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15mph104 dishant scale up
1. +
SCALE UP OF SOLIDS
Presented By :- Dishant Shah
Roll Number :-15mph104
Presented To :-Dr. Tejal Mehta
(HOD of Pharmaceutics)
DEPT. :- PHARMACEUTICAL TECHNOLOGY AND
BIOPHARMACEUTICS
2. + Introduction
īŽ 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.â
R & D
Pilot
Plant
Producti
on
3. +
īŽArt of designing of prototype using the data
obtained from the pilot plant model.
Scale
up
4. + SCALE-UP--Definition
īŽ Act of using results obtained from laboratory studies for designing a
prototype and a pilot plant process; construction a pilot plant and
using pilot plant data for designing and constructing a full scale plant
or modifying an existing plant.
īŽ It is a place were the 5 Mâs like money, material, man, method and
machine are brought together for the manufacturing of the products.
īŽ It is the part of the pharmaceutical industry where a lab scale formula
is transformed into a viable product by development of liable and
practical procedure of manufacture.
īŽ The art for designing of prototype using the data obtained from the
pilot plant model.
5. + īŽ The development of new drug products goes through many stages.
Very early clinical studies may require less than 100 unit doses for
proof of concept studies.
In most cases, scale-up occurs in several
stages. Small-scale laboratory
development from 0.5 to 2 kg can be
scaled up to 5â10 kg and then 20â100 kg
on a pilot scale.
Production scale can typically range from 200 kg to greater than
1000 kg. The ultimate goal for any product as it advances through
development is to produce a formulation and a process that will be
robust enough for routine commercial manufacture.
6. +
īŽ A sub-batch type of approach can also be implemented where scale-
up to production would involve the manufacture of increasing
numbers of subdivisions on pilot scale equipment.
īŽ Table shows the results obtained at three different manufacturing
scales with the target conditions of 100 revolutions mixing prior
to screening with a 40mesh screen and 250 revolutions mixing
after screening.
Scale-up can involve manufacturing drug product with increasing
batch sizes on larger equipment or using continuous processing on
pilot scale equipment.
8. +
Objectives of Pilot Plant
To produce
physically
and
chemically
stable
therapeutic
dosage
forms.
Review of
the
processing
equipment
Guidelines
for
production
and
process
control
Evaluation
and
validation
To identify
the critical
features of
the
process
To provide
master
manufactur
ing formula
9. +
Significance of Pilot Plant
Identification of critical features to maintain quality.
Appropriate records and reports to support GMP.
Idea about physical space required.
Production rate adjustment.
Review of range of relevant processing equipment.
Examination of formulae.
10. +
Why conduct Pilot Plant Studies ?
It is not possible to design a large scale processing plant from laboratory data alone with any
degree of success
It is not possible to predict the effects of a many fold increase in scale
A pilot plant allows investigation of a product and process on an intermediate scale before large
amounts of money are committed to full scale production
11. +
Pilot Plant can be used for
Evaluating
results for
Laboratory
studies
Product and
Process
corrections
Sensory ,
Chemical,
Microbiological
Evaluation
Shelf life and
Stability studies
Designing and
Construction of
a full size plant
or modifying
existing plant
12. + Pilot Plant Scale Up Of Tablets Design
If possible, it should be located on the ground floor to expedite the
delivery and shipment of supplies.
The design and construction of the pharmaceutical pilot plant for
tablet development should incorporate features necessary to
facilitate maintenance and cleanliness.
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.
13. + Pilot Plant Scale Up Of Tablets Design
ContinuedâĻ.
Fluorescent lighting fixtures should be the ceiling flush type.
The various operating areas should have floor drains to
simplify cleaning.
The area should be air-conditioned and humidity controlled.
High -density concrete floors should be installed.
The walls in the processing and packaging areas should be
enamel cement finish on concrete.
Equipment in the pharmaceutical pilot plant should be similar
to that used by production division- manufacture of tablets.
