Characterisation and surface-profiling techniques for composite particles produced by dry powder coating in pharmaceutical drug delivery

The production of composite particles using dry powder coating is a one-step, environmentally friendly, process for the fabrication of particles with targeted properties and favourable functionalities. Diverse functionalities, such flowability enhancement, content uniformity, and dissolution, can be developed from dry particle coating. In this review, we discuss the particle functionalities that can be tailored and the selection of characterisation techniques relevant to understanding their molecular basis. We address key features in the powder blend sampling process and explore the relevant characterisation techniques, focussing on the functionality delivered by dry coating and on surface profiling that explores the dynamics and surface characteristics of the composite blends. Dry particle coating is a solvent- and heat-free process that can be used to develop functionalised particles. However, assessment of the resultant functionality requires careful selection of sensitive analytical techniques that can distinguish particle surface changes within nano and/or micrometre ranges.

Dry powder inhalation of macromolecules using novel PEG-co-polyester microparticle carriers

This study investigated optimizing the formulation parameters for encapsulation of a model mucinolytic enzyme, a-chymotrypsin (a-CH), within a novel polymer; poly(ethylene glycol)-co-poly(glycerol adipate-co-?-pentadecalactone), PEG-co-(PGA-co-PDL) which were then applied to the formulation of DNase I. a-CH or DNase I loaded microparticles were prepared via spray drying from double emulsion (w(1)/o/w(2)) utilizing chloroform (CHF) as the organic solvent, l-leucine as a dispersibility enhancer and an internal aqueous phase (w(1)) containing PEG4500 or Pluronic(®) F-68 (PLF68). a-CH released from microparticles was investigated for bioactivity using the azocasein assay and the mucinolytic activity was assessed utilizing the degradation of mucin suspension assay. The chemical structure of PEG-co-(PGA-co-PDL) was characterized by (1)H NMR and FT-IR with both analyses confirming PEG incorporated into the polymer backbone, and any unreacted units removed. Optimum formulation a-CH-CHF/PLF68, 1% produced the highest bioactivity, enzyme encapsulation (20.08±3.91%), loading (22.31±4.34µg/mg), FPF (fine particle fraction) (37.63±0.97%); FPD (fine particle dose) (179.88±9.43µg), MMAD (mass median aerodynamic diameter) (2.95±1.61µm), and the mucinolytic activity was equal to the native non-encapsulated enzyme up to 5h. DNase I-CHF/PLF68, 1% resulted in enzyme encapsulation (17.44±3.11%), loading (19.31±3.27µg/mg) and activity (81.9±2.7%). The results indicate PEG-co-(PGA-co-PDL) can be considered as a potential biodegradable polymer carrier for dry powder inhalation of macromolecules for treatment of local pulmonary diseases.

Chitosan-modified dry powder formulations for pulmonary gene delivery

Spray-drying is an effective process for preparing micron-dimensioned particles for pulmonary delivery. Previously, we have demonstrated enhanced dispersibility and fine particle fraction of spray-dried nonviral gene delivery formulations using amino acids or absorption enhancers as dispersibility-enhancing excipients. In this study, we investigate the use of the cationic polymer chitosan as a readily available and biocompatible dispersibility enhancer. Lactose-lipid:polycation:pDNA (LPD) powders were prepared by spray-drying and post-mixed with chitosan or spray-dried chitosan. In addition, the water-soluble chitosan derivative, trimethyl chitosan, was added to the lactose-LPD formulation before spray-drying. Spray-dried chitosan particles, displaying an irregular surface morphology and diameter of less than 2 mu m, readily adsorbed to lactose-LPD particles following mixing. In contrast with the smooth spherical surface of lactose-LPD particles, spray-dried trimethyl chitosan-lactose-LPD particles demonstrated increased surface roughness and a unimodal particle size distribution (mean diameter 3.4 mu m), compared with the multimodal distribution for unmodified lactose-LPD powders (mean diameter 23.7 mu m). The emitted dose and in vitro deposition of chitosan-modified powders was significantly greater than that of unmodified powders. Moreover, the inclusion of chitosan mediated an enhanced level of reporter gene expression. In summary, chitosan enhances the dispersibility and in vitro pulmonary deposition performance of spray-dried powders.

