Sieving Method
Sieving Method
Sieving Method
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RESEARCH PAPER
ABSTRACT
Emori et al.
194
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INTRODUCTION
A wet granulation method with a high-shear mixer is
widely used to produce granules for tablets in the pharmaceutical industry. The primary purposes of wet granulation are to improve the properties of powders, i.e.,
material handling, flowability, dissolution, and compression characteristics (1). Because the wet granulation
process is known to influence final tablet characteristics,
such as content uniformity. dissolution rate, disintegration time, hardness, and friability (2), this process is
often defined as a critical process for the final tablet
characteristics. The end point determination method in
this process influences the tablet performance.
The wet granulation process, especially granulation
end point, is often controlled by subjective operator
evaluation, by power consumption of the mixer motor
(3-12), or by torque of the mixer shaft (13-19). However, the operator evaluation technique has the inherent
intra- and interoperator variability. The power consumption and torque techniques are dependent on formulation, process, and equipment variables. Thus, these
techniques are not always adequate during formulation
development and scale-up, while they are very convenient methods to determine granulation end point in production site.
The method that directly characterizes the progression of wet granulation by monitoring the wet granule
particle size distribution (wet granule sieving method;
WGSM) has been briefly developed for a proprietary
formulation containing over 70 % insoluble micronized
drug in the granulation phase, in order to control the
granulation process and to determine the end point
(20,21). The in-process method is available on the spot,
simple, fast, independent of operator evaluation, and
requires a small sample amount. A sonic sifter has been
employed as wet granule particle sizing equipment because of its small size and efficient sifting mechanism.
Since this method is also independent of mixer design
and scale, it is very useful during scale-up. A correlation between the amount of wet granules larger than 2
mm and the degree of homogeneity of liquid distribution was reported by Holm et al. (22). However, they
did not focus this work on a granulation end point
method.
If the WGSM can be shown to be applicable to other
drugs and formulations, it will provide very useful information on in-process parameters in the high shear
wet granulation process. Also, the wet granule particle
size distribution should be determined by a characterized
sieving method, since it is expected that the WGSM is
capable of validating the wet granulation process prospectively. A general sieving method to determine the
wet granule particle size distributions of various drug
formulations was selected and then characterized in the
present study (Part I).
Four model drugs with different solubilities and particle sizes were used, and formulations containing high
percentages of active ingredients in the granulation portions were employed so that the drug properties were
well reflected in the wet granulation. The following experiments were carried out:
1.
2.
3.
MATERIALS
Ethenzamide (low solubility), acetaminophen (medium solubility), and antipyrine (high solubility) were
used. Further, two bulk drug lots with different particle
sizes were used for acetaminophen, i.e., unmilled (acetaminophen) and milled (acetaminophen-milled) lots.
Mean particle sizes were 1.1 pm for ethenzamide, 192.7
pm for acetaminophen, 36.1 pm for acetaminophenmilled, and 251.8 pm for antipyrine. Ethenzamide, acetaminophen, and acetaminophen-milled were of JP
grade and purchased from Yoshitomi Pharmaceutical
Co., Ltd. (Osaka, Japan); antipyrine JP was from Yashiro Pharmaceutical Co., Ltd. (Osaka, Japan). Lactose JP
(DMV 200M; DMV Japan, Tokyo, Japan) and hydroxypropyl cellulose JP (HPC-LE-P; Shin-Etsu Chemical Co., Tokyo, Japan) were obtained commercially.
Cornstarch (Cornstarch W; Nihon Shokuhin Kakou Co.,
Ltd., Tokyo, Japan) was of food grade.
METHODS
Wet Granulation
Wet granulation was conducted in a 25-liter highshear mixer (Model FM-VG-25; Powrex Co., Osaka,
Japan) using the core formulation shown in Table 1.
