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Validation of Model-Based Melt Viscosity in Hot-Melt Extrusion Numerical Simulation
Esther S Bochmann1, Andreas Gryczke2, Karl G Wagner3
1Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany. esther.bochmann@uni-bonn.de.
Model-based melt viscosity accurately simulates amorphous solid dispersions (ASDs) in hot-melt extrusion (HME). This approach reduces computational complexity without compromising simulation accuracy for pharmaceutical development.
Area of Science:
- Pharmaceutical Engineering
- Materials Science
- Computational Fluid Dynamics
Background:
- Hot-melt extrusion (HME) is a key process for amorphous solid dispersion (ASD) manufacturing.
- Accurate numerical simulations of HME require precise melt viscosity data.
- Model-based melt viscosity offers a potential simplification for HME simulations.
Purpose of the Study:
- To validate the use of model-based melt viscosity for numerical simulations of ASDs in HME.
- To assess the accuracy and influencing factors of model-based melt viscosity in HME simulations.
- To compare energy consumption between conventional and model-based viscosity simulations.
Main Methods:
- Calculated melt viscosity of ASDs using glass transition temperature and polymer matrix rheology.
- Characterized ASD properties: density, heat capacity, rheology, API solubility, and Couchman-Karasz fit deviation.
- Employed 1D simulation software Ludovic® for numerical computations.
- Investigated vinylpyrrolidone-vinyl acetate copolymer with four APIs (celecoxib, loratadine, naproxen, praziquantel).
Main Results:
- Model-based melt viscosity generally maintained simulation accuracy for HME of ASDs.
- Identified key factors influencing simulation accuracy.
- Energy consumption analysis showed comparable results between simulation methods.
Conclusions:
- Model-based melt viscosity is a viable approach for HME simulations of ASDs.
- This method simplifies simulations without significant loss of predictive accuracy.
- The findings support the use of model-based viscosity in pharmaceutical process modeling.
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