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Design Space Estimation of the Roller Compaction Process
Umeå University, Faculty of Science and Technology, Department of Chemistry. (Computational Life Science Cluster (CLiC))
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2013 (English)In: Industrial & Engineering Chemistry Research, ISSN 0888-5885, E-ISSN 1520-5045, Vol. 52, no 35, 12408-12419 p.Article in journal (Refereed) Published
Abstract [en]

Roller compaction (RC) is a continuous process for solid dosage form manufacturing within the pharmaceutical industry achieving similar goals as wet granulation while avoiding liquid exposure. From a quality by design perspective, the aim of the present study was to demonstrate the applicability of statistical design of experiments (DoE) and multivariate modeling principles to identify the Design Space of a roller compaction process using a predictive risk-based approach. For this purpose, a reduced central composite face-centered (CCF) design was used to evaluate the influence of roll compaction process variables (roll force, roll speed, gap width, and screen size) on the different intermediate and final products (ribbons, granules, and tablets) obtained after roll compaction, milling, and tableting. After developing a regression model for each response, optimal settings were found which comply with the response criteria. Finally, a predictive risk based approach using Monte Carlo simulation of the factor variability and its influence on the responses was applied which fulfill the criteria for the responses in a space where there is a low risk for failure. Responses were as follows: granule throughput, ribbon porosity, granules particle size, and tablets tensile strength. The multivariate method orthogonal partial least-squares (OPLS) was used to model product dependencies between process steps e.g. granule properties with tablet properties. Those results confirmed that the tensile strength reduction, known to affect plastic materials when roll compacted, was not prominent when using brittle materials. While direct compression qualities are frequently used for roll compacted drug products because of their excellent flowability and good compaction properties, this study confirmed earlier findings that granules from these qualities were more poor flowing than the corresponding powder blend.

Place, publisher, year, edition, pages
American Chemical Society (ACS), 2013. Vol. 52, no 35, 12408-12419 p.
National Category
Chemical Sciences
URN: urn:nbn:se:umu:diva-71222DOI: 10.1021/ie303580yOAI: diva2:622790
Swedish Research Council, 2011-6044
Available from: 2013-05-23 Created: 2013-05-23 Last updated: 2014-11-20Bibliographically approved
In thesis
1. Multivariate Synergies in Pharmaceutical Roll Compaction: The quality influence of raw materials and process parameters by design of experiments
Open this publication in new window or tab >>Multivariate Synergies in Pharmaceutical Roll Compaction: The quality influence of raw materials and process parameters by design of experiments
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Roll compaction is a continuous process commonly used in the pharmaceutical industry for dry granulation of moisture and heat sensitive powder blends. It is intended to increase bulk density and improve flowability. Roll compaction is a complex process that depends on many factors, such as feed powder properties, processing conditions and system layout. Some of the variability in the process remains unexplained. Accordingly, modeling tools are needed to understand the properties and the interrelations between raw materials, process parameters and the quality of the product. It is important to look at the whole manufacturing chain from raw materials to tablet properties.

The main objective of this thesis was to investigate the impact of raw materials, process parameters and system design variations on the quality of intermediate and final roll compaction products, as well as their interrelations. In order to do so, we have conducted a series of systematic experimental studies and utilized chemometric tools, such as design of experiments, latent variable models (i.e. PCA, OPLS and O2PLS) as well as mechanistic models based on the rolling theory of granular solids developed by Johanson (1965).

More specifically, we have developed a modeling approach to elucidate the influence of different brittle filler qualities of mannitol and dicalcium phosphate and their physical properties (i.e. flowability, particle size and compactability) on intermediate and final product quality. This approach allows the possibility of introducing new fillers without additional experiments, provided that they are within the previously mapped design space. Additionally, this approach is generic and could be extended beyond fillers. Furthermore, in contrast to many other materials, the results revealed that some qualities of the investigated fillers demonstrated improved compactability following roll compaction.

In one study, we identified the design space for a roll compaction process using a risk-based approach. The influence of process parameters (i.e. roll force, roll speed, roll gap and milling screen size) on different ribbon, granule and tablet properties was evaluated. In another study, we demonstrated the significant added value of the combination of near-infrared chemical imaging, texture analysis and multivariate methods in the quality assessment of the intermediate and final roll compaction products. Finally, we have also studied the roll compaction of an intermediate drug load formulation at different scales and using roll compactors with different feed screw mechanisms (i.e. horizontal and vertical). The horizontal feed screw roll compactor was also equipped with an instrumented roll technology allowing the measurement of normal stress on ribbon. Ribbon porosity was primarily found to be a function of normal stress, exhibiting a quadratic relationship. A similar quadratic relationship was also observed between roll force and ribbon porosity of the vertically fed roll compactor. A combination of design of experiments, latent variable and mechanistic models led to a better understanding of the critical process parameters and showed that scale up/transfer between equipment is feasible.

Place, publisher, year, edition, pages
Umeå: Umeå University, 2014. 69 p.
Roll compaction, dry granulation, mannitol, dicalcium phosphate, design of experiments, orthogonal projections to latent structures, critical quality attributes, tablet manufacturing, quality by design, design space, near-infrared chemical imaging, texture analysis, modeling, scale up, instrumented roll, Johanson model
National Category
Other Chemistry Topics Pharmaceutical Sciences
urn:nbn:se:umu:diva-96441 (URN)978-91-7601-162-1 (ISBN)
Public defence
2014-12-12, KB3A9, KBC-huset, Umeå universitet, Umeå, 10:00 (English)
Available from: 2014-11-21 Created: 2014-11-20 Last updated: 2014-11-21Bibliographically approved

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