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“Oral Drug Delivery:
Formulation Selection Approaches CONTENTS
& Novel Delivery Technologies”
“Oral Drug Delivery: Formulation Selection Approaches Solumer™ Technology: a Viable Oral Dosage
& Novel Delivery Technologies” is published by Form Option for BCS Class II Molecules
Frederick Furness Publishing. Dr Robert Lee, Vice-President, Pharmaceutical
Development & Dr Amir Zalcenstein, CEO
Copyright © 2011 Frederick Furness Publishing. SoluBest, Ltd 26-29
All rights reserved
In this article, Dr Gopi Venkatesh, Director of R&D, and Dr Anthony Recupero, Senior
Director, Business Development, both of Aptalis Pharmaceutical Technologies (formerly
Eurand), describe a specific application of Diffucaps® technology, which allows the creation
of once-daily oral formulations of weakly basic active pharmaceutical ingredients, previously
extremely difficult to achieve, but with significant benefits to patient adherence.
facture of customised-release (CR) dosage During dissolution testing in two-stage dis- DEVELOPMENT OF ONCE-DAILY
forms using Diffucaps® technology. The solution media (first two-hour dissolution test- DOSAGE FORMS OF WEAKLY
potential for in situ formation of acid addition ing in 700 mL of 0.1N HCl and thereafter BASIC DRUGS
compounds24 is averted by using a sustained- testing in 900 mL of pH 6.8 buffer obtained
release (SR) coating membrane between the by adding 200 mL pH modifier) or upon oral Below is shown the method for the prepara-
inner organic acid layer and the weakly basic administration, water or body fluid is blocked tion25 of CR drug delivery systems comprising
drug layer. The SR-coating membrane thus from imbibing into the core as the polymeric one or more IR, SR, TPR/TSR, Delayed-Release
applied, precisely controls the release of the system is impermeable in the acidic medium (DR) bead populations, themselves containing
organic acid ensuring drug is not retained in or gastric fluid. When the pH of the medium a weakly basic, nitrogen moiety-containing API
the dosage form for lack of solubilising acid is changed to 6.8 or following exit from the such as ondansetron, carvedilol, dypiramidole,
in the Diffucaps® formulation. stomach, the penetrating dissolution medium or lamotrigine or iloperidone, which is moderately
intestinal fluid selectively dissolves the enteric soluble at pH <4, but it is practically insoluble at
DIFFUCAPS® TECHNOLOGY polymer molecules or molecular clusters start- a pH >6, and at least one pharmaceutically accept-
ing from the outermost membrane layer, thereby able organic acid as a solubiliser (see the schemat-
Diffucaps® technology in its simplistic creating tortuous nanopore channels for dis- ics of SR organic acid bead & TPR/TSR bead
form (see Schematic of the Time Pulsatile solved drug to pass through.23 containing a weakly basic drug shown in Figure 2).
Release / Time Sustained Release (TPR/TSR) The tortuosity increases with increasing The method comprises the following steps:
bead shown in Figure 1) involves the prepara- coating thickness and/or decreasing enteric a) layering an organic acid on 25-30 mesh sugar
tion of: polymer content, and consequently, the drug spheres;
(1) drug-containing cores by drug-layering on release from the TPR beads having no barrier b) applying an SR coating on acid-layered beads
inert particles coat becomes sustained with increasing thick- with a water-insoluble polymer to control the
(2) customised release (CR) beads by coating ness of the TPR coating. rate of release of the acid;
immediate release (IR) particles with one or
more functional dissolution rate controlling
polymers or waxes
(3) combining one or more functional polymer
coated Diffucaps® bead populations into
hard gelatin or hydroxypropyl methylcel-
lulose (HPMC) capsules.24
Here, Hunsik (Brian) Wang, Chief Executive Officer, and Junsang Park, PhD, Chief Scientific
Officer, both of GL PharmTech, introduce GLARS, a novel concept extended-release triple-
layered tablet delivery technology for delivery to the intestine and colon.
How did you feel when you heard your brand drug delivery products captured about 10% of
product was easily copied by a generic company the top 200 product sales, which reportedly
after the expiration of its new chemical entity reached US$14.5 billion.
patent? And what about the case when someone
from sales & marketing came and complained UNDER PRESSURE FOR
of setbacks in developing a pre-defined refor- REFORMULATION
mulation product?...
For various reasons, with which readers As product developers using oral drug deliv-
will already be familiar, individuals working ery technology, GL PharmTech is constantly
in pharmaceutical product development and considering what gaps innovators want to fill in
formulation have been under significant pres- their currently marketed products. What should
sure for some time. This pressure may have be the factor to drive reformulation?
made possible various kinds of open-innovation There are many reasons why currently mar-
by prompting the adoption of technologies or keted products could be reformulated. These
products from outside. can originate from aspects of marketing, manu-
The drug delivery industry has been work- facturing, regulation, generic competition, and
even sometimes a purely scien-
tific basis. These various rea-
“HOW DID YOU FEEL sons can come alone, together,
or complicatedly combined.
WHEN YOU HEARD YOUR BRAND Therefore, a single outside
technology or reformulated
PRODUCT WAS EASILY COPIED product could not fill all the gaps
BY A GENERIC COMPANY AFTER or cover possible voids the inno- Hunsik (Brian) Wang
vator did not feel compelled to Chief Executive Officer
THE EXPIRATION OF ITS NEW address at one time. This might T: +82 31 739 5220 (Ext. 102)
F: +82 31 739 5034
be the driving force for why
CHEMICAL ENTITY PATENT?” innovative pharma companies E: Brianwang@glpt.co.kr
REFERENCES:
www.ondrugdelivery.com
ous drug delivery technologies. The in-market sion and marumerisation to form a drug
sales of products developed at the Salisbury, core with a polymer coat.
Australia facility using its technologies are in • The second process is known as spheroni-
excess of US$500 million per year. sation, where the drug particles are fixed to
the outside of a seed core (typically a sugar
Mayne Pharma’s drug delivery systems sphere). This process provides a very tight
include: size distribution of pellets. Drug potencies
up to 60% are possible.
A leading pharmaceutical organisation built Technology to control drug release
on a heritage of 160 years of industry excel- To enable pulsed release, extended release, For both of the processes above, the desired
lence, Mayne Pharma International is a and delayed release profiles (pellet/bead drug release profile is achieved by coating
market-driven company offering a range of formulations produced using extrusion and these particles with an appropriate polymer.
drug delivery technologies. Mayne Pharma marumerisation, or spheronisation processes, Mayne Pharma International has particular
International offers contract development see below). Pellets may be tabletted or encap- expertise in polymer selection and process-
and commercial manufacture for oral and sulated. This technology is very flexible and ing. The company can also work with a wide
topical pharmaceutical products. it can be adapted to the specific formulation range of solvent systems.
needs of a particular drug substance.
