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A Demonstration of Mixing Robustness in a Direct Compression Continuous Manufacturing Process.
Wyatt J Roth1, Ahmad Almaya1, Timothy T Kramer2
1Process Design and Development, Small Molecule Design and Development, Eli Lilly and Company, Indianapolis, Indiana 46285.
Continuous mixing in direct compression manufacturing shows robustness. Higher flow rates improve tablet potency and content uniformity, with minimal impact on dissolution and physical attributes when feeders are controlled.
Area of Science:
- Pharmaceutical Manufacturing
- Chemical Engineering
- Materials Science
Background:
- Continuous manufacturing offers advantages over batch processing for pharmaceutical production.
- Direct compression is an efficient tableting method, but requires precise control of material flow and mixing.
- Understanding the impact of process parameters on critical quality attributes (CQAs) is essential for robust continuous manufacturing.
Purpose of the Study:
- To evaluate the effect of continuous mixing parameters on tablet CQAs.
- To assess the robustness of continuous direct compression manufacturing.
- To identify risks associated with continuous mixing in tablet production.
Main Methods:
- A 9-run design of experiments (DoE) was employed.
- Varied mixer speeds, orientations, and mass flow rates.
- Utilized a cohesive drug substance at low drug load with loss-in-weight feeders.
Main Results:
- Higher mass flow rates improved tablet potency, reduced startup time, and enhanced content uniformity.
- Dissolution profiles remained consistent across different mixing conditions.
- Tablet breaking force, friability, and appearance were not significantly impacted by DoE parameters.
Conclusions:
- Continuous mixing in direct compression is a robust process with low risk to CQAs.
- Precise control of continuous feeders is crucial for consistent tablet quality.
- The study demonstrates the feasibility of continuous manufacturing for specific tablet formulations.
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