Magnesium stearate (MgSt) is among the most common excipients and the most common lubricant in solid oral products. It is primarily added to tablet formulations to ease ejection during tablet compression. While commonly present in low concentrations, the addition of MgSt substantially affects the final tablet properties. Its impact is further not only concentration dependent but also varies with exposure of the formulation to shear, which worst-case results in over-lubrication. The presented study investigated the applicability of terahertz time-domain spectroscopy (THz-TDS) to monitor the shear-induced blend densification of microcrystalline cellulose blended with MgSt over a range of concentrations (0.3, 0.7, and 1.0 %). The effect of shear was investigated by variation of blending times (5 - 20 min) in a diffusion blender. THz-TDS measurements of the powder blends were acquired in transmission by measuring directly through the mixing container. The refractive index at terahertz frequencies was found to be sufficiently sensitive to resolve the densification of the blend with increased blending times. Thus, THz-TDS blend density measurements can be used as a surrogate parameter to evaluate the total shear exposure of a blend. Considerations regarding implementation are discussed. In the context the approach was integrated with the well-described THz-TDS-based tablet porosity analysis into a unified model to monitor and predict the tensile strength. Including the THz-TDS measurement on the blend allowed for a more accurate description of the tensile strength, reducing the root mean squared error by over 40 % (0.33 MPa). The possibility of monitoring the density changes of a blend non-invasively makes THz-TDS a promising process analytical technology approach for controlling the total shear impact on lubricated blends and tablet quality.

Tablet content and content uniformity are essential for the market release of the drug product. For tablets, content and uniformity are determined by the weight ratio of active pharmaceutical ingredient in the tablet and the tablets' total mass. Novel process analytical technology tools for the control of the ratio of the active pharmaceutical ingredient have been proposed and implemented, but more robust, sensitive, and fast sensors for the control of tablet mass are desirable. In the presented study terahertz time-domain spectroscopy (THz-TDS) is proposed as a potential process analyser for tablet mass. THz-TDS is based on pulsed terahertz signals, which are mapped in the time-domain. Thus, the signal amplitude and arrival time are recorded. THz-TDS measurements of a tablet with a reflection setup result in two signals - a frontside reflection and a backside transflection. The presented study demonstrates that an increase in the tablet mass results in an increase in the time delay of the backside transflection. This is a result of the high refractive index of the solid fraction compared to air. It is suggested that the time delay of the transflection can be used as an indirect measure of tablet mass for which root mean squared errors of around 1 mg were found. The potential to measure tablets at high acquisition rates (50 Hz) is explored and considered feasible. Additionally, it has been demonstrated in previous work that the time delay of the frontside reflection allows a simultaneous assessment of the tablet height. The presented methodology opens the possibility of in-line monitoring of tablet mass as part of a content and content uniformity strategy at high sampling rates in the production environment. Further, as tablet height and mass can be assessed simultaneously, monitoring and control of the compression process based on a comprehensive assessment of physical tablet attributes can also be envisioned.

Terahertz time-domain spectroscopy and differential scanning calorimetry were used to study the role of the dynamics of biomolecules decoupled from solvent effects. Lyophilized sucrose exhibited steadily increasing absorption with temperature as anharmonic excitations commenced as the system emerged from a deep minimum of the potential energy landscape where harmonic vibrations dominate. The polypeptide bacitracin and two globular proteins, lysozyme and human serum albumin, showed a more complex temperature dependence. Further analysis focused on the spectral signature below and above the boson peak. We found evidence of the onset of anharmonic motions that are characteristic for partial unfolding and molecular jamming in the dry biomolecules. The activation of modes of the protein molecules at temperatures comparable to the protein dynamical transition temperature was observed in the absence of hydration. No evidence of Fröhlich coherence, postulated to facilitate biological function, was found in our experiments.