Mayne Pharma International has comprehen- SUBA™
sive experience in the solid oral Drug Delivery Technology to improve oral bioavailability
System (DDS) market, encompassing develop- Particularly for insoluble drugs (SUBA™ SUBATM is a novel technology for enhanc-
ment and manufacture of these products. technology, see below). ing the bioavailability of poorly water solu-
ble drugs utilising a solid dispersion of drug
The company has: Technology to taste mask liquids and tablets in various polymers.
To improve palatability and aid swallowing
• more than 30 years’ experience in suc- (Cleantaste™ technology, see below). SUBATM has been shown to double the
cessfully developing DDS products for the oral bioavailability of itraconazole when
global market TECHNOLOGY TO CONTROL compared with the innovator product
• a dedicated product development facility DRUG RELEASE (Sporanox®).
which meets cGMP standards, and includes
pilot-scale plant equipment; this allows a Pellet (or bead) technology allows a vari- CLEANTASTE™
scale-up pathway from small clinical trial ety of different drug delivery profiles to be
batches to full commercial manufacture achieved by coating drug and excipient with Cleantaste™ technology allows a polymer
• proven ability to develop and successfully various polymers. The drug cores are gener- coat to be applied to very small particles
transfer manufactured product and technol- ally spheroidal in shape and have a diameter (25-150 μm diameter) to improve taste. It
ogy to other sites around the world in the range of 300-1,700 μm. Pellets can be is also possible to use this technology to
• intellectual property and formulation presented in capsule or tablet dosage forms. improve stability or to deliver sustained
capabilities to help with product life cycle release characteristics. The fine, non-gritty
management. Two types of process are used to generate texture of product produced by this tech-
the spheroidal particles (see diagram): nology lends itself to being used in orally
Mayne Pharma International has been grant- • The first of these processes, which allows dispersible tablet and liquid formulations, as
ed, or applied for, patents that protect its vari- drug potencies up to 90%, utilises extru- well as encapsulated products. Cleantaste™
acetaminophen and ambroxol have been
commercialised and launched in Australia,
the US and Japan.
SERVICES SUMMARY
Making the right choice of formulation for the first-into-human studies of a product candidate
is extremely important and has significant time and cost implications for the development
programme. Here, Robert Harris, PhD, Director, Early Development at Molecular Profiles,
describes various formulation options available and suggests methods that can be used to select
the best formulation option for a new orally delivered drug substance.
A new experimental drug substance shows molecules based on certain molecular attributes.
great promise from pre-clinical studies for the The BCS has proved a useful tool to formu-
treatment of a disease which afflicts millions of lators for classifying drug substances, but its
patients worldwide. What is the best strategy for primary purpose is for establishing criteria for
testing the drug in man for the first time? This biowaivers, and alternative ‘developability’ clas-
is a question that all companies developing new sification systems have recently been proposed.3,4
drugs face on a regular basis. How well a drug is absorbed into the blood-
Entering Phase I clinical trials is a key stream from the gastro-intestinal tract (GIT) is
milestone in any drug development project and governed predominantly by (i) drug solubility in
to reach this stage as quickly as possible is of the gastric and intestinal fluids and (ii) perme-
paramount importance – especially for those ability through cell lipid bilayers. BCS Class I
with limited budgets. Of equal importance is to drugs are freely soluble in GIT fluids and perme-
ensure that the new drug substance is adminis- ate easily through lipid bilayers. These drugs are
tered in a form that will give it the best chance well absorbed when given orally and present the
of success in early clinical assessment. A poor easiest task when choosing a formulation strat-
choice of formulation strategy can lead to poor egy. BCS Class IV drugs on the other hand are
clinical data – which can lead to re-formulation defined as poorly soluble (in GIT fluids) and per-
and a prolonged Phase I clinical programme, or meate poorly across lipid bilayers. Consequently,
even termination of the project. these drugs exhibit poor oral bioavailability and
So how do you decide what is the best for- pose the formulator the greatest challenge. Dr Robert Harris
mulation for a new drug, assuming at this stage Director, Early Development
that it is intended for oral administration? Additional physicochemical and biological fac- T: +44 115 871 8883
F: +44 115 871 8889
tors which can challenge formulators are: E: rharris@molprofiles.co.uk
KNOW YOUR DRUG SUBSTANCE • Drug instability:
– during processing or in the formulation (e.g.
Molecular Profiles Ltd
From preclinical studies, there should be apomorphine) 8 Orchard Place
sufficient information to be able to define the – in the GIT (e.g. when drug is acid labile, as Nottingham Business Park
drug according to its water-solubility and per- with omeprazole). Nottingham
meability characteristics in accordance with the • Narrow absorption window in the intestine NG8 6PX
United Kingdom
biopharmaceutics classification system (BCS).1 (e.g. acyclovir, captopril).
Also, Lipinski’s “Rule of Five” 2 is a useful tool • Drug metabolism and/or efflux within the www.molprofiles.com
in predicting the oral bioavailability of drug intestinal wall (e.g. cyclosporin A).
Drug absorption and metabolism can vary ing a drug-in-capsule/bottle approach, it should Particle size reduction
between animal species and therefore it is not be considered with caution if the compound is Increasing the overall surface area of a solid
always possible to predict the influence of bio- not BCS Class I. If a drug substance does not can lead to more rapid dissolution of the drug sub-
logical factors (e.g. pre-systemic metabolism) wet easily or if its solubility in water is poor the stance. Micronising equipment (e.g. fluid energy
on drug uptake in humans from preclinical drug may be poorly absorbed from the GIT and mills) can reduce particle size down to 2-10
animal studies. hence exhibit poor bioavailability. If there is a μm. Taking the principle of size reduction even
known history of poor or variable absorption in further, there are now technologies available to
DECIDE ON A FORMULATION animal models then a formulation strategy to produce submicron ‘nanocrystals’ through pre-
STRATEGY enhance water-solubility of the drug substance cipitation (bottom up) or wet milling (top down)
should be considered. techniques.7,8 Following particle size reduction
For first-into-human studies it is usual to Two basic principles for enhancing water- the drug substance can be dispensed into capsules,
administer the drug either as powder-in-bottle solubility of the drug substance are (i) reduction either as drug alone or as a powder blend (with
(for reconstitution prior to administration) or in of the particle size of the drug substance and (ii) excipients), depending on the required dose and
capsules, which offer the greatest flexibility for use of solubility-enhancing vehicles. flow properties of the milled drug substance.
