Twin-screw Process Research Articles

Preparation of Montmorillonite–Melamine Cyanurate and Inhibition of the Emission of Phosphine from PA6/Aluminum Hypophosphate

In order to mitigate the release of toxic phosphine from aluminum hypophosphite in twin-screw processing, montmorillonite–melamine cyanurate was prepared by three methods: (1) mechanical intercalation, (2) water intercalation and (3) in situ intercalation. The sheet spacing of montmorillonite was increased from 1.140 nm to 1.141 nm, 1.208 nm and 1.217 nm for these three methods, respectively, and scanning electron microscope (SEM) and transmission electron microscopy (TEM) proved that melamine cyanurate was successfully inserted into the montmorillonite sheets. The montmorillonite–melamine cyanurate from in situ intercalation can best inhibit the release of PH3 from aluminum hypophosphite, and the peaks of phosphine, mean values of phosphine and integral of phosphine were reduced by 81.9%, 72.1% and 72.2%, respectively. The mode of action of montmorillonite–melamine cyanuric inhibition of the emission of phosphine from aluminum hypophosphite can be attributed to the physical absorption of montmorillonite and the chemical bonding of melamine cyanurate. In addition, in situ intercalation can slightly improve flame retardancy, attributed to incomplete exfoliation of montmorillonite sheets.

Co-rotating twin screw process for continuous manufacturing of solid crystal suspension: A promising strategy to enhance the solubility, permeation and oral bioavailability of Carvedilol

Background In the current work, co-rotating twin-screw processor (TSP) was utilized to formulate solid crystal suspension (SCS) of carvedilol (CAR) for enhancing its solubility, dissolution rate, permeation and bioavailability using mannitol as a hydrophilic carrier. Methods In-silico molecular dynamics (MD) studies were done to simulate the interaction of CAR with mannitol at different kneading zone temperatures (KZT). Based on these studies, the optimal CAR: mannitol ratios and the kneading zone temperatures for CAR solubility enhancement were assessed. The CAR-SCS was optimized utilizing Design-of-Experiments (DoE) methodology using the Box-Behnken design. Saturation solubility studies and in vitro dissolution studies were performed for all the formulations. Physicochemical characterization was performed using differential scanning calorimetry , Fourier transform infrared spectroscopy, X-ray diffraction studies, and Raman spectroscopy analysis. Ex vivo permeation studies and in vivo pharmacokinetic studies for the CAR-SCS were performed. Stability studies were performed for the DoE-optimized CAR-SCS at accelerated stability conditions at 40 ºC/ 75% RH for three months. Results Experimentally, the formulation with CAR: mannitol ratio of 20:80, prepared using a KZT of 120 ºC at 100 rpm screw speed showed the highest solubility enhancement accounting for 50-fold compared to the plain CAR. Physicochemical characterization confirmed the crystalline state of DoE-optimized CAR-SCS. In-vitro dissolution studies indicated a 6.03-fold and 3.40-fold enhancement in the dissolution rate of optimized CAR-SCS in pH 1.2 HCl solution and phosphate buffer pH 6.8, respectively, as compared to the pure CAR. The enhanced efficacy of the optimized CAR-SCS was indicated in the ex vivo and in vivo pharmacokinetic studies wherein the apparent permeability was enhanced 1.84-fold and bioavailability enhanced 1.50-folds compared to the plain CAR. The stability studies showed good stability concerning the drug content. Conclusions TSP technology could be utilized to enhance the solubility, bioavailability and permeation of poor soluble CAR by preparing the SCS.

