Pharma Osd Manufacturing

Understanding Oral Solid
Dose Form (OSD)

Manufacturing
The Process/Equipment and Technology
Presented by:
Dave DiProspero
Senior Pharmaceutical Specialist
Tuesday March 18, 2014 10am

AGENDA
Session Stage Setting
OSD Processing Goals
Main Types of OSD Processes
The OSD Primary Unit Operations Matrix our road ma
Primary Unit Operations

The process; technology/equipment; process/facility considerat
The Owner/Engineer/Vendor Considerations
Wrap Up
SESSION STAGE SETTING
Who is Dave DiProspero?
Who are you?
Industry: Pharma , Equip Vendors, Service Providers, Oth

Industry Experience: >15 yrs, 5-15yrs, <5yrs
Role/Function: Engineering, Manufacturing, Management, Sale
OSD Experience: lots, some, none
STAGE SETTING
Typical Drug Delivery Systems and Drug Forms
Liquids: Suspensions, Solutions, Syrups

Creams/Ointments
Sprays/Inhalers
Transdermal Patches
Injectibles
Non conventional: Suppositories and other
THE PREFERRED DOSAGE FORM, by far:
SOLID DOSE: Tablets/Capsules

OSD PROCESSING GOALS
Primary Manufacturing Goal:

To create a formulation that has a highly repeatable distribution of ing
that are:
Compressible (in a tablet form) or Coatible (in a capsule form)
Readily/Easily ingestible (via oral means)
Bioavailable according to indication requirements
IR/SR/CR
(immediate, sustained, controlled, extended release)
MAIN PROCESS TYPES
a.) High Shear Granulation Process

(involves liquids/solids)
b.) Wet Spray Granulation Process

(involves liquids/solids)
c.) Direct Compression Process

(involves solids only)
d.) Particle Coating Process

(involves liquids/solid- usually capsules)
High Shear Granulation
made up of active drug and excipient.

Involves the addition of liquids onto th
powders to act as a conduit for densifi
Main pieces of equipment are:
1. High Shear Granulator (create the motion/energy to
solids/liquids efficiently and under control)
2. Solution Delivery System (for processing/pumping
3. Dryer (evaporate the liquids added and appropriately
the characteristics of the particles)
HSG Graphically
Dust free
Good flowability
Easy to dose/handle
Good dispersion
Compact structure
Low hygroscopic
Good solubility
High bulk density
Wet Spray Granulation
made up of active drug and excipient.

Involves the addition of liquids onto th
powders to act as a conduit for densifi
1. Low Shear Granulator/Fluid Bed (create the motion
integrate solids/liquids efficiently and under control)
characteristics of the particles). Usually same machine a
WSG Graphically
Dust free
Good flowability
Easy to dose/handle
Good dispersion
Excellent solubility
Low bulk density
Direct Compression
Entirely a dry process.

1. Tumble Blender
2. Loading/Unloading Equipment
DC Graphically
Good flowability
Easy to dose/handle
Good solubility
Easy Process
No physical changes
Particle Coating
and/or sealer onto a seed material.

Involves the application of a liquid/soli
suspension to the face of the seed mat
1. Fluid Bed Coater (create the motion/energy to integr
solids/liquids efficiently and under control)
characteristics of the particles). Usually same machine a
Coating Graphically
Low abrasion, smooth surface

Good flowability
Masking of taste and smell
Good protection against light, air and moisture
Impervious separating layers in the case of multi-
layer composition
Systematic release of active ingredients
Retardation, delayed dissolving
Visual attractiveness (pharmaceutical drug safety)
PROCESSING UNIT OPS
HSG WSG DC
Dispense Dispense Dispense Dis
* Pre-Blend ---- ----
Granulate Granulate ----
* Wet Mill * Wet Mill ----
Dry Dry ----
* Dry Mill/Sift * Dry Mill/Sift * Dry Mill/Sift
Dispense Dispense ----
Blend Blend Blend
Compress Compress Compress Cap
* Tablet Coat * Tablet Coat * Tablet Coat
Package Package Package Pa
* Optional Unit Operations

The OSD MATRIX
PRIMARY UNIT OPERATIONS
(actives, excipients, and misc m
Primary Equipment to Configure:

