Engineering Research Center for Structured Organic Particulate Systems
Thrust C:Structural Characterization and Modeling
 

 

Thrust C: Structural Characterization and Modeling#top

 Understanding and predicting structure-property-function Relationships

 Thrust Leader: Alberto Cuitiño (Rutgers)
Project Leaders: Lynne Taylor (Purdue), Rajesh Davé (NJIT), Zafar Iqbal (NJIT),
Alberto Cuitiño (Rutgers), Bo Michniak-Kohn (Rutgers)
 

A. Thrust Objective and Goals

The central objective of this Thrust is the development of the scientific understanding and quantification of the role of the structure on the observed function/performance for a particular class of materials: structured organic composites. In order to establish such a linkage between structure and function, we have identified the following goals:

1)      Develop and implement experimental techniques to survey the structural features of the composite systems. All techniques need to provide spatial resolution of the composites to reveal the internal structure. The scale of observation is dependent upon each system ranging from the molecular level to macroscopic level.

2)      Develop and implement mechanistic models to predict behavior (function) attendant to the internal structure of the composite system. These models need account for the critical features of underlying structure which are necessary to capture the dominant mechanisms associated with a given function.

3)      Develop and implement techniques to assess the performance of organic composites systems with emphasis on the capturing the evolution of the structure. In many cases, the measurable quantities represent indirect measures of the sought performance attributes, and thus, their relationships need also to be determined.

4)      Design experiments to assess the criticality of the assumed mechanisms as well as to establish measures for the degree of confidence of the developed models using both pre-established and ad-hoc techniques.

 
The accomplishment of these goals will provide a quantitative and mechanistic link between structure-function to predict the behavior of given structures and also the reverse link function-structure necessary for designing structures with a desired functionality. The path and connectivity between structure and function is schematically shown in Figure 2P-12.
 
B. Technical scientific barriers/grand challenges for Thrust C
 
Structures are ubiquitous in all materials systems from the subatomic to the macroscopic level. The key and central question is what feature at a given scale is persistent at the next level of observation. Current research efforts in this area which has resulted on a partial understanding for several material systems; leaving a more general answer as a grand and open challenge for the scientific community in the physical & chemical sciences. A derived challenge is to further quantify and model the impact of these persistent structural features in the observed response for enabling a systematic optimization of the structure for desired response. These relevant structural features should then be incorporated in the modeling approach. Within the material science and engineering community, methodologies that incorporate features at a given scale into the observed response at coarser scale are typical denoted as multiscale methods, where the central issues is how to effectively bride the length scales.
 
 
 

C. Strategic Plan and Thrust Connectivity for Thrust C

To develop the structure-function relationship, we have developed a coordinated plan where the main focus is on the material structure. The plan is composed of several complementary and interrelated efforts including: i) multiscale characterization the material structure, which will used as a database for the structural and multiscale models; ii) multiscale modeling based on the structures observed; iii) assessment of the material response attendant to its structure; iv) verification and validation of the models based on the ad-hoc experiments. The connectivity of these activities is schematically shown in Figure 2P-13, and thus the project activities naturally connect with projects in Thrusts A and B and provide information and models to Thrust D.

 

D. Key Scientific Deliverables for Thrust C

 1)     Improved understanding of microstructure formation and evolution in complex drug-polymer dispersions including the formation of lamellae structures due to eutectoid solidification.

2)     Improved understanding and quantification of the role structures on powder flow of heterogeneous mixtures, including short and long range segregation and agglomeration using a complementary experimental-computation approach.

3)     Multiscale models for predicting the mechanical behavior of granular solids including the evolution of strength during processing. The key issue is the integration of single-scale models. There are several challenges in this integration process, notably the identification of the features at the finer scale that have a persistent effect in the upper scale.

4)     Mechanistic models to predict the role of shear on the structure/porosity of consolidated materials.

5)     Experimental techniques to conduct multi-resolution characterization of defects on solid structures (porosity/cracks).

6)     Methodologies for spatially and chemically mapping structures solid systems including drug loaded polymeric films, tablets and multilayer dosages.

7)     Methodologies to assess and quantify the role of structures on drug release profiles.

Individual projects’ scientific focus is designed to help establish the knowledge base of the thrust, hence, this thrust makes strong contributions to the bottom and middle planes of the 3-plane chart as shown in Figure 2P-14. However, the project deliverables also serve to support specific test bed (shown in the top plane in Figure 2P-14) needs in addition to the thrust level goals. The ten year milestones for the Thrust C are shown in Figure 2P-15, where scientific as well as current test-bed related tasks are emphasized for the period of 5-8 years.

