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International Journal of Pharmaceutics 521 (2017) 102109

Contents lists available at ScienceDirect

International Journal of Pharmaceutics


journal homepage: www.elsevier.com/locate/ijpharm

Articial neural network modelling of continuous wet granulation


using a twin-screw extruder
Saeed Shirazian* , Manuel Kuhs, Shaza Darwish, Denise Croker, Gavin M. Walker
Department of Chemical Sciences, Bernal Institute, University of Limerick, Limerick, Ireland

A R T I C L E I N F O A B S T R A C T

Article history:
Received 29 November 2016 Computational modelling of twin-screw granulation was conducted by using an articial neural network
Received in revised form 1 February 2017 (ANN) approach. Various ANN congurations were considered with changing hidden layers, nodes and
Accepted 2 February 2017 activation functions to determine the optimum model for the prediction of the process. The neural
Available online 3 February 2017 networks were trained using experimental data obtained for granulation of pure microcrystalline
cellulose using a 12 mm twin-screw extruder. The experimental data were obtained for various liquid
Keywords: binder (water) to solid ratios, screw speeds, material throughputs, and screw congurations. The
Computational modelling granulate particle size distribution, represented by d-values (d10, d50, d90) were considered the
Model predictive control
response in the experiments and the ANN model. Linear and non-linear activation functions were taken
Wet granulation
into account in the simulations and more accurate results were obtained for non-linear function in terms
ANN
Continuous pharmaceutical manufacturing of prediction. Moreover, 2 hidden layers with 2 nodes per layer and 3-Fold cross-validation method gave
the most accurate simulation. The results revealed that the developed ANN model is capable of predicting
granule size distribution in high-shear twin-screw granulation with a high accuracy in different
conditions, and can be used for implementation of model predictive control in continuous
pharmaceutical manufacturing.
2017 Elsevier B.V. All rights reserved.

1. Introduction considered as an advanced control strategy. MPC considers each


unit operation and takes a holistic view of the manufacturing line.
The development of continuous pharmaceutical manufacturing Therefore, each unit operation should be specied and its model
has been a subject of great interest for the pharmaceutical needs to be developed to implement MPC for the manufacturing
industry. Currently, manufacturing of solid-dosage pharmaceutical line. There are different processes in the manufacturing of solid-
formulations are carried out in batch-wise operation. In batch- dosage drugs such as milling, mixing, granulation, drying, and
mode processing, each run that does not meet the requirements is coating. Granulation is the key step in manufacturing pharmaceu-
rejected which results in time and cost decits for the tical formulations, in which granules are produced from a ne
manufacturing of pharmaceutical compounds. Continuous phar- powder including an active pharmaceutical ingredient (API) and an
maceutical processing can overcome this drawback and therefore excipient. Moreover, wet granulation is the most complex unit
offer more advantages compared to batch processing. In order to operation in pharmaceutical manufacturing since many
develop continuous pharmaceutical manufacturing, each unit mechanisms are involved in the formation of granules from ne
operation in the manufacturing line should be inter-connected in powder (Rogers et al., 2013). Recently, twin-screw granulation has
an appropriate way (Lee et al., 2015). gained a lot of attention over other granulation methods due to its
A powerful tool for development of continuous pharmaceutical unique characteristics. The main advantage of twin-screw
manufacturing is model predictive control (MPC), which is granulation is that it is an intrinsic continuous process which
can promote development of continuous pharmaceutical
manufacturing (Seem et al., 2015). Other advantages of twin-
Abbreviations: ANN, articial neural network; API, active pharmaceutical screw extruder in the pharmaceutical sector are its ability to mix
ingredient; DEM, discrete element method; DoE, design of experiment; GSD, and react the feed materials, and its short residence time.
granule size distribution; MCC, microcrystalline cellulose; MPC, model predictive
In order to implement MPC approach for continuous
control; PBM, population balance model; PSD, particle size distribution; RMSE,
root-mean-squared error; SSE, sum of squared error. manufacturing, a model of each process step is required which
* Corresponding author. can be done by mathematical or computational modelling. There
E-mail address: saeed.shirazian@ul.ie (S. Shirazian).

