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 eBOOK

SOLID
DOSE

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TABLE OF CONTENTS
Under-hyped but not under-represented  4
The buzz may be around biologics, but the oral solid dose sector is still going strong

Optimizing precision blending of tablets  7


Tumble blender technology can enhance the speed and homogeneous
blending of tablets and capsules with trace levels of additives

The future of capsule supply chain analytics  12


How and why companies should focus on leveraging data and analytics
to integrate supply chains

AD INDEX
Tri-Star • www.tri-star-technologies.com  2

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Under-hyped but
not under-represented
The buzz may be around biologics, but the oral
solid dose sector is still going strong

By Karen Langhauser, Chief Content Director

T
ablets may not be as glamorous or (CDER) approved a record-high 59 NMEs.
cutting-edge as emerging sectors Oral solid dose products accounted for 31,
of the biologics markets, but or 53 percent, of the NMEs approved by
they have their upsides. Oral solid dose the FDA in 2018. This percentage of OSD
formulations are efficient and cost-effective approvals is higher than previous years (50
to manufacture, shelf stable and easy to percent in 2017 and 32 percent in 2016).
administer. Perhaps most importantly,
they are understood and accepted by Pfizer led the OSD charge in 2018 with four
patients worldwide. NME approvals. These approvals included:
Daurismo (November 2018) to treat newly
While it is true that the pharma pipeline diagnosed acute myeloid leukemia in adult
is monopolized by new biologic hopefuls patients; Lorbrena (November 2018) to
implementing novel scientific approaches treat patients with anaplastic lymphoma
such as gene therapies, small molecule kinase-positive metastatic non-small cell
drugs still dominate the U.S. market in terms lung cancer; Talzenna (October 2018)
of quantity. In fact, when it comes to new to treat locally advanced or metastatic
molecular entities (NMEs), oral solid dose breast cancer patients with a germline
products still lead the charts. In 2018, the BRCA mutation; and Vizimpro (September
U.S. Food and Drug Administration’s (FDA) 2018) to treat metastatic non-small-cell
Center for Drug Evaluation and Research lung cancer.

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If market predictions are your jam, Future If real-life action means more to you than
Market Insights projects the global OSD market predictions, drug manufacturers
pharmaceutical formulation market to grow — even those who are investing in
6.5 percent CAGR from 2017 to 2027. In biologics development — continue
terms of revenue, the market is projected to expand their traditional solid dose
to jump from $500,000 million in 2017 processing businesses.
to over $900,000 million in 2027. North
America will remain the largest market for In recent news, CDMO giant Catalent, fresh
OSD formulations, followed by Asia Pacific off a $1.2 billion gene therapy deal with
(excluding Japan) and Western Europe. Paragon Bioservices, announced that it is
Revenue from the North America market investing up to $40 million at its manufac-
alone is expected to surpass $300,000 mil- turing facility in Winchester, Kentucky to
lion by the end of 2027. increase formulation and controlled-release
tablet and capsule manufacturing capabili-
By dosage form, tablets will continue to ties and capacity.
remain preferred in the market, with sales
estimated to surpass $500,000 million by “We have a clear investment strategy at the
the end of 2027. Capsules are expected to site that is not only driven by immediate
be the second most lucrative dosage form customer needs, but also looks to the future
in the market. Of the 59 NMEs approved in anticipation of demand and new technol-
in 2018, 24 were tablets and seven ogies,” said Rick Tucker, general manager
were capsules. for Catalent Winchester.