 Major milestones for Thrust C, addressing scientific and technological deliverables are listed below:

T-C-1    Structure-Property-Function Relationships for stability of structured particles in polymeric solids
T-C-2    Structure-Property-Function Relationships for formation of API crystals in polymeric solutions
T-C-3    Develop models to predict crystallization outcome based on experimental input parameters
T-C-4    Structure-Property-Function Relationships for cohesive heterogeneous granular materials
T-C-5    Characterization of Electrostatic properties, hydrophobicity and other important properties of blend and blend 
              ingredients.
T-C-6    Characterization of various powder testers, processing conditions, and blend constituent properties 
           on compaction, tablet and dissolution properties.
T-C-7    Spatially-resolved methods for quantifying structure in particle laden films and consolidated materials
T-C-8    Implementation (phase I) of X-ray techniques, low frequency Raman, DSC, photoluminescence, 
           X-ray absorption and LIBS for particle size, polymorph/defect formation and elemental composition 
           characterization
T-C-9    Structure-Property-Function Relationships (multiscale models) for compacted granular materials.
T-C-10  Simulation tool to predict tablet properties attendant to the distribution of bond strength
T-C-11  Structure-Property-Function Relationships (multiscale models) for drug release of particle-laden films 
           and compacted materials
T-C-12  Validation of models with the incorporation of the structural information from LIBS, Chemical Imaging 
           and X-Ray CT.
T-C-13  Develop a simulation framework to guide the process of designing optimal structures for a desired drug release
              profile
T-C-14  Optimization of particle dispersion in polymeric matrixes, polymer mechanical stability, API release profiles, and
              polymer properties
T-C-15  Bio-availability characterization of orally ingested dosage forms using in the TIM-1 system by TNO.  

 E. Thrust C Projects

While the scientific challenges of the thrust are quite broad, we have identified as part of the strategic plan five interrelated and coherent projects that will allow us to address and successfully advance the critical issues required to integrate the three current test beds. These projects are:


Project C-1: Solidification and crystallization of complex drug-polymer dispersion  #top

Participants: Lynne Taylor (Lead) (Purdue), Paul Takhistov (Rutgers), Michael Harris (Purdue), SylvinaTomassone (Rutgers), Carlos Rinaldi (UPRM)
Consultants: James Litster (Purdue), Xianqin Wang (NJIT) 
Mentors: Rennan Pan, Yu Li (GSK), Oscar Liu (Schering Plough), Jim Wesley (Lilly), Chandan Bhugra (Boehringer Ingelheim)
Postdoctoral Fellows: Bernard van Eerdenbrugh (Purdue) 
Graduate Students: Jared Baird (Purdue), Qing Zhu (Purdue), Darlene Santiago (UPRM)

   Scientific Objectives (Coordinated with Thrusts A and C):

·    Develop a molecular level, thermodynamic and kinetic understanding of crystallization tendency during the solidification of drug and drug-polymer systems,

·     Establish link between glass forming ability and glass stability,

·     Prediction of drug-polymer miscibility based on molecular structures

·     Develop models to predict the influence of polymeric additives on drug crystallization,

·     Develop models to predict matrix structure as a function of polymer and drug properties, processing and storage conditions.

Technological objectives (coordinated with the TB 3)

The technological objectives of project C-1 and TB3 are to deposit and solidify API formulations with well defined, predictable properties and sufficient and consistent dissolution behavior. The objective of this research is to determine under what circumstances it is optimal to use the crystalline form of an API versus an amorphous formulation. The challenge is to avoid phase/structural changes following the time between deposition and solidification and administration to the patient. Some specific objectives include:

·    Develop methods to evaluate microstructure and phase behavior of formulations deposited as drops

·    Produce a classification system of drug crystallization tendency and recommendations for formulation route based on classification system


 
Project C-2: Granular Granular Rheology: Influence of Materials, Structure and Processing on Powder Flow #top

Faculty: Rajesh Davé (Lead) (NJIT), Fernando Muzzio (Rutgers)
Consultants: Alberto Cuitiño (Rutgers), Carl Wassgren (Purdue), Bo Michniak-Kohn (Rutgers)
Mentors: Jayant Joshi (GSK), Bruno Hancock (Pfizer), David Goldfarb (Schering Plough), Chen-Ming Lee (Boehringer Ingelheim)
Graduate Students: Lauren E. Beach (NJIT), Anagha Bhakay (NJIT), Lakxmi Gurumoorthy (NJIT), Xi Han (NJIT), Laila Jallo (NJIT), Mulukutla Tripura (NJIT)

Scientific objectives (coordinated with Thrust C)

Overall scientific objective of thrust C is to develop scientific understanding and quantification of the role of the structure (including properties of the materials) on the observed function/performance for a particular class of materials: structured organic composites. The scientific objectives of the project are aligned with that overall objective, and connect well to projects in thrusts A and B: 

·   Identify the mechanisms affecting the state and structure of cohesive granular system during flow, for the purpose of controlling the aggregation/de-aggregation, flow rate and uniformity of the powder compositions. (effect of flow on structure)

·    Develop a suite of experimental techniques to assess the powder flow characteristics and the degree of agglomeration of cohesive powders.