dose adjustment. Choosing a formulation will Brief descriptions of typical solubility-
depend on the properties of the drug substance enhancing formulation strategies are given Solubility-enhancing vehicles
and the target dose. Decision trees can be very below. Regardless of the formulation strategy For each of the strategies described below
effective tools in helping select the most appro- chosen, it is vital to assess drug solubility fol- the resulting formulation can be filled into
priate formulation strategy.5,6 Figure 1 is an lowing dilution of the test formulations in capsule shells for administration. Capsule fill-
example of a decision tree which can be used to aqueous media. The dissolution test procedures ing machines which are suitable for this pur-
select a suitable formulation strategy for first- used should simulate both gastric and intestinal pose include the IN-CAP® (Dott. Bonapace,
into-human clinical trials. conditions (in terms of pH, fluid volume, etc). Limbiate, Italy), suitable for powders or liq-
The simplest formulation strategy is not to uids/semi-solids, and the CFS 1200 (Capsugel)
formulate – just administer the drug substance which is suitable for liquids/semi-solids.
with no additional excipients. In this case the
required quantity of drug active is added directly Solution/semi-solid capsule formulations:
to a container (for reconstitution with a suitable If the drug can be dissolved in a suitable
liquid prior to ingestion) or to a capsule. This pharmaceutically acceptable vehicle then it may
approach is widely used within the industry as be appropriate to consider preparation of a solu-
it significantly reduces the time and cost for tion of the drug which can be filled into cap-
progressing to first-into-man studies. For small sules. The main benefit of this approach is that
quantities of units the active is weighed into pre-dissolving the compound overcomes the
each capsule or bottle by hand. For large quanti- initial rate limiting step of particulate dissolu-
ties of capsules or where the required dose is tion in the aqueous environment within the GIT.
< 10 mg, capsule filling can be achieved accu- However, a potential problem is that the
rately by use of specialised precision powder drug may precipitate out of solution when
dosing equipment (for example, Xcelodose® the formulation disperses in the GIT, par-
(Capsugel, Peapack, NJ, US), as shown in ticularly if the solvent is miscible with water
Figure 2). (e.g. polyethylene glycol). If the drug is suf-
The ‘drug-in-capsule/bottle’ approach is par- ficiently lipophilic to dissolve in a lipid vehicle
ticularly suited for BCS Class I compounds, there is less potential for precipitation on dilu-
which are absorbed easily from the GIT. Figure 2: Xcelodose® precision powder tion in the GIT, as partitioning kinetics will
Although there are obvious benefits in adopt- dispenser. favour the drug remaining in the lipid drop-
IN WHICH EDITION
COULD YOUR
COMPANY APPEAR?
WWW.ONDRUGDELIVERY.COM
In this article, Camille Rivail, Business Development Analyst, and Jean Chatellier, PhD, Vice-President, Alliance Management, both of Flamel
Technologies, describe the company’s LiquiTime technology, which enables liquid formulations that are palatable, can incorporate various
modified-release profiles, and are stable with long shelf-lives. The technology meets the need for liquid oral formulations in the large and growing
number of patients who have difficulty swallowing conventional tablets and capsules, including the young and the elderly.
Paediatric and geriatric drug delivery are major adding sweeteners and flavors to mask the The multiparticulate nature of the dosage form
challenges in drug development: it is estimated taste is often not sufficient. minimises inter- and intra-individual variation as
that 50% of the population have difficulties in • A lack of enteric or modified drug delivery tech- compared with conventional tablets or capsules.
swallowing solid oral dosage forms. This is espe- nologies as compared with tablets and capsules.
cially true among children under 12 years and the • Stability issues of drugs in liquid form.
elderly; there is a real need for age-adapted for-
mulations to promote better treatment compliance. LiquiTime, Flamel Technologies’ innovative
Indeed, patients have been found to break delivery platform, meets these different challenges.
tablets into fragments in order to facilitate Based on a multi-microparticles approach,
administration or to adapt the dose, generating LiquiTime allows stable, controlled-release, ready-
major risks such as inaccurate dosing, or stabil- to-use liquid oral suspensions, with good “mouth
ity issues of the residual fragments. feel”, of one or several combined drugs over time.
Liquid formulations are thus one of the most The microparticles (shown in Figure 1)
appropriate dosage forms for these subpopula- are composed of a drug core coated with a
Camille Rivail
tions, as they allow better compliance compared proprietary multifunctional diffusion film. The Business Development Analyst
with classic tablets or capsules as well as better expertise developed by Flamel in coating in
dose adaptability (age- and weight-dependent). fluidised beds allows accurate and reproducible
However, a number of challenges are related coating on very small drug cores to manufacture
to the use of liquid formulations: microparticles with narrow size distribution and
• The palatability or taste of the solution, which final particle diameters below 200 μm.
must be sufficiently agreeable in flavour to be The microparticles size and the narrow
consumed. With respect to bitter-tasting drugs, distribution optimise mouth-feel, generating a
smooth, liquid formulation with the possibility
to adjust the flavour using aroma agents. The
encapsulation of the active within the micropar-
ticles allows taste-masking, even for the most Dr Jean Chatellier
Vice-President, Alliance
unpleasant-tasting drugs.
Management
LiquiTime enables tailoring and accurate fit-
ting of any release profile, especially zero-order
Flamel Technologies SA
kinetics, to optimise pharmacokinetics (Figure 2)
33 avenue du Dr Georges Levy
for a wide range of therapeutic applications and 69693 Vénissieux Cedex
drugs (unlike ion exchange resin-complex tech- France
nology, which is limited solely to ionic drugs).
T: +33 472 783 434
200µm Other benefits may also be obtained, such
F: +33 472 783 446
as the possibility to mix immediate-release and E: licensing@flamel.com
extended-release kinetics for fast onset and
Figure 1 : Flamel Technologies’ www.flamel.com
extended release, or the possibility of mixing
LiquiTime-based coated microparticles
have an average diameter <200 µm. different drugs with different release kinetics.
% cumutalive released
24 months of storage. 60
The physical properties of LiquiTime, such as Prototype I
50
viscosity, density, have been optimised to ensure 40 Prototype II
precise and reproducible sampling to be delivered
30
with existing marketed dosing devices (for exam-
20
ple, plastic syringes), allowing flexible and accu-
10
rate dose titration adapted to individual patients.
Development time of LiquiTime formulations 0
0 2 4 6 8 10 12 14 16 18 20 22 24
has been optimised through the use of cutting-edge
Time (hours)
equipment and the skill and experience of the
Flamel development team. Beyond the lab, cGMP
Figure 2: This graph illustrates the different zero-order release profiles achieved for
manufacturing of clinical trial material and scale-
LiquiTime-based formulations (easily tailored to obtain the appropriated targeted
up to commercial size can be rapidly executed at product profile).
