Intelligent Manufacturing of Pharmaceutical Film Coating Using Terahertz Pulsed Imaging, Optical Coherence Tomography and Numerical Modelling
Lead Research Organisation:
University of Liverpool
Department Name: Electrical Engineering and Electronics
Abstract
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Publications
Zhang Z
(2019)
Sub-surface imaging of soiled cotton fabric using full-field optical coherence tomography.
in Optics express
Zhang Z
(2017)
Spinning disk as a spatial light modulator for rapid infrared imaging
in IET Microwaves, Antennas & Propagation
Zhang J
(2017)
Non-destructive analysis of flake properties in automotive paints with full-field optical coherence tomography and 3D segmentation.
in Optics express
Shen Z
(2016)
Vertically-oriented nanoparticle dimer based on focused plasmonic trapping.
in Optics express
Shen Z
(2016)
Trapping and rotating of a metallic particle trimer with optical vortex
in Applied Physics Letters
Pei C
(2018)
A quantitative comparison of in-line coating thickness distributions obtained from a pharmaceutical tablet mixing process using discrete element method and terahertz pulsed imaging
in Chemical Engineering Science
Liu, Lin
(2016)
Terahertz Imaging with Compressed Sensing
in Proceedings of 2016 Ieee 9th Uk-Europe-China Workshop on Millimetre Waves and Terahertz Technologies (Ucmmt)
Lin, Hungyen
(2016)
Studying the Pharmaceutical Film Coating Process with Terahertz Sensing, Optical Coherence Tomography and Numerical Modelling
in 2016 41st International Conference on Infrared, Millimeter, and Terahertz Waves (Irmmw-Thz)
| Description | This is a joint collaborative project between Cambridge University and Liverpool University, aiming to achieve real-time in-situ process control of advanced tablet manufacturing by the integration of process modeling and in-process diagnostic capability. The sensing technology is based on terahertz (THz) and optical coherence tomography (OCT) inline sensors. We have successfully achieved all major objectives of the project. At Liverpool we have successfully developed a compact and portable fibre-based OCT sensor and the associated data acquisition, feature extraction, and signal processing and communication algorithms suitable for in-line process monitoring applications. The developed OCT sensor, together with a THz sensor, has been successfully integrated into a lab-scale pharmaceutical coater (Cambridge University) with the inline monitoring capability demonstrated experimentally. Two peer-reviewed papers have been published in J. Pharm. Sci., and an additional one has been accepted for publication in the same journal. The research results may lead to research impact on pharmaceutical industry and beyond. Pfizer has expressed interest in the developed technology and we have since performed two site trials at Pfizer (Sandwich, UK) although we could not perform trial measurements in other Pfizer sites outside UK because of budget and time constrains. Initial discussion with GSK (Brentford, UK) was also very encouraging. Furthermore, we have measured 22 different common coatings, aiming to have a thorough evaluation of the applicability and capability of OCT to investigate pharmaceutical film-coated tablets. We did find that although OCT has been demonstrated to be able to directly measure the film coating thickness of pharmaceutical tablets in real-time and in a non-destructive and contactless manner, it can not be used to measure some coatings particularly these containing titanium dioxide. This 'negative' result is important for the decision maker of pharmaceutical industry and we have since submitted this work for publication in J. Pharmaceutical Science. THz sensor, on the other hand, can be used to measure all tablet coatings. Outside pharmaceutical industry sector, the related sensing technology may also find applications in automobile industry (preliminary results have been published in Applied Optics) and medical imaging (one paper published in Optics Express). In addition, one self-funded PhD student has published two papers on plasmonic confinement and enhancement (Applied Physics Letters; Optics Express) which is related in that the same concept might be applicable for high-resolution THz and OCT imaging that may lead to new academic research and application opportunities. Two more papers related to this grant have been published. |
| Exploitation Route | Bosch Packaging Technology Ltd (Liverpool, UK), one of our project partners, was very interested and planned to adopt the developed OCT and THz into their coating drum to strengthen their position as the world leading supplier of pharmaceutical manufaturing equipment. Unfortunately the Bosch headquarter in Germany has decided to close the entire UK site and this had a negative impact on the adoption of the developed technology. The developed technology will be used to in an EPSRC-funded project (global challenge fund) where i am a co-Investigator: Development of New Low-Cost Point of Care Imaging Technologies for Diabetic Eye Disease in China, EP/R014094/1). |
| Sectors | Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
| Description | The developed sensor technology has been used in a new medical imaging device. Please also refer to the impact description provided for EP/L019922/1. |
| First Year Of Impact | 2017 |
| Sector | Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
| Impact Types | Economic,Policy & public services |
| Description | A novel sensor for coating process monitoring |
| Amount | £12,034 (GBP) |
| Organisation | University of Liverpool |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 04/2016 |
| End | 03/2017 |
| Description | Development of New Low Cost Point of Care Diagnostic Technologies for Diabetic Retinopathy in China |
| Amount | £1,150,450 (GBP) |
| Funding ID | EP/R014094/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 02/2018 |
| End | 01/2021 |
| Title | High-resolution optical coherence tomography hardware and software |
| Description | A high-resolution OCT instrument with the data acquisition and data processing software, suitable for non-destructive evaluation of a wide range of coatings or layered structures. |
| Type Of Material | Technology assay or reagent |
| Year Produced | 2016 |
| Provided To Others? | Yes |
| Impact | is helping final year project students and PhD research students from within and outside my School. |
| Description | Alternative ways to measure the removal process |
| Organisation | Unilever |
| Department | Unilever UK R&D Centre Port Sunlight |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | feasibility study: to apply the developed technology to study the removal of fats from substrate. |
| Collaborator Contribution | The partner provided the test samples and also small fund to cover the ruling cost. |
| Impact | Journal paper |
| Start Year | 2017 |
| Title | Online OCT sensor |
| Description | A portable optical coherence tomography (OCT) device has been developed. It has high data acquisition speed (40,000 waveforms per second) thus is well suitable for online monitoring coating process. |
| Type Of Technology | Systems, Materials & Instrumental Engineering |
| Year Produced | 2015 |
| Impact | This device will enable real time inline process monitoring and control thus it will have a positive impact on the process analytical control (PAT) and the manufacturing of high value pharmaceutical products. |
| Description | Analysis of pharmaceutical coatings using optical coherence tomography |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Delivered an invited talk at a major pharmaceutical company. Discussed potential collaboration work. |
| Year(s) Of Engagement Activity | 2016 |
| Description | Quantitative analysis of coatings using optical coherence tomography |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | invited talk at the Pigment and Colour Science Forum (1-2 October 2019 | Berlin, Germany) which is an industry-organised international workshop. Potential collaborations with a German company who has since sent some test samples. |
| Year(s) Of Engagement Activity | 2019 |
| URL | https://www.pigmentmarkets.com/pigment-color-science-forum/agenda2019 |
| Description | Terahertz time-domain imaging: development and industry applications |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Keynote at the 2016 IET Colloquium on Millimetre-wave and Terahertz Engineering & Technology, Imperial College London, UK (London, 31st March 2016) |
| Year(s) Of Engagement Activity | 2016 |
| Description | Visitors from Industry |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | Regional |
| Primary Audience | Industry/Business |
| Results and Impact | Introduce optical coherence tomography technology to visitor from one of the largest car paint company. The company has subsequently provided some test samples and we are currently look for funding opportunities to move this forward. |
| Year(s) Of Engagement Activity | 2015 |