Quality by Design (QbD) based process optimisation to develop functionalised particles with modified release properties using novel dry particle coating technique


Quality by Design (QbD), a current trend employed to develop and optimise various critical pharmaceutical processes, is a systematic approach based on the ethos that quality should be designed into the product itself, not just end tested after manufacture. The present work details a step-wise application of QbD principles to optimise process parameters for production of particles with modified functionalities, using dry particle coating technology. Initial risk assessment identified speed, air pressure, processing time and batch size (independent factors) as having high-to-medium impact on the dry coating process. A design of experiments (DOE) using MODDE software employed a D-optimal design to determine the effect of variations in these factors on identified responses (content uniformity, dissolution rate, particle size and intensity of Fourier transform infrared (FTIR) C = O spectrum). Results showed that batch size had the most significant effect on dissolution rate, particle size and FTIR; with an increase in batch size enhancing dissolution rate, decreasing particle size (depicting absence of coated particles) and increasing the FTIR intensity. While content uniformity was affected by various interaction terms, with speed and batch size having the highest negative effect. Optimal design space for producing functionalised particles with optimal properties required maximum air pressure (40psi), low batch size (6g), speed between 850 to 1500 rpm and processing times between 15 to 60 minutes. The validity and predictive ability of the revised model demonstrated reliability for all experiments. Overall, QbD was demonstrated to provide an expedient and cost effective tool for developing and optimising processes in the pharmaceutical industry.

Publication DOI: https://doi.org/10.1371/journal.pone.0206651
Divisions: College of Health & Life Sciences > Aston Pharmacy School
College of Health & Life Sciences
College of Health & Life Sciences > Chronic and Communicable Conditions
College of Health & Life Sciences > Applied Health Research Group
Additional Information: © 2018 Dahmash et al. This is an open access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.
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Related URLs: https://journal ... al.pone.0206651 (Publisher URL)
PURE Output Type: Article
Published Date: 2018-11-01
Accepted Date: 2018-10-17
Authors: Dahmash, Eman Z
Al-Khattawi, Ali (ORCID Profile 0000-0002-2498-2817)
Iyire, Affiong
Al-Yami, Hamad
Dennison, Thomas J
Mohammed, Afzal R (ORCID Profile 0000-0002-5212-3040)



Version: Published Version

License: Creative Commons Attribution

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