Production of unit dose constructs
Dissolvable unit dose constructs and their method of manufacture are disclosed in which the unit dose constructs are formed of a composition including a polymer matrix that includes a water soluble polymer, active ingredient, and a liquid carrier. The composition is deposited directly, such as by stenciling, to form individual unit doses without the need to cut and convert long, continuous rolls of film.
1. A method of forming a dissolvable unit dose construct comprising:
providing a muco-adhesive composition comprising a polymer matrix, the polymer matrix comprising a water soluble polymer, the composition further comprising an active ingredient and a liquid carrier; and
depositing the composition onto a foil substrate as a plurality of individual dosage units; and
removing at least a portion of the liquid carrier from the individual dosage units, wherein the foil substrate is a treated foil substrate having a modified surface energy on the side on which the composition is deposited.
2. The method of claim 1 , wherein a first area of the treated foil substrate has a modified surface energy on the side on which the composition is deposited that is lower than a surface energy of a second area on the side of the treated foil substrate on which the composition is deposited.
3. The method of claim 1 , wherein the step of removing liquid carrier includes drying the composition by the application of heat, vibration, ultrasound, or a combination thereof.
4. The method of claim 1 , wherein the composition is provided as a thixotropic paste having a viscosity in the range of 20,000 cps to 500,000 cps at a shear rate in the range of 0.05 s −1 to 10 s −1 .
5. The method of claim 1 , further comprising, after the step of depositing, depositing a second composition to form multi-layered individual dosage units.
6. The method of claim 1 , wherein the step of depositing includes depositing the paste onto the foil substrate in a predetermined geometric shape having at least three sides.
7. The method of claim 6 , wherein the predetermined geometric shape includes a rounded corner.
8. The method of claim 1 , wherein the water soluble polymer comprises cellulose or a derivative thereof.
9. The method of claim 1 , wherein the active ingredient comprises a pharmaceutical drug.
10. The method of claim 1 , comprising depositing adjacent individual unit doses having different areas.
11. The method of claim 1 , wherein the individual dosage units are dissolvable films.
12. The method of claim 1 , wherein the individual dosage units are tablets or wafers.
13. The method of claim 1 , wherein the step of removing is carried out in an atmosphere having a lower oxygen content than air.
14. The method of claim 1 , wherein the step of removing is carried out in an atmosphere having less than 45% relative humidity.