Functionalised particles using dry powder coating in pharmaceutical drug delivery:promises and challenges

Introduction: Production of functionalised particles using dry powder coating is a one-step, environmentally friendly process that paves the way for the development of particles with targeted properties and diverse functionalities. Areas covered: Applying the first principles in physical science for powders, fine guest particles can be homogeneously dispersed over the surface of larger host particles to develop functionalised particles. Multiple functionalities can be modified including: flowability, dispersibility, fluidisation, homogeneity, content uniformity and dissolution profile. The current publication seeks to understand the fundamental underpinning principles and science governing dry coating process, evaluate key technologies developed to produce functionalised particles along with outlining their advantages, limitations and applications and discusses in detail the resultant functionalities and their applications. Expert opinion: Dry particle coating is a promising solvent-free manufacturing technology to produce particles with targeted functionalities. Progress within this area requires the development of continuous processing devices that can overcome challenges encountered with current technologies such as heat generation and particle attrition. Growth within this field requires extensive research to further understand the impact of process design and material properties on resultant functionalities.

Enhancement of the total phenolic compounds and antioxidant activity of aqueous Citrus limon L. pomace extracts using microwave pre-treatment on the dry powder

The effect of microwave pre-treatment on the levels of total phenolic compounds, flavonoids, proanthocyanidins and individual major compounds as well as the total antioxidant activity of the dried lemon pomace was investigated. The results showed that microwave pre-treatment significantly affected all the examined parameters. The total phenolic content, total flavonoids, proanthocyanidins, as well as the total antioxidant activity significantly increased as the microwave radiation time and power increased (e.g., 2.5 folds for phenolics, 1.4 folds for flavonoids and 5.5 folds for proanthocyanidins), however irradiation more than 480 W for 5 min resulted in the decrease of these parameters. These findings indicate that microwave irradiation time and power may enhance higher levels of the phenolic compounds as well as the antioxidant capacity of the dried lemon pomace powder. However, higher and longer irradiation may lead to a degradation of phenolic compounds and lower the antioxidant capacity of the dried lemon pomace.

Improved treatment of nicotine addiction and emerging pulmonary drug delivery

Nicotine addiction remains the leading cause of death and disease in developed and developing nations and a major cause of mortality around the world. Currently, nicotine replacement therapies (NRTs), bupropion, and varenicline are approved by the regulatory agencies as first-line treatments for nicotine addiction. Emerging evidence indicates that varenicline and bupropion have some therapeutic limitations for treating nicotine addiction with oral route of administration. Thus, continued investigation of innovative drug delivery for nicotine addiction remains a critical priority. This review will discuss some novel strategies and future directions for pulmonary drug delivery, an emerging route of administration for smoking cessation. It is anticipated that the advancement of knowledge on pulmonary drug delivery will provide better management for nicotine addiction and other addictive disorders.

Colloidal drug probe : method development and validation for adhesion force measurement using atomic force microscopy

This study demonstrates a novel technique of preparing drug colloid probes to determine the adhesion force between the drug salbutamol sulphate (SS) and the surfaces of polymer microparticles to be used as carriers for the dispersion of drug particles from a dry powder inhaler (DPI) formulation. Initially model silica probes of approximately 4 μm size, similar to a drug particle used in DPI formulations, were coated with a saturated SS solution with the aid of capillary forces acting between the silica probe and the drug solution. The developed method of ensuring a smooth and uniform layer of SS on the silica probe was validated using X-Ray Photoelectron Spectroscopy (XPS) and Scanning Electron Microscopy (SEM). Using the same technique, silica microspheres preattached on the AFM cantilever were coated with SS. The adhesion forces between the silica probe and drug coated silica (drug probe) and polymer surfaces (hydrophilic and hydrophobic) were determined. Our experimental results showed that the technique for preparing the drug probe was robust and can be used to determine the adhesion force between hydrophilic/hydrophobic drug probe and carrier surfaces to gain a better understanding on drug carrier adhesion forces in DPI formulations.