Co-rotating twin screw process for continuous manufacturing of solid crystal suspension: A promising strategy to enhance the solubility, permeation and oral bioavailability of Carvedilol

Background In the current work, co-rotating twin-screw processor (TSP) was utilized to formulate solid crystal suspension (SCS) of carvedilol (CAR) for enhancing its solubility, dissolution rate, permeation and bioavailability using mannitol as a hydrophilic carrier. Methods In-silico molecular dynamics (MD) studies were done to simulate the interaction of CAR with mannitol at different kneading zone temperatures (KZT). Based on these studies, the optimal CAR: mannitol ratios and the kneading zone temperatures for CAR solubility enhancement were assessed. The CAR-SCS was optimized utilizing Design-of-Experiments (DoE) methodology using the Box-Behnken design. Saturation solubility studies and in vitro dissolution studies were performed for all the formulations. Physicochemical characterization was performed using differential scanning calorimetry , Fourier transform infrared spectroscopy, X-ray diffraction studies, and Raman spectroscopy analysis. Ex vivo permeation studies and in vivo pharmacokinetic studies for the CAR-SCS were performed. Stability studies were performed for the DoE-optimized CAR-SCS at accelerated stability conditions at 40 ºC/ 75% RH for three months. Results Experimentally, the formulation with CAR: mannitol ratio of 20:80, prepared using a KZT of 120 ºC at 100 rpm screw speed showed the highest solubility enhancement accounting for 50-fold compared to the plain CAR. Physicochemical characterization confirmed the crystalline state of DoE-optimized CAR-SCS. In-vitro dissolution studies indicated a 6.03-fold and 3.40-fold enhancement in the dissolution rate of optimized CAR-SCS in pH 1.2 HCl solution and phosphate buffer pH 6.8, respectively, as compared to the pure CAR. The enhanced efficacy of the optimized CAR-SCS was indicated in the ex vivo and in vivo pharmacokinetic studies wherein the apparent permeability was enhanced 1.84-fold and bioavailability enhanced 1.50-folds compared to the plain CAR. The stability studies showed good stability concerning the drug content. Conclusions TSP technology could be utilized to enhance the solubility, bioavailability and permeation of poor soluble CAR by preparing the SCS.

Co-rotating twin screw process for continuous manufacturing of solid crystal suspension: A promising strategy to enhance the solubility, permeation and oral bioavailability of Carvedilol.

In the current work, co-rotating twin-screw processor (TSP) was utilized to formulate solid crystal suspension (SCS) of carvedilol (CAR) for enhancing its solubility, dissolution rate, permeation and bioavailability using mannitol as a hydrophilic carrier. In-silico molecular dynamics (MD) studies were done to simulate the interaction of CAR with mannitol at different kneading zone temperatures (KZT). Based on these studies, the optimal CAR: mannitol ratios and the kneading zone temperatures for CAR solubility enhancement were assessed. The CAR-SCS was optimized utilizing Design-of-Experiments (DoE) methodology using the Box-Behnken design. Saturation solubility studies and in vitro dissolution studies were performed for all the formulations. Physicochemical characterization was performed using differential scanning calorimetry , Fourier transform infrared spectroscopy, X-ray diffraction studies, and Raman spectroscopy analysis. Ex vivo permeation studies and in vivo pharmacokinetic studies for the CAR-SCS were performed. Stability studies were performed for the DoE-optimized CAR-SCS at accelerated stability conditions at 40 ºC/ 75% RH for three months. Experimentally, the formulation with CAR: mannitol ratio of 20:80, prepared using a KZT of 120 ºC at 100 rpm screw speed showed the highest solubility enhancement accounting for 50-fold compared to the plain CAR. Physicochemical characterization confirmed the crystalline state of DoE-optimized CAR-SCS. In-vitro dissolution studies indicated a 6.03-fold and 3.40-fold enhancement in the dissolution rate of optimized CAR-SCS in pH 1.2 HCl solution and phosphate buffer pH 6.8, respectively, as compared to the pure CAR. The enhanced efficacy of the optimized CAR-SCS was indicated in the ex vivo and in vivo pharmacokinetic studies wherein the apparent permeability was enhanced 1.84-fold and bioavailability enhanced 1.50-folds compared to the plain CAR. The stability studies showed good stability concerning the drug content. TSP technology could be utilized to enhance the solubility, bioavailability and permeation of poor soluble CAR by preparing the SCS.