·    Quantify the effect of agglomerates formation and break up on the flow behavior (effect of structure on flow).

·    Develop a methodology, validated using multiple modes of characterization and correlating the knowledge of material & particle properties, structure, and processing, for powder testing using small samples for the purpose of predictive powder flowability determination.

·    Indentify the material properties as well as their necessary modifications for the powder composition that will promote better flow when majority of the blend ingredients are cohesive.

·    Advance the mechanistic constitutive modeling for cohesive granular systems reflecting their complexities such as yield stress, failure surfaces, coexistence of multiple constitutive regimes and density hysteresis.


Technological objectives (coordinated with the TB 1)

The technological objectives for the project involve use and development of powder testing techniques and characterization of pharmaceutical blends and compositions. In cases where the flow must be improved, either pre-coating or judicious blending of flow-aids and lubricants will be used for improving the flow; however, quantitative characterization and the ability for predictive selection of blend ingredients, mode of flow enhancement, and processing conditions are crucial. Technological objectives are:

 ·  Select, install, and qualify existing equipment for powder testing. This includes shear cell(s), rheometers (GDR and FT4), Flodex and Hosokawa Powder Tester.

·   Select powder blends based on test-bed 1 requirements, in at least two categories, e.g., moderate (20-40%) and high drug (>80%) concentrations. Evaluate the powder properties with and without the presence of flow-aids and lubricants.

·   Prepare blends with pre-treated APIs (nano-coated, or surface modified, done after input from industry mentors) and evaluate their properties. It is expected that the amount of flow-aids required will be less for pre-treated APIs in contrast to blends.

·   Develop and/or modify powder testing apparatus suitable for characterizing blends containing pre-treated cohesive powders; e.g., Sevilla Powder Tester, Vibrated Packed Density tester, etc.

·   Employ and/or develop methods for quantifying properties such as surface energy, hydrophobicity and electrostatic properties of the blend constituents. Connect this work with project A-6 activities.

·   Examine the feasibility of drawing from the DEM work from project B-2 to correlate the powder properties with processing conditions for blending operation. 

·   Coordinate experimental plans and blend compositions between related projects, e.g., A-6, B-2 and B-1, and thus prepare powder blends for downstream projects, B-4, B-5, C-4, and C-5 so that influence of powder flow and structure is understood on compaction, tablet and dissolution properties. This also includes evaluation of feeder and mixer performance as a function of powder flow properties.

·   Develop a knowledge base and correlations between results from various powder testers, processing conditions, and blend constituent properties. Based on this and input from other projects, develop guidelines for achieving API blends that flow better and have less stickiness (triboelectric charging, etc.) and hence less problems in subsequent processing, while avoiding adverse effects on tablet and dissolution properties.

  

Project C-3: Structural Characterization of Composite Solids #top

Faculty: Zafar Iqbal (Lead) (NJIT), Rodolfo Romañach (UPRM), Bo Michniak (Rutgers), Alberto Cuitiño (Rutgers), Fernando Muzzio (Rutgers), Dor Ben-Amotz (Purdue), Xianqin Wang (NJIT), Ken Morris (Hawaii), Lynne Taylor (Purdue)
Consultants: Carl Wassgren (Purdue), Rajesh Dave (NJIT)
Mentors: Renuka Nair (GSK), Xia Dong (Lilly), Shirlynn Chen (Boehringer Ingelheim), Luis Martindejuan, Eli Crossman (P&G)
Graduate Students: Anna K. Zarow (NJIT)

Scientific objectives (coordinated with Thrust C)
 
The central objectives of the project will be coordinated with those of Thrust C to provide:

·   multiscale characterization of the structure of organic composites in the form of polymeric films, consolidated granular solids and tablets to develop on-line sensing technologies and a structure-function relationship which will be used as a database for structural and multiscale models;

·   assessment of the material response as a function of its structure;

·   and verification and validation of the models based on multiscale materials structure and performance obtained in this project and ad-hoc experiments performed in the other four inter-related projects under Thrust C.

 Technological objectives (coordinated with test beds)

     This project will support the key objectives of all three test beds. In Test Bed 1 involved with the continuous manufacturing of tablets under automatic control, the structural characterization data will facilitate the development of predictive models and provide insights into mitigating the problems of segregation, agglomeration, and compact quality via the characterization of defect distribution to assess the mechanical properties of the compacted ribbon and tablets that are key to dosage form manufacture and performance as well as the focus of advanced modeling in this area.

