Hello good people of the world! Today we’re talking about architectural considerations in the design of oral solid dose (OSD) manufacturing facilities.
In addition to normal architectural standards, the following must be considered for OSD manufacturing facilities:
Manufacturing process flow
Personnel flow
Equipment flow (clean and dirty)
Waste flow
Risks to consider when mapping flows include:
Risk of contamination from outside contaminates
Risk of cross-contamination
Risk of mix-up
Risk mitigations should consider:
Process containment
Isolators
Environmental controls
Room size
Transition spaces and airlocks
Personnel controls such as gowning
Administrative controls such as frequency of operation
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Hello good people of the world! Continuing the series on oral solid dosage forms, today we’re going to talk about unit operations typical in a oral solid dose manufacturing process.
Typical OSD processes may include some combination of weighing/dispensing, material transfer, blending, granulation, drying, milling/sieving, compression, encapsulation, and coating. Some considerations around each step may include:
Weighing/Dispensing: includes sampling for quality purposes. Materials to be sampled typically include: APIs, excipients, primary and secondary packaging, cleaning agents. Sampling areas must be protected from contamination.
Material Transfer: material flows should be documented and reviewed, with the intention of minimizing any contamination.
Blending: materials are typically blended to ensure a uniform composition, prior to downstream process steps. Many methods exist, including: tumble blending, bin blending, and agitator mixers.
Granulation: granulation is the process of combining particles into a granule. Many methods of granulation exist: wet massing/extrusion, high shear, spray, speronization, and hot melt extrusion, for example.
Drying: the purpose of the drying step is to remove any excess moisture from the drug product. Drying methods include: tray , fluidized bed, and spray drying.
Milling/Sieving: the purpose of this process step is to reduce granule size to conform to specification. Some methods include: impact/hammer mills, conical mills, and oscillating horizontal screens.
Compression: compression is used to create tablets.
Encapsulation: encapsulation is used to create capsules.
Coating: coating is used to apply a coat to tablets
In the next post we’ll cover supporting equipment and quality systems. What process steps do you use in your OSD process? Comment below!
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Validation, Qualification, and Commissioning For Pharma, Biotech, and Med Device Industries