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Objectives of the Pilot Plant
Reasons for pilot plant
Significance of pilot plant
Importance of the Pilot Plant
Pilot plant design for tablets
Pilot plant scale-up techniques for capsules
What is Pilot plant :
“Defined as a part of the
pharmaceutical industry where a lab scale formula is
transformed into a viable product by the development
of liable practical procedure for manufacture.”
R & D Production
“The art of designing of prototype using the
data obtained from the pilot plant model.”
Objectives of Pilot Plant
“Find mistakes on small scale and make profit on
To produce physically and chemically stable
therapeutic dosage forms.
Review of the processing equipment.
Guidelines for productions and process control.
Evaluation and validation.
To identify the critical features of the process.
To provide master manufacturing formula.
REASONS FOR BUILDING A PILOT PLANT
• To evaluate on process of large change in
scale up operation.
• To find and examine all by-products or waste .
• To produce a trail lot of quantities of material.
• Clinical studies ,analytical development
,process development, stability testing.
SIGNIFICANCE OF PILOT PLANT
• Examination of formulae.
• Review of range of relevant processing
• production rate adjustment.
• Idea about physical space required.
• Appropriate records and reports to support
• Identification of critical features to maintain
Importance of Pilot Plant
Examination of formulae.
Review of range of relevant processing
The specification of the raw materials.
The physical space required.
Appropriate records and reports to support
Pilot Plant design for Tablets
The primary responsibility of the pilot plant staff is to
ensure that the newly formulated tablets developed by
product development personnel will prove to be
efficiently, economically, and consistently
reproducible on a production scale.
The design and construction of the pharmaceutical
pilot plant for tablet development should incorporate
features necessary to facilitate maintenance and
If possible, it should be located on the ground floor to
expedite the delivery and shipment of supplies.
Material handling system
In the laboratory, materials are simply scooped or poured
by hand, but in intermediate- or large-scale operations,
handling of this materials often become necessary.
If a system is used to transfer materials for more than one
product steps must be taken to prevent cross
Any material handling system must deliver the accurate
amount of the ingredient to the destination.
The type of system selected also depends on the
characteristics of the materials.
More sophisticated methods of handling materials such as
vacuum loading systems, metering pumps, screw feed
Powders to be used for encapsulation or to be
granulated must be well blended to ensure good drug
Inadequate blending at this stage could result in discrete
portion of the batch being either high or low in potency.
Steps should also be taken to ensure that all the
ingredients are free of lumps and agglomerates.
For these reasons, screening and/or milling of the
ingredients usually makes the process more reliable and
The equipment used for blending are:
Double cone blender
Slant cone blender
Orbiting screw blenders vertical and horizontal high
SCALE UP CONSIDERATIONS
Time of blending .
Size of blender.
The most common reasons given to justify granulating
1.To impart good flow properties to the material,
2.To increase the apparent density of the powders,
3.To change the particle size distribution,
4.Uniform dispersion of active ingredient.
Traditionally, wet granulation has been carried out using,
Sigma blade mixer,
Heavy-duty planetary mixer.
Used in tablet formulations to make powders more
compressible and to produce tablets that are more resistant
to breakage during handling.
In some instances the binding agent imparts viscosity to
the granulating solution so that transfer of fluid becomes
This problem can be overcome by adding some or all
binding agents in the dry powder prior to granulation.
Some granulation, when prepared in
production sized equipment, take on a dough-like
consistency and may have to be
subdivided to a more granular and porous mass
to facilitate drying.
This can be accomplished by passing the wet
mass through an oscillating type granulator
with a suitably large screen or a hammer mill
with either a suitably large screen or no screen
The most common conventional method of drying a
granulation continues to be the circulating hot air oven, which
is heated by either steam or electricity.
The important factor to consider as part of scale-up of an oven
drying operation are airflow, air temperature, and the depth of
the granulation on the trays.
