Prediction of Dry Powder Inhaler Formulation Performance From Surface Energetics and Blending Dynamics

The Purpose of these studies was to investigate the ability of surface energy measurements and rates of mixing in dry powder inhaler formulations to predict aerosol dispersion performance. Two lactose carrier systems comprising either spray dried or milled particles were developed such that they had identical physical characteristics except for surface morphology and surface energies avoiding confounding variables common in other studies. Surface energy measurements confirmed significant differences between the powder systems. Spray dried lactose had a higher surface entropy (0.20 vs. 0.13 mJ/m2K) and surface enthalpy (103.2 vs. 79.2 mJ/m2) compared to milled lactose. Mixing rates of budesonide or fluorescein were assessed dynamically and significant differences in blending were observed between lactose systems for both drugs. Surface energies of the lactose carriers were inversely proportional to dispersion performance. In addition, the root mean square of blending rates correlated positively with aerosol dispersion performance. Both techniques have potential utility in routine screening dry powder inhaler formulations

Prediction of dry powder inhaler formulation performance from surface energetics and blending dynamics

The Purpose of these studies was to investigate the ability of surface energy measurements and rates of mixing in dry powder inhaler formulations to predict aerosol dispersion performance. Two lactose carrier systems comprising either spray dried or milled particles were developed such that they had identical physical characteristics except for surface morphology and surface energies avoiding confounding variables common in other studies. Surface energy measurements confirmed significant differences between the powder systems. Spray dried lactose had a higher surface entropy (0.20 vs. 0.13 mJ/m2K) and surface enthalpy (103.2 vs. 79.2 mJ/m2) compared to milled lactose. Mixing rates of budesonide or fluorescein were assessed dynamically and significant differences in blending were observed between lactose systems for both drugs. Surface energies of the lactose carriers were inversely proportional to dispersion performance. In addition, the root mean square of blending rates correlated positively with aerosol dispersion performance. Both techniques have potential utility in routine screening dry powder inhaler formulations

Investigation of electrostatic charging phenomena in dry powder inhalers and the effect on deposition

Dry powder inhalers (DPI) are an important drug delivery option, for the treatment of respiratory diseases, and, increasingly, for the delivery of systemically acting drugs and vaccines. Most DPI formulations consist of micronized drug blended with larger carrier particles. The interactions between drug and carrier are a major determinant of DPI performance. Electrostatic interactions between particles are recognized as one mode of particle interaction. Simulations, in vitro and in vivo studies indicate that electrostatic charge affects the delivery and deposition of aerosol particles in the lung. Yet, the occurrence and origins of electrostatic charge on medicinal aerosol particles are poorly investigated and understood. The major physicochemical properties of two drugs (albuterol sulfate and budesonide) and a number of excipients (lactose, glucose and calcium phosphate) were assessed. Deposition studies with model formulations using the electrical low pressure impactor showed that micronized drug particles are subject to significant triboelectrification. Particle charge levels were shown to be several orders of magnitude larger than had previously been estimated. A multivariate experimental design framework was employed to investigate the effects of various formulation factors on the charging of the two drugs; it was shown that several formulation variables, in particular the excipient, have profound effects on charge acquired by micronized drug particles available to the lungs. The charging behavior observed in deposition studies agreed largely with bulk electrostatic measurements conducted on the raw materials. It was thus concluded that the origin of the charge was contact charging between particles of the formulation. The charging behavior was further elucidated through inverse gas chromatography measurements, in which the surface acid/base properties of the excipients were determined. Surface acid/base parameters, which characterize the tendency of a material to act as electron donor or acceptor in intermolecular interactions, correlated with the charges obtained in Faraday well experiments and particle charges acquired during DPI actuation, which suggests the three phenomena are closely related. The rank-order observed (from least to most electron withdrawing) was albuterol, lactose, glucose, calcium phosphate, budesonide. The study provides a mean of characterization that can be used to predict charging propensity which can assist the DPI product development process

Aerodynamic and Electrostatic Properties of Model Dry Powder Aerosols: a Comprehensive Study of Formulation Factors