Topical Micro-Emulsion of 5-Fluorouracil by a Twin Screw Processor-Based Novel Continuous Manufacturing Process for the Treatment of Skin Cancer: Preparation and In Vitro and In Vivo Evaluations.

5-Fluorouracil (5-FU), a BCS class III drug, has low oral bioavailability and is cytotoxic in nature causing severe systemic side effects when administered through the intravenous route. Topical drug delivery could potentially mitigate the systemic side-effects. Microemulsions (MEs) would be an apt solution due to enhanced partitioning of the drug to the skin. However, conventional methods for preparing MEs are inefficient since they are not continuous and are very tedious and time-consuming processes hence revealing the need for the development of continuous manufacturing technology. In our study, 5-FU MEs were prepared using a continuous manufacturing Twin Screw Process (TSP) and its efficiency in the treatment of skin cancer was evaluated. Water-in-oil MEs were prepared using isopropyl myristate as the oil phase and Aerosol OT and Tween 80 as the surfactants. The average particle size was observed to be 178 nm. Transmission electron microscopy was employed to confirm the size and shape of the MEs. FTIR study proved no physical or chemical interaction between the excipients and the drug. In vitro drug release using vertical diffusion cells and ex vivo skin permeation studies showed that the drug was released sustainably and permeated across the skin, respectively. In in vitro cytotoxicity studies, 5-FU MEs were accessed in HaCat and A431 cell lines to determine percentage cell viability and IC50. Skin irritation and histopathological examination implied that the 5-FU MEs did not cause any significant irritation to the skin. In vivo pharmacodynamics studies in rats suggested that the optimised formulation was effective in treating squamous cell carcinoma (SCC). Therefore, 5-FU MEs efficiently overcame the various drawbacks faced during oral and intravenous drug delivery. Also, TSP proved to be a technique that overcomes the various problems associated with the conventional methods of preparing MEs.

Mechanical Performances Analysis and Prediction of Short Plant Fiber-Reinforced PLA Composites.

Plant fiber-reinforced polylactic acid (PLA) exhibits excellent mechanical properties and environmental friendliness and, therefore, has a wide range of applications. This study investigated the mechanical properties of three short plant fiber-reinforced PLA composites (flax, jute, and ramie) using mechanical testing and material characterization techniques (SEM, FTIR, and DSC). Additionally, we propose a methodology for predicting the mechanical properties of high-content short plant fiber-reinforced composite materials. Results indicate that flax fibers provide the optimal reinforcement effect due to differences in fiber composition and microstructure. Surface pretreatment of the fibers using alkali and silane coupling agents increases the fiber-matrix interface contact area, improves interface performance, and effectively enhances the mechanical properties of the composite. The mechanical properties of the composites increase with increasing fiber content, reaching the highest value at 40%, which is 38.79% higher than pure PLA. However, further increases in content lead to fiber agglomeration and decreased composite properties. When the content is relatively low (10%), the mechanical properties are degraded because of internal defects in the material, which is 40.42% lower than pure PLA. Through Micro-CT technology, the fiber was reconstructed, and it was found that the fiber was distributed mainly along the direction of injection molding, and the twin-screw process changes the shape and length of the fiber. By introducing the fiber agglomeration factor function and correcting the Halpin-Tsai criterion, the mechanical properties of composite materials with different contents were successfully predicted. Considering the complex stress state of composite materials in actual service processes, a numerical simulation method was established based on transversely isotropic material using the finite element method combined with theoretical analysis. The mechanical properties of high-content short plant fiber-reinforced composite materials were successfully predicted, and the simulation results showed strong agreement with the experimental results.

Solvent Free Twin Screw Processed Silybin Nanophytophospholipid: In Silico, In Vitro and In Vivo Insights.