Flamel’s US FDA-approved industrial plant.
LiquiTime is protected by a strong IP portfo- MICROPUMP Medusa enables the controlled delivery from
lio, including several granted patents in territo- one day up to 14 days of non-modified drugs
ries including the US, EU and Japan. The Micropump micro-encapsulation oral that remain fully active (as opposed to protein
drug delivery platform, for the formulation engineering or chemical modification approach-
KEY BENEFITS OF LIQUITIME and the controlled release of chemical drugs, is es). It may be used to develop Biobetters with
designed to increase absorption time, particular- potentially improved efficacy, reduced toxic-
• Easy to swallow, good mouth feeling, taste ly for drugs only absorbed in the small intestine, ity and enhanced patient compliance. Several
masked and to deliver the drug to specific sites in the Medusa-based products are at various clinical
• Liquid formulations stable over 24 months gastro-intestinal tract. Micropump allows tailor- stages of development. Flamel’s lead internal
• Applicable to a wide range of drugs, not lim- ing the exact kinetics required to optimise the Medusa-based product candidate IFN-a XL
ited to ionic drugs as with resin-complex based final product and offers the advantage of easily (long-acting interferon alpha-2b) is currently
technology and accurately mixing microparticles with dif- the subject of a Phase II trial in HCV patients.
• Zero-order kinetics ferent release kinetics, in different ratios, with DeliVax*, Medusa’s vaccine application,
• Combination of immediate-release and extend- every individual particle performing indepen- permits the efficient formulation of vaccines.
ed-release kinetics possible dently. A single Micropump formulation can be These versatile drug delivery platforms may
• Combination in the same formulation of differ- presented in various dosage forms such as cap- be used to address threshold formulation prob-
ent drugs with different release kinetics possible sule, tablet, sachet or oral suspensions without lems such as poor solubility, aggregation and
• Use GRAS materials to warrant safety affecting the release rate. instability for both chemical and biological
• Rapid development time under cGMP conditions Flamel has developed US FDA- and drugs. Flamel’s innovative delivery platforms
• Ease to scale-up to industrial scale EMA-approved products and manufactures are used for the lifecycle management of mar-
• Clinical Proof of Concept achieved in humans Micropump-based microparticles. keted products, including Biobetters, and the
for a liquid suspension of an undisclosed drug development of new compounds with many
for treatment of children TRIGGER LOCK™ unique competitive advantages:
• Broad and strong IP protection
In addition to Micropump and LiquiTime, • Improvement of drug characteristics such as
ABOUT FLAMEL TECHNOLOGIES Flamel has developed another oral drug delivery efficacy, bioavailability and pharmacokinetics
technology, Trigger Lock™, which provides • Improvement of the drug safety profile with a
Flamel Technologies SA (NASDAQ: FLML) controlled release of narcotic and opioid analge- noticeable diminution of peak dose concentra-
is a leading drug delivery company focused on the sics while deterring tampering (particles cannot tions, which in turn allows administration of
goal of developing safer, more efficacious formu- be crushed to extract the active). higher effective doses and potentially greater
lations of drugs that address unmet medical needs. efficacy
Flamel Technologies has collaborations MEDUSA • Potential improvement of patient compliance
with a number of leading pharmaceutical and due to reduced side-effects and greater con-
biotechnology companies, including Baxter, Medusa is a proprietary injectable nanogel venience
GlaxoSmithKline (Coreg CR®, carvedilol phos- platform for the formulation and/or the extended • Protection of market position through patent
phate), Merck Serono and Pfizer. release of a broad range of biologics (including extension and/or product differentiation
Its product development pipeline includes proteins, antibodies, peptides and vaccines) • Extension of market to new indications and
biological and chemical drugs formulated with and of small molecules. The nanogel has been new patient populations.
the Micropump®, Medusa® and other propri- proven to be safe and biodegradable (DMF filed
etary platforms. with the FDA in February 2011). * pending trademarks
Oral thin films were first launched in 2004 for systemic drug delivery and are now widely
accepted. In this article, Scott Barnhart, MS, Technical Director, and Martha Sloboda,
MBA, Business Manager, both of ARx, LLC, detail the latest formulation and manufacturing
techniques for oral thin films and describe how novel forms with, for example, controlled-
release capabilities are emerging.
Rapidly dissolving oral thin films (OTFs; see selection and absorption rate are all considered
Figure 1) are widely accepted by patients and so that an equivalent or an improved product
caregivers for their ease-of-delivery, portability profile may be produced over existing liquids,
and accurate dosing. Since the first commercial capsules and tablets. The robustness of thin-film
launch of OTFs for systemic drug delivery in dosage forms has been demonstrated through
2004, 1 the platform has evolved as more phar- 24-month ICH stability studies.
maceutical researchers evaluate ways to apply Ongoing research is extending the dissolv-
the benefits of this technology across more able film technology to more complicated
markets and therapeutic classes for localised systems for modified or controlled release.
and systemic drug delivery. This also includes applications for topical
As a result of these efforts, new applications delivery. In some cases, there is convergence
are emerging. Advances in chemistries and the with transdermal technology that enables
manufacturing processes used in the formula- films to have more tangible adhesive prop-
tion and scale-up of this technology play a sig- erties such as increased dwell time in the
nificant role in advancing the potential of OTFs mouth or other alternative delivery sites. This Martha Sloboda
beyond immediate-release oral applications. work relies on a strong understanding of the Business Manager
T: +1 717 227 3326
suitability, compatibility, and availability of
E: msloboda@arglobal.com
OTF FORMULATION material sets.
energy required to remove the volatile liquid compound particle size distributions fall within each thin film drug product. API concentra-
during the film casting process. typical OTF production requirements. tions are typically limited to 50% of the final
A number of taste-masking options exist and unit mass. However, the size of the final unit
RELEASE LINERS have been used in the development of OTFs. strip is adjustable to deliver the proper dose.
This includes sophisticated masking technology Thicker OTFs can be produced to yield higher
Significant research and expertise derived specifically designed for highly bitter materials strengths. In this case, it is up to the formulator
from the transdermal arena has resulted in a with an affinity for the oral cavity. Key consid- to determine at what point the thickness of the
wide range of release liner technologies that erations in selecting any taste-masking approach product detracts from the desired disintegra-
may be used as processing aids in the manu- beyond palatability include cost, impact to API tion profile. Furthermore, a formulator can
facture of OTFs. These materials are comprised particle size or mass and solvent compatibility. elect to produce multiple formulas to obtain
of a plastic film or paper substrate coated with Researchers have some latitude in both multiple strengths for a specific API, or pro-
silicone or non-silicone chemistries for a clean how much API can be incorporated and how duce a single formula that is cut into multiple
release of the film when appropriate in the con- other product attributes can be tailored for strengths based on the size of the unit area. For
version process. By coating a compounded liq-
uid formulation to a continuous web of release
liner material, film manufacturers are able to 30 mm
maintain the integrity of the OTF film product
throughout the manufacturing process because
this component provides added strength, sup- 15 mm
port and environmental protection to wound
rolls of OTF film prior to finishing. Release lin-
ers can be incorporated strictly as a processing
aide that is removed in the film finishing stage,
20 mm 20 mm
or as seen in new product launches, this com-
ponent can remain affixed to the OTF to aid in
dispensing and administering the drug product.
