Apparatus and method for pharmaceutical production

Abstract

An apparatus and method for producing a pharmaceutical and pharmaceutical-like product is provided. The apparatus and method dispense a liquid dose onto a carrier substrate. The apparatus and method provide for continuous movement of the carrier substrates during the process. The apparatus and method reduce batch dosage errors and provide real-time release of the product.

Description

RELATED APPLICATIONS [0001] This application is related to, and claims priority in, co-pending U.S. Provisional Application Ser. No. 60 / 621,992, filed Oct. 25, 2004, the disclosure of which is incorporated herein by reference. This application is also related to, and claims priority in, co-pending U.S. Provisional Application Ser. No. 60 / 578,245, filed Jun. 9, 2004, the disclosure of which is incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to the manufacture of pharmaceutical and pharmaceutical-like product. More particularly, the present invention relates to an apparatus and process for manufacturing pharmaceutical and pharmaceutical-like product. [0004] 2. Description of Related Art [0005] Contemporary tablet manufacturing methods use wet granulation or direct compression approaches to add the active ingredient into the tablet ingredients. After mixing to achieve homogeneity, tablets are produced, w...

AI Technical Summary

Benefits of technology

The solution achieves high content uniformity with less than 5% relative standard deviation, reduces production time and costs, and ensures real-time quality control, minimizing waste and enabling continuous production with precise dosage control.

Problems solved by technology

These types of contemporary batch manufacturing techniques suffer from drawbacks due to their inefficiency and inaccuracy.

When the active ingredient in the batch is not equally distributed, such as, for example, an unacceptable concentration, the non-homogeneity of the active ingredient will be distributed throughout the entire batch rendering all of the tablets unacceptable.

Additionally, inadequate mixing in other ingredients will be distributed throughout the entire batch rather than just to individual tablets.

Contemporary machines that manufacture pharmaceutical product suffer from the drawback of having a large footprint.

The use of separate units adds labor and time to the process, such as, for example, requiring the product to be moved between different machines.

This delay increases production time and increases manufacturing costs.

Contemporary machines and techniques also require a longer time and added labor to change over to different products, if the machine is capable of doing so at all.

However, these batch-sampling techniques suffer from drawbacks because of their inefficiency and inaccuracy.

If the chosen unacceptable samples do not have the same characteristics as other acceptable product in the batch, then acceptable product may be discarded along with the rejected samples or at least need to undergo more costly testing.

Batch-sampling can be particularly inaccurate where the error or flaw in the process is random, non-repeating or of a non-linear nature.

Such flaws or errors in the manufacturing process may provide for only a fraction of the product of the batch being unacceptable but result in an entire batch being discarded or re-tested, as a result of the use of batch sampling.

Another significant drawback of batch-sampling techniques is where the chosen samples meet the required tolerances, but where a fraction of the batch is in fact unacceptable and not represented in the tested sample.

In such a situation, unacceptable product may be provided to the consumer because of the inherent flaw in the quality control method.

An additional drawback in batch-sampling techniques is that the testing is done at the end of the process and provides little, if any, information for corrective action to be taken with regard to the manufacturing process and its various steps.

The batch-sampling technique can provide overall information for sampled product, but does not indicate at which point or which particular step in the process that a flaw is occurring, such as, for example, inadequate dosing or detrimental heating.

Another drawback of batch-sampling technique is that it is done off-line of the manufacturing process, which adds time to the overall manufacturing process, and can also be labor intensive.

The cost in time and labor is increased where more stringent standards are applied to a particular product so the batch-sampling technique utilizes a higher portion of samples for testing.

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