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  • Pound/square inch (gauge)
  • Aerosols

    1. 1. Manufacturing ofAerosols and Quality control By; Syed Umar Farooq M.Pharmacy Department of pharmaceutics Care college of Pharmacy Kakatiya university
    2. 2. contents1. Definition2. Classification3. Advantages4. Components of aerosol system5. Manufacturing6. Quality control
    3. 3. Definition
    4. 4. Product Produces a comes out in wet coat the form of aParticle size Particles are 200 in Foam/Froth 50 diameter
    5. 5. Advantages• A dose can be removed with out contamination of materials.• Stability is enhanced for those substances adversely affected by oxygen and or moisture.• sterility can be maintained When it is an important factor,
    6. 6. Advantages contd….• The medication can be delivered directly to the affected area in a desired form, such as spray, steam, quick breaking foam or stable foam.• Irritation produced by the mechanical application of topical medication is reduced or eliminated.• Ease of convenience of application. Application of medication in thin layer
    7. 7. Components of aerosol package
    8. 8. propellants• These are compressed gases at 70 to 80 p.s.i.g• Compressed gases such as CO2 or nitrogen or• Liquefied gases like halogen derivatives such as some saturated hydro carbons like methane ethane etc…• A large no of liquid propellants some of which are refrigerants gases also have been developed• Eg. T.F.D.C.E ,T.C.M.F.E etc….
    9. 9. Liquefied gases are preferredcomparing to compressed gases
    10. 10. Based on material to be propelledTwo phase system Three phase system• Product is solid and • Product is immiscible insoluble in propellant with propellant and• Or it is solid or liquid dissolved in liquid which dissolves in it which also does not mix• If a product is insoluble with propellant solid than it can be • Gas suitably suspended and • Product and system will have one • Liquid propellant liquid phase and a gaseous phase
    11. 11. containers• Container material are designed such that they with stand pressures as high as 140 to 180 p.s.i.g at 54 C1. Metals such as aluminum, stain less steel and tin plated steel Very rare incompatible cases Stain less steel containers are generally avoided because of high cost2. Glass uncoated or plastic coated In Glass containers practically no corrosion3. Plastics polymeric amides, acetyl co polymers
    12. 12. valves• The modern day aerosol valves are multifunctional i.e they deliver product in desired form• As well as in measured quantities when ever required• Components of aerosol valves• Gaskets :affix valve on container• Housing• Stem• Dip tube
    13. 13. Metered valve aerosols• some metering type of valves have been designed which permit only a specified amount of product to come out at any go• Such valves actually consist of two valves chambers both of which are connected to actuator
    14. 14. when actuator button is inclosed position upper chambervalve is in closed position andpower chamber valve is openrequired amount of product isfilled
    15. 15. ActuatorActuatorsenableclosing andopening ofthe valves
    16. 16. Manufacturing In general Manufacturing of aerosols takes place in two stagesManufacturing • Addition ofof concentrate propellant
    17. 17. • This manufacturing procedure is quite different from non aerosol pharmaceuticals product• This require Q.C measures during filling operation to ensure both concentrate and propellant are brought together in the proper proportion• The aerosol concentrate is prepared and sample is tested (early detection prevents loss of other components)• Once the propellant is added product is sealed in to a container with a valve
    18. 18. Methods• 1.cold filling method 2.pressure filling method• This method requires This method chilling of all is carried out at room components including temperature utilizing concentrate and pressure equipments propellant to temperature -30 f or - 40 fThe type of product and size ofcontainer usually influence method to beused
    19. 19. cold filling method product concentrate ischilled to -40 F added to thechilled containerThan the chilledpropellant is added
    20. 20. • A valve is then crimped• then the container passed through a heated water bath in which content are heated to 130 F This is To test for leak and strength of container Container is air dried and spray tested if necessaryDrawbacks..• This method is restricted to non aqueous products• And those products not adversely affected by low temperatures in the range of -40 F
    21. 21. Pressure filling method• When first developed its slower than cold filling method• With development of new techniques speed of this method has been greatly increased• Valve is crimped concentrate added to container at room temperature Then the propellant is added through the value /under the cap
    22. 22. • Since the valve contain extremely small opening (0.018 to 0.030 inch)• This step is slow and limits production• With development of rotary filling machines which allow propellant to be added around and through the valve stem the speed has been increased For those products adversely affected by air the air in headspace is evacuated prior to adding of propellant
    23. 23. Pressure burette for laboratory filling of aerosols
    24. 24. Pressure method is preferredto the cold method1. As some solutions, emulsions, suspensions and other preparations cant be chilled2. There is less danger of contamination of the product with moisture3. High production speed can be achieved4. Less propellant is lost5. And the method is not limited
    25. 25. Filling machine
    26. 26. Quality Control & Evaluation OfPharmaceutical Aerosols • QUALITY CONTROL TESTS It Includes • 1. Propellants • 2. Valves, Actuator. Dip Tubes • 3. Containers • 4. Weight Checking • 5. Leak Testing • 6. Spray Testing
    27. 27. 1.Propellents • All Propellants are accompanied by Specification sheet. Parameter Tested By Identification Purity Gas Chromatography Moisture, Halogen, • Non-Volatile Residue Determination
    28. 28. 2.Valves, Actuator, Dip-tubes • This done according to standard procedure as found in Military Standards “MIL-STD-105D”. For metered dose aerosols test methods was developed by ‘Aerosol Specification Committee’ ‘Industrial Pharmaceutical Technical Section ‘Academy Of Pharmaceutical Sciences • . The object of this test is to determine magnitude of valve delivery & degree of uniformity between individual valves. Standard test solutions were proposed to rule out variation in valve delivery.