Silybin (SIL) is a polyphenolic phytoconstituent that is commonly used to treat liver disorders. It is difficult to fabricate an orally delivered SIL product due to its low oral bioavailability (0.95%). Therefore, the current research focusses on the development of a novel composition of a phospholipid complex, termed as nanophytophospholipid, of SIL by employing a unique, solvent-free Twin Screw Process (TSP), with the goal of augmenting the solubility and bioavailability of SIL. The optimised SIL-nanophytophospholipid (H6-SNP) was subjected to physicochemical interactions by spectrometry, thermal, X-ray and electron microscopy. The mechanism of drug and phospholipid interaction was confirmed by molecular docking and dynamics studies. Saturation solubility, in vitro dissolution, ex vivo permeation and preclinical pharmacokinetic studies were also conducted. H6-SNP showed good complexation efficiency, with a high practical yield (80%). The low particle size (334.7 ± 3.0 nm) and positively charged zeta potential (30.21 ± 0.3 mV) indicated the immediate dispersive nature of H6-SNP into nanometric dimensions, with good physical stability. Further high solubility and high drug release from the H6-SNP was also observed. The superiority of the H6-SNP was demonstrated in the ex vivo and preclinical pharmacokinetic studies, displaying enhanced apparent permeability (2.45-fold) and enhanced bioavailability (1.28-fold). Overall, these findings indicate that not only can phospholipid complexes be formed using solvent-free TSP, but also that nanophytophospholipids can be formed by using a specific quantity of lipid, drug, surfactant, superdisintegrant and diluent. This amalgamation of technology and unique composition can improve the oral bioavailability of poorly soluble and permeable phytoconstituents or drugs.

Twin-Screw Continuous Mixing Can Produce Dry Powder Inhalation Mixtures for Pulmonary Delivery

The feasibility of twin-screw corotating extruder as a continuous process mixer to prepare dry powder inhalation (DPI) powders was investigated. Interactive mixtures of 1% micronized budesonide, 0.3% magnesium stearate and 98.7% alpha-lactose monohydrate were manufactured using a Leistritz Nano-16 extruder at various processing conditions. One set of GFM (grooved mixing) elements were included in the screw profile to provide distributive mixing of conveyed powders with the goal of resulting in a homogeneous mixture. Residence time in the twin-screw mixer was modelled to quantify mixing efficiency. Comparative powders were also prepared using either low or high-shear batch mixing to compare the effect of mixing methods on the properties of the budesonide dry powder inhalation formulation. Twin screw mixing results in homogeneous mixtures with aerosol performance comparable to that of high-shear batch mixing. Scanning electron microscopy confirmed that twin screw mixing produces particles with morphology like that of low and high-shear batch mixing. X-ray diffraction (XRD) analysis verified that there was no form change of the drug due to twin-screw processing. Statistical regression was used to probe the relationship between twin screw mixing process parameters such as screw speed and feed rate and aerosol performance. The twin screw mixing process was found to be robust, as no significant differences in aerosol performance were found for various processing parameters.

Influence of Twin-Screw Processing Conditions on Structure and Properties of Polypropylene – Organoclay Nanocomposites

Abstract This study looks at the influence of extrusion parameters such as screw speed, feed rate and barrel temperature on the nanocomposite structure (size of agglomerates, level of intercalation and exfoliation) and its consequences on final mechanical properties. Nanocomposites of polypropylene, maleated polypropylene and organomodified montmorillonite, with respective mass fractions of 85/10/5, were prepared in a co-rotating twin-screw extruder using a masterbatch dilution method. The nanocomposites structure was quantified by scanning and transmission electron microscopy, X-ray diffraction and dynamic rheometry. Relationships between the microstructure at different levels (size and number of agglomerates, interlayer distance, melt yield stress to quantify the exfoliation level) and the processing conditions were established, revealing that specific mechanical energy received during extrusion was the key parameter controlling this microstructure. Mechanical properties in uniaxial tension (apparent Young's modulus) were measured and related to the microstructural parameters resulting from extrusion conditions.