If the granulation bed is too deep or too dense, the drying
process will be inefficient, and if soluble dyes are involved,
migration of the dye to the surface of the granules.
Drying times at specified temperatures and airflow rates must
be established for each product, and for each particular oven
Fluidized bed dryers are
an attractive alternative
to the circulating hot air
The important factor
considered as part of
scale up fluidized bed
dryer are optimum loads,
rate of airflow, inlet air
Reduction of Particle size
Compression factors that may be affected by the particle size
distribution are flowability, compressibility, uniformity of
tablet weight, content uniformity, tablet hardness, and tablet
First step in this process is to determine the particle size
distribution of granulation using a series of “stacked” sieves of
decreasing mesh openings.
Particle size reduction of the dried granulation of production
size batches can be carried out by passing all the material
through an oscillating granulator, a hammer mill, a mechanical
sieving device, or in some cases, a screening device.
Type of blending equipment often differs from that using
In any blending operation, both segregation and mixing
occur simultaneously are a function of particle size, shape,
hardness, and density, and of the dynamics of the mixing
Particle abrasion is more likely to occur when high-shear
mixers with spiral screws or blades are used.
When a low dose active ingredient is to be blended it may
be sandwiched between two portions of directly
compressible excipients to avoid loss to the surface of the
Equipments used for mixing
Sigma blade mixer.
Twin shell blender.
High shear mixer
Slugging (Dry Granulation)
A dry powder blend that cannot be directly compressed
because of poor flow or compression properties.
This is done on a tablet press designed for slugging, which
operates at pressures of about 15 tons, compared with a normal
tablet press, which operates at pressure of 4 tons or less.
Slugs range in diameter from 1 inch, for the more easily
slugged material, to ¾ inch in diameter for materials that are
more difficult to compress and require more pressure per unit
area to yield satisfactory compacts.
If an excessive amount of fine powder is generated during the
milling operation the material must be screened & fines
recycled through the slugging operation.
Granulation by dry compaction can also be achieved by
passing powders between two rollers that compact the material
at pressure of up to 10 tons per linear inch.
Materials of very low density require roller compaction to
achieve a bulk density sufficient to allow encapsulation or
One of the best examples of this process is the densification of
Pilot plant personnel should determine whether the final drug
blend or the active ingredient could be more efficiently
processed in this manner than by conventional processing in
order to produce a granulation with the required tabletting or
The ultimate test of a tablet formulation and granulation
process is whether the granulation can be compressed on a
high-speed tablet press.
During compression, the tablet press performs the
1.Filling of empty die cavity with granulation.
2.Precompression of granulation (optional).
3.Compression of granules.
4.Ejection of the tablet from the die cavity and take-off of
When evaluating the compression characteristics of a particular
formulation, prolonged trial runs at press speeds equal to that to be
used in normal production should be tried.
Only then are potential problems such as sticking to the punch
surface, tablet hardness, capping, and weight variation detected.
High-speed tablet compression depends on the ability of the press
to interact with granulation.
Following are the parameters to be considered while choosing
speed of press.
1.Granulation feed rate.
2.Delivery system should not change the particle size distribution.
3.System should not cause segregation of coarse and fine particles,
nor it should induce static charges.
The die feed system must be able to fill the die
cavities adequately in the short period of time that
the die is passing under the feed frame.
The smaller the tablet , the more difficult it is to
get a uniform fill a high press speeds.
For high-speed machines, induced die feed
systems is necessary.
These are available with a variety of feed paddles
and with variable speed capabilities.
So that optimum feed for every granulation can
After the die cavities are filled ,the excess is removed
by the feed frame to the center of the die table.
Compression of the granulation usually occurs as a
single event as the heads of the punches pass over the
lower and under the upper pressure rollers.
This cause the punches to the penetrate the die to a
preset depth, compacting the granulation to the
thickness of the gap set between the punches.
The rapidity and dwell time in between this press event
occurs is determined by the speed at which the press is
rotating and by the size of compression rollers.