Microbial Contamination can be
Avoided by the following ways:
17. +
Stages Of Production Of Tablets
īĩ Material handling
īĩ Dry blending
īĩ Granulation
īĩ Drying
īĩ Reduction of particle size
īĩ Special Granulation techniques
ī Dry blending
ī Direct compression
ī Slugging (dry granulation)
18. +
Material Handling
īŽ 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.
īŽ If a system is used to transfer materials for more than one
product steps must be taken to prevent cross contamination.
īŽ Any material handling system must deliver the accurate amount
of the ingredient to the destination.
īŽ The type of system selected also depends on the
characteristics of the materials.
īŽ More sophisticated methods of handling materials such as
vacuum loading systems, metering pumps, screw feed system.
īŽ There is no or minimal loss of material .
19. +
Dry Blending
īŽ Dry blending process uses a binary
cohesive-powder mixture which contains two
different sizes, it is well known that finer
particles adhere preferentially on the surface
of the coarse particles. This type mixture has
been called an interactive mixture. The
blending of fine and coarse particles breaks
down the agglomerates of fine and coarse
powders, and produces an electric charge by
contact and collision between particles.
20. +
Dry Blending Continued
īŽ Powders to be used for encapsulation are to be granulated
and must be well blended to ensure good drug distribution.
īŽ Inadequate blending at this stage could result in discrete
portion of the batch being either high or low in potency.
īŽ Steps should also be taken to ensure that all the
ingredients are free of lumps and agglomerates.
īŽ For these reasons, screening and/or milling of the
ingredients usually makes the process more reliable and
reproducible.
25. +
Granulation
īŽ Granulation is defined as a ââprocess whereby small
particles are gathered into larger, permanent masses in
which the original particles can still be identifiedââ
The most common reasons to justify granulating are :
īŧ To impart good flow properties to the material,
īŧ To increase the apparent density of the powders,
īŧ To change the particle size distribution,
īŧ Uniform dispersion of active ingredient.
26. +
Scale Up Considerations
Two systems are called
geometrically similar if they
have same ratio of
characteristic linear
dimensions
Two geometrically similar
systems are called kinetically
similar if they have same
ratio of velocities between
corresponding system points
Two kinematically similar
systems are dynamically
similar when they have
forces between
corresponding points
Two process are considered similar if they are
Geometrically, Kinetically and Kinematically similar :
27. +
Types of Granulation
īŽ Wet methods which utilize some form of liquid to bind the
primary particles.
Equipment Used :
1. Sigma blade mixer
2. Heavy duty planetary mixer
īŽ Dry methods which do Granulation Minimizes the
technical risks.
Equipment Used :
1. Roller Compaction mill
2. Shear mill
īŽ Fluidized Granulation
28. +
Wet Granulation
īŽIt is employed low-shear
mixers or the mixers/blenders
normally used for dry
blending such as ribbon
mixers.
īŽ There are a number of
products currently
manufactured using these
low-shear granulators.
29. +
Binders Used
In wet-granulation process, binders promote size enlargement to produce
granules and thus improve flowability of the blend during the manufacturing
process.
īŽ Natural Polymers: Starch, Pregelatinized Starch
īŽ Synthetic polymers: PVP, Methyl cellulose, HPMC
īŽ New Natural and Synthetic binders: Khaya gum, Leucaena leucocephala
seed gum, Anacardium occidentale gum, Gellan gum, Combination of
detarium gum and veegum.
īŽ New synthetic binders: Maltrodextrins, Chitosan derivatives
30.
31. â Multifunctional processorsâ are used that are capable of
performing all functions required to prepare a finished
granulation, such as dry blending, wet granulation, drying, sizing
and lubrication in a continuous process in a single equipment.