Powders were weighed and added to the bowl of the
195
Table 1
Formulation Compositionfor Wet Granulation
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Component
D w
Cornstarch
Lactose
Hydroxypropyl cellulose
Total
3000
252
588
120
3960
Table 2
Amount of Water Added and Mixing Time for Wet Granulation
Sampling
Time Point
1st
2nd
3rd
4th
5th
1st
2nd
3rd
4th
1st
2nd
3rd
4th
1st
2nd
3rd
4th
Ethenzamide
Acetaminophen
Acetaminophen-milled
Antipyrine
-~
~
~~~
~~~~
Cumulative
Water Amount
(%)a
15.0
17.1
18.2
19.3
19.3
8.0
9.1
10.2
12.4
10.0
12.1
14.3
16.6
5.0
5.0
6.1
8.4
Cumulative
Mixing Time
(rnin)
8.8
11.0
12.7
14.3
15.3
4.0
5.4
6.8
11.0
6.5
8.7
10.8
13.1
3.8
6.8
9.3
13.4
Emori et al.
196
Drying
7 P
Main Blade
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Blade
-
\\
197
70 r
50
.-
a
5
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01st sampling
_i
EBB@
! 2nd
B@B@ 3rd
30
4th
0
Pan
106
150
180
250
425
850
1700
Pan
106
r
!
-0-
60
40
50
Over850pm
+ Under 180pm
.=.
50
3
E
a,
.r,
3rd
4th
5th
----
250
425
1700
850
(b)
---.
'r,
30
Over 1700pm
-C- Under425pm
-0-
20
' 0O
2nd
180
LL
1st
150
1st
2nd
3rd
4th
Emori et al.
198
70
70
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1st sampling
2nd
3rd
4th
a,
a
Pan
106
150
180
250
10
850 1700
425
Pan
106
a,
2
a
1;
11
180
250
425
850
1700
I
8o
+Under425pm
Over850ym
60
+
loo
LL
+OUnder250ym
v e r
.
.-a
1st
150
2nd
3rd
4th
1st
2nd
3 rd
4th
between the dry-sized and the wet granules of ethenzamide are shown in Fig. 6. All results of the four
granulations are also listed in Table 3. For the up-fraction of ethenzamide, stronger sieving conditions (40%
for 1 and 3 min; and 80% for 0.5, 1, and 3 min) provided very high correlation coefficients ( r = 0.99530.9991), and also for the down-fraction all conditions
showed a good correlation (r = 0.9019-0.9616).
Regarding acetaminophen-milled, only three stronger
sieving conditions (intensities of 20%, 40%, and 80%
of full-scale amplitude for 3 min) produced up- and
down-fractions of wet granules, whereas the clear
changes in up- and down-fractions of the dry-sized granules were observed. Continuous decrease in small particle size fraction and increase in large particle size fraction of wet granules with the wet granulation
80
60
40
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v)
Q)
2
20
0
50
40
5 30
.-c
E 20
0
9
: o
3
c
Q)
10
50
40
30
b/
20%
40%
20
A
20%
15
10
Q)
0 25
20
15
40%
.o
10
20
199
20
80%
15
10
10
0 20 40 60 80
20
40
60
Percent Down-Fraction
Percent UpFraction
of Dry-Sized Granules
of Dry-Sized Granules
0 / 0 0.5 rnin, 0 /
1 rnin,
a / A 3 rnin.
Figure 6 . Correlations between dry-sized granules and wet
granules of ethenzamide.
granule formation of acetaminophen appeared to be
weak, contrary to the granulation of acetaminophenmilled.
There were no remarkable differences in correlation
coefficient for the up-fraction of antipyrine among the
sieving conditions ( r = 0.8082-0.8962), and all except
weaker conditions (20% and 40% for 0.5 min) showed
good correlation coefficients for the down-fraction ( r =
0.9252-0.9747).
The evaluation results of wet sieving conditions are
summarized in Table 4. Each formulation had its own
ideal sieving conditions. In all of the four different wet
granulations, however, the strongest sieving condition
evaluated in this study (intensity of 80% of full-scale
amplitude and sieving time of 3 min) showed good correlations between wet and dry-sized granules for both
up- and down-fractions.
It is also hypothesized that wet granulation involves
an increase in mean particle size of component particles.
Emori et al.
