Study of the Influence of Spheronization and Drying Conditions on the Physico-Mechanical Properties of Neutral Spheroids Containing Avicel PH 101 and Lactose

Cushioning pellets based on microcrystalline cellulose - Crospovidone blends for MUPS tableting

Compaction of multiple-unit pellet system (MUPS) tablets has been extensively reported to be potentially challenging. Thus, there is a need for non-segregating cushioning agents to mitigate the deleterious effect of the compaction forces. This study was designed to investigate the use of porous pellets as cushioning agents using different drying techniques to prepare pellets of various porosities and of different formulations. The pellets fabricated were characterized for their porosity and crushing strength. Subsequently, MUPS tablets were prepared using blends of polymer-coated pellets and custom-designed cushioning pellets by compacting at different pressures. The effects of pellet volume fraction and dwell time on the pellet coat damage, as well as the tensile strength of the resultant MUPS tablets were also investigated. Compacts with coated pellet volume fraction of 0.21 exhibited the best cushioning effect when tableted at different compression speeds with both gravity and force feeders. The findings from this study showed that cushioning pellet porosity was highest when drying was carried out by freeze drying, followed by fluid bed drying and oven drying. There was an inverse relationship between cushioning pellet porosity and strength. The tensile strength of tablets prepared from freeze dried pellets was highest. The protective effect of the cushioning pellets was principally dependent on their porosity. Also, pellet volume fraction in the compacts and compaction pressure used had remarkable effect on pellet coat damage. When unprocessed powders were compacted by automatic die filling, capping and lamination problems were observed. However, tablets of reasonable quality were made with the cushioning pellets. Freeze dried pellets containing crospovidone were found to be promising as cushioning agents and had enabled the production of MUPS tablets even at higher compaction pressures, beyond the intrinsic crushing strength of the coated pellets.

Influence of the porosity of cushioning excipients on the compaction of coated multi-particulates

The compaction of multiple unit-pellet system (MUPS) tablets poses considerable challenges due to potential compaction-induced damage to the functional polymer coat and segregation of pellets from other excipients during the tableting process. This study was designed to investigate the impact of porous pellets as cushioning agent without issues related to segregation while tableting. Different drying techniques were applied to produce microcrystalline cellulose (MCC) pellets with various porosities. Sodium chloride was also added to the pellet formulation as a pore forming agent to generate a porous skeleton after production and aqueous extraction. The pellets fabricated were characterized for their porosity, crushing strength and yield pressure. Tablets were prepared using unlubricated pellets and their tensile strengths determined. Blends containing polymer-coated pellets and cushioning pellets of various porosities were compacted at different compaction pressures. The porous pellets exhibiting the best cushioning effect were used for MUPS tableting at different compression speeds with both gravity and force feeders. The findings from this study showed that pellet porosity was highest when drying was carried out in a freeze dryer, followed by fluid bed and least porous from the oven. There was an inverse relationship between pellet porosity and strength. The protective effect of cushioning pellets was mainly dependent on their porosity. The porosity of pellets manufactured by leaching NaCl from MCC-NaCl (1:1) pellets were 2.14-, 2.57- and 4.88-fold higher than that of MCC PH101 only pellets for oven, fluid bed and freeze dried pellets, respectively. Although the porosity of MCC PH101-NaCl (1:3) pellets was highest, they exhibited less cushioning effect than MCC PH101-NaCl (1:1). It was inferred that a good balance between porosity and bulk density of cushioning pellets was essential to be effective at protecting the coated pellets from damage during compaction. Compared with MUPS tablets prepared using unprocessed MCC PH105, the tablets prepared with the porous freeze dried MCC PH101 (NaCl fraction leached) pellets had improved drug content uniformity and were mechanically stronger.

