Method and system for optimizing film production and minimizing film scrap

#The present invention relates to maximizing the efficiency and minimizing the cost of producing film that is dosed with agents and medicaments. Specifically, the present invention relates to a process and system for minimizing the waste of materials in the processing of film doses.

#When film dosages are manufactured, especially self-supporting film dosages, the film is generally formed into individual doses. There is often scrap, either in liquid, mixed form or in solid form, associated with the manufacturing and processing steps. This scrap results in unusable and therefore wasted material. When such wasted material includes precious material such as active drugs and pharmaceuticals, this wasted material can be extremely expensive. Current processes and manufacturing designs employ systems that result in scrap in liquid and/or solid form. Thus, the current processes and manufacturing designs are inefficient and ultimately may cost a higher amount to make individual dosage forms.

#It is desirable to solve the present problems associated with the art to yield a more efficient manufacturing process to form individual film doses, especially those containing an active component.

#FIG. 1 is a schematic view of an apparatus suitable for preparation of a pre-mix, addition of an active, and subsequent formation of the film.

#FIG. 2 is a schematic view of an exemplary drying step for the film sheet of the present invention.

#FIG. 3 is a representation of a drying process of the present invention.

#Film systems embody a field of technology that has major advantages in areas of administering drug, medicament, and various other active and agent delivery systems to an individual in need thereof. In order to provide a desirable final product which exhibits advantageous characteristics and desirable properties, the processing and manufacturing of film strips and film technology is technologically demanding and cumbersome.

#As used herein, the terms “pharmaceutical”, “medicament”, “drug” and “active agent” may be used interchangeably, and refer to a substance or composition useful for the prevention or treatment of a condition. The terms may include pharmaceuticals, neutraceuticals, cosmetic agents, biologic agents, bioeffective substances, and the like.

#It will be understood that the term “film” includes delivery systems of any thickness, including films, sheets, discs, wafers, and the like, in any shape, including rectangular, square, or other desired shape. The film may be in the form of a continuous roll of film or may be sized to a desired length and width. The films described herein may be any desired thickness and size suitable for the intended use. For example, a film of the present invention may be sized such that it may be placed into the oral cavity of the user. Other films may be sized for application to the skin of the user, i.e., a topical use. For example, some films may have a relatively thin thickness of from about 0.1 to about 10 mils, while others may have a somewhat thicker thickness of from about 10 to about 30 mils. For some films, especially those intended for topical use, the thickness may be even larger, i.e., greater than about 30 mils. In addition, the term “film” includes single-layer compositions as well as multi-layer compositions, such as laminated films, coatings on films and the like. The composition in its dried film form maintains a uniform distribution of components through the application of controlled drying of the film. Films may include a pouch or region of medicament between two films.