    29. 29. Test Solutions:• Test Solutions Ingredients % w/w Test Solutions ‘A’ Test Solutions ‘B’ Test Solutions ‘C’ .• Isopropyl myristate 0.10% 0.10% 0.10%• Dichlorodifluoro methane 49.95% 25.0% 50.25%• Dichlorotetrafluoro ethane 49.95% 25.0% 24.75%• Trichloromonofluoro methane - 24.9%• Alcohol USP - 49.9% - Specific Gravity @ 25 °c 1.384 1.092 1.388
    30. 30. Testing Procedure::• Take 25 valves & placed on containers, Filled with specific test solution• Actuator with 0.020 inch orifice is attached.• Valve is actuated to fullest extent for 2 sec. Repeat this for total 2 individual delivery from each 25 test units.• Individual delivery wt in mg. Valve delivery per actuation in µL = Specific gravity of test sol n Valve Acceptance : Deliveries Limit’s 54 µL or less ± 15% 55 to 200 µL ± 10%
    31. 31. Valve acceptance• Of 50 delivery If 4 or more are outside limits : valves are rejected If 3 delivery are outside limits : another 25 valves are tested : lot is rejected if more than 1 delivery outside specification If 2 delivery from 1 valve are beyond limits : another 25 valves are tested : lot is rejected if more than 1 delivery outside specification•
    32. 32. 3.Containers:• Containers are examined for defects in lining. Q.C aspects includes degree of conductivity of electric current as measure of exposed metals. Glass containers examined for Flaws.(defects)
    33. 33. 4. Weight Checking• Weight Checking Is done by periodically adding tarred empty aerosol container to filling lines which after filling with concentrate are removed & weighed. Same procedure is used for checking weight of Propellants.
    34. 34. 5.Leak Test:• Leak Test Is done by measuring the Crimp’s dimension & ensuring that they meet specification• . Final testing of valve closure is done by passing filled containers through water bath(temp is checked repeatedly and values are recorded) 6. Spray Testing . It is done ` To clear dip tube of pure propellant & concentrate, To check for defects in valves & spray pattern.
    35. 35. Evaluation Tests• A. Flammability & combustibility:• 1.Flash point 2.Flash Projection• B. Physicochemical characteristics:• 1.Vapour pressure 2.Density• 3.Moisture content• 4.Identification of Propellants C. Performance:• 1. Aerosol valve discharge rate• 2. Spray pattern• 3.Dosage with metered valves• 4. Net contents• 5.Foam stability• 6 Particle size determination• D. Biological testing: 1.Therapeutic activity 2.Toxicity studies
    36. 36. A. Flammability & combustibility:• 1.Flash point: Apparatus : Open Cup Tag Apparatus Test liquids temp. is allowed to increase slowly & temp. at which vapors Ignite is called as Flash Point .• 2.Flame Projection: Product is sprayed for 4 sec onto flame & exact length is measured with ruler.•
    37. 37. B. Physicochemical characteristics:• The pressure can be measured simply with a pressure gauge /through use of water bath ,test gauge and special equipments like• . Vapor Pressure » Can Puncturing Device.• 2. Density » Hydrometer, » Pycnometer.• 3. Moisture » Karl Fisher Method,• 4. Identification » Gas Chromatography, » IR Spectroscopy.
    38. 38. C. Performance: :• : 1.Aerosol valve discharge rate : Aerosol product of known weight is discharged for specific time. By reweighing the container, the change in the wt. per time dispensed is the Discharge rate in gm/sec.• 2. Spray pattern : The method is based on the impingement of spray on piece of paper that has treated with Dye-Talc mixture.
    39. 39. 3. Dosage with metered valves :• : Reproducibility of dosage determined by: Accurate weighing of filled container followed by dispensing several dosage. containers again reweighed & diff. in wt. divided by no. of dosage dispensed gives average dose.• 4. Net Contents :• Tarred cans placed on filling lines are reweighed & then difference in wt. is equal to net content. In Destructive method : opening the container & removing as much of product possible.
    40. 40. 5. Foam stability :• The life of a foam can range from few seconds to an hour Various Methods are used• Visual Evaluation,• Time for given mass to penetrate the foam,• Time for given rod to fall which is inserted into the foam,• Rotational Viscometer.
    41. 41. 6.Partical Size Determination :• a). Cascade Impactor :• Principle : Stream of particle projected through a series of nozzle & glass slides at high velocity, larger particle are impacted on low velocity stage , & smaller on higher velocity stage.• b) . Light Scattering Decay :• Principle : As aerosol settles under turbulent condition, the changes in the light of a Tyndall beam is measured.
    42. 42. D. Biological testing: :• : 1.Therapeutic Activity : » For Inhalation Aerosols : is depends on the particle size. » For Topical Aerosols : is applied to test areas & adsorption of therapeutic ingredient is determined.• 2.Toxicity : » For Inhalation Aerosols : exposing test animals to vapor sprayed from Aerosol container.• For Topical Aerosols : Irritation & Chilling effects are determined.
    43. 43. References:• The Theory & Practice Of Industrial Pharmacy” by Leon Lachman, H.A.Liberman, Joseph Kanig, 3 rd Edition, Varghese Pub., page no. 613-618.• Remington’s “The Science & Practice Of Pharmacy” 3 rd Edition, Volume-I, page no.1014-1015.•