The impact of formulation variables on aerodynamic and electrostatic properties of dry powder aerosol particles is of great importance to the development of efficient and reproducible inhaler products. Systematic evaluation requires a well-designed series of experiments using appropriate methods. A factorial experimental design was employed. In broad terms, the conditions considered were two drugs, albuterol and budesonide, in combination with different excipients, drug concentrations, delivered doses, and metering system (capsule composition) and sampled under different flow conditions using standard entrainment tubes. Samples were collected in an electrical low-pressure impactor, to evaluate distribution of electrostatic properties, and an Andersen eight-stage nonviable cascade impactor, to estimate aerodynamic particle size distribution, concurrently. The deposition studies allowed calculation of approximate per particle charge levels for drug. The results showed very high particle charge levels, often in the 1,000-10,000 of elementary charges per particle range, orders of magnitude higher than charge levels predicted by the Boltzmann charge distribution. The charge levels are considerably higher than had previously been estimated (200e per particle)

Mathematical approach for understanding deagglomeration behaviour of drug powder in formulations with coarse carrier

This is an Open Access article distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives License ( http://creativecommons.org/licenses/by-nc-nd/4.0/ ), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is properly cited, and is not altered, transformed, or built upon in any way.Deagglomeration of cohesive particles in combination with coarse carrier is a key requirement for inhaled formulations. The aim of the project was to propose a mathematical approach to understand aerosolization behaviour of micronized particles alone and in formulation with carriers. Salbutamol sulphate and salmeterol xinafoate were blended separately with fine lactose (ratio 1:4) and fine and coarse lactose (1:4:63.5). Laser diffraction was employed to characterize the powder median particle size. The deagglomeration of micronized materials followed an asymptotic monoexponential relationship. When the coarse lactose was added, the relationship fitted a bi-exponential equation showing an easily and a poorly dispersed fraction. Using model hydrophobic and hydrophilic APIs, this study has demonstrated the utility of an analytical approach that can parameterize deagglomeration behaviour of carrier-free and carrier-based inhalation formulations. The analytical approach provides the ability to systematically study the effect of material, formulation and processing factors on deagglomeration behaviour.Peer reviewe

Evidence for the existence of powder sub-populations in micronized materials : Aerodynamic size-fractions of aerosolized powders possess distinct physicochemical properties

This article is distributed under the terms of the Creative Commons Attribution License which permits any use, distribution, and reproduction in any medium, provided the original author(s) and the source are credited.Purpose: To investigate the agglomeration behaviour of the fine ( 12.8 µm) particle fractions of salmeterol xinafoate (SX) and fluticasone propionate (FP) by isolating aerodynamic size fractions and characterising their physicochemical and re-dispersal properties. Methods: Aerodynamic fractionation was conducted using the Next Generation Impactor (NGI). Re-crystallized control particles, unfractionated and fractionated materials were characterized for particle size, morphology, crystallinity and surface energy. Re-dispersal of the particles was assessed using dry dispersion laser diffraction and NGI analysis. Results: Aerosolized SX and FP particles deposited in the NGI as agglomerates of consistent particle/agglomerate morphology. SX particles depositing on Stages 3 and 5 had higher total surface energy than unfractionated SX, with Stage 5 particles showing the greatest surface energy heterogeneity. FP fractions had comparable surface energy distributions and bulk crystallinity but differences in surface chemistry. SX fractions demonstrated higher bulk disorder than unfractionated and re-crystallized particles. Upon aerosolization, the fractions differed in their intrinsic emission and dispersion into a fine particle fraction (< 5.0 µm). Conclusions: Micronized powders consisted of sub-populations of particles displaying distinct physicochemical and powder dispersal properties compared to the unfractionated bulk material. This may have implications for the efficiency of inhaled drug deliveryPeer reviewe

Evaluation studies of a sensing technique for electrostatic charge polarity of pharmaceutical particulates

Electrostatic charge due to inter-particle and particle-wall contacts may generate significant hazards during the processing of particulates within the pharmaceutical industry. Although charge behaviour of particulates is erratic and not easy to predict, it would be desirable to characterise the tendency of tribocharging prior to manufacturing. The work reported in this paper concentrates on a new and novel techniques for the detection of the active ingredient and excipient in a bipolar material. Three different case studies are presented for demonstration of the applicability of the method in different practical situations. Work confirmed through an experimental rig set-up indicates that materials that accumulate opposite charge via contact and rubbing can be detected from their charge sign as well as their relative magnitude. The results reported clearly demonstrated that the developed method for charge characterisation is a useful tool to understand how the charges are distributed in a population of particles showing a number of advantages over conventional methods

Study of the Emitted Dose After Two Separate Inhalations at Different Inhalation Flow Rates and Volumes and an Assessment of Aerodynamic Characteristics of Indacaterol Onbrez Breezhaler® 150 and 300 μg