http://dx.doi.org/10.1016/j.ijpharm.2017.02.009
0378-5173/ 2017 Elsevier B.V. All rights reserved.
S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109 103

predict the granule size, liquid content, and porosity as a function


Nomenclature
of process parameters.
Subsequently, Barrasso et al. (Barrasso et al., 2015 Barrasso and
d D-value of particle size distribution (micron)
Ramachandran, 2015) utilized the DEM approach for the estima-
f Predicted value
tion of aggregation kernel in solution of population balance model.
L/S Liquid to solid ratio
The results showed a better prediction of particle size distribution
K Number of experimental subsets for ANN validation
compared to semi-empirical aggregation kernel.
n Number of experiments
The results of mechanistic models developed for twin-screw
R2 Coefcient of determination
granulation revealed that these mechanistic models are quite slow
x Linear combination of input factors
for the use of MPC in the development of continuous pharmaceu-
y Measured value
tical manufacturing. However, these mechanistic models can be
used for the process design and optimization (Barrasso et al., 2015;
Subscript
Kumar et al., 2013, 2015).
i Experiment set
The main disadvantage of aforementioned mechanistic models
is that it is not fast enough to be used as a model for the
development of MPC approach in continuous manufacturing. In
MPC, the model of process should be able to run within a few
are different approaches for mathematical modelling of granula- seconds in order to predict the future behaviour of the process.
tion process including; population balance model (PBM), discrete Therefore, these mechanistic models fail to be applied for MPC, and
element method (DEM), and hybrid models. In hybrid models, both in fact faster models are required for industrial applications.
PBM and DEM models are used to benet the advantages of both Recently, some researchers have tried to reduce the solution time
methods in modelling of granulation. For PBM, the changes of for mechanistic model by utilizing ANN. Barrasso et al. (Barrasso
granule properties such as size distribution are calculated. et al., 2014) developed a hybrid model by coupling PBM and
However, DEM tracks the motion of each individual particle along articial neural network (ANN) for describing wet granulation. The
the space, this is based on Newtons second law (Rogers et al., main aim of a hybrid model is to make the solution time faster. The
2013). Given that particle size is an important product character- results showed that ANN is capable of simulation for wet
istic, these models primarily focus on predicting the particle size granulation process, although it does not look at the mechanisms
distribution in granulation. However, in wet granulation the liquid associated with the granulation. A list of different mechanistic and
content and porosity are also very important for subsequent hybrids models applicable to wet granulation are reported by
processes, such as tabletting. Kumar et al. (Kumar et al., 2013; Rogers et al., 2013).
Some theoretical and experimental work using twin-screw Data-driven models have proved to be robust and efcient for
extruder has been carried out to simulate continuous wet the application of simulation and prediction of pharmaceutical
granulation. Several researchers have investigated predictive processes. An important class of data-driven models is articial
modelling of wet granulation by using PBM and DEM modelling. neural network (ANN) which is powerful in process prediction
Barrasso et al. (Barrasso et al., 2015) developed a multi- (Kazemi et al., 2016; Puri et al., 2016). ANN is usually used for
dimensional population balance model for the prediction of modelling of complex processes in which mechanistic models fail
granule properties in a twin-screw granulation. Lumped-parame- to predict the process or are computationally expensive.
ter and compartment approach were used for the numerical ANN has been used for predication of some pharmaceutical
solution of population balance equations. This model was able to processes such as milling. Kazemi et al. (Kazemi et al., 2016)

Table 1
Design of experiments for ANN simulation of wet granulation.