Containment Devices (LEV, Downflow Booth, I
Container Handling (bags, drums, supersacks,
(ergonomic lifts, inverters, manipulators)
Sifters/Mills (Bench, vibratory, etc)
Scales/Controllers (Bench, Floor, Printers)
Typical Equipment
Dispensing Configuration
Process/Facility Considerations

Blender (Vee, Cone, Ribbon, IBC)
Charging Devices (inverters, lifts, vacuum
Handling Equipment (lifts, bins, drums, et
Dust Collection (Hoods, Horseshoes, etc)
Controls, Batch Record Printers
Safety Enclosures, Barriers and Alarms
Typical Equipment
Primary Equipment to Configure :

Charging Devices (inverters, lifts, vacuum, e
Granulator (Gral, Vertical, PK)
Solution Prep System
Mills (Wet/Dry)
Dryer (Fluid Bed, PK)
Handling Equipment (lifts, bins, drums, etc)
Typical Equipment
Granulation Configurations
Primary Equipment To Configure:
Charging Devices (inverters, lifts, vacuum, fu

Feed Control and Down Chutes
Tablet Press or Encapsulator
Metal Detector, De-Duster, Tester, etc
Collection Containers (Pail, Drum, Poly IBC
Typical Equipment
Compression Configuration

Charging Devices (inverters, lifts, vacuum, sc
Coater w/Guns
Solution Prep System
Unloading Devices
Collection Containers (Pail, Drum, Poly IBC
Testing Equipment
Typical Equipment
Coating Configuration
OWNER/ENGINEER/VENDOR
CONSIDERATIONS
OSD Facility upgrade and build projects benefit from close communication an
collaboration among owner/engineer/vendor parties.
Once A&E is selected, owner and engineer should pre-plan and strategize on t
various technology/vendors options.
Involve the operators. They know better than the engineers
Consider a focused pre-qual strategy

Vendor profile/Budget Bid/Presentations/Short Listing
Address the Integration aspects early and impacts of vendor to vendor
More Bids = More time = More $
Consider sole source in ideal cases
Check references and make visits

Vendor Acknowledgement
A special thanks and acknowledgement to several vendo

WRAP UP/THANK YOU
Dave DiProspero
Senior Pharmaceutical Consultant
CRB Consulting Engineers

220 West Germantown Pike Suite 170
Plymouth Meeting, PA 19462
484.690.9800
856.562.0944
Dave.diprospero@crbusa.com
Please feel free to contact me at any tim

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What are the main types of oral solid dose processes discussed?

What are the main types of oral solid dose processes discussed?

What are the primary unit operations involved in granulation?

What are the primary unit operations involved in granulation?

Understanding Oral Solid

Dose Form (OSD)

Tuesday March 18, 2014 10am

Session Stage Setting

OSD Processing Goals

Main Types of OSD Processes

The OSD Primary Unit Operations Matrix our road ma

Primary Unit Operations

The Owner/Engineer/Vendor Considerations

Who is Dave DiProspero?

Who are you?

Industry: Pharma , Equip Vendors, Service Providers, Oth

Liquids: Suspensions, Solutions, Syrups

THE PREFERRED DOSAGE FORM, by far:

SOLID DOSE: Tablets/Capsules

Primary Manufacturing Goal:

a.) High Shear Granulation Process

b.) Wet Spray Granulation Process

c.) Direct Compression Process

d.) Particle Coating Process

made up of active drug and excipient.

made up of active drug and excipient.

Entirely a dry process.

and/or sealer onto a seed material.

Low abrasion, smooth surface

* Optional Unit Operations

(actives, excipients, and misc m

Primary Equipment to Configure:

Primary Equipment to Configure:

Primary Equipment to Configure :

Primary Equipment To Configure:

Charging Devices (inverters, lifts, vacuum, fu

Primary Equipment to Configure:

Involve the operators. They know better than the engineers

Consider a focused pre-qual strategy

Address the Integration aspects early and impacts of vendor to vendor

More Bids = More time = More $

Consider sole source in ideal cases

Check references and make visits

A special thanks and acknowledgement to several vendo

CRB Consulting Engineers

Please feel free to contact me at any tim

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