Direct Compaction Drug Product Process Modeling.

Most challenges during the development of solid dosage forms are related to the impact of any variations in raw material properties, batch size, or equipment scales on the product quality and the control of the manufacturing process. With the ever pertinent restrictions on time and resource availability versus heightened expectations to develop, optimize, and troubleshoot manufacturing processes, targeted and robust science-based process modeling platforms are essential. This review focuses on the modeling of unit operations and practices involved in batch manufacturing of solid dosage forms by direct compaction. An effort is made to highlight the key advances in the past five years, and to propose potentially beneficial future study directions.

Predictive Approach to Understand and Eliminate Tablet Breakage During Film Coating.

Pharmaceutical tablets can be susceptible to damage such as edge chipping or erosion of the core during the tablet coating process. The intersection of certain process parameters, equipment design, and tablet properties may induce more significant tablet damage such as complete tablet fracture. In this work, a hybrid predictive approach was developed using discrete element method (DEM) modeling and lab-based tablet impact experiments to identify conditions that may lead to tablet breakage events. The approach was extended to examine potential modifications to the coating equipment and process conditions in silico to mitigate the likelihood of tablet breakage during future batches. The approach is shown to enhance process understanding, identify optimal process conditions within development constraints, and de-risk the manufacture of future tablet coating batches.

Quantifying and reducing powder shear sensitivity when manufacturing capsules with lubricants.

The purpose of this work was to develop a methodology that quantifies the extent of shear induced during an encapsulation process and show how formulation composition and manufacturing process designs can be changed to reduce the negative impact on drug product quality attributes. The powder feed system used in a dosing disc type pharmaceutical capsule filling machine induced additional shear of the powder prior to slug formation. The shear occurred both in the hopper portion, via the rotation of the feed auger and impeller, and in the powder bowl via the tamping pin agitation and/or shear against the stationary surfaces such as the powder level scraper. The extent of shear was quantified to assess the impact of further dispersing the hydrophobic lubricant, magnesium stearate, in both active and placebo formulations. Stratified samples over the course of the encapsulation run showed suppression in the drug dissolution profiles and decrease in the interparticulate tensile strength of the encapsulated product. The amount of shear (duration and rate) induced during the encapsulation unit operation can be much greater than that from typical bin blending operations and therefore requires consideration during product design and scale-up to ensure product robustness.

Stress results from two-dimensional granular shear flow simulations using various collision models.

Collision resolution is one of the key elements in a discrete element method algorithm for modeling granular flows. Several collision models have been proposed for this process. The hard-particle collision approach is typically used for dilute systems, or for those in which the assumption of binary and instantaneous particle-particle contact remains valid. As the solids fraction increases, however, multiple, enduring collisions can occur and a soft-particle approach is more appropriate for resolving the collision dynamics. In this work, the delineation between dilute and dense systems and the suitability of contact models are explored for a range of solid fractions. Stress results for two-dimensional shear flow simulations are compared using several collision models including an event-driven hard-particle model, a hysteretic spring soft-particle collision model following Walton and Braun [J. Rheol. 30, 949 (1986)], and a hybrid hard-particle-with-overlap model following Hopkins and Louge [Phys. Fluids A 3, 47 (1991)]. Results show that stresses are accurately predicted for a range of solids fractions, coefficients of restitution, and friction coefficients by both the hard-particle-with-overlap and soft-particle models so long as a sufficiently large loading stiffness is used for the soft-particle model. Additional results investigating the accuracy of the collision models and the amount of collisional overlap are presented as functions of the simulation time step and model parameters.

Modeling the motion and orientation of various pharmaceutical tablet shapes in a film coating pan using DEM.

Film coating uniformity is an important quality attribute of pharmaceutical tablets. Large variability in coating thickness can limit process efficiency or cause significant variation in the amount or delivery rate of the active pharmaceutical ingredient to the patient. In this work, the discrete element method (DEM) is used to computationally model the motion and orientation of several novel pharmaceutical tablet shapes in a film coating pan in order to predict coating uniformity. The model predictions are first confirmed with experimental data obtained from an equivalent film coating pan using a machine vision system. The model is then applied to predict coating uniformity for various tablet shapes, pan speeds, and pan loadings. The relative effects of these parameters on both inter- and intra-tablet film coating uniformity are assessed. The DEM results show intra-tablet coating uniformity is strongly influenced by tablet shape, and the extent of this can be predicted by a measure of the tablet shape. The tablet shape is shown to have little effect on the mixing of tablets, and thus, the inter-tablet coating uniformity. The pan rotation speed and pan loading are shown to have a small effect on intra-tablet coating uniformity but a more significant impact on inter-tablet uniformity. These results demonstrate the usefulness of modeling in guiding drug product development decisions such as selection of tablet shape and process operating conditions.

Discrete element method (DEM) simulations of stratified sampling during solid dosage form manufacturing.

Discrete element model (DEM) simulations of the discharge of powders from hoppers under gravity were analyzed to provide estimates of dosage form content uniformity during the manufacture of solid dosage forms (tablets and capsules). For a system that exhibits moderate segregation the effects of sample size, number, and location within the batch were determined. The various sampling approaches were compared to current best-practices for sampling described in the Product Quality Research Institute (PQRI) Blend Uniformity Working Group (BUWG) guidelines. Sampling uniformly across the discharge process gave the most accurate results with respect to identifying segregation trends. Sigmoidal sampling (as recommended in the PQRI BUWG guidelines) tended to overestimate potential segregation issues, whereas truncated sampling (common in industrial practice) tended to underestimate them. The size of the sample had a major effect on the absolute potency RSD. The number of sampling locations (10 vs. 20) had very little effect on the trends in the data, and the number of samples analyzed at each location (1 vs. 3 vs. 7) had only a small effect for the sampling conditions examined. The results of this work provide greater understanding of the effect of different sampling approaches on the measured content uniformity of real dosage forms, and can help to guide the choice of appropriate sampling protocols.

The coefficient of rolling resistance (CoRR) of some pharmaceutical tablets.

Experiments have been conducted to measure the coefficient of rolling resistance (CoRR) of some pharmaceutical tablets and several common materials, such as glass beads and steel ball bearings. CoRR values are required as inputs for discrete element method (DEM) models which can be used to model particulate flows and solid dosage form manufacturing processes. Until now there have been no CoRR data reported for pharmaceutical materials, and thus these new data will help to facilitate more accurate modeling of pharmaceutical systems.

Process modeling in the pharmaceutical industry using the discrete element method.

The discrete element method (DEM) is widely used to model a range of processes across many industries. This paper reviews current DEM models for several common pharmaceutical processes including material transport and storage, blending, granulation, milling, compression, and film coating. The studies described in this review yielded interesting results that provided insight into the effects of various material properties and operating conditions on pharmaceutical processes. Additionally, some basic elements common to most DEM models are overviewed. A discussion of some common model extensions such as nonspherical particle shapes, noncontact forces, and interstitial fluids is also presented. While these more complex systems have been the focus of many recent studies, considerable work must still be completed to gain a better understanding of how they can affect the processing behavior of bulk solids.