Run L/S Screw speed (rpm) Powder ow rate (g/h) Screw conguration d10 (Micron) d50 (Micron) d90 (Micron)
1 0.54 64 49.75 2 kneading zones 15.07 88.535 328.8
2 0.94 200 98 2 kneading zones 151.35 417.2 1004.15
3 1.22 86 98.2 2 kneading zones 357.35 759.9 1202
4 0.54 200 69.33 2 kneading zones 23.885 130.2 360.3
5 1.22 200 61.47 2 kneading zones 307.15 689.95 1038.7
6 1.22 50 82 2 kneading zones 445.65 767 1105
7 1.21 200 49.4 1 kneading zone 385.75 1008.2 1303
8 0.78 200 49.75 1 kneading zone 65.195 271.6 653.5
9 1.21 115 49.5 1 kneading zone 455.15 1052.65 1313.5
10 0.49 185 67.55 1 kneading zone 14.605 67.46 342
11 0.65 50 97.6 1 kneading zone 10.57 76.865 342.6
12 0.52 50 97.05 1 kneading zone 8.33 35.805 300.5
13 1.22 50 82 1 kneading zone 177.5 440.55 831.8
14 0.55 200 98.6 conveying elements only 25.06 113.25 291.35
15 1.22 200 98.15 conveying elements only 332.55 860.65 1250
16 0.76 200 99.2 conveying elements only 66.91 241.2 641.45
17 0.59 85 51 conveying elements only 35.02 164.7 384.45
18 1.12 72 53.25 conveying elements only 186.775 367.975 820.125
19 0.48 50 49.8 conveying elements only 18.42 102.745 341.2
20 0.50 200 95.05 2 kneading zones with cutting elements 7.585 22.425 113.75
21 1.20 58 82 2 kneading zones with cutting elements 330.7 865.6 1273.5
22 0.66 200 49.65 2 kneading zones with cutting elements 35.605 188 490.7
23 0.54 50 61.45 2 kneading zones with cutting elements 14.875 87.55 342.7
24 1.22 200 97.38 2 kneading zones with cutting elements 325.4 763 1154
104 S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109

Fig. 1. Screws used for wet granulation experiments.

applied the computational intelligence-based models for simula- The experiments were designed based on a Custom-designed
tion of oscillating milling. Genetic programming was coupled with DoE considering feed ow rate, screw speed, liquid to solid ratio (L/
ANN in order to predict the particle size during the milling process. S), and screw congurations as factors and particle size distribu-
The model capability in the prediction of d50 values conrmed that tion in terms of d-values as a response. The designed experiments
the ANN is a powerful tool for simulation of pharmaceutical and the obtained d-values of particle size are listed in Table 1. Fig. 1
processes specically for complex unit operations. illustrates the photo of two screws used in this work, and the screw
Therefore, there is a requirement for the development of a conguration can be seen schematically in the Supplementary le.
robust, reliable and fast model to be used for the prediction of high- The obtained granules were dried overnight in an oven at 40  C
shear wet granulation. The main aim this study is to develop a and then characterized using dry powder dispersion laser
methodology to predict the wet granulation process in an efcient diffraction (Microtrac S3500). As the size limit for Microtrac
manner. The predictive method is based on the simulation of this S3500 is 1.4 mm, a sieve was used prior to laser diffraction to
process using articial neural network. An effort is made to build a measure the mass of material greater than 1.4 mm. Consequently
robust, reliable, and fast model of processing which can be used for the recorded d-values of particle size are for the mass fraction
implementation of model predictive control in pharmaceutical smaller than 1.4 mm. As the% mass fraction > 1.4 mm was usually
manufacturing. Both linear and non-linear models are investigated less than 1%, this was considered adequate.
at different network topologies to nd the optimum network for
wet granulation. The model predictions are then compared with 3. Modelling
experimental data obtained on a 12 mm twin-screw extruder. To
the best of our knowledge, there is no work on ANN modelling of 3.1. ANN conguration
high shear twin-screw granulation of pharmaceutical formula-
tions. For the development of the ANN model, in addition to screw
conguration, three process parameters including liquid to solid
2. Experiments ratio (L/S), screw speed, and powder ow rate were considered as
inputs. On the other hand, d-values of particle size distribution
Wet granulation experiments were conducted via a twin-screw including d10, d50, and d90 were considered as response
extruder, ZE12 (ThreeTec, Switzerland) with screw diameter of parameters. Basically, ANN models consist of three layers; i.e.
12 mm and length-to-diameter ratio 40:1. Microcrystalline cellu- input, hidden and output layers (Kazemi et al., 2016). Important
lose (MCC, Avicel pH 101 Pharmatrans) was used as a formulation parameters in development of ANN include: validation method,
model and water as a binder throughout the experiments. A activation function, hidden layers, and number of nodes in each
peristaltic pump (Watson Marlow 520SN) was used for adding layer of network. These parameters were taken into account to nd
water and a gravimetric feeder (Three-Tec, Switzerland) for feeding out the optimum ANN topology for predicting the process. Finding
the powder. the optimum ANN topology is challenging since there is no
straightforward procedure for this, and usually a trial and error
Table 2
Comparisons between different ANN topologies in terms of nodes and activation
functions.

