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Tacsi K, Stoffán G, Galata DL, Pusztai É, Gyürkés M, Nagy B, Szilágyi B, Nagy ZK, Marosi G, Pataki H. Improvement of drug processability in a connected continuous crystallizer system using formulation additive. Int J Pharm 2023; 635:122725. [PMID: 36804519 DOI: 10.1016/j.ijpharm.2023.122725] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/21/2022] [Revised: 01/17/2023] [Accepted: 02/11/2023] [Indexed: 02/19/2023]
Abstract
Continuous crystallization in the presence of polymer additives is a promising method to omit some drug formulation steps by improving the technological and also pharmacological properties of crystalline active ingredients. Accordingly, this study focuses on developing an additive-assisted continuous crystallization process using polyvinylpyrrolidone in a connected ultrasonicated plug flow crystallizer and an overflow mixed suspension mixed product removal (MSMPR) crystallizer system. We aimed to improve the flowability characteristics of small, columnar primary plug flow crystallizer-produced acetylsalicylic acid crystals as a model drug by promoting their agglomeration in MSMPR crystallizer with polyvinylpyrrolidone. The impact of the cooling antisolvent crystallization process parameters (temperature, polymer amount, total flow rate) on product quality and quantity was investigated. Finally, a spatially segmented antisolvent dosing method was also evaluated. The developed technology enabled the manufacture of purified, constant quality products in a short startup period, even with an 85% yield. We found that a higher polymer amount (7.5-14%) could facilitate agglomeration resulting in "good" flowability without altering the favorable dissolution characteristics of the primary particles.
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Affiliation(s)
- Kornélia Tacsi
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary.
| | - György Stoffán
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Dorián László Galata
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Éva Pusztai
- Department of Chemical and Environmental Process Engineering, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Martin Gyürkés
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Botond Szilágyi
- Department of Chemical and Environmental Process Engineering, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Zsombor Kristóf Nagy
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Department of Organic Chemistry and Technology, Faculty of Chemical Technology and Biotechnology, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, Hungary.
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Tacsi K, Stoffán G, Pusztai É, Nagy B, Domokos A, Szilágyi B, Nagy ZK, Marosi G, Pataki H. Implementation of sonicated continuous plug flow crystallization technology for processing of acetylsalicylic acid reaction mixture. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117255] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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Domokos A, Madarász L, Stoffán G, Tacsi K, Galata D, Csorba K, Vass P, Nagy ZK, Pataki H. Real-Time Monitoring of Continuous Pharmaceutical Mixed Suspension Mixed Product Removal Crystallization Using Image Analysis. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00372] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- András Domokos
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - Lajos Madarász
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - György Stoffán
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - Kornélia Tacsi
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - Dorián Galata
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - Kristóf Csorba
- Budapest University of Technology and Economics, Department of Automation and Applied Informatics, H-1111 Budapest, Hungary
| | - Panna Vass
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - Zsombor K. Nagy
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Budapest University of Technology and Economics, Department of Organic Chemistry and Technology, H-1111 Budapest, Hungary
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Domokos A, Nagy B, Gyürkés M, Farkas A, Tacsi K, Pataki H, Liu YC, Balogh A, Firth P, Szilágyi B, Marosi G, Nagy ZK, Nagy ZK. End-to-end continuous manufacturing of conventional compressed tablets: From flow synthesis to tableting through integrated crystallization and filtration. Int J Pharm 2020; 581:119297. [PMID: 32243964 DOI: 10.1016/j.ijpharm.2020.119297] [Citation(s) in RCA: 23] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/02/2020] [Revised: 03/28/2020] [Accepted: 03/30/2020] [Indexed: 10/24/2022]
Abstract
An end-to-end continuous pharmaceutical manufacturing process was developed for the production of conventional direct compressed tablets on a proof-of-concept level for the first time. The output reaction mixture of the flow synthesis of acetylsalicylic acid was crystallized continuously in a mixed suspension mixed product removal crystallizer. The crystallizer was directly connected to a continuous filtration carousel device, thus the crystallization, filtration and drying of acetylsalicylic acid (ASA) was carried out in an integrated 2-step process. Steady state was reached during longer operations and the interaction of process parameters was evaluated in a series of experiments. The filtered crystals were ready for further processing in a following continuous blending and tableting experiment due to the good flowability of the material. The ASA collected during the crystallization-filtration experiments was fed into a continuous twin-screw blender along with microcrystalline cellulose as tableting excipient. After continuous blending Near-Infrared spectroscopy was applied to in-line analyze the drug content of the powder mixture. A belt conveyor carried the mixture towards an eccentric lab-scale tablet press, which continuously produced 500 mg ASA-loaded compressed tablets of 100 mg dose strength. Thus, starting from raw materials, the final drug product was obtained by continuous manufacturing steps with appropriate quality.
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Affiliation(s)
- András Domokos
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary; Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Brigitta Nagy
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary; Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Martin Gyürkés
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Attila Farkas
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Kornélia Tacsi
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Yiqing Claire Liu
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Attila Balogh
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Paul Firth
- Alconbury Weston Ltd. (AWL), Stoke-on-Trent, Staffordshire ST4 3PE, United Kingdom
| | - Botond Szilágyi
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - György Marosi
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary
| | - Zoltán K Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States; Department of Chemical Engineering, Loughborough University, Loughborough, LE11 3TU, United Kingdom.
| | - Zsombor Kristóf Nagy
- Budapest University of Technology and Economics, Organic Chemistry and Technology Department, H-1111 Budapest, Hungary.
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