ACTIVE INGREDIENTS
Figure 3: The manufacturing techniques for oral thin films are well understood and lend themselves to holding exceptionally tight
tolerances throughout the process.
example, 10 mg strength of a given formula tronics market for enabling multi-lane simul- ABOUT ARX, LLC
could become a 5 mg strength dose by halving taneous coating. 3 By applying this technique
the unit size with no additional formulary work to OTF manufacturing, the potential exists ARx, LLC, a wholly owned subsidiary of
required (see Figure 2). to coat incompatible materials, or synergistic Adhesives Research, Inc (AR), was created in
Looking forward, the use of micronised and chemistries, side-by-side without triggering any 2005 to address the growing global need for
nano particle APIs in OTFs opens the door for pre-dose reaction. innovative delivery of active drug-containing
potentially more effective drug delivery methods. Packaging has commonly been a single- systems. This was a natural extension of AR’s
With the increased surface area of the API and unit dosage format that accommodates one or 20+ years of experience manufacturing pressure-
the larger direct-contact surface area of the film, two strips per pouch and enables portability of sensitive adhesives and components for transder-
there is the possibility to improve bioavailability the product. It also allows for multiple-count mal and other pharmaceutical applications.
and to increase uptake from the mucosal surface. options to accommodate dispensing needs and ARx is dedicated to developing and manufac-
By modifying the residence time of the OTF on regional requirements. However, a number of turing innovative pharmaceutical products, includ-
the mucosal tissue in conjunction with the micro- new, stable formats are emerging that maintain ing adhesive laminates and dissolvable films,
nised or nano-API, early stage work suggests that dose integrity while also offering a more cost- for customised drug delivery platform technolo-
this type of system has the potential to effectively effective dispensing option that complies with gies. As part of this commitment, in 2007, ARx
deliver drugs in a shorter timeframe. stability and regulatory requirements. opened a new, state-of-the-art 25,000 square-foot
The manufacturing flexibility of OTFs (2,323 m2) pharmaceutical manufacturing facil-
OTF MANUFACTURE reduces capital requirements and capacity con- ity designed to manufacture dissolvable film,
sumption. It also enables formulators to con- transdermal, and buccal drug delivery systems for
Based on precision adhesive coating technol- sider new options for delivery. Because these over-the-counter, prescription and biopharmaceu-
ogies used for decades in the transdermal indus- manufacturing approaches are also well under- tical products. The globally-compliant facility tri-
try, the manufacturing techniques for OTFs are stood and controlled, robust, efficient develop- ples ARx’s manufacturing capacity and laboratory
well-understood and lend themselves to holding ment can occur from bench to commercial scale. space to support the rapid growth in the industry.
exceptionally tight tolerances throughout the pro-
cess. The precision-coating techniques derived THE FUTURE OF OTFS REFERENCES
from transdermal production are now used
for producing OTF base chemistries into final The application of OTFs now extends beyond 1. “Novartis launches first systemic OTC in film
individual doses with unit tolerances as tight as traditional immediate release oral dosage forms. strip format.” Available at: http://www.in-phar-
± 2.5% around the potency target.2 Specialised Development of topical films, probiotic strips,4 matechnologist.com/Materials-Formulation/
coat-weight monitoring systems and liquid dep- and controlled-release OTF products are new Novartis-launches-first-systemic-OTC-in-film-
osition techniques enable any OTF product to forms made possible through this delivery for- strip-format. Accessed October 1, 2009.
hold and maintain consistent cross and down- mat’s flexibility, proven robustness and stability. 2. Van Arnum, P. “Pediatric Formulations:
stream uniformity during manufacture. This The future of OTF formulation and process- Technical and Regulatory Considerations:
continuous process monitoring also lends itself ing is a direct reflection of evolving healthcare A Roundtable.” Pharm. Tech 2009. 33 (8)
to process analytical technology (PAT) initia- needs. Demographically, most established mar- Outsourcing Resources suppl. s58-s67.
tives and identifying any processing variability kets have aging populations that benefit from 3. Greb, E. “Are Orally Dissolving Strips Easy
in real time (Figure 3). simple, easy-to-dispense and dose products. for Manufacturers to Swallow?” Available at:
Coating technology from other markets con- As emerging markets require flexibility in the http://pharmtech.findpharma.com/pharmtech/
tinues to advance OTF production and cost- number of units dispensed at any given time and article/articleDetail.jsp?id=615617&sk=&
effectiveness. Multi-functional mixers drawn providers continue to look for options that can date=&pageID=3. Accessed October 5, 2009.
from the food industry enable multiple products increase compliance, minimise dosage levels 4. “Ganeden Biotech Introduces the First
to be manufactured out of the same process and frequency, and reduce costs. OTFs have Probiotic Thin Strip.” Available at: http://
footprint. New approaches in coating techniques increasingly become the solution to satisfy all news.prnewswire.com/ViewContent.
are leading to more sophisticated OTF construc- of these needs. In addition development teams aspx?ACCT=109&STORY=/www/story/09-
tions. An example of this can be seen in the are able to capitalise on the flexibility of OTFs 15-2009/0005094056&EDATE=. Accessed
adhesive coating techniques utilised in the elec- by adapting the technology for their program. September 28, 2009.
In this article, Mark Mitchnick, MD, Chief Executive Officer, and Robert Lee, PhD, Vice-
President, Pharmaceutical Development, both of Particle Sciences, and Amir Zalcenstein, PhD,
Chief Executive Officer, SoluBest, introduce Particle Sciences’ formulaic DOSE™ system
for dosage form development and drug delivery technology selection, and discuss one such
technology, Solubest’s Solumer™, a scalable solid dispersion approach based on spray drying
that is suitable for BCS Class II APIs and NCEs.