33. +
Dry Method
īŽ Dry compaction technique like
roller compaction is commonly
used in the Pharmaceutical
industry. There are a number
of drug substances which are
moisture sensitive and cannot
be directly compressed
34. + Roller Compaction Scale-up
īŽ SCALE-UP BACKGROUND
âThere is no such thing as a standard approach to solve compactor
scale-up or compactor equipment changes in the pharmaceutical production
processââ
īŽ Factors in scaling-up a pharmaceutical compaction process or equipment
technology transfer involve a number of issues and technologies.
īŽ Numerous considerations go beyond the specific process and technology that
evolve from the pilot plant to the manufacturing technical operations centre.
īŽ Most of these concerns are centred on the plantâs current operations, and its
previous use or manufacture of dry granulations using roller compaction
technology.
35. +
īą Carver Press Scale-Up to Roller Compactor
īŽ Gereg and Capolla developed process parameters determined by a
model laboratory bench scale Carver press, modelC, which were
translated to production scale compactor parameters.
īŽ study provided a method to predict whether a material is suitable for
roller compaction.
īŽ Their study objectives were to characterize properties of the material
to identify process parameters suitable to achieve the necessary
particle size and density using the dry granulation process and then
translate laboratory information to a production scale roller
compactor.
īŽ The following roller compaction scale-up examples illustrate
technology strategies that identify equipment design features,
process parameters, and evaluations defining roller compaction
scale-up processes.
36. +
īŽ The compactor produced very similar powder granule characteristics as the
Carver press. Various lactose materials, available as lactose monohydrate or
spray dried lactose monohydrate, were used as the model compounds.
īŽ Results indicated that a parametric correlation could be made between the
laboratory bench Carver press and the production scale compactor, and that
many process parameters can be transferred directly.
īŽ The selected compaction force value was converted to the total compaction
force by multiplying the surface area of a compact by the selected
compaction pressure using Equation (1).
F= PÃA (1)
where, F is the total force between rolls, P the selected pressure, and A the
compact surface area.
īŽ Actually, information developed from a Carver press was correlated
and scaled-up to a production scale Fitzpatrick roller compactor,
Model IR 520
37. +
īŽ The roller compactorâs full axial rolls produced compacts in the form of
ââsticks.ââ The un milled compacts from both machines had the same density,
1.3 g/cm3. The milled roller compacts produced comparative granules except
for bulk density and correspondingly the Carr index values.
īŽ The milled compacts generated slightly larger particles where the round slugs
produced from the Carver press produced a greater number of fines.
īŽ The compactor flow rate for the milled roller compacted material was twice
as fast as that of the Carver pressâ granules, but both flow rates were deemed
acceptable.
38. + Slugging Vs. Compaction Technology
Blend ingredients
Mill blend
Blend milled ingredients
Slug blend
Size slugs
Blend ingredients
Compress final granulation
A new antibiotic tablet was introduced internationally in three
countries.
Two countries did not have compactors to manufacture the product.
Theirprocess consisted of the following unit operations:
39. +
īŽ The success in manufacturing the tablet formulation (with varying
batch sizes of 250â900 kg) and achieving reproducible tablet physical
results was due in part to the robustness of the formulation design and
the active drugâs compressibility characteristics.
īŽ In the third country, roller compaction was substituted for the
slugging process. While the sizing of the slugs and compacts were
completed on different machines, and the particle size results were
not exactly the same in each situation, the tablet content uniformity
results were equivalent
īŽ Content uniformity relative standard deviations of 1.5â2.0% (n=10
tablets) were routinely achieved. The tablet dissolution profiles
averaged 95% or higher within 30 minutes in each country.
41. +
īŽ The compaction trials were conducted with and without vacuum de aeration.
The compact was carefully collected directly on a #10-mesh screen.
īŽ Powder particles, that were not compacted (i.e., those particles which were
not attached to the compact, for example, fines bypassing roll compaction
and the non-adhering compacted powder particles) were weighed and
separated.
īŽ The compact was not milled. The parameters are noted in Table 4.
42. +
īļ Roller Compactor Pilot to Scale-Up Level
īŽ The effects of the scale-up from laboratory to pilot plant on granulation,
tablet physical properties, and drug release of samples produced with roll
compaction were compared with samples produced by direct compression.
