A study on in-line tablet coating--the influence of compaction and coating on tablet dimensional changes

Prior to coating, tablets are usually stored for a definite period to enable complete strain recovery and prevent subsequent volumetric expansion-related coating defects. In-line coating is defined as the coating of tablets immediately after compaction. In-line coating will be expected to improve manufacturing efficiencies. In this study, the possibility of in-line coating was studied by evaluating the influence of compaction and coating on tablet dimensional changes. The use of tapered dies for compaction was also evaluated. Two types of tablet coaters which presented different coating environments, namely the Supercell™ coater and pan coater, were employed for coating. The extent of tablet dimensional changes was studied in real time using optical laser sensors in a controlled environment. After compaction, tablet dimensional changes were found to be anisotropic. In contrast, coating resulted in isotropic volume expansion in both the axial and radial directions. Pan coating resulted in significantly greater tablet dimensional changes compared to Supercell™ coating. There was no significant difference in dimensional changes of tablets coated in line or after complete viscoelastic strain recovery for Supercell™ coating. However, significantly different dimensional changes were observed for pan coating. The use of tapered dies during compaction was found to result in more rapid viscoelastic strain recovery and also significantly reduced tablet dimensional changes when tablets were immediately coated after compaction using the pan coater. In conclusion, the Supercell™ coater appeared to be more suitable for in-line tablet coating, while tapered dies were beneficial in reducing tablet dimensional changes when the pan coater was employed for in-line coating.

A study on microwave-induced melt granulation in a single pot high shear processor

Microwave-induced high shear melt granulation was compared with conventional melt granulation performed in the same processor. Admixtures of lactose 200M and anhydrous dicalcium phosphate were granulated with polyethylene glycol 3350. Different heating mechanisms in the two processes necessitated the use of different parameters for process monitoring and control. Mixer power consumption was suitable for monitoring agglomerate growth under microwave-induced heating. Product temperature was a better indicator of agglomeration propensity in conventional melt granulation. These were attributed to the disparities in heat acquisition rates and heating uniformities of the powders as well as variation in baseline mixer power consumption between the two processes.

Effect of oil loading on microspheres produced by spray drying

Oil-loaded microspheres were produced by spray drying emulsions consisting of fish oil and modified starch suspensions with different oil loadings. The emulsion stability was assessed by oil droplet size analysis. Microspheres were characterized in terms of size, morphology, yield and microencapsulation efficiency. It was found that an increase in oil loading resulted in emulsions containing larger oil droplets. This corresponded with larger mean microsphere diameters and rounder microspheres. However, high oil loadings produced lower yields and affected microencapsulation efficiencies.

Investigation of the release of aspirin from spray-congealed micro-pellets

The release behaviour of aspirin from spray-congealed hydrogenated soybean oil micro-pellets of different sizes was studied. The purpose of this study was to investigate the effect of particle size of micro-pellets on the drug release profile and mechanism. Micro-pellets produced were sieved into several fractions and their drug content and dissolution profiles in two media were determined. The dissolution mechanism was studied by fitting the data to release kinetic models. Micro-pellets with high encapsulation efficiency were successfully produced. The micro-pellets were able to sustain the release of aspirin in pH 1.2 and pH 6.8 dissolution media. As particle size of micro-pellets increased, the drug release rate decreased. The drug release mechanism was affected by the size of micro-pellets. Micro-pellets in the range of 90-250 microm tended to follow the first order or Higuchi model. However, micro-pellets in the range of 250-355 microm were found to follow zero-order release model. This result showed that drug release could be modified by controlling the size of micro-pellets and that controlled release of drug might be achieved by using larger size micro-pellets.

Impact of cross-linker on alginate matrix integrity and drug release

Sodium alginate, a biopolymer, was employed in the formulation of matrix tablets. They cracked or laminated at acidic pH, compromising their dissolution performance. Improved mechanical strength and reduced barrier permeability of calcium alginate gel provided the rationale for cross-linking the alginate matrix to sustain drug release. Studies had suggested that the incorporation of soluble calcium salts in alginate matrix tablets could sustain drug release at near-neutral pH due to in situ cross-linking. However, results from the present study showed otherwise when gastrointestinal pH conditions were simulated. Significant reduction in drug release rate was only observed when an external calcium source was utilized at low concentration. High calcium ion concentrations caused matrix disintegration. In contrast, matrices pre-coated by calcium alginate could sustain drug release at pH 1.2 followed by pH 6.8 for over 12h. The presence of cross-linked barrier impeded matrix lamination and preserved matrix structure, contributing to at least three-fold reduction in drug release at pH 1.2. Zero order release as well as delayed burst release could be achieved by employing appropriate grade of alginate and cross-linking conditions.