OSD percentage of Novel Drug Approvals

2018 2017 2016 2015 2014 2013


(53%) (50%) (32%) (53%) (46%) (63%)

31 of 59 NMEs were oral 23 of 46 NMEs were 7 of 22 NMEs were  24 of 45 NMEs were 19 of 41 NMEs were 17 of 27 NMEs were
solid dose products solid dose products; solid dose products: solid dose products:  solid dose products: solid dose products:
24 tablets, 7 capsules 17 tablets, 5 capsules 7 tablets 15 tablets, 9 capsules 10 tablets, 9 capsules 12 tablets, 5 capsules

*Information courtesy of U.S. FDA

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Last August, Boehringer Ingelheim broke of the same drug. Controlled release ver-
ground on what it is calling its “Solids sions of solid dose drugs can reduce the
Launch facility” at its tablet production dose frequency and provide more uniform
site in Ingelheim, Germany. The facility will drug delivery. This can ensure safety and
open in 2020. In April of last year, Mayne improve the efficacy of drugs, as well as
Pharma’s CDMO business, Metrics Con- increase patient compliance. New formats
tract Services, opened a new $80-million for OSD drugs, such as bi-layer tablets,
oral solid dose commercial manufactur- have become increasingly popular, enabling
ing facility in Greenville, North Carolina. controlled delivery of different drugs with
Last February, generic-drug manufacturer pre-defined release profiles.
Amneal Pharmaceuticals announced plans
to expand its solid dose and softgel manu- Additional improvements have been made
facturing plant in Long Island, New York. in areas such as bioavailability, taste mask-
ing and chemical stabilization, further
Opportunity for solid dose forms is being securing the OSD’s place in the market. As
driven by new drug formulations. Recent the sector continues to enhance its process
research has focused on controlled drug understanding, the market will see higher
delivery, which offers definite advantages quality, more effective and more evolved
over a conventional release formulation solid dose products. 

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Optimizing precision
blending of tablets
Tumble blender technology can enhance the speed and homogeneous
blending of tablets and capsules with trace levels of additives

By Gregg Muench, Vice President of Business Development, GEMCO

T
o meet stringent regulatory multiple key blends in a time-consuming
requirements, such as the United and costly process.
States Pharmacopeia (USP),
National Formulary (NF) or U.S. Food “We have to essentially achieve results
& Drug Administration (FDA), as well within our blend uniformity requirements
as production and budgetary demands, for every batch, whether the formula
pharmaceutical manufacturers require is predominantly active ingredients
high-volume precision blending of and several excipient ingredients, or
formulations on equipment that provides predominantly excipient ingredients
exceptional batch-to-batch consistency and with very small amounts of active
repeatable results. ingredient,” says Douglas Van Pelt, Senior
Director of Operations at Sigmapharm
When manufacturing compressed tablets or Laboratories LLC, a privately held specialty
capsules, however, the blending of several pharmaceutical company based in
solid ingredients is easier and more uni- Bensalem, PA that develops, manufactures
form if the ingredients are approximately and markets generic and branded products
the same size. It is more difficult to create in tablet and capsule form. “Homogeneity
precise blends with trace ingredients (<1%) is very important because our finished
that are vastly dissimilar in size and den- products are only as good as how well we
sity. In some cases, this might require doing blend them.”

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“Homogeneity is very important because our finished


products are only as good as how well we blend them.”
— Douglas Van Pelt

“A typical blend uniformity specification of and paddle mixers, which use blades or
90 percent to 110 percent with a standard paddles to push material, face a number
deviation of not more than five percent can of challenges.
be a challenge, but when you produce tab-
lets with dosing as low as five micrograms First, these mixers are limited to moving the
like we do, that is a much more difficult material within the confines of their active
endeavor. We are consistently and success- area. The mechanics force the material
fully doing that here,” Van Pelt adds. bed outward, leaving dead spots inside the
vessel where material moves more slowly or
Fortunately, with tumble blending equip- remains stationary.
ment that is engineered to meet the
requirements of the application, the process Also, because these units are stationary, they
can be simplified to rapidly produce a more have one stationary port at the bottom of
precise, homogenous blend containing nec- the machine. This port has a long neck, which
essary trace elements. Such blending can isolates the material from any processing
not only eliminate the need for key blends, force during mixing. Operators often need to
but also produce a better distribution of empty the discharge area and manually rein-
active ingredients. troduce it back into the top of the mixer. This
means some portions of the mix will receive
Advancements in dryer technology can fur- more additive than others. In fact, such mixers
ther improve quality and speed production, typically cannot accommodate blends with
giving pharmaceutical manufacturers even seven percent or less of any one ingredient.
greater control over the process along with
additional savings. Another issue lies in the positioning of the
intensifier bars or fluidization zones. These
LIMITATIONS OF TRADITIONAL intensifier bars should ideally be located
MIXING EQUIPMENT in the mixing zone, where every particle
Traditional equipment such as plow, ribbon, passes through. Many times, however,