Parameters that determine dissolution and efficacy of itraconazole and its relevance to recalcitrant dermatophytoses

INTRODUCTION

Recalcitrant dermatophytoses is on the rise. Though myriad factors contribute to recalcitrance including terbinafine resistance, itraconazole largely remains sensitive. However, there are increasing instances of patients not responding adequately to itraconazole despite low MICs, probably due to issues plaguing the pelletization process, resulting in suboptimal quality. Data on this topic was searched on pubmed using the search items: itraconazole, MIC, MFC, quality, assay, pharmacokinetics, pharmacodynamics, dermatophytoses, and recalcitrance. Areas covered: A detailed analysis of the manufacturing process of itraconazole with emphasis on pelletization and parameters affecting the dissolution and bioavailability is presented. Important formulation factors including drug-polymer ratio, polymer type, coating thickness, bead size, and number are discussed. Also covered is the rationale of dosimetry of itraconazole in dermatophytoses based on the skin pharmacokinetics and MIC of the organism. Expert opinion: The process of pelletization has multiple components aiming to achieve maximum dissolution of the drug. Variations in the process, pellet quality, number, and polymer determine absorption. Morphometric analysis of pellets is a simple method to quantify quality of the drug. Once the process has been standardized, dosimetry depends on the route of secretion and site of infection, accounting for the variation of doses from 100 mg to 400 mg/day.

Theoretical and Experimental Studies of the Controlled Release of Tetracycline Incorporated into Bioactive Glasses

Several authors have studied the release profile of drugs incorporated in different devices. However, to the best of our knowledge, although many studies have been done on the release of tetracycline, in these release devices, no study has investigated if the released compound is actually the tetracycline, or, instead, a degraded product. This approach is exploited here. In this work, we analyse the influence of two drying methods on the tetracycline delivery behaviour of synthesised glasses using the sol-gel process. We compare the drying methods results using both theoretical models and practical essays, and analyse the chemical characteristic of the released product in order to verify if it remains tetracycline. Samples were freeze-dried or dried in an oven at 37°C and characterised by several methods such as Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), thermogravimetric analysis (TG), differential thermogravimetric analysis (DTG), differential thermal analyses (DTA) and gas adsorption analysis (BET). The released concentration of tetracycline hydrochloride was studied as a function of time, and it was measured by ultraviolet spectrophotometry in the tetracycline wavelength. The drug delivery profiles were reasonably consistent with a diffusion model analysis. In addition, we observed higher release rates for the freeze-dried compared to those dried in an oven at 37°C. This higher release can be attributed to larger pore size for the freeze-dried sample systems with tetracycline, which promoted more water penetration, improving the drug diffusion. The analysis of the solution obtained in the release tests using high-performance liquid chromatography- mass spectrometry (HPLC-MS) confirmed that tetracycline was being released.

Miniaturization in pharmaceutical extrusion technology: feeding as a challenge of downscaling

In recent years, extrusion technology has shifted the focus of pharmaceutical research due to versatile applications like pelletization, bioavailability improvement or manipulation of solid-state properties of drugs, continuous granulation, and the development of novel solid dosage forms. Meanwhile, a major effort has been devoted to the miniaturization of equipment in pharmaceutical extrusion technology, particularly with regard to the requirements of the development of new chemical entities and formulations. In the present study, a lab-scale twin-screw extruder was investigated in order to determine the limitations imposed by the feeding systems. The wet extrusion process was considered as challenging because both a powder and a liquid feeder have to be considered. Initially, the accuracy and uniformity of the powder and liquid feeder were tested independently of the extrusion process. After modification of the powder feeder, both feeders were investigated in conjunction with extrusion. Based on this, an optimization of the liquid feeder was required and completed. Both feeder modifications reduced the variability of the moisture content in the extrudates 10-fold. This led to a reliable small-scale extrusion process.

Effects of drying methods on the physicochemical and compressional characteristics of Okra powder and the release properties of its metronidazole tablet formulation

A study has been made of the effects of sun and oven drying methods on the physicochemical characteristics and compressibility of Okra powder and the release properties of its metronidazole tablet formulation. Corn starch was used as the reference standard. The mechanical properties of the tablets were evaluated using crushing strength and friability, while the release properties were determined using the disintegration times and dissolution rates. The results obtained showed that sun-dried Okra powder had smaller particle size, exhibited good flow and possessed higher hydration and swelling capacities compared to the oven dried samples. The compressibility of Okra powders assessed by the indices of plasticity from Heckel (Py) and Kawakita plots (Pk) showed that sun dried Okra powders had higher Py but lower Pk values than the oven-dried Okra powder. Metronidazole tablets formulated with oven dried Okra powder formed stronger tablets than tablets containing sun dried Okra powder. Generally, tablets containing sun dried Okra powders had faster disintegration and dissolution than tablets formulated with oven-dried powder. The results suggest that the choice of drying method during the processing of pharmaceutical raw materials is critical to its physicochemical properties and the release properties of its tablet formulations.

