 0.35% (w/w) for drug quantification in the bulk. Similarly, the analysis of the capsules led to RSEP of 1.9-6.5% and LOQ of 0.01-0.41% (w/w). On the other hand, ultrasound attenuation resulted in RSEP of 2.3-4.4% and LOQ of 0.1-0.6% (w/w). Moreover, ultrasound velocity provided an interesting analytical response in cases where the drug strongly affected the density or compressibility of the SEDDS. We conclude that ultrasonic resonator technology and Raman spectroscopy constitute suitable methods for drug quantification in SEDDS, which is promising for their use as process analytical technologies.

Investigation of a 2-step agglomeration process performed in a rotary processor using polyethylene glycol solutions as the primary binder liquid

The purpose of this research was to investigate the use of polyethylene glycol (PEG) solutions as the primary binder liquid in a 2-step agglomeration process performed in a rotary processor and characterize the resulting granules and their tableting characteristics. This was done by granulation of binary mixtures of microcrystalline cellulose (MCC) and either lactose, calcium phosphate, acetaminophen, or theophylline, in a 1:3 ratio, using a 50% (wt/wt) aqueous solution of PEG and water as the binder liquid. Formulations containing lactose were agglomerated using 5 different amounts of the PEG binder solution, giving rise to a PEG content in the range of 6% to 43% (wt/wt). The process outcome was characterized according to adhesion, yield, and water requirement, and the prepared granules were characterized according to size, size distribution, and flow properties as well as tableting properties. The agglomeration of all mixtures resulted in high yields of free-flowing agglomerates and gave rise to good reproducibility of the investigated agglomerate characteristics. The process allowed for the incorporation of 42.5% (wt/wt) PEG, which is higher than the percentage of PEG reported for other equipment. Tablets of sufficient strength could be prepared with all investigated excipients using 20% wt/wt PEG; higher PEG contents gave rise to adhesion and prolonged disintegration. In conclusion, agglomeration in a torque-controlled rotary processor using solutions of PEG as the primary binder liquid was found to be a robust process, suitable for the incorporation of high contents of PEG and/or drug compounds.