Use of swirling airflow to enhance coating performance of bottom spray fluid bed coaters

As there is strong interest in coating increasingly smaller particles or pellets for use in compacted dosage forms, there is a need for better small particle coating systems. This study explored the use of swirling airflow to enhance the performance of the bottom spray coating system. Firstly, pellet coating in the non-swirling airflow of conventional Wurster coating was compared with that of swirling airflow in precision coating under standardized conditions. Secondly, precision coating was studied in greater details at different airflow rates (60-100m(3)/h) and partition gaps (6-22mm). Precision coating was found to have higher Reynolds numbers (Re) than Wurster coating, indicating higher turbulence. It produced coated pellets of better properties than Wurster coating, having less agglomeration and gross surface defects, more uniform coats, increased flow and tapped density, and slower drug release. Higher surface roughness did not affect the yield. In precision coating, increasing airflow rates decreased the degree of agglomeration but had minimal effect on pellet quality attributes (colour intensity, colour uniformity and surface roughness) and yields. Increasing partition gaps increased the degree of agglomeration proportionally, but this effect was small. However, greater changes in yield, surface roughness, colour intensity and colour uniformity were detected. This study showed that precision coating, while having a higher drying ability, was able to maintain the same yield and produce coated pellets with superior quality compared to Wurster coating. In precision coating, airflow rate had greater influence on the drying of pellets while partition gap had greater influence on pellet quality attributes.

Feasibility of eliminating premixing for the production of pellets in a rotary processor

This current study aims to explore the feasibility of eliminating the premixing step for making pellets in a rotary processor. Microcrystalline cellulose (MCC) and lactose were used as starting materials. They could be loaded into the rotary processor separately using three different loading configurations (Methods I, II, and III) or as MCC:lactose blend, which was prepared in the separate mixer prior to loading (Method IV). Physical properties of the pellets prepared in Methods I-III were evaluated and compared against those prepared using a premixed blend (Method IV). The effects of loading configuration on pellet quality can be assessed by comparing the pellets prepared in Methods I, II, and III. Physical characterization of pellets included mean size, size distribution, oversized fraction, and shape. No significant difference in pellet properties could be attributed to the effect of premixing. Pellet properties were not significantly affected by the different loading configurations either. This study demonstrated that homogeneous powder blends are not required for the production of pellets in rotary processing. The tumbling action of the powders at the start of rotary processing is sufficient to ensure adequate powder mixing. However, it may be judicious to cofeed the different powders to achieve some preliminary mixing during loading under extreme processing conditions.

Torque rheological parameters to predict pellet quality in extrusion-spheronization

This study explored the feasibility of predicting the quality of microcrystalline cellulose (MCC) pellets prepared by extrusion-spheronization using torque rheological characterization. Rheological properties of eleven MCC grades as well as their binary mixtures with lactose (3:7) at various water contents were determined using a mixer torque rheometer (MTR). Derived torque parameters were: maximum torque and cumulative energy of mixing (CEM). CEM values of MCC powders (CEM((MCC))) could be attributed to their physical properties such as crystallinity, V(low P) and V(total) (volumes of mercury intruded in their pores at low pressure and the total intrusion volume), bulk and tapped densities. For both MCC powders and their binary mixtures, strong correlation was observed between their torque parameters and the properties of their pellets formed with 30 and 35% (w/w) water. Since this relationship was valid over a broad water content range, rheological assessment for pre-formulation purposes need not be performed at optimized water contents. These results demonstrated the usefulness of torque rheometry as an effective means of comparing and evaluating MCC grades especially when substitution of equivalent grades is encountered. In so doing, the tedious and expensive pre-production (pre-formulation and optimization) work can be considerably reduced.

Investigation of Wetting Behavior of Nonaqueous Ethylcellulose Gel Matrices Using Dynamic Contact Angle

PURPOSE

This study reports the development of a method based on dynamic contact angle to investigate the wetting behavior of non-aqueous ethylcellulose (EC) gel matrices intended for topical drug delivery.

METHODS

Non-aqueous gel matrices were prepared from the three fine particle grades of EC and propylene glycol dicaprylate/dicaprate. Dynamic contact angle measurements of sessile drops of water and isopropylmyristate (IPM) on EC gel matrices were performed using a dynamic contact angle analyzer equipped with axisymmetric drop shape analysis of the sessile drop images. Gel density was determined by weighing known volumes of gel samples.

RESULTS

The EC gel matrices were wetted by both water and IPM, with much higher wettability by the latter. Increased EC concentration and polymeric chain length decreased the extent and rate of wetting. Linear correlation was observed between wetting parameters and rheological as well as mechanical properties of EC gel matrices.