Incidence of drying on microstructure and drug release profiles from tablets of MCC-lactose-Carbopol and MCC-dicalcium phosphate-Carbopol pellets

The influence of intragranular excipients (lactose or dicalcium phosphate) and the drying procedure and conditions (oven-drying and freeze-drying after freezing at -30 or -196 degrees C) on the properties of tablets of MCC-Carbopol pellets was evaluated. The drying procedure caused remarkable differences in pellet size and porosity (freeze-dried pellets were 3-fold more porous than those oven dried). Theophylline release from pellets was completed in less than 30 min and followed first-order kinetics, with a rate closely related to the intragranular porosity. The total porosity of the tablets (5-10%) was conditioned by the compression force (10-20 N), the drying procedure applied to the pellets and the coexcipient nature. Their intergranular porosity ranged inversely to the initial porosity of pellets due to the greater deformability of the most porous ones. A wide range of theophylline release rates were achieved depending on the drying procedure; tablets prepared from freeze-dried pellets sustained the release for 3h. Most profiles showed a bimodal kinetics with an initial zero-order release (while the tablets did not completely disintegrate) that changed, after a certain time, to a first-order kinetics. The intergranular porosity determined drug release rate up to disintegration. Then, the release kinetics became first-order and the rate constant, which was conditioned by the intragranular porosity, showed a complex dependence on the drying procedure, the compression force, and the nature of coexcipient. In sum, the modulation of drug release profiles from tablets of MCC-Carbopol pellets through an adequate control of the effects of the coexcipient nature, the drying procedure of pellets, and the compression force on the inter- and intragranular porosity opens interesting possibilities to control the release of hydrosoluble drugs.

Effects of drying technique on extrusion–spheronisation granules and tablet properties

Extrusion-spheronisation was used to generate smooth, highly spherical granules of a microcrystalline cellulose/propyl gallate/water paste. Freeze-drying retained the shape and size of the granules, whereas oven-drying produced roughened granules due to the uneven shrinkage of the wet powders. Compaction of one size fraction indicated that the granule strength differed noticeably, with the oven-dried samples producing tablets of lower voidage for a given applied compaction pressure. There was a reasonable correlation between tablet crushing strength and voidage. Major differences were observed in tablet dissolution, with the freeze-dried material exhibiting a two-regime behaviour and an initial dissolution rate constant an order of magnitude greater than the oven-dried form. Both the voidage and dissolution characteristics are postulated to be determined by the microstructure established during drying.

Thermogravimetric analysis for the determination of water release rate from microcrystalline cellulose dry powder and wet bead systems

The purpose of this work was to determine the total amount of water contained in dry powder and wet bead samples of microcrystalline cellulose, MCC, (Avicel PH-101), taken from various stages of the extrusion/marumerization process used to make beads and to determine the kinetic rates of water release from each sample. These samples were allowed to equilibrate in controlled humidity chambers at 25 degrees C. The total amount of water in each sample, after equilibration, was determined by thermogravimetric analysis (TGA) as a function of temperature. The rates of water release from these samples were determined by using isothermal gravimetric analysis (ITGA) as a function of time. Analysis of the results for these studies suggest that water was released from these systems by several different kinetic mechanisms. The water release mechanisms for these systems include: zero order, second order, and diffusion controlled kinetics. It is believed that all three kinetic mechanisms will occur at the same time, however; only one mechanism will be prominent. The prominent mechanism was based on the amount of water present in the sample.