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traditional mixers have their intensifier bars even turbulence in all corners of the mix
in dead zones. When this happens, the through a combination of macro and micro
material will not be fluidized properly, and blending. This can eliminate the need for
active ingredients will not be incorporated key blends and produce a better distribu-
throughout the batch. tion of active ingredients.

Traditional mixers also tend to waste expen- Macro blending is achieved by rotating the
sive additives. Because additives being shaped vessel, allowing the material bed
added to the vessel initially contact only a to fall away from the vessel’s walls. Tumble
very small portion of the material, they get blender vessel shapes are engineered to
quickly absorbed into the material bed. The create a repeatable pattern in which the
typical response is to add more additives to entire bulk material moves to form a homoge-
achieve the desired mix concentration, which nous mixture. The blender moves at a precise
drives up the cost. speed, with the vessel wall at a precise angle,
so that the material cascades over itself.
Finally, because the pharmaceutical man- There is no additional force from paddles,
ufacturer is now wetting the material with plows, or spiral ribbons – just gravity.
higher quantities of the additives, a longer
drying stage is required to achieve the tar- While this occurs, micro mixing (if needed)
geted results. simultaneously proceeds via agitator
blades located in the mixing zone center
THE BENEFITS OF TUMBLE of the vessel, where fine processing in the
BLENDING AND VACUUM material transpires. This allows for a gentle
TUMBLE DRYING repeatable pattern that maintains a supe-
To address the deficiencies of traditional rior blending design while preserving the
mixers, a growing number of pharmaceuti- product’s physical characteristics. Together,
cal manufacturers utilize tumble blending. the macro and micro mixing evenly expose
As a low-impact processing technique for each particle to six times more active blend-
handling sensitive or abrasive solids, tumble ing per revolution than traditional mixers.
blending is commonly used to create pre-
cise pharmaceutical blends that contain Because Sigmapharm’s Van Pelt had suc-
trace ingredients (<1%) that are vastly dis- cessfully used tumble blenders at a previous
similar in size and density. company, he trusted their capabilities.

In contrast to traditional mixing, to elim- “At my previous employer, I made a prod-


inate dead spots, tumble blenders apply uct that had a narrow therapeutic range

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While typical tray drying relies solely on heat, vacuum


tumble drying equipment can utilize gas purging.

using a 30 cubic foot tumble blender,” operational advantage, compared to time


says Van Pelt, who notes that blend unifor- consuming manual loading methods.
mity specification was a very stringent 95
percent to 105 percent, not a typical 90 per- “The [tumble blender] lifts the drum con-
cent to 110 percent. “The potency was 0.125 taining the material to be blended against a
milligrams inside a 125-milligram tablet, and gasket forming a dust-tight seal,” he says.
we were able to achieve blend uniformity
in 15 minutes, with good repeatable results According to Van Pelt, the tumble blender
every time.” then rotates until the drum is inverted while
opening the discharge valve allows the
The tumble blender was provided by contents to flow into the blender. The valve
GEMCO, a NJ-based manufacturer of then shuts automatically and the emptied
tumble blending and vacuum tumble drying drum returns to the loading position. The
equipment. According to Van Pelt, Sig- latest version allows for a pre-programmed
mapharm has effectively implemented a discharge sequence where the blender
30 cubic foot V blender and a one cubic rotates back and forth several times in the
foot slant cone blender from the tumble discharge mode to further ensure that the
blender manufacturer. drum empties completely. “The entire oper-
ation is essentially dust free,” he says.
With the preciseness of the technology,
a V-shape tumble blender is capable of In addition to tumble blending, a growing
achieving a standard deviation of less than number of pharmaceutical manufacturers are
two percent, and a slant cone configuration finding that vacuum tumble drying equip-
can achieve a standard deviation as low as ment offers significant advantages as well.
0.33 percent.
Most pharmaceutical powders for process-
Van Pelt also appreciates the unique tumble ing contain solvents or free radicals that
blender loading option that provides an need to be removed to dry them effectively.