No. First layer Second layer Average RMSE

Linear Non-linear Linear Non-linear


1 1 1 1 1 102.98
2 1 1 1 2 84.68
3 1 1 2 1 105.95
4 1 1 2 2 80.06
5 1 2 1 1 82.26
6 1 2 1 2 71.37
7 1 2 2 1 61.04
8 1 2 2 2 93.16
9 2 1 1 1 78.12
10 2 1 1 2 89.85
11 2 1 2 1 65.44
12 2 1 2 2 93.83
13 2 2 1 1 60.57
14 2 2 1 2 65.31
15 2 2 2 1 85.69
16 2 2 2 2 48.95
17 0 1 0 1 89.40
18 0 2 0 2 71.98
19 1 0 1 0 104.60
20 2 0 2 0 107.10
Fig. 2. Topology of boosted ANN.
S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109 105

approach is utilized for building an appropriate model. Kfold show the model accuracy. Coefcient of determination which is
method was used as validation in which K = 3 showed the best dened as (Barrasso et al., 2015):
results. The latter means that the whole experimental measure- X 2
ments are divided into three sections, and each set of data is 2
f i  yi
R 1  Xi 1
evaluated for validation and the best t is selected. Therefore, y  yi 2
i i
among 24 experimental runs listed in Table 1, 16 runs were used for
training of the network and 8 runs were used to validate the built where R2 refers to coefcient of determination. f and y refer to
ANN model. JMP Pro 12 software was used for ANN modelling and predicted and observed values, respectively. i also refers to the set
analysis of the results. The software is capable of considering of experimental runs.
categorical factors as input for ANN tting. Moreover, the goodness of ANN t is reported as root-mean-
squared error which is dened as follows:
3.2. Model assessment sX
2
f  yi
i i
RMSE 2
The developed ANN model is used for prediction of d-values in n
twin-screw granulation in which the predictability of model is where n refers to the number of measurements
assessed through comparing the predicted values with observed
(experimental) values. Two statistical parameters were used to

Fig. 3. Experimental versus predicted d-values.


106 S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109

4. Results and discussion (SAS_Institute, 2016):

e2x  1
4.1. Experimental results 3
e2x 1
The experimental data obtained from measuring d-values of where x is a linear combination of input variables
particle size distribution are reported in Table 1. As seen, 24 Up to four nodes were considered for each layer (two linear and
experiments were run and d-values for each run were measured two non-linear) and the results were compared in terms of average
and reported as d10, d50, and d90. Rather than tting the ANN RMSE for overall training and predictions. Increasing the number of
model to all d-values and particle sizes, these three d-values were nodes greater than two increased the solution time and no
chosen to t the model to avoid the complexity of objective signicant improvement was observed. Since the objective
function in parameter estimation. Moreover, for industrial function may have different local minima, multi-start technique
applications the granule size range are of great importance rather was used for parameter estimation and tting. This means that the
than the whole particle size distribution (Barrasso et al., 2015). ANN tries to estimate the tting parameters by different initial
points in order to nd the global minimum of objective function.
4.2. Determination of hidden layers and nodes The iteration parameter was set to be 10 for multi-start technique
(Kazemi et al., 2016).
Basically, ANN consists of layers and nodes in which increasing The results are listed in Table 2. As shown, the ANN topology
hidden layers and notes would make the ANN model more exible. with two nodes for both hidden layers considering a combination
In this work, two hidden layers and up to four nodes per layer were of non-linear and linear activation functions shows the best
considered for the development of ANN. However, more nodes and performance in tting the experimental data. However, the results
layers could be considered but the solution time would increase are not still satisfactory given that the model could be used as
considerably. Since the main aim of ANN model in this work is to be reliable tool for prediction of process.
used for MPC application, the solution time is the most important
criterion for ANN development. For each hidden layer, an 4.3. Boosting the network
activation function is required to estimate the value of response.
The activation function applies at the nodes of hidden layers and is The ANN developed so far with two hidden layers and two
a transformation of a linear combination of input variables. For this nodes per layer has shown to be weak for accurate prediction of
work, two different activation functions are considered including granule size in twin-screw granulation. Considering this, an
linear and non-linear. For linear activation function, the linear attempt was made to build a more robust and reliable model to
combination of input variables are not transformed whereas for predict the process. To do this, the trained networks were made
non-linear, the hyperbolic tangent function is used as follows more robust by boosting approach. Boosting is used of construct