Onbrez Breezhaler® is a low-resistance capsule-based device that was developed to deliver indacaterol maleate. The study was designed to investigate the effects of both maximum flow rate (MIF) and inhalation volume (Vin) on the dose emission of indacaterol 150 and 300 μg dose strengths after one and two inhalations using dose unit sampling apparatus (DUSA) as well as to study the aerodynamic characteristics of indacaterol Breezhaler® using the Andersen cascade impactor (ACI) at a different set of MIF and Vin. Indacaterol 150 and 300 μg contain equal amounts of lactose per carrier. However, 150 μg has the smallest carrier size. The particle size distribution (PSD) of indacaterol DPI formulations 150 and 300 μg showed that the density of fine particles increased with the increase of the primary pressure. For both strengths (150 μg and 300 μg), ED1 increased and ED2 decreased when the inhalation flow rate and inhaled volume increased. The reduction in ED1 and subsequent increase in ED2 was such that when the Vin is greater than 1 L, then 60 L/min could be regarded as the minimum MIF. The Breezhaler was effective in producing respirable particles with an MMAD ≤5 μm irrespective of the inhalation flow rate, but the mass fraction of particles with an aerodynamic diameter <3 μm is more pronounced between 60 and 90 L/min. The dose emission of indacaterol was comparable for both dose strengths 150 and 300 μg. These in vitro results suggest that a minimum MIF of 60 L/min is required during routine use of Onbrez Breezhaler®, and confirm the good practice to make two separate inhalations from the same dose

Evaluation of a new dispersion technique for assessing triboelectric charging of powders

In a number of applications, especially in pharmaceutical drug development, there is often a very small powder quantity available for evaluating the manufacturability of new drugs. However, it is highly desirable to be able to quickly evaluate processing issues, and where possible using the smallest powder quantity. In the present work, a proprietary commercial powder dispersion device (the disperser of Malvern© Morphologi G3) is adapted to evaluate the triboelectric charging tendency. A very small powder quantity (as small as 0.1 mg) is dispersed by a pressure pulse of compressed gas such as air or nitrogen. This causes the particles to become air borne and collide with the containing walls, resulting in dispersion and leading to triboelectric charge transfer between the particles and the walls. In this work, the charging propensity of a number of materials is evaluated and the effect of particle surface functional groups on the tribo-electric charge transfer is analysed. Model materials with a well-defined shape (glass ballotini) but with different silane groups deposited on their surfaces as well as a number of organic crystalline particles (such as aspirin, α-lactose monohydrate and paracetamol) are tested. Following dispersion the particles move immediately to a Faraday cup placed directly underneath the disperser. Therefore, particle charge is measured with no decay. The method can differentiate charging of different polymorphs of the same material, different silane groups on the surfaces of glass ballotini and different crystal morphologies obtained from crystallisation from various solvents

Formulation Pre-screening of Inhalation Powders Using Computational Atom–Atom Systematic Search Method

The synthonic modeling approach provides a molecule-centered understanding of the surface properties of crystals. It has been applied extensively to understand crystallization processes. This study aimed to investigate the functional relevance of synthonic modeling to the formulation of inhalation powders by assessing cohesivity of three active pharmaceutical ingredients (APIs, fluticasone propionate (FP), budesonide (Bud), and salbutamol base (SB)) and the commonly used excipient, α-lactose monohydrate (LMH). It is found that FP (−11.5 kcal/mol) has a higher cohesive strength than Bud (−9.9 kcal/mol) or SB (−7.8 kcal/mol). The prediction correlated directly to cohesive strength measurements using laser diffraction, where the airflow pressure required for complete dispersion (CPP) was 3.5, 2.0, and 1.0 bar for FP, Bud, and SB, respectively. The highest cohesive strength was predicted for LMH (−15.9 kcal/mol), which did not correlate with the CPP value of 2.0 bar (i.e., ranking lower than FP). High FP–LMH adhesive forces (−11.7 kcal/mol) were predicted. However, aerosolization studies revealed that the FP–LMH blends consisted of agglomerated FP particles with a large median diameter (∼4–5 μm) that were not disrupted by LMH. Modeling of the crystal and surface chemistry of LMH identified high electrostatic and H-bond components of its cohesive energy due to the presence of water and hydroxyl groups in lactose, unlike the APIs. A direct comparison of the predicted and measured cohesive balance of LMH with APIs will require a more in-depth understanding of highly hydrogen-bonded systems with respect to the synthonic engineering modeling tool, as well as the influence of agglomerate structure on surface–surface contact geometry. Overall, this research has demonstrated the possible application and relevance of synthonic engineering tools for rapid pre-screening in drug formulation and design