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Traditionally, to dry such powdered prod- takes a long time to affect the entire mass,
uct, manufacturers use tray dryers, where dynamic vacuum tumble drying dries
wet material is laid in thin layers on multiple pharmaceutical powder energetically as
racks of heated trays. However, this can lead it rotates inside the vessel. This dries the
to uneven drying as heat is applied. Also, powder faster, more evenly, with less labor,
volatile material may be trapped on bottom and is particularly helpful in reducing resid-
layer particles as a crust forms on the top ual organic solvents.
layer of material. As the inner materials are
insulated from the inert atmospheric drying PROTECTING QUALITY
process, they remain unstable. AND THE BOTTOM LINE
Some pharmaceutical manufacturers may
As a solution, advanced vacuum tumble be inclined to use traditional blending and
drying equipment can resolve such issues drying methods because of their familiarity
and speed drying while reducing cost. While with such systems. However, those who
typical tray drying relies solely on heat, take advantage of the superior capabilities
vacuum tumble drying equipment can utilize of tumble blending and vacuum tumble
gas purging in addition to heat application. drying systems will protect product qual-
ity, process control, and the bottom line
In contrast to tray drying that essentially to a degree not possible with traditional
dries statically from the surface first and systems. 

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The future of capsule


supply chain analytics
How and why companies should focus on leveraging
data and analytics to integrate supply chains

By Brian Garrett, Supply Chain Manager, Americas, Lonza Pharma & Biotech

M
any pharmaceutical companies represent uncharted territory for many
face challenges in matching companies. These technologies are the
upstream supply chain capacity future of supply chain analytics, present-
with downstream capsule demand. For ing new ways for companies to gather and
example, if downstream is growing as sales react to information more quickly and ulti-
increase while upstream is constrained mately lowering their costs for production
because of shrinking or otherwise allocated and improving quality control. This is espe-
production capacity, the company will cially important for capsule supply chains,
have problems. How can firms streamline as oral dosage formulations remain widely
the relationship between upstream and popular and comprise the largest category
downstream, and make optimized decisions of pharmaceutical dosage form.
more quickly?
NEW TECHNOLOGIES IN THE
Some companies are looking to data and CAPSULE SUPPLY CHAIN
analytics to do just that, finding that an Innovative companies are harnessing sev-
integrated supply chain also has benefits in eral emerging technologies to increase
terms of operational efficiency and quality integration in their supply chains. The
control. Emerging technologies and inno- common denominator among all these
vations like the Internet of Things (IoT), big applications of new technologies is the
data, blockchain and artificial intelligence integration of the supply chain between

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vendors and customers. As one piece of a internet-capable devices is expected to


partnered supply chain gains an advantage grow from 8 billion in 2016 to 30 billion
from the innovative use of data and analyt- in 2020 enabling a drastic increase in the
ics, everyone should gain the same edge. information flowing to the internet.1 This
data can be tapped into by industry and
Since capsules and other oral solid dosage used to optimize the supply chain.
forms are among the most widely used
dosage forms, ensuring a secure and effi- As the IoT grows, it continues to generate
cient capsule supply chain is a priority for large amounts of data, commonly referred
many pharmaceutical companies. Inte- to as “big data.” The pharmaceutical man-
grated capsule supply chains are likely to ufacturing industry is among the sectors
become only more important for pharma- leading the charge in generating big data,
ceutical manufacturers and drug developers and some pharma companies are taking
around the world as the use of generic advantage of the increasing data at their
medicine continues to increase worldwide. fingertips to make better business deci-
sions. Big data can be as granular as the
One example of emerging technology number of opted-in patients receiving a
with implications for capsule supply is IoT, seasonal diagnosis — such as the flu or
which refers to the integration of the phys- allergies — in a region, or as conceptual as
ical and digital worlds. IoT advancements total volume of a specific pharma-grade
create new ways to generate and collect raw material sold in a time period. If the
data, which companies can use through- supply chain is integrated and partnered
out the supply chain to improve efficiency appropriately it can ebb and flow together
and patient experiences. The number of as outlook or trends change. The more data