Drying of poloxamer hydrogel films

The drying of hydrogel films formed by Poloxamer 407 poly(ethylene oxide)-poly(propylene oxide)-poly(ethylene oxide) amphiphilic block copolymer was investigated at various air relative humidity (RH) conditions ranging from 11 to 97%. Initially, the amount of water lost increased linearly with the drying time. After this linear region (stage I), a nonlinear behavior was observed (stage II). The drying rate increased with decreasing RH, thus greatly shortening the drying time. A decrease of the film thickness also shortened the drying time; however, the drying mechanism did not change. Three models for one-dimensional water diffusion were used to fit the experimental results at different RH conditions and film thicknesses. Model 1 assumes semi-infinite medium and constant diffusion coefficient, and fits very well the data in stage I of the drying process. The fitted water diffusion coefficient (D) is 5 x 10(-10) m(2)/s, whereas the effects of the RH are captured by a proportionality constant (alpha) that appears in the boundary condition. Model 2 considers a finite (constant) film thickness and captures the experimental observations over the whole drying period for the same D and alpha as in Model 1. The analytical solutions available for Models 1 and 2, used together with the experimentally derived model parameters D and alpha, allow for easy estimation of drying time and water loss from Poloxamer hydrogel films of various compositions and thicknesses and at different relative humidities. Numerical solutions for water diffusion under conditions of decreasing film thickness and diffusion coefficient being a function of concentration are also presented (Model 3). It becomes apparent from the fit of the data to the different models that the drying rate is more sensitive to the boundary condition at the film-air interface (represented by alpha) than to the diffusion in the film. It is notable that the alpha values obtained from the fits of the Poloxamer hydrogel drying rate are comparable to those obtained from drying of water films under the same experimental conditions.

A study on the effect of drying techniques on the mechanical properties of pellets and compacted pellets

Microcrystalline cellulose (MCC) pellets produced by a standard extrusions/spheronisation process with a 40% ethanol/water mixture as the fluid component, were dried by four different techniques, namely: freeze-drying, fluid-bed drying, hot air oven drying and desiccation with silica-gel to less than 5% (w/w) water content. A 1.0-1.18mm size fraction of the dried pellets were characterised structurally and mechanically in terms of, shape, density/porosity (open and closed), pore volume/pore volume distribution, surface area, surface tensile strength, shear strength, deformability, linear strain and elastic modulus. An amount of 600, 700 and 750mg of the same size fraction of each pellet batch were compacted to the same tablet thickness and the tensile strength and volumetric elastic recovery of the resulted compacts were determined. Analysis of variance was used to assess the significance of the drying process on the property of the pellets and their compacts. The drying process did not influence the shape of the pellets, but all the other properties were affected to some extent. Pellets dried by freeze-drying were more porous, with most of the pores open to the atmosphere and had a higher surface area than pellets dried by the other methods. Pellets dried by desiccation contained the highest proportion of closed pores. The decrease in tensile strength of the pellets, which occurred with the increase in porosity could presumably be due to ease of crack initiation and propagation between the MCC fibres. The weaker pellets broke instantly before they were subjected to appreciable strain. The porous pellets needed a higher compressing pressure and work of compaction to produce tablets of the same mass and dimensions. This reflected their compressibility, i.e. relative decrease in volume of the pellet bed during compression. The strength and volumetric elastic recovery of the compacts increased with the increase of their porosity. The drying techniques, which produced porous, deformable and weak pellets, produced stronger tablets. The value of the volumetric elastic recovery of the compacts was also observed to increase with the value of compaction pressure.

Effect of drying rate on porosity and tabletting behaviour of cellulose pellets

The purpose of this study was to investigate the effect of drying rate during static drying on certain physical properties of pellets. Pellets were prepared from microcrystalline cellulose by granulation with different agglomeration liquids (various ethanol/water ratios) and thereafter dried without agitation at different drying rates. The dry pellets were characterised with respect to their shape, porosity, and compression shear strength and the tensile strength of tablets formed from pellets with low and high drying rates was determined. Drying of the pellets occurred at a falling rate and the reduction in liquid content with time obeyed a first order type of relationship. An increased drying rate did not affect the shape and surface texture of the dried pellets and did not cause them to fracture. However, the drying conditions did affect pellet porosity, with an increased drying rate resulting in more porous pellets. Through a relationship with pellet porosity, the drying rate also affected the deformability of the pellets (as assessed from Kawakita 1/b values) and their ability to form tablets. Owing to a strong effect of porosity on pellet compactability, marked changes in tablet tensile strength with variations in drying rate may be obtained.

