Novel laser-based method to improve pharmaceutical tablet manufacturing

A recent study by M. Lück et al. [1] presents a novel laser-based method that enhances the manufacturing of pharmaceutical tablets. The method focuses on roll compaction, where powdered materials are compressed between two rotating rollers to form dense ribbons. These ribbons are later milled into granules and pressed into tablets.

One major challenge in roll compaction is determining the ribbon solid fraction. This property measures how tightly the material is packed. It directly affects granule behavior and influences tablet quality, strength, and consistency.

Current challenges in measurement

Traditionally, manufacturers measure ribbon solid fraction using off-line testing. They remove samples from the production line and analyze them separately. This method is accurate but slow, and it prevents real-time adjustments.

Some companies have tried near-infrared spectroscopy and infrared thermography for in-line monitoring. However, these technologies have limits in accuracy and practical use.

Laser-based method for real-time control

The researchers developed a laser triangulation system for roll compaction. This laser-based method measures ribbon thickness in real time. As a result, manufacturers can adjust the process immediately.

The system works by directing a laser beam onto the ribbon surface. It measures the reflected beam to calculate thickness. The method also accounts for elastic recovery, which is the slight expansion after the ribbon leaves the rollers. This information improves the accuracy of compaction control.

The study used the following formulation:

Material	Function	Manufacturer
Microcrystalline cellulose (Vivapur® 102)	Binder	JRS Pharma, Germany
Fine powder hydroxypropyl cellulose (NISSO HPC SSL SFP)	Binder	Nippon Soda, Japan
Polyvinylpyrrolidone K 25 (Kollidon® 25)	Binder	BASF, Germany
Dibasic calcium phosphate anhydrous (DI-CAFOS® A60)	Filler	Chemische Fabrik Budenheim KG, Germany
Ibuprofen, granulated (Ibuprofen DC 100)	Active	IPC Process Center Dresden, Germany

Use of mathematical models

The laser-based method integrates with simplified versions of Johanson’s rolling theory and the Midoux model. These models estimate ribbon solid fraction from the thickness data.

The researchers found that the laser system tracked elastic recovery with high precision. Its position did not affect the accuracy of the models. Once calibrated, the system worked reliably under different conditions. Moreover, the method removed the need for slow manual testing.

Impact on pharmaceutical manufacturing

This laser-based method allows manufacturers to maintain consistent tablet quality. It also improves efficiency, increases yield, and reduces waste. Since it enables real-time monitoring and control, the process becomes more reliable and cost-effective.

Continue reading the original article here

Source: ingredientpharm, website Novel Laser-Based Method to Enhance Tablet Manufacturing, Journal of Pharmaceutical Sciences 113(4), 1020-1028, 2024. doi: 10.1016/j.xphs.2023.10.013

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