CONCLUSIONS

The EC gel matrices exhibited both hydrophilic and lipophilic properties, with predominance of the latter. The extent and rate of wetting was governed by a balance of chemical and physical characteristics of the gel. EC gel matrices showed desirable wetting behavior in their function as a moisture-barrier, bioadhesive and vehicle for topical drug delivery.

Influence of partially cross-linked alginate used in the production of alginate microspheres by emulsification

Spherical and discrete calcium alginate microspheres had been produced by the emulsification technique. The microencapsulation process was highly efficient, but drug release from microspheres was rapid. A more orderly chain arrangement of the polymeric chains would give rise to a stronger and less permeable matrix capable of sustaining drug release. Therefore, the potential of using partially cross-linked alginate in the production of microspheres by emulsification was explored. The size and roundness of the microspheres, its drug content and drug release property were determined. The more viscous alginate solutions when reacted with more calcium salt added resulted in larger microspheres produced. Microspheres made from partially cross-linked alginate exhibited lower drug content and higher T75% values in drug release studies. This was due to decreased flexibility of the polymer chains which were partially held together by calcium ions, reducing subsequent interaction with the calcium ions resulting in lower drug entrapment efficiency and a more permeable microsphere matrix.

Development of Novel Nonaqueous Ethylcellulose Gel Matrices: Rheological and Mechanical Characterization

PURPOSE

This study reports the rheological and mechanical characterization of novel non-aqueous ethylcellulose gel matrices intended for topical drug delivery. An attempt was also made to explain the molecular interaction within the gel systems from a molecular conformational approach.

METHODS

Nonaqueous gel matrices were prepared from three fine particle grades of ethylcellulose and propylene glycol dicaprylate/dicaprate. Continuous and oscillatory shear rheometry was performed using a cone-and-plate rheometer and mechanical characterization was performed using a universal tensile tester.

RESULTS

The gel matrices exhibited prominent viscoelastic behaviour, yield stress and thixotropy. Rheological and mechanical properties showed significant upward trends with increased polymeric chain length and polymer concentrations. Good linear correlations were obtained between rheological and mechanical properties. The solvent molecular conformation was found to play a role in affecting the formation of gel networks via intermolecular hydrogen bonding between ethylcellulose polymer chains.

CONCLUSIONS

Ethylcellulose was successfully formulated as a nonaqueous gel with propylene glycol dicaprylate/dicaprate. The novel nonaqueous gel exhibited rheological profiles corresponding to a physically cross-linked three dimensional gel network, with suitable mechanical characteristics for use as a vehicle for topical drug delivery. Molecular conformation of the solvent was found to influence the molecular interactions associated with formation of ethylcellulose gel networks.

Wet Spheronization by Rotary Processing—A Multistage Single‐Pot Process for Producing Spheroids

Spheronization is an agglomerative size enlargement process for producing spherical agglomerates that have many technological and therapeutical advantages. Rotary processing is an efficient multistage, single-pot spheroid production method. The rotary processor can be used for spheroid production, drying as well as coating. In the course of spheroid production, centrifugal, fluidizing, and gravitational forces act upon the product from different directions and collectively contribute to the spheroid formation process during rotary processing. The outcome of the process depends on the complex interactions between the equipment, formulation, and process variables.

Roller Compaction of Crude Plant Material: Influence of Process Variables, Polyvinylpyrrolidone, and Co‐milling

Roller compaction of a milled botanical (Baphicacanthus cusia) with and without a binder, polyvinylpyrrolidone (PVP) was conducted. Effects of co-milling on binder function and flowability of the powder blend was also investigated. Flakes were comminuted, and the size and size distribution, friability, Hausner ratio, and Carr index of the granulations were determined. Crude herb should be reduced to a suitable size for it to be successfully roller compacted. Larger-sized and less friable granules were obtained with decreasing roller speed. Addition of PVP affected the flowability and binding capacity of the herbal powder blend, which influenced size and friability of the granules. Co-milling of PVP with the herbal powder enhanced the flow of the blends and the effectiveness of the binder, which contributed favorably to the roller-compacted product. Roller compaction is a convenient and cost-effective granulating technique suitable for milled botanicals. Co-milling can be used to improve the properties of roller-compacted products.

