On the use of temperature measurements as a Process Analytical Technology (PAT) for the monitoring of a pharmaceutical freeze-drying process

The measurement of product temperature is one of the methods that can be adopted, especially in the pharmaceutical industry, to monitor the freeze-drying process and to obtain the values of the process parameters required by mathematical models useful for in-line (or off-line) optimization. Either a contact or a contactless device and a simple algorithm based on a mathematical model of the process can be employed to obtain a PAT tool. This work deeply investigated the use of direct temperature measurement for process monitoring to determine not only the product temperature, but also the end of primary drying and the process parameters (heat and mass transfer coefficients), as well as evaluating the degree of uncertainty of the obtained results. Experiments were carried out with thin thermocouples in a lab-scale freeze-dryer using two different model products, sucrose and PVP solutions; they are representative of two types of commonly freeze-dried products, namely those whose structures are strongly nonuniform in the axial direction, showing a variable pore size with the cake depth and a crust (leading to a strongly nonlinear cake resistance), as well as those whose structures are uniform, with an open structure and, consequently, a cake resistance varying linearly with thickness. The results confirm that the model parameters in both cases can be estimated with an uncertainty that is in agreement with that obtained with other more invasive and expensive sensors. Finally, the strengths and weaknesses of the proposed approach coupled with the use of thermocouples was discussed, comparing with a case using a contactless device (infrared camera)

Effect of different good solvents in flash nano-precipitation via multi-scale population balance modeling-CFD coupling approach

A computational and modeling approach is used to highlight the key factors that affect polymer nanoparticles (NP) formation in flash nano-precipitation (FNP), when the good solvent, e.g., acetone, is replaced by acetonitrile, tetrahydrofuran and tert-butanol. A population balance model is coupled with computational fluid dynamics to study the kinetics effects on FNP. The mean NP size is predicted in terms of mean radius of gyration via the Flory law of real polymers. The effect of different good solvents is modeled in terms of solute–solvent interactions, using the Flory–Huggins theory and Hansen solubility parameters. Promising results show how the proposed methodology is able to investigate the role played by different good solvents, analyzing single factors at the time. A deep insight into both the dynamics of mixing and the dynamics of aggregation is therefore reached and the main mechanisms involved are pointed out, showing a good agreement with experimental data

The Effect of Human Error on the Temperature Monitoring and Control of Freeze Drying Processes by Means of Thermocouples

Monitoring product temperature is mandatory in a freeze-drying process, in particular in the process development stage, as final product quality may be jeopardized when its temperature trespasses a threshold value, that is a characteristic of each product being freeze-dried. To this purpose thermocouples are usually inserted in some of the vials of the batch to track product dynamics. The position of the thermocouple inside the vials strongly affects the reading of the temperature evolution during the freeze-drying process and, thus, it is necessary to place them in the right position, in such a way that correct information about product temperature is obtained. In this work, at first, the probability of the operational error resulting into a wrong positioning of the thermocouple inside the vial has been estimated experimentally. Then, the effect of this error has been assessed in terms of risk of exceeding the limit temperature in the primary drying step. Both 4R and 10R vials have been considered, and the investigation evidenced that the probability of incorrect thermocouples placement can reach 30% for 10R vials, and about 32% for 4R vials. These probability values increase, respectively, to 47 and 39% when the trays containing the vials are shifted to their final position. Then, through IR thermal imaging it has been possible to evaluate the temperature gradients in a vial, pointing out that the temperature difference between the product at the center of the vial, where the thermocouple is supposed to be, and that of the wall, that is quite often measured by the thermocouples, can be about 1°C. Therefore, associated to each thermocouple reading there is a probability distribution of product temperature. These figures can be used to assess the risk of exceeding the limit temperature in a freeze-drying process and, thus, to quantify suitable safety margins when evaluating thermocouple readings to take into account the operational errors, given a risk tolerability criteria

Nanoparticles obtained by confined impinging jet mixer: poly(lactide-co-glycolide) vs. Poly-ε-caprolactone

This paper is focused on the production and characterization of polymeric nanoparticles obtained by nanoprecipitation. The method consisted of using a confined impinging jet mixer (CIJM), circumventing high-energy equipment. Differences between the use of poly-ε-caprolactone (PCL) and poly(lactide-co-glycolide) (PLGA) as concerns particle mean size, zeta potential, and broad-spectrum antibiotic florfenicol entrapment were investigated. Other analyzed variables were polymer concentration, solvent, and anti-solvent flow rates, and antibiotic initial concentration. To our knowledge, no data were found related to PLGA and PCL nanoparticles comparison using CIJM. Also, florfenicol encapsulation within PCL or PLGA nanoparticles by nanoprecipitation has not been reported yet. The complexity of the nanoprecipitation phenomena has been confirmed, with many relevant variables involved in particles formation. PLGA resulted in smaller and more stable nanoparticles with higher entrapping of florfenicol than PCL.Fil: Turino, Ludmila Noelia. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo Tecnológico para la Industria Química. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnológico para la Industria Química; ArgentinaFil: Stella, Barbara. Università di Torino; ItaliaFil: Dosio, Franco. Università di Torino; ItaliaFil: Luna, Julio Alberto. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo Tecnológico para la Industria Química. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnológico para la Industria Química; ArgentinaFil: Barresi, Antonello A.. Politecnico di Torino; Itali