Large Lot Size VMI Program

Lots Ordered: 9
Lots Needed: 4.5
Source: Lonza Pharma & Biotech

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Emerging technologies are the future of supply


chain analytics, presenting new ways for
companies to gather and react to information.

suppliers and vendors share quickly and A final emerging trend with implications
efficiently, the faster the supply chain can for the capsule supply chain is blockchain
capitalize on the opportunities that result. technology. This is the technology behind
cryptocurrency, which uses a digital ledger
Once IoT has generated data that has shared between companies and entities
landed in the realm of big data, turning it through partnerships. This concept of a
into something actionable requires inter- shared digital ledger is a robust mecha-
pretation. How to start and where to focus nism for verifying and maintaining security
can be a difficult decision for supply chain and transparency throughout the supply
leadership, but even worse is when the rec- chain. For example, supply chains where
ognition techniques are built around status blockchain exists could do more to guar-
quo expectations. Artificial intelligence antee source and quality of ingredients
(AI) tools can be deployed to analyze or products used in drug development
and anticipate supply chain trends both and manufacturing.
upstream and downstream in directions
that common spreadsheet-style analyses SUPPLY CHAIN
are not looking. From future demand and INTEGRATION ADVANCEMENTS
capsule purchasing patterns to potential A key platform pharmaceutical compa-
raw material shortages to shifts in regional nies are implementing is Electronic Data
or global demands, status quo analyses may Interchange (EDI). EDI links vendor and
not be dynamic enough to capture oppor- supplier together, potentially up and down
tunity and generate results. In the scope of the supply chain. A system in which EDI
pharmaceuticals, this could mean saving has been established allows for seamless
lives or not. Some companies are applying and instantaneous data-sharing between
these tools to better predict what’s ahead partners up and down the supply chain,
throughout the supply chain and more from capsule manufacturers to custom-
quickly recognize optimal responses to ers to distributors to pharmacies. EDI can
supply chain and market needs, end-to-end. generate immediate optimizations in terms

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of savings, efficiency and quality control time-intensive tasks and promote sus-
and can help ensure the right people have tainability by eliminating paper waste
the right data to make smarter supply associated with old systems. Transaction
chain decisions. costs can drop by 30 percent with the
implementation of an EDI system, and the
The pharmaceutical industry is under great overall supply chain cycle can be sped up
pressure to drive cost down as the shift by more than 60 percent.1
to generics occurs globally. EDI removes
wasted administrative effort, especially in Another advancement that is optimizing the
the purchasing process, while establishing capsule supply chain is the Vendor-Man-
a lock-step supply chain. In the traditional aged Inventory (VMI) program, in which
purchasing process, the buyer generates an the capsule supplier eliminates the admin-
order and sends it to a supplier, oftentimes istrative burden of planning and ordering
via email these days. The vendor then sends capsules, giving the vendor the responsi-
back an invoice — another document — bility of tracking and resupplying inventory
which then has to be responded to. Many of within known parameters agreed upon
these documents are restrictive and often between supplier and customer.
have no capacity to be automated.
VMI systems can range in complexity. Some
On the other hand, EDI allows a vendor and are quite simple: For example, the vendor
customer to link their systems together, goes physically to the warehouse, counting
passing information directly and instantly. inventory and replenishing what’s miss-
The partners use enterprise resource plan- ing, oftentimes considered a Kanban VMI
ning (ERP) platforms to connect their system. Others are far more sophisticated.
purchasing, shipping and invoicing data, In some VMI systems, the customer can pro-
linked via “translator” systems that ensure vide a forecast of what they expect to need,
information is in the right format for prompt and the supplier will produce and deliver
sharing and integration. capsule inventory based on the forecast.
In the most advanced VMI relationships,
Overall, EDI systems provide informa- the customer and vendor are integrated
tion more quickly, enabling responsive systematically and can optimize inventory
and deliberate decision-making based on end-to-end, so the supplier restores prod-
current needs rather than historical data, uct almost as soon as the customer needs it.
potentially allowing inventory reduction. Because of the integration, the supply chain
They also provide real-time engagement is optimized end-to-end, ensuring working
between suppliers and vendors, automate capital is kept to a minimum. The seamless