43. +
Fluidized Bed Granulations
īŽFluid Bed Granulation is a process by
which granules are produced in single
equipment by spraying a binder
solution onto a fluidized powder bed.
The material processed by fluid bed
granulation are finer, free flowing and
homogenous. The system involves
the heating of air and then directing it
through the material to be processed .
Later the same air exists through the
voids of the product.
44. +
FLUIDIZED BED GRANULATIONS
īŽ Process Inlet Air Temperature
īŽ Atomization Air Pressure
īŽ Air Volume
īŽ Liquid Spray Rate
īŽ Nozzle Position and Number of Spray Heads
īŽ Product and Exhaust Air Temperature
īŽ Filter Porosity
45. +
Scale Up Considerations
Process air temperature :
1.Selected to achieve desired
product temperature.
2. Adjusted with process air
volume
Process Air Volume :
1.Produces fluidization pattern.
2.Delivers heat to the product
3.Changes should be at the same
time and magnitude ( batch to
batch )
46. +
Applications of Granulation
To increase the
uniformity of drug
distribution in the
product
To densify the
material
To enhance the
flow rates and rate
uniformity
To facilitate
metering or
volumetric
dispensing
To reduce
dust
47. + Varying Drying Techniques for
Granulation
Sr.No. Granulation
Technique
Drying
Technique
1 Wet Granulation a. Tray or Fluid Bed Dryer
b. Vacuum /Gas
c. Stripping/microwave
d. Spray dryer
e. Extrusion/ spheronization / pelletization
2. Dry Granulation a. Dry compaction
b. Slugging mill
c. Roller compactor
49. +
Drying
īŽThe most common
conventional method of
drying a granulation
continues to be the
circulating hot air oven,
which is heated by
either steam or
electricity.
50. +
Drying Continued
īŽ 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.
īŽ Drying times at specified
temperatures and airflow rates
must be established for each
product, and for each particular
oven load.
52. +
Tray dryer
Drying times at specified temperatures and air flow rates
for each product
Monitoring drying process by use of moisture and
temperature probes
Depth of Granulation Trays
Air Temperature
Air Flow
54. + Reduction of Particle size
īŽ Compression factors that may be
affected by the particle size
distribution are flowability,
compressibility, uniformity of tablet
weight, content uniformity, tablet
hardness, and tablet color
uniformity.
īŽ First step in this process is to
determine the particle size
distribution of granulation using a
series of âstackedâ sieves of
decreasing mesh openings.
55. +
Reduction of Particle Size
Continued
īŽ 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.
īŽ As part of the scale-up of a milling or sieving operation, the lubricants
and glidents, which in the laboratory are usually added directly to the
final blend, are usually added to the dried granulation during the
sizing operation.
īŽ This is done because some of these additives, especially magnesium
stearate, tend to agglomerate when added in large quantities to the
granulation in a blender.
56. +
Problems Due to Improper Particle
Size
Large particle size- Insufficient filling of die
cavity- weight variation
For colored Granulation- coarser
the granulation-mottling
Too many fines â Flowabiity
problems â wt variation
Capping (occurs if speed of press
is increased )
60. +
Use Of Lubricants and Glidants
In Lab : Added to the final blend
Scale Up : Added to the dry granulation during size reduction
This is done because additives like magnesium stearate
,agglomerate when added in large quantities to the granulation in
a blender
61. +
Blending
īŽ Type of blending equipment often differs from that using in
laboratory.
īŽ 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 action.
īŽ Particle abrasion is more likely to occur when high-shear
mixers with spiral screws or blades are used.
īŽ 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
blender.
62. +
Scale Up of Blending
Blender
Loads
Blender
size
Mixing
speeds
Mixing
times
Bulk
density
of raw
material
Characte
ristics of
the
material
65. +
Characteristics of the material
īŽ Fragile particles or agglomerates: more readily abbraided ī more fines ī
improper mixing ī flow problems, fill problems, content uniformity
problems.
