Application of Dominance-Based Rough Set Approach for Optimization of Pellets Tableting Process

Native starch derived from different botanical sources as an effective co-cushioning agent in MUPS tablets

Compaction of sustained release coated pellets into multi-unit pellet system (MUPS) tablets has been associated with damage to the functional polymer layer, leading to a loss in desired sustained release function. Many filler materials and complex processes have been studied on their ability to mitigate compaction-induced pellet coat damage. Among these, native or unprocessed starches included in the filler material have not been explored well despite being a simple strategy. Sustained release pellets with ethylcellulose or acrylic coats were compacted into MUPS tablets with different filler materials, containing microcrystalline cellulose and native starch at 25 %, w/w or 40 %, w/w derived from rice, tapioca, corn, or potato. The MUPS tablet tensile strength and the extent of pellet coat damage were evaluated. Although starch weakened the tablets, rice and tapioca starch significantly mitigated pellet coat damage the most by 10 - 44 % (p < 0.008). Higher starch concentrations and higher compaction pressures led to a greater cushioning effect, which was indicated to result from reduced plastic deformation and increased particle rearrangement of the filler material. Pellets coated with acrylic benefitted more from starch and experienced less coat damage than pellets with ethylcellulose coats. This research demonstrates the use of native starches as a simple method to mitigate pellet coat damage in MUPS tablets.

Cushion-coated pellets for tableting without external excipients

Multiple-unit dosage forms prepared by compacting pellets offer important manufacturing and compliance advantages over pellet-filled capsules. However, compaction may negatively affect the release control mechanism of pellets, and subunits may not be readily available after intake. Application of a cushioning layer to the starting units is here proposed as a strategy to obtain tablets with satisfactory mechanical strength, rapid disintegration and maintenance of the expected release profile of individual subunits while avoiding the use of mixtures of pellets and excipients to promote compaction and limit the impact of the forces involved. Cushion-coating with PEG1500, a soft and soluble material, was proved feasible provided that the processing temperature was adequately controlled. Cushioned gastro-resistant pellets were shown to consolidate under relatively low compaction pressures, which preserved their inherent release performance after tablet disintegration. Adhesion problems associated with the use of PEG1500 were overcome by applying an outer Kollicoat® IR film. Through design of experiment (DoE), robustness of the proposed approach was demonstrated, and the formulation as well as tableting conditions were optimized. The tableted cushion-coated pellet systems manufactured would allow a relatively high load of modified-release units to be conveyed, thus setting out a versatile and scalable approach to oral administration of multiple-unit dosage forms.