An increasing number of compounds com- Tmelt (ºC) ΔHmelt (J/g) Tmelt (ºC) ΔHmelt Particle size
(J/gdrug) nm
ing out of discovery are poorly soluble. By
some estimates 40-70% of new lead com- Reservatrol 267.4 253.6 199.1 14.0 1224
pounds in development fall into this cat- Hesperetin 231.0 166.2 No peak of melting 1310
egory.9,10 Additionally many new compounds Nifedipine 172.4 113.4 140.9 8.4 749
also exhibit poor permeability. In 1993, the Fenofibrate 81.5 74.3 64.4 9.3 669
Biopharmaceutical Classification System Tacrolimus 135.0 60.5 118.0 52.0 836
(BCS) 11,12,13,14 was proposed as a way to facili-
Clarithromycin 227.6 70.2 207.9 40.1 1190
tate the marketing of generic drugs. The system
Albendazole 215.2 209.7 161.4 31.2 555
classifies a given compound by its aqueous
Fenbendazole 239.2 166.3 203.7 8.9 892
solubility and gut permeability.
Beyond its regulatory use, the BCS provides Itraconazole 169.7 84.4 155.6 21.9 910
a very useful framework in which to evalu- Particle Sciences
ate APIs and chart a logical course to achieve
the desired pharmacokinetics (PK), including Figure 1: Comparative Thermodynamic Characteristics (Melting Temperatures and
greater bioavailability. For BCS II and IV mol- Melting Energies) of Various Unformulated APIs and their Corresponding Solumer™
ecules, where solubility is the main or largely Formulations.
contributing limiting property, there are a num-
ber of approaches including increasing surface a BCS Class I molecule, the prototypical formula- in water. The drug and polymer solutions are then
area through particle size reduction, surface tion could be a simple powder-filled capsule. For mixed and spray dried. The exact compositions of
morphology modification and solid solutions. a poorly water-soluble molecule, BCS Class II or the feed stocks are determined in an extensive, yet
IV, such a simple system is unlikely to provide efficient, preformulation phase utilising Design
ONE POSSIBLE SOLUTION: any commercially helpful data, speed develop- of Experiment (DoE) methodology, when appro-
SOLUMER™ TECHNOLOGY ment or bring to light clinically relevant findings. priate. Key drivers include the APIs solubility
Therefore, a FIH formulation designed to deliver in various organic solvents, the APIs molecular
Generating human data as quickly as possible the drug in a commercially viable way is, in our weight, the solubilities of the polymeric excipi-
is a goal of every drug developer and there are view, important. For drugs with limited aqueous ents, and the compatibility of the API and poly-
several philosophies as to how best to achieve first solubility, one such approach is Solumer™, a meric excipients in the spray drying solution.
in human (FIH) dosing. It has been estimated that patented dual polymer system utilising GRAS In the context of the Solumer technology,
3-6 formulation changes occur from FIH to com- excipients and traditional processing techniques. amphiphilic polymers are defined as soluble
mercialisation.15 At Particle Sciences, we believe In this approach, the API is solubilised in an both in organic solvents and in water.
that FIH experience should be in a formulation organic solvent, usually ethanol. An amphiphilic Examples of amphiphilic polymers suitable
that will provide useful developmental data. For and a hydrophilic polymer are separately mixed for use with Solumer include but are not lim-
Solu-Naproxen
Naproxen
Figure 2: Comparason of X-ray Diffraction Patterns of Figure 3: Differential Scanning Calorimetry of Naproxen API
Naproxen API (Naproxen) and Naproxen processed (Raw Naproxen) and Naproxen processed using the Solumer™
using the Solumer™ Technology (Solu-Naproxen). Technology (SoluNaproxen 294-153).
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Call for Presentations, please visit www.theconferenceforum.org
Keynote
Dr Robert Langer, PhD, David H. Koch Institute Professor, MIT
Key Topics
Opportunities by Therapeutic Categories and the Challenges Associated with Them
BD&L Panel on Delivery Technologies & Partnering Requirements
Young Biotech CEO Panel: Formulation & Delivery Needs
Targeted Therapeutic Agents: Eliminating the “Spam” of Drug Delivery
Drug Delivery Devices: Current Clinical Needs and Market Opportunities
Drug Delivery Technology Showcase
Emerging and Enabling Technologies for Biologics
Innovative Technologies for Small Molecules
One-On-One Meeting Sessions and Networking
Drug Delivery International Ltd has developed oral drug delivery preparations that provide
a range of drug-release profiles that can be developed for single- or multiple-drug delivery.
The profiles can combine separate pulse releases, or an initial release combined with delayed,
sustained release. Here, Carol Thomson, PhD, Chief Operating Officer, Drug Delivery
International, explains how the preparations’ behaviour in man has been demonstrated using
the nuclear imaging technique, gamma scintigraphy. Dr Thomson outlines how potential
applications in sleep maintenance, pain management and cardiovascular disease have been
demonstrated in this way, although the formulations are not limited to these therapeutic areas;
indeed, they could be applied to a broad range of drugs and disease groups.
There are many benefits offered by controlled particularly beneficial for drugs with a narrow
drug delivery systems. For example, sustained- therapeutic window.
release technologies allow prolonged delivery Further, there is an expanding body of
of a therapeutic dose, thus reducing the numberevidence concerning the relationship between
of times that a patient needs to take their medi-
circadian rhythms and the responsiveness of the
cation while maintaining a steady state of drugbody to drugs. As a consequence of this rela-
in the bloodstream, and time-delayed release tionship, the absorption, distribution, metabo-
introduces a lag time before dose release, lism and elimination of a drug and its subse-
providing pulsatile delivery of drug to specific
quent therapeutic efficacy and/or toxicity can
sites, such as the colon, or at a specific time.
vary considerably with the circadian cycle.
Temporal control of drug release has par- Drug Delivery International (DDi) is a start-
ticular advantages in the treatment of disor- up formulation development company that spe-
ders that demonstrate a circadian pattern, suchcialises in providing solutions for “difficult”
as cardiovascular disorders, asthma, anxiety formulations, such as those for drugs with
poor solubility, poor bioavail-
ability or other properties that
“THE ABSORPTION, DISTRIBUTION, prevent APIs from reaching the
market or achieving their full
METABOLISM AND ELIMINATION therapeutic potential. DDi has an
OF A DRUG AND ITS SUBSEQUENT expanding intellectual property Dr Carol Thomson
portfolio, providing licensing or
Chief Operating Officer
THERAPEUTIC EFFICACY AND/OR collaborative research opportu- T: +44 141 552 0126
nities in controlled release and E: c.thomson@dd-int.com
TOXICITY CAN VARY CONSIDERABLY chronopharmaceutics.
