Innovative Approaches in Excipient Co-Processing: A Comprehensive Review

Year : 2025 | Volume : 12 | Issue : 02 | Page : 34 51
    By

    Reetuli Banasode,

  • Shraddha Bandgar,

  • Shital Doijad,

  • Shruti Kamble,

  • Raju Rathod,

  1. Content Writer, Precedence Research Pvt Ltd. Pune, Maharashtra, India
  2. Lecturer, Department of Pharmaceutics, Shree Ambabai Talim Sanstha’s Diploma in Pharmacy College, Miraj, Maharashtra, India
  3. Student, Department of Pharmaceutics, Dr. Shivajirao Kadam College of Pharmacy, Kasabe Digraj, Sangli, Maharashtra, India
  4. QA, Analyst, Arihant Pharmaceutical, Sangli, Maharashtra, India
  5. Assistant Professor, Department of Pharmaceutics, Shree Ambabai Talim Sanstha’s Diploma in Pharmacy College, Miraj, Maharashtra, India

Abstract

Co-processing of existing excipients is an innovative strategy in pharmaceutical formulation that offers a cost-effective, efficient alternative to the development of entirely new excipients. This process involves combining two or more well-established excipients to create new material with enhanced properties, thereby improving the functionality, performance, and manufacturability of pharmaceutical products. By leveraging the unique characteristics of each excipient, co-processing can significantly enhance attributes, such as flowability, compressibility, solubility, stability, and bioavailability, depending on the intended application. The co-processing process typically involves several key steps. Initially, the selection of compatible excipients is critical, as their chemical and physical properties must complement each other to achieve the desired outcome. This is followed by optimizing the ratio of the excipients to balance their individual strengths. The final step involves employing suitable methods to achieve uniformity and consistency in the final product. Common techniques include co-granulation, spray drying, hot melt extrusion, and solvent evaporation. These methods enable the formation of homogeneous mixtures with improved physical and chemical characteristics, leading to better performance in pharmaceutical formulations. The benefits of co-processing are numerous. It can improve drug release profiles, reduce production costs, enhance product stability, and improve patient compliance through optimized dosage forms. However, there are potential drawbacks, including the complexity of formulation development, the need for extensive characterization to ensure product quality, and potential regulatory challenges related to the approval of new co-processed materials. Overall, co-processing represents a valuable approach that offers innovative solutions to pharmaceutical formulation challenges, enabling the development of more effective, efficient, and patient-friendly drug products. This review discusses the steps involved in co-processing, different methods for combining excipients, as well as the benefits and drawbacks of the process. It also highlights examples of co-processed excipients currently available, including commercial options.

Keywords: Co-processed excipients (CPE), adjuvants, melt granulation, pharmaceutical formulation, microcrystalline cellulose

[This article belongs to Trends in Drug Delivery ]

How to cite this article:
Reetuli Banasode, Shraddha Bandgar, Shital Doijad, Shruti Kamble, Raju Rathod. Innovative Approaches in Excipient Co-Processing: A Comprehensive Review. Trends in Drug Delivery. 2025; 12(02):34-51.
How to cite this URL:
Reetuli Banasode, Shraddha Bandgar, Shital Doijad, Shruti Kamble, Raju Rathod. Innovative Approaches in Excipient Co-Processing: A Comprehensive Review. Trends in Drug Delivery. 2025; 12(02):34-51. Available from: https://journals.stmjournals.com/tdd/article=2025/view=216467


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Regular Issue Subscription Review Article
Volume 12
Issue 02
Received 09/05/2025
Accepted 31/05/2025
Published 09/07/2025
Publication Time 61 Days
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