Fig. 4. Residuals of ANN ttings for different d-values.


S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109 107

larger additive ANN models by tting a sequence of smaller


models. Basically, in boosting a model, each of the smaller models
which is already built is t on the scaled residuals of the previous
model. Afterward, the models are combined to form the larger nal
models. It should be pointed out that boosting uses validation to
assess how many component models are required to t. Boosting is
often faster than tting a single large ANN model. However, the
base model should consist of a 1 to 2 node model, or else the
advantage of faster tting may be lost if a large number of models is
specied (SAS_Institute, 2016). The boosting was performed for all
networks consisting of a maximum of 2 nodes per layer. (see
Table 2). For boosting the network, the maximum number of
models were set to be 15 and the best results were obtained with
the network consisting of 2 nodes per layer with non-linear
activation function (No. 18 in Table 2). Finally, the model consists of
15  2 = 30 nodes in each hidden layer with non-linear activation
function. The topology of boosted ANN is shown in Fig. 2.

4.4. Model validation

The boosted ANN is rst trained/calibrated using experimental


data (16 runs) in order to estimate the unknown tting parameters.
Once the model is calibrated, it is then used for the prediction of
experimental data (8 runs). The trained and predicted results
developed by ANN were compared with experimental data to
assess the accuracy of the ANN. The results are shown in Figs. 3 and
4. The statistical parameters of ttings are also shown in Fig. 5. In
Fig. 3, predicted values for d10, d50, and d90 are compared with
experimental values for both training and validation. In Fig. 4
residuals of ttings are shown for training and validation also. As
shown, the predicted results match rather well with experimental
results for different d-values, however a slight deviation is
observed for validation d90 values. The coefcient of determina-
tion in all cases equal 0.99 except for training of d90. Therefore, the
results reveal that boosting is a powerful tool for making more
robust and reliable ANN models. Furthermore, the developed ANN Fig. 5. Fitting parameters of training and validation.
is very fast and can predict the effect of various parameters on
granule size with high accuracy. This is a promising approach for congurations on the granule properties. The effect of three
development of MPC for continuous pharmaceutical manufactur- process parameters and screw conguration on granule size are
ing. illustrated in Fig. 6. As shown, the most paramount parameter is
The model ndings reveal that the developed ANN is a liquid to solid ratio in which increasing L/S increases the granule
promising tool for modelling of twin-screw granulation of size signicantly. This behaviour is attributed to the increasing
pharmaceutical formulations. However, the results of ANN aggregation rate with L/S so that larger particles/granules are
modelling are compared with other modelling approaches used formed during the process. However, this is not always favourable
for twin-screw granulation. The main modelling approach used for in wet granulation as it may result in formation of over-sized
twin-screw granulation is population balance model in which the granules that must be milled after granulation. Therefore, the
change of particle properties are tracked during the process. liquid addition ow rate should be closely/accurately controlled. It
Barrasso et al. (Barrasso et al., 2015, 2014) developed multi- is also observed that increasing powder ow rate results in lower
dimensional population balance models for twin-screw granula- particle size. The latter could be due to reduction of residence time
tion. The model could predict the granule size distribution, liquid of particles inside the granulator with increasing powder ow rate.
content, and porosity. The modelling results were compared with Therefore, the particles do not have enough time to get wetted and
experimental data obtained from a 16 mm extruder. The model was agglomerate inside the extruder.
further developed by coupling PBM with DEM and ANN. The Screw speed does not have considerable effect on granule size,
comparisons are shown in Table 3 in terms of overall R2 in however increasing screw speed results in a small increase in
prediction of granule size. It is evident that the developed ANN is particle size which could be due to a higher mixing rate between
more accurate than other developed mechanistic models devel- the powder and liquid binder. Finally, the largest particles are
oped to date for prediction of twin-screw granulation. Moreover, observed for screw conguration with two kneading zones. With
ANN method is much faster than mechanistic models for the
prediction of process. In the following sections, the effect of
Table 3
different parameters on granule size are investigated by using the Comparisons between ANN results developed in this work and other modelling
developed ANN. results in literature.