Drying behaviour of two sets of microcrystalline cellulose pellets

The objective was to study contraction and densification of two sets of microcrystalline cellulose pellets, prepared using water (W) or a 25/75% w/w water/ethanol (W/E) mixture, during drying. The pellets were dried on microscope slides, photographed and weighed at set times. The porosity of the dry pellets was determined by mercury pycnometry. From pellet size, weight and porosity data, contraction and densification of the pellets and the relationship of these to the liquid content of the pellets during drying were calculated. Both types of pellets contracted and densified during drying. The initial porosity was similar for both types, but the final porosity of the dry pellets was higher for the W/E pellets. Thus, the difference in final pellet porosity between the two types was caused by a difference in densification during drying rather than a different degree of densification during the pelletisation procedure. The contraction rate and the relationships between contraction and the volume of removed liquid, and contraction and the degree of liquid saturation differed between the two types of pellet. The difference in drying behaviour between the two types of pellets can be explained by a liquid related change in both contraction driving force and contraction counteracting force or by a different contraction mechanism.

Emulsion/solvent evaporation as an alternative technique in pellet preparation

Paracetamol/Eudragit RS, paracetamol/ethylcellulose, and paracetamol/cellulose acetate pellets of different drug/polymer ratios (w/w) were prepared by the dissolution/solvent evaporation technique. These pellets were then characterized by particle size distribution analysis, ultraviolet (UV) spectroscopy, differential thermal analysis, and scanning electron microscopy (SEM). Hard gelatin capsules were filled with each particle size fraction of these pellets, and in vitro dissolution studies were performed to verify the capability of each series of pellets to control drug release. Pellets were spherical, presented a polynucleated microcapsule structure, and under certain experimental conditions, the yield of the preparation process reached very high values. The dissolution studies pointed out the slow paracetamol release from these pellets.

The effect of humidity on samples of microcrystalline cellulose taken from the extrusion/marumerization process

The purpose of this work was to examine the sorption and desorption of water by various samples of microcrystalline cellulose, MCC (Avicel PH-101), taken from the extrusion/marumerization process, and to provide data that may explain how water affects the MCC polymer matrix during the formation of beads. Two isopiestic (humidity) studies were conducted: the first used samples exposed directly to controlled humidity conditions, whereas the second used samples that were freeze-dried before being exposed to controlled humidity conditions. Water sorption and desorption were determined gravimetrically. When both sets of samples were initially exposed to low-humidity conditions, they reached equilibrium by desorbing water. When these samples were initially exposed to high-humidity conditions, the high moisture content samples desorbed water, whereas the low moisture content and the freeze-dried samples sorbed water to reach equilibrium. When the first set of samples was initially exposed to high- and then to low-humidity conditions, they reached the same water content achieved by being equilibrated directly at the low-humidity condition. However, samples that were initially exposed to low- and then to high-humidity conditions had equilibrium water contents that were lower than those achieved by being equilibrated directly at the high-humidity condition. The original MCC systems exhibit a hysteretic effect above 85%, whereas the freeze-dried systems have a broader range hysteretic effect starting at 20% relative humidity. The results suggest that the internal structure of the MCC polymer fibers must change with the sorption and desorption of water, supporting the autohesion theory.

Extrusion and spheronization in the development of oral controlled-release dosage forms

The concept of multiparticulate dosage forms was introduced in the 1950s. With the increasing use of multiparticulate controlled release (CR) oral dosage forms, in recent times there has been a rise in interest in the methods of preparing these dosage forms. A method that has gained increased usage over the past few years is that of extrusion and spheronization. It has been extensively explored as a potential technique and also as a future method of choice for preparation of multiparticulate CR dosage forms. In this review an attempt is made to outline the general process of extrusion and spheronization and to assess its importance in the development of multiparticulate CR oral dosage forms.