Colloidal drug probe : Method development and validation for adhesion force measurement using Atomic Force Microscopy

This study demonstrates a novel technique of preparing drug colloid probes to determine the adhesion force between a model drug salbutamol sulphate (SS) and the surfaces of polymer microparticles to be used as carriers for the dispersion of drug particles from dry powder inhaler (DPI) formulations. Model silica probes of approximately 4 lm size, similar to a drug particle used in DPI formulations, were coated with a saturated SS solution with the aid of capillary forces acting between the silica probe and the drug solution. The developed method of ensuring a smooth and uniform layer of SS on the silica probe was validated using X-ray Photoelectron Spectroscopy (XPS) and Scanning Electron Microscopy (SEM). Using the same technique, silica microspheres pre-attached on the AFM cantilever were coated with SS. The adhesion forces between the silica probe and drug coated silica (drug probe) and polymer surfaces (hydrophilic and hydrophobic) were determined. Our experimental results showed that the technique for preparing the drug probe was robust and can be used to determine the adhesion force between hydrophilic/ hydrophobic drug probe and carrier surfaces to gain a better understanding on drug carrier adhesion forces in DPI formulations.

Solubility of ibuprofen in aqueous ethanol at low ethanol contents

The solubility of ibuprofen was measured in water (W) - ethanol (E) mixtures from 0 to 50% w/w ethanol at 10, 25 and 40 °C by the dissolution method using UV spectrophotometry to determine the ibuprofen concentrations. The UV calibration for ibuprofen in different water - ethanol mixtures showed Beer - Lambert linearity, however the slopes differed, which indicated the structure of the drug is influenced by the solvent system i.e. the water - ethanol ratio. The ibuprofen solubility in water (zero ethanol) is low (~ 50 ppm) but increases near exponentially with increasing ethanol content. At 40 °C, there is phase separation between 34% and 63% w/w E/(E+W). The solubility data will be used to select precipitation crystallizer conditions to directly produce free flowing ibuprofen particles (<5 m) for developing a dry powder inhaler (DPI) formulation for lung delivery.

Effect of water vapour stabilization of raw materials on the quality of the inhalation product

Generation of raw materials for dry powder inhalers by different size reduction methods can be expected to influence physical and chemical properties of the powders. This can cause differences in particle size, size distribution, shape, crystalline properties, surface texture and energy. These physical properties of powders influence the behaviour of particles before and after inhalation. Materials with an amorphous surface have different surface energy compared to materials with crystalline surface. This can affect the adhesion and cohesion of particles. Changes in the surface nature of the drug particles results in a change in product performance. By stabilization of the raw materials the amorphous surfaces are converted into crystalline surfaces. The primary aim of the study was to investigate the influence of the surface properties of the inhalation particles on the quality of the product. The quality of the inhalation product is evaluated by measuring the fine particle dose (FPD). FDP is the total dose of particles with aerodynamic diameters smaller than 5,0 μm. The secondary aim of this study was to achieve the target level of the FPD and the stability of the FPD. This study was also used to evaluate the importance of the stabilization of the inhalation powders. The study included manufacturing and analysing drug substance 200 μg/dose inhalation powder batches using non-stabilized or stabilized raw materials. The inhaler formulation consisted of micronized drug substance, lactose <100μm and micronized lactose <10μm. The inhaler device was Easyhaler®. Stabilization of the raw materials was done in different relative humidity, temperature and time. Surface properties of the raw materials were studied by dynamic vapour sorption, scanning electron microscopy and three-point nitrogen adsorption technique. Particle size was studied by laser diffraction particle size analyzer. Aerodynamic particle size distribution from inhalers was measured by new generation impactor. Stabilization of all three raw materials was successful. A clear difference between nonstabilized and stabilized raw materials was achieved for drug substance and lactose <10μm. However for lactose <100μm the difference wasn’t as clear as wanted. The surface of the non-stabilized drug substance was more irregular and the particles had more roughness on the surface compared to the stabilized drug substances particles surface. The surface of the stabilized drug particles was more regular and smoother than non-stabilized. Even though a good difference between stabilized and non-stabilized raw materials was achieved, a clear evidence of the effect of the surface properties of the inhalation particles on the quality of the product was not observed. Stabilization of the raw materials didn’t lead to a higher FPD. Possible explanations for the unexpected result might be too rough conditions in the stabilization of the drug substance or smaller than wanted difference in the degree of stabilization of the main component of the product <100μm. Despite positive effects on the quality of the product were not seen there appears to be some evidence that stabilized drug substance results in smaller particle size of dry powder inhalers.