The process analytical technology (PAT) framework is well established and integral to facilitate process understanding, enable a transition from batch to continuous manufacturing, and improve product quality. Near-infrared (NIR) spectroscopy has been established as a standard PAT tool for many process analytical challenges, including monitoring powder blend homogeneity. However, alternative technologies for monitoring powder blending are of interest due to the importance of the blending step in manufacturing solid oral dosage forms. Terahertz time-domain spectroscopy (THz-TDS) is therefore explored in this study as an alternative tool for monitoring blend homogeneity with the potential for endpoint control in a batch blending process. Powder blends of microcrystalline cellulose (MCC) and dibasic calcium phosphate dihydrate and blends of MCC and granulated α-lactose monohydrate were investigated non-invasively at various compositions using THz-TDS in transmission mode for acquiring spectra from samples enclosed in the blending container. It was found that attenuation- and phase-related parameters acquired with THz-TDS could reliably resolve physical changes related to the homogeneity of the blend. Further evaluations revealed that changes in the bulk density of the blend, in addition to the intrinsic optical properties of the materials, played a critical role in the observed trends for both systems. In contrast, the scattering contribution of the powder was mainly crucial for the attenuation-related parameter in blends with materials of high refractive indices. Finally, THz-TDS measurements were acquired throughout a blending process mimicking a continuous acquisition. The method could follow blending dynamics and resulted in reasonable predictive errors of the content of 0.5 - 2.5 %. Relative standard deviations for high content blends (20 %) were acceptable (3 - 7 %) whereas at low contents (5 %) significantly higher values (9 - 35 %) were found. Based on these findings, THz-TDS is a feasible PAT tool for monitoring blend homogeneity and controlling high content blend processes, although precision and accuracy is considered to improve with a more suitable interface.

Terahertz time-domain spectroscopy and differential scanning calorimetry were used to study the role of the dynamics of biomolecules decoupled from solvent effects. Lyophilised sucrose exhibited steadily increasing absorption with temperature as anharmonic excitations commence as the system emerges from a deep minimum of the potential energy landscape where harmonic vibrations dominate. The polypeptide bacitracin and two globular proteins, lysozyme and human serum albumin, showed a more complex temperature dependence. Further analysis focused on the spectral signature below and above the boson peak. We found evidence for the onset of anharmonic motions that are characteristic for partial unfolding and molecular jamming in the dry biomolecules. The activation of modes of the protein molecules at temperatures comparable to the protein dynamical transition temperature was observed in the absence of hydration. No evidence for Fr\"ohlich coherence, postulated to facilitate biological function, was found in our experiments.

Roller compaction before tableting is a common unit operation to increase the processability of powders. Terahertz time-domain spectroscopy (THz-TDS) has recently been introduced as a potential process analytical technology (PAT) for measuring tablet porosity based on the refractive index of the tablet. Tablet porosity is a governing parameter for tablet disintegration and dissolution. The first aim of this study was to investigate tablets prepared from roller-compacted materials with THz-TDS to explore its usefulness for particle size evaluation of granules in tablets. Secondly, the impact of roller compaction and granule size before tablet compression on the established THz-TDS based measurement of tablet porosity was investigated. Microcrystalline cellulose and α-lactose monohydrate were roller compacted separately at five specific compaction forces (2, 4, 8, 12, and 16 kN cm-1) and fractionated into three size fractions. Tablets were prepared from the fractionated and unfractionated granules at twelve tableting pressures and subjected to THz-TDS transmission measurements. It was possible to use the scattering behaviour of the tablets at terahertz frequencies to describe the granulated materials' particle size changes during tableting. At the same time, prediction of porosity was impaired due to the deviation of the refractive index in strongly scattering samples. A correction method was introduced in which the porosity error was corrected based on the tablet's scattering behaviour, resulting in an improved prediction of tablet porosity. In conclusion, THz-TDS is considered a promising technique for the process monitoring of tableting based on its sensitivity to porosity and particle size changes within the tablet non-destructively, with a possible application as part of an in-process control strategy of the tableting of granulated or non-granulated materials.

The quality control of pharmaceutical tablets is still based on testing small sample numbers using at- and off-line testing methods. Traditional in-process controls, such as tablet mass, height, mechanical strength, and disintegration time are time- and resource-consuming and poorly suited to support an effective transition towards continuous manufacturing. Another suitable parameter to monitor during production would be tablet porosity. Porosity can be linked to mechanical strength and disintegration but typically requires knowledge of tablet dimensions and mass. Tablet porosity measurements based on terahertz time-domain spectroscopy (THz-TDS) offer a fast and non-destructive approach to in-process control testing for physical tablet properties. This study presents THz-TDS reflection measurements as an alternative to the previously reported transmission setup. It is shown that the proposed method can determine porosity based on the reflected amplitude from the tablet surface, but also allows for precise determination of tablet height in the same measurement. The tablet mass can be estimated by combining the height and porosity measurements. This opens up for the opportunity to determine the tablet's mechanical strength by using the possible correlation to the determined porosity.

