Skip to main content
PMC home page
AAPS PharmSciTech logoLink to AAPS PharmSciTech
. 2014 Mar 30;7(4):E2–E11. doi: 10.1208/pt070483

Modeling weight variability in a pan coating process using Monte Carlo simulations

Preetanshu Pandey 1,✉, Manoj Katakdaunde 1, Richard Turton 1,✉
PMCID: PMC2750320  PMID: 16584150

Abstract

The primary objective of the current study was to investigate process variables affecting weight gain mass coating variability (CVm) in pan coating devices using novel video-imaging techniques and Monte Carlo simulations. Experimental information such as the tablet location, circulation time distribution, velocity distribution, projected surface area, and spray dynamics was the main input to the simulations. The data on the dynamics of tablet movement were obtained using novel video-imaging methods. The effects of pan speed, pan loading, tablet size, coating time, spray flux distribution, and spray area and shape were investigated. CVm was found to be inversely proportional to the square root of coating time. The spray shape was not found to affect the CVm of the process significantly, but an increase in the spray area led to lower CVms. Coating experiments were conducted to verify the predictions from the Monte Carlo simulations, and the trends predicted from the model were in good agreement. It was observed that the Monte Carlo simulations underpredicted CVms in comparison to the experiments. The model developed can provide a basis for adjustments in process parameters required during scale-up operations and can be useful in predicting the process changes that are needed to achieve the same CVm when a variable is altered.

Keywords: Pan coating, video imaging, mass coating variability, Monte Carlo, spray shape

Full Text

The Full Text of this article is available as a PDF (444.9 KB).

References

  • 1.Pandey P, Song Y, Turton R. Modelling of Pan-Coating Processes for Pharmaceutical Dosage Forms. In: Salaman AD, Hounslow MJ, Seville JPK, editors. Granulation. Amsterdam, The Netherlands: Elsevier BV; 2007. [Google Scholar]
  • 2.Pandey P. Studies to Investigate Variables Affecting Coating Uniformity in a Pan Coating Device. Morgantown, WV: West Virginia University; 2006. [Google Scholar]
  • 3.Pandey P, Turton R. Movement of different shaped particles inside a pan coating device using novel video-imaging techniques. AAPS PharmSciTech. 2005;6:E237–E244. doi: 10.1208/pt060234. [DOI] [PMC free article] [PubMed] [Google Scholar]
  • 4.Turton R. challenges in the modeling and prediction of coating of pharmaceutical dosage forms. Powder Technol. In press.
  • 5.Khakhar D, McCarthy J, Shinbrot T, Ottino J. Transverse flow and mixing of granular materials in a rotating cylinder. Phys Fluids. 1997;9:31–43. doi: 10.1063/1.869172. [DOI] [Google Scholar]
  • 6.Mann U. Analysis of spouted-bed coating and granulation, I: batch operation. Ind Eng Chem Proc Des Dev. 1983;22:288–292. doi: 10.1021/i200021a019. [DOI] [Google Scholar]
  • 7.Denis C, Hemati M, Chulia D, et al. A model of surface renewal with application to the coating of pharmaceutical tablets in rotary drums. Powder Technol. 2003;130:174–180. doi: 10.1016/S0032-5910(02)00262-0. [DOI] [Google Scholar]
  • 8.Pandey P, Song Y, Kahiyan F, Turton R. Simulation of particle movement in a pan coating device using discrete element modeling and its comparison with video-imaging experiments. Powder Technol. 2006;161:79–88. doi: 10.1016/j.powtec.2005.09.003. [DOI] [Google Scholar]
  • 9.Pandey P, Song Y, Kahiyan F, Turton R. Comparison of experimentally determined parameters of particle motion with predictions from a new MATLAB-based DEM code; New York, NY: AICHE; 2003. pp. 334–339. [Google Scholar]
  • 10.Cahn D, Fuerstenau D. Simulation of diffusional mixing of particulate solids by Monte Carlo techniques. Powder Technol. 1967;1:174–182. doi: 10.1016/0032-5910(67)80029-9. [DOI] [Google Scholar]
  • 11.Nakamura H, Abe E, Yamada N. Coating mass distribution of seed particles in a tumbling fluidized bed coater, Part 2. Monte Carlo simulation of particle coating. Powder Technol. 1998;99:140–146. doi: 10.1016/S0032-5910(98)00097-7. [DOI] [Google Scholar]
  • 12.Kushaari K, Pandey P, Song Y, Turton R. Monte Carlo simulation to determine coating uniformity in a Wurster fluidized bed coating process. Powder Technol. 2006;166:81–90. doi: 10.1016/j.powtec.2006.05.001. [DOI] [Google Scholar]
  • 13.Sherritt R, Chaouki J, Mehrotra A, Behie L. Axial dispersion in the three-dimensional mixing of particles in a rotating drum reactor. Chem Eng Sci. 2003;58:401–415. doi: 10.1016/S0009-2509(02)00551-1. [DOI] [Google Scholar]
  • 14.Rogers R, Gardner R. A Monte Carlo method for simulating dispersion and transport through horizontal rotating cylinders. Powder Technol. 1979;23:159–167. doi: 10.1016/0032-5910(79)87002-3. [DOI] [Google Scholar]
  • 15.Black J. Particle Motion and Heat Transfer in Rotary Drums. Edinburgh, UK: Edinburgh University; 1988. [Google Scholar]
  • 16.Kohav T, Richardson J, Luss D. Axial dispersion of solid particles in a continuous rotary kiln. AIChE J. 1995;41:2465–2476. doi: 10.1002/aic.690411112. [DOI] [Google Scholar]
  • 17.Sandadi S, Pandey P, Turton R. In-situ, near real-time acquisition of particle motion in rotating pan coating equipment using imaging techniques. Chem Eng Sci. 2004;59:5807–5817. doi: 10.1016/j.ces.2004.06.036. [DOI] [Google Scholar]
  • 18.Pandey P, Turton R. A study to quantify the effects of mixing aids during a coating operation in an industrial scale roating pan coater. AAPS J. 2004;6:1–1. [Google Scholar]
  • 19.Pandey P, Joshi N, Hammerman E, Turton R, Ergun J. Scale-up of a pan coating process. AAPS PharmSciTech. In press. [DOI] [PMC free article] [PubMed]
  • 20.Lefebvre AH. Atomization and Sprays. New York, NY: Taylor and Francis; 1988. [Google Scholar]
  • 21.Pandey P, Turton R. Investigation of operating parameters that affect uniformity in pan coating devices. World Congress on Particle Technology 5; April 23–27, 2006; Orlando, FL. 2006.
  • 22.Cheng XX, Turton R. The prediction of variability occurring in fluidized bed coating equipment, II: the role of non-uniform particle coverage as particles pass through the spray zone. Pharm Dev Technol. 2000;5:323–332. doi: 10.1081/PDT-100100547. [DOI] [PubMed] [Google Scholar]
  • 23.Kadam KL. Granulation Technology for Bioproducts. Boca Raton, FL: CRC Press; 1990. [Google Scholar]
  • 24.Porter S. Scale-up of film coating. In: Levin M, editor. Pharmaceutical Process Scale-up #118. New York, NY: Marcel Dekker; 2002. pp. 275–276. [Google Scholar]
  • 25.Pandey P, Turton R. Experimental determination of surface appearance times for spherical particles in rotating drum devices with and without the presence of liquid spray; New York, NY: AICHE; 2003. [Google Scholar]

Articles from AAPS PharmSciTech are provided here courtesy of American Association of Pharmaceutical Scientists

RESOURCES