Neue Aspekte zur effektiven bronchialen Applikation inhalativer Medikamente im Kindesalter

Zur bronchialen Deposition von Arzneimitteln stehen im Wesentlichen drei Inhalationssysteme zur Verfügung: (1) Dosier-Aerosole (pressurized Metered Dose Inhaler, pMDI), (2) Trockenpulver-Inhalatoren (Dry Powder Inhaler, DPI) und (3) Druckluftvernebler zur Feuchtinhalation. Der Erfolg einer Inhalationstherapie hängt neben anderen Faktoren (s.u.) wesentlich vom Depositionsverhalten des als Aerosol inhalierten Medikamentes ab. Wie viel wirksame Substanz lagert sich an welchen Stellen der Atemwege ab und welche Dosis erreicht letztlich die kleinen Atemwege? Einflussfaktoren sind hier vor allem die Partikelgröße und die Inhalationstechnik. So verlangen beispielsweise DPI’s einen respiratorischen Spitzenfluss (PIF) von mindestens 30 l/min, wohingegen bei der Verwendung von pMDI’s ein gleich bleibender PIF von 40 bis 90 l/min erwünscht ist. Die für das jeweilige Inhalationssystem optimale Atemtechnik muss also vom Patienten erlernt werden. Mit den eigenen Arbeiten soll das Verständnis inhalativer Vorgänge sowie die bronchiale Deposition von inhalativen Medikamenten bei pädiatrischen Patienten verbessert werden. Aus der Vielzahl der Inhalatoren wählten wir für unsere Versuche fünf Systeme aus, deren unterschied-liche Anforderungen an den Patienten repräsentativ überprüft wurden: (1) DPI mit mittlerem Widerstand: Diskus®, (2) DPI mit hohem Widerstand: Turbohaler®, (3) pMDI: Autohaler®, (4) pMDI für Säuglinge: Budiair® mit verschiedenen Vorsatzkammern (Babyhaler®, AeroChamber® Plus small und medium) und (5) nachfüllbarer DPI mit niedrigem Widerstand: MAGhaler®. Für unsere Studien unverzichtbar war außerdem ein Testsystem, mit dem die Fähigkeit der Patienten überprüft und verbessert werden kann, einen bestimmten Inhalator effektiv zu benutzen, d.h. das gewünschte Atemmanöver durchzuführen und damit eine optimale Medikamenten-Deposition zu erreichen. Erste Untersuchungen ergaben, dass die kommerziell auf dem Markt verfügbaren Testsysteme suboptimal sind, weil sie sich nur auf die Messung des PIF’s konzentrieren und andere für die Deposition wichtige Parameter (Beschleunigung, Inhaltionsdauer etc.) außer Acht lassen. Wir entwickelten daher den Inhalation-Manager, der die Dokumentation des gesamten Atemmanövers ermöglicht. Es handelt sich dabei um ein computerbasiertes Mess- und Kontrollsystem, das unmittelbar nach der Inhalation ein optisches feedback des gesamten Manövers inklusive des generierten Partikelspektrums liefert. Die daraus weiterentwickelte Schulungssoftware ermöglicht die individuelle Schulung verschiedener Inhalationsmanöver auch mit neuen Inhalatoren. Patient und Arzt erhalten eine optische Rückmeldung, die den Erfolg oder Misserfolg der Inhalation erkennen lässt. Erste Schulungen mit dem neuen System von pädiatrischen Patienten mit Asthma bronchiale verliefen positiv: der Anteil der optimalen Inhalationsmanöver und damit auch der Therapieerfolg stiegen an. Allerdings zeigte sich auch, dass verschiedene Systeme nicht gleichzeitig geschult werden sollten. Generelle Schwierigkeiten bereitet die Inhalationstherapie von Kindern bis etwa zum 4. Geburtstag, da diese meist gar kein Inhalationsmanöver erlernen können. Die Medikamente müssen somit durch den Ruheatemfluss ins Bronchialsystem transportiert werden, wobei Dosieraerosole mit Vorsatzkammern (Spacer) oder Vernebler mit Masken zum Einsatz kommen sollten. Bei der Inhalation mit Spacer war bislang unklar, wie viel Prozent der Nominaldosis letztlich in die Lunge gelangen und therapeutisch wirksam werden. Unsere in-vitro Studien mit einem Dosieraerosol und verschiedenen Spacern zeigten, dass nach fünf Atemzügen maximal 20% der Nominaldosis das Gerät bzw. den Spacer verlassen. Nach nur einem Atemzug und bei Verwendung bestimmter Spacer (großes Totraumvolumen) beträgt dieser Wert sogar nur 5%. Dieses Ergebnis belegt, dass man vom Säuglings- bis zum Erwachsenenalter nahezu die gleiche Nominaldosis verabreichen kann, da durch unterschiedliche Inhalationsmanöver und –systeme die wirksame Dosis extrakorporal auf die altersentsprechende Dosis reduziert wird. Ein besonderes Problem ergibt sich schließlich bei der Feuchtinhalation mit Druckluftverneblern. Hier darf die Kompatibilität von unterschiedlichen Inhalationslösungen nicht außer Acht gelassen werden. So gaben in unserer Mukoviszidose-Ambulanz viele Betroffene an, aus Zeitgründen unterschiedliche Inhalationslösungen bei der Feuchtinhalation zu mischen. Physikalisch-chemische Inkompatibilitäten können dann die Wirksamkeit der Therapie beeinträchtigen und auch zu unerwünschten Nebenwirkungen führen. In einer interdisziplinären Arbeitsgruppe mit Chemikern und Pharmazeuten untersuchten wir daher die Mischbarkeit von häufig genutzten Inhalationslösungen (Salbutamol, Ipratropium, Cromoglicinsäure, Budenosid, Tobramycin und Dornase Alpha) und stellten die Ergebnisse (mögliche Inhaltionskombinationen) tabellarisch zusammen.