Formulation and in vitro and in vivo availability of diclofenac sodium enteric-coated beads

Diclofenac sodium enteric-coated beads were prepared using the conventional pan coating technique. Eudragit L100 was used as a pH-dependent release-controlling polymer. The beads were evaluated for their particle size distribution, drug loading efficiency, flowability, in vitro release in 0.1 N HCl (pH 1.2) and phosphate buffer (pH 6.8), and bioavailability in beagle dogs relative to the commercial enteric-coated tablets Voltaren. The beads showed a narrow particle size distribution in which 83% of the beads were in the range of 1-2 mm. The actual yield of the beads was 90.5% and their drug loading was 92%. The beads released about 8% of the drug during 2 hr of dissolution in 0.1 N HCl, and the commercial tablets released no drug. In phosphate buffer (pH 6.8) both formulations released their drug content in 1 hr. Both formulations are, therefore, in compliance with the USP requirements for release from enteric-coated dosage forms. The in vivo availability study in six beagle dogs revealed that the formulated enteric-coated beads filled in hard gelatin capsules had a 197.54% bioavailability relative to that of the commercial Voltaren tablets. The tablets showed a significantly lower (p < 0.05) area under curve for 0-8 hr (AUC0-8 hr) of 13.44 +/- 15.02 micrograms hr/ml compared to 26.55 +/- 5.19 micrograms hr/ml for the capsules. The capsules showed a nonsignificantly (p > 0.05) higher peak plasma concentration (Cmax) of 6.77 +/- 0.67 micrograms/ml compared to 5.88 +/- 7.38 micrograms/ml for the tablets. The time to reach peak (Tmax) values were 2 +/- 1.48 and 2.25 +/- 1.08 hr for the capsules and tablets, respectively. The capsules showed less interdog variability with respect to Cmax (CV% 34.6) and AUC (CV% 19.55) compared to CV% 79.9 and 111.76, respectively, for the commercial tablets.

Comparison between a twin-screw extruder and a rotary ring die press. Part II: influence of process variables

The influence of different processing steps on pellet quality was investigated: granulation/extrusion and spheronization. Pellets were produced at two levels of water content on two different types of extruders: a twin screw extruder and a rotary ring die press. In order to control the spheronization process each extrudate was rounded in two spheronizers using two radial velocities, respectively. Pellet shape and size were selected to describe the pellet quality. Under constant spheronization conditions the extrudates behaved dissimilar on the two spheronizers. This could be attributed to the geometry of the friction plates. The spheronizer with the rougher surface applied more mechanical energy to the extrudate and wet pellets which reduced the water content necessary for the formation of good pellets. Eliminating the influence of the spheronization process, high differences were observed in the quality of the extrudates produced by the two extruders. This confirmed the results from the first part of this study. Due to the crystallite-gel-model the different extruder types apply different mechanical stress on the extrudate which affect the network structure of the microcrystalline cellulose gel. The twin-screw extruder produced a more delicate network with a lower water movement. This led to a shift of the optimal moisture content towards higher values. Compared with spheronization, process changes in the granulation/extrusion process were more critical.

Mechanical properties of single pellets containing acrylic polymers

Three aqueous-based acrylic latex dispersions, Eudragit L 30 D, NE 30 D, and RS 30 D, were incorporated as granulating binders into a powder blend of microcrystalline cellulose and anhydrous lactose by wet massing. Spheronized pellets were prepared by extrusion-spheronization and the mechanical properties of single pellets, including the tensile strength at break and the Young's modulus were determined from the stress-strain profiles using a Chatillon TCD-200 tension/compression digital test gauge. The influence of particle size and plasticizer on the mechanical properties of pellets containing Eudragit RS 30 D was investigated. All bead formulations deformed by brittle fracture under a diametral compression force. The mechanical strength was found to be influenced by the adhesive strength between the polymers and the powder particles instead of the cohesive strength of each polymer. The Young's modulus and the tensile strength were also significantly influenced by the type and concentration of polymer, the presence of plasticizer, and the particle size of the beads. The results were related to the properties of the polymers and the fracture mechanisms of the beads. Furthermore, the polymer type and the incorporation of plasticizer influenced the susceptibility of the moistened extruded granules to the shearing forces during the spheronization process, which influenced the surface morphological properties of the pellets.