      In Test Bed 2 involving particle engineering to form three-dimensional solid gel-based strip films, the interactions between the film matrix and the surface of the active organic particles, are critical for the production of composite films comprised of well-controlled distributions of particles, which will be obtained from the techniques implemented in this project. Chemical mapping results together with x-ray diffraction and micro-tomography data obtained in this project, will provide particle size distributions of the active ingredients ranging from the nano- to the micro-scale. Stabilization of nanoparticles in the strip films will allow a good formulation of drugs with poor solubility coupled with bioavailability and very low dosage. Characterization techniques, such as near-IR and Raman spectroscopy using chemical mapping and imaging in combination with chemometrics, will be used for inspection of the uniformity and spatial distribution of the active ingredient in the films.

      This project will facilitate optimization of the drop-on-demand technology being developed in Test Bed 3, where the goal is to controllably deposit three dimensional dosage structures of the active ingredient onto an edible thin film substrate. This will be achieved by providing detailed characterization of the particle size, morphology and crystal form distributions of the active ingredients. Moreover, some techniques like near-IR and Raman spectroscopy can also perform investigations of the chemical interaction of the drug with the substrate in real-time in order to help understand and optimize the drop-on-demand process.

 

Project C-4: Bonding of Granular Solids #top
 
Faculty: Alberto Cuitiño (Lead) (Rutgers), Carl Wassgren (Purdue), James Litster (Purdue)

Consultants: Ken Morris (Hawaii)

Mentors: Brendan Walsh (GSK), Steve Hammond (Pfizer), David Goldfarb (Schering Plough). Vijay Joguparthi (Boheringer Ingelheim), Luis Martindejuan, Eli Crossman (P&G) 

Scientific objectives (coordinated with Thrust C)

The scientific goals of this project have been identified to overcome the main barriers to advance the overall goals of Thrust C. These goals are:

·  Identification of the dominant mechanisms responsible for bonding (development of strength) during consolidation of compaction of granular systems

·    Development of multiscale modeling and simulation strategies to account for powder related properties (size distribution, shape, surface characteristics, etc) and processing conditions

·    Development of 3D mechanistic continuum models for confined granular systems describing both tensile and compressive regime under different degree of confinement

·    Design and implementation of experimental test to verify and validate the models, including biaxial and tri-axial testing. 

Technological objectives (coordinated with the TB 1)

This project is concerned with the development of an integrated experimental and computational framework to understand role of the process environment and the material properties of relevant formulations on the structure and bonding strength of the consolidated materials. The technological objectives will be coordinated via Thrust B into TB1 to provide tools that will allow the design of dosage forms in continuous manufacturing platform. The proposed methodology will allow to mechanistically inform the models needed for controlled the tabletting and roller compaction operations. In addition it will provide spatially resolved characterization of the compact, which will be use to identify and quantify the severity of defects.

 

Project C-5: Drug Release from Complex Solids   #top
   
Faculty: Bo Michniak-Kohn (Lead) (Rutgers), Madeline Torres (UPRM), Rodolfo Pinal (Purdue), Alberto Cuitiño (Rutgers), Fernando Muzzio (Rutgers)
Mentors: Shadi Madieh (GSK), Oscar Liu (Schering Plough), David Sperry (Lilly), Shirlynn Chen (Boehringer Ingelheim), Richard Hsia (Sepracor)
Graduate Students: Anagha Bhakay (NJIT)

  Scientific objectives (coordinated with Thrust C)

 ·   Development of experimental techniques to quantify the drug release profiles of tablets and films including chemical imaging of actives in tablets and polymer films

·    Development of experimental techniques to assess the evolution of the microstructure during the dissolution

·    Development of mechanistic models for drug release accounting for drug distribution and properties of the matrix

·    Develop a strategy for model validation and parameter determination for dissolution of heterogeneous systems

·    Develop a simulation framework to guide the process of designing optimal structures for a desired drug release profile

 Technological objectives (coordinated with testbeds)

·    Perform dissolution testing of tablets and polymer films

·    Correlate matrix characteristics with drug release parameters

·    Examine the distribution of actives and excipients using chemical imaging and relate to processing conditions and dissolution characteristics (in conjunction with Project C-3)

·    Develop mechanistic models to explain dissolution properties of tablets and films

·    Correlate the dissolution rate of the drug with the microstructure for drug polymer films

·    Develop and implement level-set models to simulate coupled drug dissolution and surface erosion

·    Determine and calibrate constitutive parameters for level-set dissolution model

·    Develop new approaches to measurement of dissolution /drug release that relate more closely to drug release and bioavailability in the body. Initially this will involve the use of new equipment from TNO (The Netherlands) that is a gastrointestinal in vitro model for drug release.

·    Identify physicochemical parameters that are critical to promote higher particle loadings while avoiding particle segregation

·    Optimize particle dispersion in polymeric matrixes, polymer mechanical stability, drug release profiles, and polymer properties

 
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