Lighthouse Probe™ - online measurement

Lighthouse Probe™ - DAD

High Shear Granulation Endpoint Detection

Online Process Monitoring

• Suitable for monitoring blend homogeneity, moisture, density, by correlating spectra, physical granule properties by correlating scattering effect
• More consistent batches resulting in better tablets
• Non-destructive and direct online analysis of granule quality
• Very fast spectroscopic technology using Diode Array Detector (other spectroscopic technologies possible)
• Reliable and robust process interfacing to guarantee representative measurements.

Main Benefits

• NIR spectra contain physical and chemical information about the measured product, allowing good correlations with traditional granulation parameters like density, particle size etc.
• Using the Lighthouse Probe™ – DAD sensor for endpoint determination will give more consistency between batches in granule properties, enabling optimisation of subsequent processing steps.
• Less waste thanks to a more consistent quality of the batches. Real-time availability of the product data like moisture content and density will decrease risks and reduce waiting time for the finished batch to be released to the next processing step.
• Because of the fast moving product during granulation, short measurement cycles are needed. The latest Diode Array Detectors can take spectra in only a few milliseconds, allowing the customer to take chemical images of very small quantities of material or, by averaging these spectra over time, to adjust the measured volume of product to what is normally used in offline measurements. Other configurations are possible but speed of measurement is traded-off against the gain in resolution.
• More accurate modelling thanks to the possibility to clean the probe prior to taking a reference measurement for modelling.
• Enhanced reliability thanks to the automation of the system. The LightHouse Probe™ – DAD will perform a health check prior to usage to guarantee a correct measurement during process. This health check can also run online during production to ensure correct endpoint determination.

Suggested Configuration

For initial test work or for mobile test equipment, a manual probe is suggested while automated wash and CIP probes are designed for production. 

For single pot processing including drying, a CIP probe is advised combined with a complete integration to change models between granulation and drying regime.

The LightHouse Probe™ fits on a standard 2” port, standard adaptor or weld-in ports can be provided. It is available as manual probe, automated wash probe and automated CIP probe.

Case Study

Genzyme reduces probe fouling and improves NIR data using the Lighthouse Probe™.

Genzyme, one of the world’s leading biotechnology companies, was looking for a PAT solution to control the high shear granulation of a development product by measuring a critical product attribute, rather than relying purely on time based processing or impeller current loading. The company used an optimized Lighthouse Probe™ to get representative NIR data of a granulation process. Read the article to learn how the data was then correlated to moisture content, bulk/tapped density and particle size of the final product.

Lighthouse Probe™ - NDC

Efficient Moisture measurement in fluidized bed dryers

Online Process Monitoring

• “Plug and play”, no model development needed
• No window fouling thanks to patented in process window cleaning
• Reduced variability between drying batches and reduced waste
• Suitable for all water based drying processes, solvent based processes on request
• Accurate moisture measurement to better than ±0.25%.

Main Benefits

• Low Cost of Ownership:
• no need for model development. The Online LOD sensor uses NDC’s proprietary measurement algorithm, based on 20 years experience. Calibration requirements are limited to adjustment of the outputs slope and intercept, which can be done by the customer’s operators.
• no need to wait for laboratory results. The finished batch can be released to the next processing step immediately when the drying step is finished.
• Window fouling does not mean end of measurement. The probe can be manually or automatically retracted through a scraper seal to remove the deposits. Automated probes can even wash their windows on the machine without stopping or endangering the on-going drying process.
• Improved Batch-to-Batch Consistency. Using the Online LOD sensor for endpoint determination will give more consistency between batches in moisture content of dried granules, enabling optimisation of product quality prior to the tablet press and eliminating the risk of over-/under-drying.
• The Online LOD sensor is delivered with a filter wheel suited for moisture measurement. Dedicated filter wheels for solvent supplied on request.
• The Online LOD sensor is delivered ready to measure the moisture content of a pharmaceutical powder within a range of 1% to 20% with a projected accuracy of ±0.25% subject to calibration verification and suitable compendial method.

Suggested Configuration

The Online LOD sensor is a LightHouse Probe™ equipped with an NDC PF710e gauge.

1. For initial test work or for mobile test equipment: manual probe
2. For integrated systems and if the probe is meant to stop the drying: automated CIP probe with additional soft- and hardware package.
3. For organic solvents, dedicated filter wheels can be provided per solvent

The probe can be mounted by welding a port into the vessel or alternatively by replacing a window with a specific adaptor.

The LightHouse Probe™ is available as manual probe, automated wash probe and automated CIP probe.