īŽ Particle abbraision is more when high-shear mixing with spiral screws or
blades are used.
īŽ Tumble blenders: for prolonged mixing
īŽ Bulk density of raw materials considered in selection of the blender and
determining optimum blender load.
īŽ Excessive granulation: poor content uniformity, poor lubrication & improper
color dispersion.
67. +
Dry Granulation (or Slugging)
īŽ A dry powder blend that cannot be directly compressed
because of poor flow or compression properties.
īŽ 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.
īŽ Slugs range in diameter from 1 inch, for the more easily
slugged material, to . inch in diameter for materials that
are more difficult to compress and require more
pressure per unit area to yield satisfactory compacts.
īŽ If an excessive amount of fine powder is generated
during the milling operation the material must be
screened & fines recycled through the slugging
operation.
69. +
Granulation Handling Feed System
Handling of
finished
granulation
Scale up studies
determine effect
of handling
system on
content
uniformity and
particle size
distribution
Segregation
effects tablet
weight ,
thickness and
hardness
Cleaning
procedure
should be well
documented
and validated
70. +
Direct Compaction
īŽ 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.
īŽ Materials of very low density require roller compaction to
achieve a bulk density sufficient to allow encapsulation or
compression.
īŽ One of the best examples of this process is the densification
of aluminum hydroxide.
īŽ 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 tableting or
encapsulation properties.
71. +
Direct Compression
Ejection of the tablet from the die cavity and take - off of compressed tablet.
3. Compression of granules.
2. Pre compression of granulation (optional).
1. Filling of empty die cavity with granulation.
During compression, the tablet press performs the following functions:
The ultimate test of a tablet formulation and granulation process is whether the
granulation can be compressed on a high-speed tablet press.
72. +
Scale Up Considerations
Component
s of Blender
Mixing
speed
Mixing Time
Mixing
Action
Blender
Load (
overload
retards free
flow of
granules
and
decreases
efficiency of
blender , if
less load
powder
simply
slides off
without
mixing )
75. +
Manufacturing steps for Direct
Compression
Particle
characteristics
(mixing and
segregation):
size, size
distribution,
shape, static
charge
Blender
load
Optimum
mixing
speed
Blending
time
Optimizing
the
process
and
validation
of its
performan
ce
Control Factors :-
76. +
Aspects for Optimization
īŽ Order of addition of components to the blender
īŽ Mixing speed: can be varied with the original direction as necessary
īŽ Mixing time: excessive mixing may fracture the fragile excipients and
ruin their compressibility
īŽ Use of auxiliary dispersion material within the mixer (chopper blade
within a twin shell mixer):
īŽ a) Increase efficiency
b) Reduce agglomerates
77. Mixing action:
Determined by the mechanics of the mixer.
Changed by converting from one blender to the other or by
modifying the blender through addition of baffles or plates,
which would alter the mixing characteristics.
Blender load: affects efficiency
Overload: reduced free flow of granules and reduced
efficiency
Localized concentration: content uniformity
Small load: sliding and rolling of powders in the blender, no
proper mixing & increased time for mixing.
78. īĩ Suitable for thermolabile and moisture
sensitive APIâs
īĩ Chances of batch-to-batch variation are
negligible, because the unit operations
required for manufacturing processes is fewer.
īĩParticle size uniformity
79. +
Demerits
īŽ Excipient Related
1. Problems in the uniform distribution of low dose drugs.
2. High dose drugs having high bulk volume, poor compressibility and
poor flowability are not suitable for direct compression. For example,
Aluminium Hydroxide, Magnesium Hydroxide
3. Direct compression diluents and binders must possess both good
compressibility and good flowability.
4. Many active ingredients are not compressible either in crystalline or
amorphous forms.
5. May lead to unblending because of difference in particle size or density
of drug and excipients. Similarly the lack of moisture may give rise to
static charges, which may lead to unblending.