DDi has developed a series
WITH THE CIRCADIAN CYCLE.” Drug Delivery International Ltd
of novel delivery systems, based Basement Medical Block
on compressed tablet technol- Glasgow Royal Infirmary
and hypercholesterolemia. In such cases, the ogy, that can be readily configured to provide 84 Castle Street
development of controlled-release formulations immediate, biphasic (two pulses of drug(s) Glasgow, G4 0SF
United Kingdom
that deliver the payload at an optimal time separated by a defined delay) or time-delayed
can greatly enhance the therapeutic effects of sustained release patterns of one or more drugs www.drugdeliveryinternational.com
the drug and reduce the dose required. This is for a wide range of medical applications. The
IN WHICH EDITION
SHOULD YOUR
COMPANY APPEAR?
WWW.ONDRUGDELIVERY.COM
In this article, Gary Norman, Product Development Manager, Encap Drug Delivery, gives an overview of the various processes and technologies
the company employs for the development of capsule-based formulations. Particular advantages of these formulations over traditional
presentations are described.
Liquid-fill formulation is one of the fastest grow- with aqueous media. An example of a marketed appropriate vehicles which are suitable for fill-
ing sectors of the drug delivery market, increas- product that uses a SMEDDS type formulation ing into hard shell capsules.
ing at a rate of 30% per annum. This is due to the is Neoral, an oral formulation of cyclosporine
number of highly potent chemical and biological from Novartis (Basel, Switzerland). TARGETED DELIVERY
drugs moving through development pipelines In addition, Encap can offer the possibility
today particularly for cancer treatments. to explore formulation screening for this type In addition to the liquid-filled capsule technol-
of formulation using excipients from a range ogy Encap has other complimentary technologies
BIOAVAILABILITY ENHANCEMENT of manufacturers including Gattefossé (Saint- such as targeted delivery of capsules. Targeted
Priest, France). Encap has experience of a wide delivery could be as simple as enteric coating.
For drugs with low solubility or bioavailabil- range of functional “bioavailability-enhancer” However, for targeted delivery of capsules to the
ity, Encap Drug Delivery has a range of formu- excipients which are fully approved from a reg- colon our ENCODE® technology is utilised.
lation options and technologies which will give ulatory perspective and include the screening of ENCODE is Encap Drug Delivery’s umbrel-
drugs the best chance of success. These include such excipients during pre-formulation studies. la trademark for technologies that deliver cap-
solid solutions and solid suspensions of drugs A formulation strategy for poorly soluble
in polymeric vehicles, emulsions and self emul- drugs is the use of solid solutions, which are
sifying lipidic systems. Liquid and semi-solid molecular dispersions of drug molecules in a
filled hard capsule lipidic formulations are also polymer matrix. This conversion of the drug into
ideally suited to compounds with low aqueous the amorphous state produces material which
solubility, poor permeability and consequently dissolves more rapidly than the corresponding
low or variable bioavailability. crystalline drug substance. The incorporation of
Formulations which increase the solubility the drug substance into hydrophilic polymeric
of the active or indeed present the drug as a materials such as polyvinylpyrollidone (PVP)
solution can have a significant impact on the and polyethylene glycol (e.g. PEG6000) can
bioavailability of such drugs. Lipidic vehicles produce additional solubility enhancing effects. Mr Gary Norman
are generally well absorbed from the GI tract Solid solutions can be prepared by dis- Product Development Manager
T: +44 1506 448 080
and in many cases this approach can significant- solving the drug and the polymer in a suitable
F: +44 1506 448 081
ly improve the oral bioavailability compared volatile solvent. On removing the solvent (by E: GNorman@encapdrugdelivery.com
with administration of the solid drug substance. spray drying) an amorphous drug/polymer
Encap has expertise in the use of self- complex is formed. In some cases it is possible
Encap Drug Delivery
emulsifying vehicles and has developed a num- to dissolve the drug in the molten polymer and Units 4, 5 & 6
ber of self-emulsifying drug delivery systems fill directly into hard capsules. On cooling, the Oakbank Park Way
(SEDDS) and self-microemulsifying drug deliv- drug is entrapped in an amorphous state within Livingston
West Lothian, EH53 0TH
ery systems (SMEDDS) for the oral admin- the water-soluble matrix.
United Kingdom
istration of drugs with poor water solubility. In many cases, improvements in drug disso-
These are formulations which form emulsions lution and bioavailability can also be achieved www.encapdrugdelivery.com
or micro-emulsions spontaneously on contact using dispersions or suspensions of drugs in
sules to the colon. One such technology in this for either new indications or extending the shelf idly to progress clinical candidates through the
area is ENCODEpHloral, a specialised patented life due to patents lapsing. development process. The use of powder fill
colonic target coating. capsules without formulation using equipment
ENCODEPHloral is a dual-trigger mechanism, DELIVERY OF BIO-MOLECULES such as the Xcelodose (Capsugel, Peapack, NJ,
utilising pH and the microbiota in the colon, for US) has been very well accepted by the industry
delivery of the drug accurately and consistantly to Delivering therapeutically active large mol- for first-in-man studies. This has been a valu-
the colon, either for topical delivery such as anti- ecules by the oral route has been a challenge and a able innovation. However, a draw-back is that
inflammatory drugs for ulcerative colitus / Crohn’s goal for several decades. The oral route of admin- the capsule output makes it difficult to support
disease. For certain drugs, systemic delivery may istration for these substances is problematic for larger-scale trials without the need for long
be achieved via the colon with increased bioavail- many reasons: proteolysis by gastric and pancre- manufacturing campaigns running into many
ability due to lower expression of the PGP efflux atic enzymes; high acidity in the stomach; and lim- days for a single batch. Liquid-fill encapsulation
mechanism and/or due to the absence of certain ited absorption through the GI tract for instance. provides an alternative route to rapidly progress
enzymes in the colon, such as CYP 3A4, which However the benefits of oral delivery are clear, simple formulations of actives into the clinic
may degrade a drug if it is a CYP3A4 substrate. with the ease of administration and improved which is capable of accommodating batch-to-
patient compliance being the major advantages. batch variations in API (particle size, shape,
DUOCAP TECHNOLOGY density and flow characteristics) and can scale
Encap can employ a number of strategies: easily from bench to high speed machines.