Larger the compressions roller, the more gradually
compression force is applied and released.
Pilot Plant scale-up techniques for
Capsules are solid dosage forms in which the drug
substance is enclosed in either a hard or soft soluble
container or shell of a suitable form of gelatin.
Steps in capsule production
1.Mixing of ingredient
2.Granulation and lubrication
3.Making of capsules
4.Filling of capsules
6.Packing and labeling
The manufacturing process for capsulated products
often same to that tablets.
Both tablets & capsules are produced from ingredients
that may be either dry blended or wet granulated to
produce a dry powder or granule mix with uniformly
dispersed active ingredients.
To produce capsules on high speed equipment ,the
powder blend must have the uniform particle size
distribution, bulk density & compressibility required
to promote good flow properties & result in the
formation of compact of the right size and sufficient
cohesiveness to be filled in to capsule shells.
Manufacture of Hard Gelatin Capsules
1. Shell composition :
Prepared by the hydrolysis of collagen.
Gelatin in its chemical and physical properties, depending
upon the source of the collagen and extraction.
There are two basic types of gelatin:
Type – A and Type – B.
The two types can be differentiated by their isoelectric points
(7.0 – 9.0 for type A and 4.8 – 5.0 for type B) and by their
viscosity and film forming characteristics.
Combination of pork skin and bone gelatin are often used to
optimize shell characteristics.
The physicochemical properties of gelatin of most interest to
shell manufactures are the bloom strength and viscosity.
Various soluble synthetic dyes (“coal tar dyes”) and insoluble
pigments are used.
Not only play a role in identifying the product, but also may
play a role in improving patient compliance.
E.g., white, analgesia; lavender, hallucinogenic effects; orange or
yellow, stimulants and antidepressants.
Opaquing agents :
Titanium dioxide may be included to render
the shell opaque.
Opaque capsules may be employed to provide
protection against light or to conceal the
When preservatives are employed, parabens
are often selected.
The racks of gelatin coated pins then pass into a
series of four drying oven.
Drying is mainly done by dehumidification.
A temperature elevation of only a less degrees is
permissible to prevent film melting.
Under drying will leave the films too sticky for
IV. Stripping :
A series of bronze jaws strip the cap and body
portions of the capsules from the pins.
V. Trimming :
The stripped cap and body portions are delivered
to collects in which they are firmly held.
As the collects rotate, knives are brought against
the shells to trim them to the required length.
VI. Joining :
The cap and body portions are aligned
concentrically in channels and the two portions
are slowly pushed together.
3) Sorting :
The moisture content of the capsules as they are from the
machine will be in the range of 15 – 18% w/w.
During sorting, the capsules passing on a lighted moving
conveyor are examined visually by inspectors.
Defects are generally classified according to their nature and
potential to cause problems in use.
4) Printing :
In general, capsules are printed before filling.
Generally, printing is done on offset rotary presses having
throughput capabilities as high as three-quarter million
capsules per hour.
Three larger size are available for veterinary use: 10,
11, and 12 having capacities of about 30, 15, and 7.5
The largest size normally acceptable to patient is a
The standard shape of capsules is traditional,
symmetrical bullet shape.
Some manufactures have employed distinctive shapes.
e.g. Lilly’s pulvule tapers to a bluntly pointed end.
Smith Kline Beacham’s spansule capsules taper at
both the cap and body ends.
6) Sealing :
Capsules are sealed and somewhat reshaped in
the Etaseal process.
This thermal welding process forms an indented
ring around the waist of the capsule where the
cap overlaps the body.
7) Storage :
Finished capsules normally contain an
equilibrium moisture content of 13-16%.
To maintain a relative humidity of 40-60% when
handling and storing capsules.
Filling of hard gelatin capsules
Equipment used in capsule filling operations
involves one often of two types of filling systems.
Zanasi or Martelli encapsulator:
Forms slugs in a dosatar which is a hollow tube
with a plunger to eject capsule plug.