Untersuchung der Adhäsionskräfte in interaktiven Pulvermischungen zur Inhalation und deren Veränderung in Abhängigkeit von der Dichtigkeit der Verpackung

Die Untersuchung der Adhäsionskräfte mit Colloid Probe Technik, einer Weiterentwicklung der Rasterkraftmikroskopie (Atomic Force Microscopy=AFM), an erzeugten Carrier- und Wirkstoffkristallen bei Laborbedingungen und unter Einfluss der Luftfeuchte zeigte, dass die Adhäsion von Tiotropiumbromid Monohydrat an Mannitol deutlich höher ist als an Lactose Monohydrat. Die Kohäsionskräfte des Wirkstoffes sind stärker als die Adhäsionskräfte an Carriermaterialien. Auf dieser Grundlage wurde die Hypothese aufgestellt, dass eine Mischung mit Mannitol als Carrier eine kleinere Feinpartikeldosis liefert als eine Mischung mit Lactose. Diese Theorie wurde an interaktiven Pulvermischungen unter Variation von verschiedenen Einflussfaktoren überprüft. Die binare und ternäre Lactose-basierte Mischung lieferte unabhängig vom Kapselmaterial (Gelatine- und Polyethylenkapsel) eine höhere Feinpartikeldosis als die entsprechenden Mannitol-basierten Formulierungen. Die ternäre Komponente bewirkte nur bei Mannitol-basierten Mischungen eine Verbesserung der Feinpartikeldosis. Die detaillierte Untersuchung der aerodynamischen Verteilung ternärer Mischungen zeigte, dass das Kapselmaterial nur unter dem Einfluss der Luftfeuchte und Permeabilität der Blisterverpackung die interpartikulären Wechselwirkungen beeinflusst. Mischungen mit Mannitol als Carrier lieferten unabhängig vom Kapselmaterial, von Luftfeuchte/Lagerungsbedingungen und Permeabilität der Blisterverpackung eine kleinere Feinpartikeldosis als Mischungen mit Lactose als Carrier. Die Carrierart, die Permeabilität der Blisterverpackung und die Luftfeuchte wurden als Haupteinflussfaktoren auf die aerodynamischen Eigenschaften identifiziert. Es konnte gezeigt werden, dass AFM einen wertvollen Beitrag zum Verständnis der interpartikulären Wechselwirkungen leistet und aufgrund prädiktiver Eigenschaften hilfreich in der Entwicklung inhalativer Darreichungs-formen sein kann.