Utilizing four different model substances, the effect of size on the dynamics of one-component lyophilized (freeze-dried) products was studied with terahertz time-domain spectroscopy and differential scanning calorimetry. While sucrose exhibited the well-known behavior of increasing absorption with temperature observed in small organic molecular systems, the polypeptide bacitracin and the two globular proteins lysozyme and human serum albumin (HSA) showed a more complex temperature dependence. Further analysis was performed on the extrapolated vibrational density of states and the boson peak that showed that localized onset of motions influences the spectrum widely without necessarily leading to an alteration of the rate of absorption change at a single frequency far below room temperature.

Cryoconcentration upon large-scale freezing of monoclonal antibody (mAb) solutions leads to regions of different ratios of low molecular weight excipients, like buffer species or sugars, to protein. This study focused on the impact of the buffer species to mAb ratio on aggregate formation after frozen storage at -80 °C, -20 °C, and - 10 °C after 6 weeks, 6 months, and 12 months. An optimised sample preparation was established to measure Tg' of samples with different mAb to histidine ratios via differential scanning calorimetry (DSC). After storage higher molecular weight species (HMWS) and subvisible particles (SVPs) were detected using size-exclusion chromatography (SEC) and FlowCam, respectively. For all samples, sigmoidal curves in DSC thermograms allowed to precisely determine Tg' in formulations without glass forming sugars. Storage below Tg' did not lead to mAb aggregation. Above Tg', at -20 °C and - 10 °C, small changes in mAb and buffer concentration markedly impacted stability. Samples with lower mAb concentration showed increased formation of HMWS. In contrast, higher concentrated samples led to more SVPs. A shift in the mAb to histidine ratio towards mAb significantly increased overall stability. Cryoconcentration upon large-scale freezing affects mAb stability, although relative changes compared to the initial concentration are small. Storage below Tg' completely prevents mAb aggregation and particle formation.

Understanding of the molecular mobility in freeze-dried matrices is of high importance for the assessment and prediction of the stability of lyophilized biotech drugs. In this project, lyophilizates of different sucrose to monoclonal antibody (mAb) ratio are assessed with terahertz spectroscopy to determine the mobility of the glassy sugar/protein matrix. Upon increasing the amount of mAb present, the behavior deviates from that of well-known small molecular systems. Samples containing more than 75% mAb show an interesting feature at about 300K that requires further characterization.

Material deformation behaviour has a critical impact on tablet formation. Fragmentation is one of the key mechanisms affecting the strength of a final compact, however, quantitative methods for estimating fragmentation are often complex, destructive and time-consuming. The purpose of this study was to investigate the applicability of terahertz time-domain spectroscopy (THz-TDS) to quantify fragmentation upon tableting. Up to five size fractions of microcrystalline cellulose (MCC), dibasic calcium phosphate (DCP), and lactose monohydrate (lactose) in the range of < 125 mu m up to the range of 355-500 mu m were compressed into tablets and analysed with THz-TDS. The effective refractive index and absorbance spectra of whole tablets were measured in transmission, and the optical properties were clearly affected by fragmentation upon compression. The scattering observed from the absorbance spectra was fitted into a power law equation (y = A nu(E)). It was observed that up to pressures of 50 MPa the values of parameter A that were extracted from the power law fit decreased exponentially with increasing compression pressure. For higher compression pressures the value of A remained constant. This observation was more pronounced for DCP, followed by lactose and then MCC and the effect was more pronounced for larger compared to smaller initial particles. The non-destructive measurements correlated with previously obtained results based on particle size distribution measurements of the particles before compression and those obtained from destructive analysis of tablets. The terahertz method can resolve similar differences in fragmentation behaviour upon compression compared to the particle size analysis but requires no sample preparation.