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Since oral solid dosage forms are among


the most widely used, ensuring a secure and
efficient capsule supply chain is a priority.

supply chain becomes more competitive level. Using this process, the number of lots
and can respond rapidly to market needs produced and delivered can be drastically
without building wasteful, excess inventory reduced, leading to significant savings in
that is only later recognized as unneeded. quality testing. As the supply chain inte-
grates, the lot size can be determined
Like EDI systems, successful VMI inte- dynamically, optimizing all facets of the
grations lead to considerable benefits in supply chain. The lot size can therefore be a
terms of lower costs, risks and oversight. function of demand outlook, not just a fixed
They tend to simplify inventory man- level of inventory that does not recognize
agement, contracts between partners, growth or decline on the horizon. In fact, an
warehousing, administration and scheduling integrated VMI system can generate sav-
raw materials. ings as high as 50 percent in quality control
testing by reducing the number of lots
They can also lead to substantial quality delivered to a customer1 while improving
control savings by optimizing lot sizes to the responsiveness.
minimize testing costs for specific lots. For
example, consider a customer buying cap- Let’s consider some examples to illustrate
sules at various points in the year, roughly the power of pharmaceutical supply chain
10 million capsules at a time. In a traditional integration as it continues to develop. A
system, the customer probably places an patient goes to the doctor’s office where
individual order and lot each time they want she is prescribed medicine for an illness.
more inventory, after which the vendor Current technological tools allow that
puts the order in their schedule, produces information to be placed in a data set as it
it and ships it as available. With even the passes from the doctor’s computers to the
most basic VMI system, the customer and pharmacy to the patient’s hands.
vendor decide in advance on a minimum
inventory level and the vendor replenishes Now imagine a local outbreak of conta-
capsule stock when it depletes below that gious disease, like the flu. As prescriptions

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are written and medicine delivered to industry into the future of supply chain inte-
patients, AI tools can analyze the supply gration. Companies are finding new ways
chain data generated by that activity as it to anticipate future downstream capsule
becomes available in big data sources, allow- supply needs and seamlessly match them
ing vendors and customers to see where to upstream production, lowering waste
the outbreak is taking place. That kind of and reducing costs for everyone. Consid-
insight can help optimize resource allocation ering the advancements that are showing
through the supply chain by passing infor- up throughout our supply chain, no one
mation to pharmacies, distribution channels company will have all of these advanced
and manufacturers about future expected systems in place to recognize all of the
demand for capsules and capsule technol- opportunities at hand.
ogy, and where they should send supply.
As more information is gathered over time Imagine, however, an integrated partnership
and integration continues, the entire capsule chain that shares data up-and down-supply
supply chain can react simultaneously to chain. As one of the partner’s advancement
changing conditions and new developments. helps them recognize a shift, everyone who
is integrated appropriately with them can
Companies focused on leveraging data and recognize and respond quickly. The result
analytics to integrate their supply chain can is a partnership that drives costs down,
get started by focusing on three steps: quality up and responsiveness to the maxi-
1. Identify their priority partners for supply mum. As integration continues, companies
chain integration. throughout the supply chain will find new
2. Quantify the benefits of implementing ways to use technology to simplify and
changes, in terms of savings. optimize the capsule supply chain, with
3. Look for new and innovative ways to benefits for everyone — from manufacturers
use data and analytics to ensure down- to patients. 
stream and upstream capsule supply
needs are matched in real time. REFERENCES
1. Garrett, B. (2018, May 24). The Supply
New data collection and analytics tech- Chain Revolution [webinar]. Pharmaceu-
nologies are bringing the pharmaceutical tical Technology

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