Formation of compacts in a die plate using
tamping pins to form a compact.
In this both system, the scale-up process
involve bulk density, powder flow,
compressibility, and lubricant distribution.
Overly lubricated granules are responsible for
delaying capsule disintegration and dissolution.
OSAKA MODEL R-180
SEMI AUTOMATIC CAPSULE
Manufacture of Soft Gelatin
I. Composition of the shell:
Similar to hard gelatin shells, the basic component of
soft gelatin shell is gelatin; however, the shell has been
The ratio of dry plasticizer to dry gelatin determines the
“hardness” of the shell and can vary from 0.3-1.0 for
very hard shell to 1.0-1.8 for very soft shell.
Up to 5% sugar may be included to give a “chewable”
quality to the shell.
The residual shell moisture content of finished capsules
will be in the range of 6-10%.
The types of vehicles used in soft gelatin capsules fall in to two
1. Water immiscible, volatile or more likely more volatile
liquids such as vegetable oils, mineral oils, medium-chain
triglycerides and acetylated glycerides.
2. Water miscible, nonvolatile liquids such as low molecular
weight PEG have come in to use more recently because
of their ability to mix with water readily and accelerate
dissolution of dissolved or suspended drugs.
All liquids used for filling must flow by gravity at a
temperature of 350c or less.
The sealing temperature of gelatin films is 37-400C.
III.Manufacture process :
A. Plate process :
The process involved
• Placing the upper half of a plasticized gelatin sheet
over a die plate containing numerous die pockets,
• Application of vacuum to draw the sheet in to the die
• Filling the pockets with liquor or paste,
• Folding the lower half of gelatin sheet back over the
filled pockets, and
• Inserting the “ sandwich” under a die press where the
capsules are formed and cut out.
B. Rotary die press:
In this process, the die cavities are machined in to
the outer surface of the two rollers.
The die pockets on the left hand roller form the left
side of the capsule and the die pockets on the right
hand roller form the right side of the capsule.
Two plasticized gelatin ribbons are continuously and
simultaneously fed with the liquid or paste fill
between the rollers of the rotary die mechanism.
As the die rolls rotate, the convergence of the
matching die pockets seals and cuts out the filled
C. Accogel process:
In general, this is another rotary process involving
• A measuring roll,
• A die roll, and
• A sealing roll.
As the measuring roll and die rolls rotate, the measured doses
are transferred to the gelatin-linked pockets of the die roll.
The continued rotation of the filled die converges with the
rotating sealing roll where a second gelatin sheet is applied
to form the other half of the capsule.
Pressure developed between the die roll and sealing roll seals
and cuts out the capsules.
4. Bubble method:
The Globex Mark II capsulator produces truly
seamless, one-piece soft gelatin capsules by a
A concentric tube dispenser simultaneously
discharges the molten gelatin from the outer annulus
and the liquid content from the tube.
By means of a pulsating pump mechanism, the
liquids are discharged from the concentric tube
orifice into a chilled-oil column as droplets that
consists of a liquid medicament core within a molten
The droplets assume a spherical shape under surface
tension forces and the gelatin congeals on cooling.
The finished capsules must be degreased and dried.
IV. Soft/Liquid-filled hard gelatin capsules:
Important reason: the standard for liquid filled
capsules was inability to prevent leakage from hard
As banding and of self-locking hard gelatin
capsules, together with the development of high-resting
state viscosity fills, has now made
liquid/semisolid-filled hard gelatin capsules.
As with soft gelatin capsules, any materials filled
into hard capsules must not dissolve, alter or
otherwise adversely affect the integrity of the shell.
Generally, the fill material must be pumpable.
Three formulation strategies based on having a high resting
viscosity after filling have been described.
1. Thixotropic formulations,
2. Thermal-setting formulations,
3. Mixed thermal-Thixotropic systems.
The more lipophilic contents, the slower the release rate.
Thus, by selecting excipients with varying HLB balance,
varying release rate may be achieved.