Influence of Twin-Screw Processing Conditions on the Mechanical Properties of Biocomposites

In order to evaluate the effect of processing conditions, composites of MaterBi-Y matrix with 15wt% sisal fibers are obtained with different temperature profiles and speeds of rotation of the screw, using a twin-screw extruder. Three different temperature profiles are selected. The speeds of rotation are 25, 60, and 80 rpm. The samples are obtained by compression at 180°C and 700 MPa for 10 min. The mechanical properties of composites increase when the rotation speed changes from 25 to 60rpm and then decreases. Fiber breakage increases with rotational speed, but aspect ratio increases too. Increased modulus with fiber aspect ratio is easily understood because longer fibers carry more tensile loads as a result of increase in transfer length. The decrease in the mechanical properties at a high rotational speed can be due to the degradation of the matrix. The impact properties increase when temperature increases. The decrease in impact properties at temperatures above 185°C can be due to the thermal decomposition of the material.

Serum separation in molten ice creams produced by low temperature extrusion processes

The microstructure and kinetics of serum separation due to creaming of air bubbles in molten ice creams produced using the novel twin and single screw low temperature extrusion processes are investigated. The measured fat globule size distributions are bimodal for both ice creams. However, the concentration of primary fat globules is much larger for the twin screw extruded ice cream than that obtained using single screw. The latter contained higher concentration of fat aggregates. A broader bubble size distribution involving larger bubbles is observed for the single screw extruded ice cream compared with that for twin screw process. The initial rate of serum separation in molten twin screw extruded ice cream. This is because the former ice cream contained smaller bubbles and the serum separated from it is more viscous due to the presence of more small fat globules. The initial rate of serum separation in molten twin screw extruded ice cream is less than half of that for the single screw extruded ice cream.

Practical Aspects of Processing in Intermeshing Twin Screw Extruders

Rules of thumb are presented addressing aspects of twin screw processing to serve as guidelines for understanding and assessing performance of such equipment. Simple equations permit estimates of drag flow capacity, degree of fill, and residence time. Recommendations are made concerning conducting pilot scale tests and estimating scale-up consequences.

Fluorescence Image Analysis of Process Cheese Manufactured with Trisodium Citrate and Sodium Chloride

Fluorescence imaging and cryomicrotomy were used to study the size and shape distribution of fat particles in a model process cheese product. The technique generated data with reproducibility and consistency as confirmed by the statistical results. The process cheese product was manufactured with Cheddar cheese, NaCl, and trisodium citrate in a batch-type, twin-screw process cheese cooker with a 4.5-kg capacity. After reaching 65.5°C, samples were collected from each batch at cooking times of 0, 5, 10, and 15min. The geometry of fat particles (circularity and diameter of the area equivalent circle) from both types of model process cheese was evaluated. Fat particles in the process cheese product that was manufactured with trisodium citrate were more circular than those in the process cheese manufactured with NaCl only. The diameter of the area equivalent circle of fat particles in process cheese containing trisodium citrate decreased and stabilized after 5min of cooking time, but those in process cheese containing NaCl did not change.

Experimental Studies for Optimizing Screw and Die Design When Compounding Fiberglass Strand on the Co-Rotating Twin Screw Extruder

Compounding fiberglass strand on a co-rotating twin screw extruder re quires a balance in process (screw and die) design. Certain physical mechanical proper ties, such as notched Izod, mirror preserved glass length while flexural properties are a function of preserved glass length as well as fiber-matrix adhesion. Reduction in glass attrition requires a very mild screw configuration and minimal average shear rate in the extruder and die, while good adhesion is promoted by complete glass wetting requiring an effective mixing screw and die restriction. This article will present the results of a designed experiment and the application of computer-aided modelling techniques in defin ing an optimum twin screw process configuration for fiberglass compounding.