DuoCapTM is a single, oral-dosage unit that • Formulation is designed for optimal biomol-
comprises a capsule-in-a-capsule and offers ecule chemical and conformational stability WHY CONSIDER A LIQUID FILL
broad therapeutic applications. The inner and in a part aqueous environment which is still FORMULATION FOR A FIRST-IN-
outer capsules may contain the same active compatible with capsules MAN STUDY?
drug providing multiple release profiles from • Avoid exposure to stomach and targeted deliv-
the dosage unit, for exampe, an immediate- ery to small intestine using enteric coating For the oral dosing route of administration,
release formulation from the outer capsule • Targeted delivery to colon using ENCODE there are several dosage form options generally
and a controlled-release formulation from the technologies used for first-in-human studies: API in bottle;
inner capsule. • As well as delivery of proteins and peptides, powder in bottle; API into capsule; and tradi-
In addition to modifying the release profiles our approach can also be used for domain tional formulations of tablets/capsules. Each
it is also possible to target the inner and outer antibodies, oligonucleotides and oral vaccines. approach has associated advantages and disad-
capsule to different areas of the GI tract (small vantages. In many instances a liquid-filled hard
intestine or colon), with the appropriate coating Case Study: capsule may be a more appropriate formulation
as discussed earlier. Alternatively, the capsules A water-soluble protein which is stable in for numerous reasons including:
may contain different actives for use with com- an aqueous environment, was provided as a
bination therapies or actives that are incompat- concentrate in an aqueous buffer (phosphate • Best chance bioavailability for API
ible in a single capsule. buffer solution (PBS)), which was diluted to the • Protects hygroscopic and oxidation sensitive
Combination therapies are currently of sig- required concentration with water. The diluted compounds including proteins and peptides
nificant interest, demonstrated by the recent protein/buffer solution was then incorporated • Ideal for cytotoxic APIs
launches of CombodartTM (GlaxoSmithKline) into a novel formulation containing 28% water. • Removes issues caused by API variability
and VimovoTM (Pozen/AstraZeneca). A hard-shell gelatine capsule was then filled (particle size, shape, crystal habit, density,
The inner capsule may contain liquid, semi- with the formulation and the capsule was closed polymorphic form or moisture)
solid, powder or pellet formulations and the and banded. After stability testing, the capsule • Eliminates compatability issues between shell
outer capsule contains liquid or semi-solid for- was found to remain stable without softening and API
mulations (see Figure 1). or cracking after three months stability storage, • Provides a scalable formulation that may be
Combination drugs have not been as common and the formulation retained its protein concen- suitable up to Proof of Concept and beyond.
in the industry as one may think. This may be due tration and activity. This therefore provided a
to stability issues between the actives. The advent viable route for the formulation of proteins (and ENHANCED STABILITY
of capsule-in-capsule technology allows both peptides) in stable aqueous media for adminis-
API’s to be kept distinctly separate. Therefore, tration in capsule form. The chemical stability of oxygen-, mois-
it is likely that combination drugs may become ture- and light-sensitive drugs can be signifi-
more common in the Pharmaceutical industry. FAST CLINICAL DEVELOPMENT cantly improved by using liquid or semi-solid
Fewer new drugs are being discovered and devel- capsule products. By dissolving the drug in
oped and current drugs seem to be getting more Liquid-fill encapsulation can provide a valu- non-aqueous vehicles which are compatible
of the spotlight in terms of being re-formulated able tool to enable drug developers more rap- with capsules, this problem of instability can be
In this piece, Dale Natoli, Vice-President, Natoli Engineering Company, Inc, provides a brief overview of multi-tip tooling for tablet presses,
and provides some guidelines for selecting the most appropriate equipment.
Multi-tip tooling isn’t new to the pharmaceuti- The solid multi-tip configuration (Figure 2),
cal industry; the unique tool configuration has which is machined from a single piece, is becom-
been used for more than 150 years. At the start ing more popular. It requires no disassembly for
of the tablet compression industry, single-sta- cleaning, eliminating reassembly and ensuring
tion tablet presses were used in production and proper alignment of punch tips in the die. However,
were commonly outfitted with multi-tip tooling it allows fewer punch tips in relation to tablet size.
to increase tablet production and reduce labour, Before investing in multi-tip tooling, verify
maintenance, energy, space requirements and that your tablet press has turret punch guides
the number of presses. When the high-speed and die sockets that are in good condition, with
16-station rotary tablet press was introduced no excessive wear. Worn guides and/or worn Figure 1: Assembly configuration
comprising the punch body, cap, and
in the late 1800s, the single-station press and die pockets can create punch-tip misalignment,
individual punch tips.
multi-tip tooling lost popularity. which in turn causes premature tip wear, exces-
Soon after the introduction of the rotary tablet sive head and cam wear, and tool binding in the
press, the industrial, confectionery, and food indus- punch guide and tip binding in the die. You can
tries implemented multi-tip tooling, and today the easily check the condition of the turret with a
pharmaceutical industry is following suit. turret inspection kit, which is available from
Multi-tip tooling is available in two common most tooling manufacturers. Inspect the turret for
configurations: assembly (or multi-piece), and wear periodically, regardless whether single-tip
solid. When choosing the configuration, con- or multi-tip tools are used. Inspection will alert
sider the tool type, tablet size, and the number you to premature tool wear and tooling failure.
of tips per punch. Also consider tool handling For tablet presses with tablet rejection sys- Figure 2: Solid configuration, machined
practices, cleaning, and inspection. The sup- tems, many companies use validation punches, from a single piece.
plier will help you decide which configuration which are identical to the other punches except
is best. Most tooling suppliers have selection for a slight deviation in their working and
guidelines for each tool type. overall lengths. The validation punch verifies
The assembly configuration consists of the the operation of the reject system by produc-
punch body, cap, and individual punch tips (see ing tablets of different hardness, thickness, and
Figure 1). The biggest advantage of the assembly weight. While some pharmaceutical companies
is the removable punch tips. If one of the punch are turning to multi-tip tooling, other companies
tips is damaged, it can easily be replaced so the are more reticent, investigating the effect on
punch can return to service. If a punch tip on product flow, compression and ejection forces,
the solid configuration (Figure 2) is damaged, and tablet reject systems, among others.
the entire tool must be replaced, which is costly. But multi-tip tooling can definitely pay Dale Natoli
Vice-President
Cleaning and sanitising the assembly con- off. For example, a US pharmaceutical com-
figuration requires disassembling the punch pany I worked with produced approximately T: +1 636.926.8900
tips from the punch body, cleaning and drying 8,540 pellets per minute using single-tip tooling. F: +1 636.926.8910
each component, and reassembling. Although When they switched to nine-tip tooling, produc- E: sales@natoli.com
reassembly should be quick and easy, if any tion reached approximately 76,860 pellets per
of the mating parts become damaged or even minute. That’s an 800 percent increase without Natoli Engineering Company, Inc
nicked, or if a slight amount of debris or corro- additional personnel or equipment! 28 Research Park Circle
sion interferes, the punch tips won’t align. If the Is your product a candidate for multi-tip St Charles, MO 63304
United States
punch tips don’t align properly and the punch is tooling? Check with your supplier. In today’s
returned to service, the tooling may fail prema- economy, increasing tablet production while www.natoli.com
turely or damage the press. cutting operating costs is especially attractive.
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