Formation of alginate microspheres produced using emulsification technique

This study investigated the formative process of alginate microspheres produced using an emulsification technique. The alginate microspheres were produced by cross-linking alginate globules dispersed in a continuous organic phase using various calcium salts: calcium chloride, calcium acetate, calcium lactate and calcium gluconate. The size, shape, drug content and Ca2+ content of the microspheres were evaluated. The tack, viscosity and pH of the calcium salt solution and percentage of Ca2+ partitioned into the organic phase were determined. Microscopic examination of the test emulsion at various stages of the emulsification process was also carried out. The propensity of cross-linking reaction was found to be dependent on successful collision between alginate and calcium salt globules. Examination of the characteristics of microspheres indicated that the formed microsphere was a resultant product of alginate globule clustering. The growth propensity of microspheres was promoted by the higher rate and extent of cross-linkage which was governed by the pH, tack and/or Ca2+ content of the cross-linking solution, as well as the dissociation constant and diffusivity of the calcium salt. Overall, the amount of free Ca2+ cross-linked with alginate in the formed microspheres was in the following order: calcium acetate > calcium chloride + calcium acetate > calcium chloride + calcium gluconate; calcium chloride + calcium lactate > calcium chloride. In microencapsulation by emulsification, the mean size of the microspheres produced can be modified by varying the tack, pH and Ca2+ content of the cross-linking solution and through the use of a combination of calcium salts. The shape of the microspheres produced was, nonetheless, unaffected by the physicochemical properties of the cross-linking solution.

Ultrafine grinding using a fluidized bed opposed jet mill: effects of feed load and rotational speed of classifier wheel on particle shape

Circularity, aspect ratio, modelx, and pellips were employed to study the effects of process parameters, namely varying feed loads and rotational speeds of the classifier wheel, of the fluidized bed opposed jet mill on the shape of the micronized particles produced. The Shapiro-Wilk statistical test showed that 80.0% of the shape distributions of the four descriptors were not normal. Therefore, the Kruskal-Wallis test, which is a nonparametric statistical test, was employed to analyze the data. Micronized particles were more spherical and less elongated, as indicated respectively by higher median circularity and lower median modelx values when compared to unmilled lactose. These descriptors were able to indicate that the particles had been micronized. When feed loads of 250 and 350 g were used, increasing the rotational speed of the classifier wheel was found to bring about a decrease in span values of all the shape descriptors, indicating that the micronized particles were more uniform in shape. Micronized particles produced had lower median aspect ratio values than the unmilled lactose, whereas a higher feed load of 450 g resulted in the production of micronized particles that were less uniform in shape and more elliptical in nature, as reflected by the lower median pellips values. A higher feed load of 450 g caused a high level of impingement of particles on to the rotating classifier wheel, causing decreased classifier wheel efficiency, and this resulted in a less well-controlled micronization process. Thus, aspect ratio and pellips were sensitive to the changes in performance of the classifier wheel. The four shape descriptors were proposed to be used collectively as indicators for the monitoring of the micronization process.

Influence of teardrop studs on rotating frictional base plate on spheroid quality in rotary spheronization

The effects of teardrop-shaped studs on the quality of rotary processed spheroids were investigated. The spheroids were produced under similar conditions using three rotating frictional base plates with teardrop studs of different height, volume, cross-sectional area and surface area. Spheroid properties were rated by size, size distribution, shape, friability and density. The amounts of lumps and fines produced, and the adhesion of material on the rotating frictional base plates was also looked into. The dimension of the teardrop studs on the rotating frictional base plate affected spheroid quality. The resultant shear forces and energy input during rotary spheronization differed depending on the different height, volume, cross-sectional area and surface area of studs. With the increase in height, volume, cross-sectional area and surface area of studs on the frictional base plate, the mass median diameter, e(R) and circularity of spheroids increased with corresponding decrease in span, lumps and fines. Although the frictional base plate with shortest studs had little adhesion, it may not supply enough shear force and energy input for the spheronization process, resulting in a less stable process. A balance between energy input and adhesion on the rotating frictional base plate was needed in order to optimize the production of spheroids by rotary processing.

Release characteristics of pectin microspheres prepared by an emulsification technique

The potential application of pectin as a matrix polymer for making microspheres by an emulsification technique was explored, and the drug release property of these pectinate microspheres containing drug cores of varying aqueous solubilities: sulphanilamide, sulphaguanidine and sulphathiazole, was investigated using different dissolution media. The size and size distribution, specific surface area, drug content and drug release property of the pectinate microspheres were determined. The solubility and solution pH of drugs and their propensity to interact with pectin were characterized. Pectinate microspheres were successfully prepared by external gelation, using a modified emulsification technique. The kinetics of drug release from the microspheres best fitted Higuchi's model. Interestingly, the lowest percentage of drug released was produced by microspheres which were smallest in size and, therefore, largest in specific surface area, and containing sulphanilamide, the most aqueous soluble and the lowest molecular weight drug. Mathematical correlation study indicated that the drug release profile of pectinate microspheres was notably affected by the drug content and the extent of drug-pectin interaction in the microspheres. Generally, a higher percentage of drug was released from the microspheres with a higher drug content and/or lower extent of drug-pectin interaction. The extent of drug-pectin interaction was highest in microspheres containing sulphanilamide, followed by sulphaguanidine and sulphathiazole, opposite to that of drug content.