200
Table 3
Correlations Between Dly-Sized and Wet Granules for Up- and Down-Fractions
UP
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Wet Sieving
Intensity and Time
Ethenzamidea
20% 0.5 min
1 min
3 min
40% 0.5 rnin
1 rnin
3 min
80% 0.5 min
1 min
3 min
Acetaminophenb
20% 0.5 min
1 min
3 min
40% 0.5 rnin
1 min
3 min
80% 0.5 rnin
1 min
3 min
Acetaminophen-milledC
20% 3 min
40% 3 rnin
80% 3 min
Antipyrined
20% 0.5 min
1 min
3 min
40% 0.5 rnin
1 min
3 rnin
80% 0.5 min
1 min
3 min
Down
Wet Fraction
(Over)
Slope
Correlation
Coefficient (r)
Wet Fraction
(Under)
Slope
Correlation
Coefficient (r)
1700 pm
1700 pm
850 pm
1700 pm
1700 pm
1700 p m
1700 pm
1700 pm
1700 pm
0.6493
0.6850
1.2192
0.5922
0.6309
0.5961
0.5848
0.5380
0.5275
0.8628
0.8867
0.8352
0.9382
0.9956
0.9991
0.9953
0.9982
0.9990
250 pm
250 pm
180 pm
250 pm
250 pm
180 pm
250 pm
250 pm
180 pm
0.1193
0.2045
0.3098
0.1272
0.2107
0.3502
0.1455
0.2361
0.2735
0.9343
0.9616
0.9019
0.9309
0.9524
0.9090
0.9522
0.9529
0.9482
1700 pm
1700 pm
1700 pm
1700 pm
1700 pm
1700 p m
1700 pm
1700 pm
1700 pm
2.1314
4.0278
4.358 1
5.4895
5.7928
6.2327
4.7072
5 4842
5.7838
0.7005
0.9187
0.9706
0.9796
0.9864
0.9902
0.9642
0.9593
0.9795
1700 pm
1700 pm
1700 pm
1700 pm
1700 pm
1700 p m
1700 pm
1700 pm
1700 pm
0.4500
0.8835
0.9276
1.1860
1.2445
1.3325
0.9507
1.1234
1.1858
0.6985
0.9506
0.9704
0.9985
0.9999
0.9990
0.9205
0.9285
0.9488
850 pm
850 pm
425 pm
0.4522
0.0785
0.3455
0.9899
0.7210
0.9035
425 pm
425 pm
425 pm
0.4719
0.2085
0.3634
0.9600
0.5719
0.9828
1700 pm
1700 pm
1700 pm
1700 pm
1700 p m
1700 pm
1700 pm
1700 prn
1700 pm
0.5369
0.5094
0.5098
0.4734
0.4614
0.4432
0.3930
0.3941
0.3798
0.8950
0.8927
0.8962
0.8172
0.8174
0.8243
0.8082
0.8193
0.8189
850
850
850
850
850
850
850
850
850
0.2193
0.3032
0.5934
0.1191
0.2684
0.4239
0.1896
0.3192
0.4155
0.8212
0.9400
0,9747
0.8279
0.9264
0.9400
0.9371
0.9294
0.9252
pm
pm
pm
pm
pm
pm
pm
pm
pm
aUp-fractionand down-fraction of dry-sized granules are over 850 pm and under 180 pm, respectively.
hUp-fractionand down-fraction of dry-sized granules are over 1700 pm and under 425 pm, respectively.
CUp-fractionand down-fraction of dry-sized granules are over 425 pm and under 250 pm, respectively.
dUp-fraction and down-fraction of dry-sized granules are over 850 pm and under 425 pm, respectively.
20 1
Table 4
Evaluation of Wet Sieving Conditions
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Wet Sieving
Intensity and Time
20%
40%
80%
Ethenzamide
Evaluationa
AcetaminophenAcetaminophen
Milled
Antipyrine
0.5 rnin
1 min
3 min
0.5 rnin
1 min
3 min
0.5 min
1 min
3 min
aA: both correlation coefficients between dry-sized and wet granules for up- and down-fractions are more than 0.9; B: one coefficient is more than 0.9 and another 0.8 to 0.9; C: both coefficients are 0.8 to 0.9; D: one or both coefficients are less than 0.8;
E: Up- and/or down-fraction is not produced.
A\
600
1200 1800 0
600
1200
1800
-0-
/+
AM,+
I+
B M , d /+
/+
BU,
/+
B M , U 1-0Open; 1st sampling, Close; 2nd sampling.
-G-
CM,
BL.
Emori et al.
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202
REFERENCES
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