6. Non-uniform distribution of colour, especially in tablets of deep colours.
80. +
Demerits
īŽ Process Related
i) Capping, lamination, splitting, or layering of tablets related to
air entrapment during direct compression. When air is
trapped, the resulting tablets expand when the pressure of
tablet is released, resulting in splits or layers in the tablet.
ii) In some cases require greater sophistication in blending and
compression equipment.
iii) Expensive equipment
81. +
Slugging (Dry Granulation)
īŽ For dry powder blend that cannot be directly
compressed because of poor flow or
compression properties.
īŽ Done on a tablet press designed for slugging.
īŽ Pressure of 15 tons; normal: 4 tons or less
īŽ Speed is slow since poorly flowable powders
require more time to be compressed.
īŽ Diameter of slugs:
īŽ 1 inch for more easily slugged material
īŽ ž inch for materials difficult to compress
83. +
īŽ Materials of very low density require roller compaction to achieve
a bulk density sufficient to allow encapsulation or compression.
E.g.- densification of aluminium hydroxide
84. + Granulation handling & Feed Systems
īŽ Additional handling can affect content uniformity of the drug and the particle size
distribution.
īŽ Segregation due to static charges may lead to flow problems through tablet
press hoppers and feed frames.
īŽ This affects tablet weight, thickness and hardness. Finally poor content
uniformity.
īŽ More sophisticated equipment ī cleaning problem.
īŽ Equipment to be engineered for efficient and total cleaning.
īŽ Well written, documented and validated cleaning procedures are essential for
such systems.
85. +
Compression
īŽ Functions of a tablet press:
īŧ Filling of empty die cavity with granulation.
īŧ Pre compression of granulation (optional).
īŧ Compression of granules.
īŧ Ejection of the tablet from the die cavity and take-
off of compressed tablet.
ī Potential problems such as sticking to the punch
surface, tablet hardness, capping, and weight
variation detected.
86. +
īŽ Control factors while selecting the speed of the 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.
īŽ 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.
īŽ The smaller the tablet , the more difficult it is to get a uniform fill at high
press speeds.
87. +
īŽ Slowing down the press speed or using larger compression rollers
can often reduce capping in a formulation.
īŽ High level of lubricant or over blending can result in a soft tablet,
decrease in wettability of the powder and an extension of the
dissolution time.
īŽ Binding to die walls can also be overcome by designing the die to
be 0.001 to 0.005 inch wider at the upper portion than at the center
in order to relieve pressure during ejection.
93. +
Tablet Coating
īŽ Tablet coating, which at one time consisted of sugar
coating in conventional coating pans, has undergone many
changes because of new developments in coating
technology and changes in safety and environmental
regulations.
There are mainly 3 important techniques involved in coating .
They are :
īļ Sugar Coating
īļ Film Coating
īļ Enteric Coating
94. +
Scale Up Considerations
The tablet
loading of the
coating pan
Spray rate of
the coating
solution
Quantity of
solution
required
Volume of air
used during
coating
95. +
Equipments Used
īŽ The standard coating pan
īŽ The perforated coating pan
īŽ Accela cota system
īŽ Hi-coatersystem
īŽ Dria coater
īŽ Glatt coater
īŽ Fluidized bed (air suspension) coater
97. Medicine is not only a science; it is also an art. It does not
consist of compounding pills and plasters; it deals with
the very processes of life, which must be understood
before they may be guided.
99. +
References :-
īŽ Encyclopaedia of pharmaceutical technology, 3rd edition 2007,
volume-1 by james swarbrick, page number 3193-3217.
īŽ Good manufacturing Practises for Pharmaceuticals, volume 109, 5th
edition, 2002 By Sidney. H. willing and for pharmaceutical Process
scale up edited by Michael Levin. Page number 115-258.
īŽ Pharmaceutical process scale up, volume 157, 2nd edition 2006, by
Michael Levin. Page number 237-265