Model R2 Ref.
4.5. Effect of process parameters on granule size
Multi-dimensional PBM 0.805 Barrasso et al. (2015)
Coupled ANN-PBM-DEM 0.97 Barrasso et al. (2014)
Once the ANN model is validated, it can be used as a predictive ANN 0.99 (This work)
tool to evaluate the effect of various process parameters and screw
108 S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109

4.6. Effect of process parameters on span of GSD

The span of GSD is important for the analysis and investigation


of granule size distribution (GSD) obtained from continuous wet
granulation. Span of size distribution is a parameter which
indicates the width of size distribution. It shows if the granules
are distributed in a narrow or broad way and is important for
tabletting since the granule size affects the tablet properties, for
example dissolution and disintegration. The span of granule size
distribution can be formulated as:
d90  d10
Span 4
d50
Therefore, span of particle size distribution indicates how far
apart the 10 percent (d10) and 90 percent (d90) points are,
normalized with the midpoint of PSD (d50). In granulation of
pharmaceutical formulations, a narrow particle size is desired.
Fig. 6. Effect of process parameters and screw congurations on granule d-values Given that the values of d90, d10, and d50 from the granule size
calculated by developed ANN.
distribution are calculated, the span of granule size distribution for
each experimental run can be easily calculated by using Eq. (4). The
effect of process parameters and screw congurations on span of
two kneading zones, there is more mixing between powder and GSD for all 24 experimental runs are illustrated in Fig. 7. The results
liquid binder and the number of collision between particles are shown as contour of span (response variable) versus screw
increases. Therefore this results in the formation of larger particles. speed and liquid to solid ratio. Four screw congurations are

Fig. 7. Effect of process parameters and screw congurations on span of particle size distribution.
S. Shirazian et al. / International Journal of Pharmaceutics 521 (2017) 102109 109

considered to investigate the effect of this parameter on span. As Acknowledgments


shown, the most important parameter affecting the span values is
L/S ratio in which the span values change from 1 up to 7. The reason This work was funded by Science Foundation Ireland (SFI)
for this behaviour could be due to the liquid distribution during the under the following grants:
process. At low L/S ratio, the liquid binder is not distributed well Model Predictive Control of Continuous Pharmaceutical Pro-
and some particles are not wet enough to form granules. The latter cesses(13/IA/1980).
would cause formation of a non-uniform or broad granule The equipment used in this work was funded by Science
distribution containing ne powder, medium-sized and large Foundation Ireland (SFI) under the following grants:
granules. On the other hand, it is evident that increasing screw Model Predictive Control of Continuous Pharmaceutical Pro-
speed slightly decreases span values. This behaviour could be cesses(13/IA/1980).
attributed to mixing the powder and liquid binder thoroughly by
increasing the screw speed in which results in narrower granule Appendix A. Supplementary data
size distribution.
The inuence of screw conguration reveals that the lowest Supplementary data associated with this article can be found, in
span values (narrower GSD) are obtained for screw with 2 the online version, at http://dx.doi.org/10.1016/j.
kneading zones. The latter could be due to well mixing of liquid ijpharm.2017.02.009.
binder and powder and higher formation of granules during the
process. References

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