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Barbălată CI, Porfire AS, Ambrus R, Mukhtar M, Farkas Á, Tomuță I. Process development of inhalation powders containing simvastatin loaded liposomes using spray drying technology. J Liposome Res 2024; 34:421-434. [PMID: 37998080 DOI: 10.1080/08982104.2023.2287588] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2023] [Accepted: 10/14/2023] [Indexed: 11/25/2023]
Abstract
The development of an inhalation powder (IP) for cancer therapy is desired to improve the therapeutic response and patient compliance. The latest studies highlighted that statins, a class of drugs used in hypercholesterolemia, can have anticancer and antiinflammatory properties. Therefore, the aim of the study was to develop an IP containing liposomes loaded with simvastatin using spray drying technology, as well as to investigate the influence of formulation factors on the quality attributes of the IP by means of experimental design. Results highlighted that the composition of liposomes, namely type of phospholipid and cholesterol concentration, highly influences the quality attributes of IP, and the use of optimal concentrations of excipients, i.e. D-mannitol and L-leucine, is essential to preserve the characteristics of liposomes throughout the spray drying process. The in vitro characterization of the optimal IP formulation revealed that the total percentage of released drug is higher from the IP formulation compared to the powder of active substance (53.38 vs. 42.76%) over a period of six hours, and 39.67% of dry particles have a size less than 5 µm, making them suitable for inhalation. As a conclusion, spray drying technology can be effectively used in the development and preparation of IP containing liposomes.
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Affiliation(s)
- Cristina-Ioana Barbălată
- Department of Pharmaceutical Technology and Biopharmaceutics, Faculty of Pharmacy, 'Iuliu Hatieganu' University of Medicine and Pharmacy, Cluj-Napoca, Romania
| | - Alina Silvia Porfire
- Department of Pharmaceutical Technology and Biopharmaceutics, Faculty of Pharmacy, 'Iuliu Hatieganu' University of Medicine and Pharmacy, Cluj-Napoca, Romania
| | - Rita Ambrus
- Faculty of Pharmacy, Institute of Pharmaceutical Technology and Regulatory Affairs, University of Szeged, Szeged, Hungary
| | - Mahwash Mukhtar
- Faculty of Pharmacy, Institute of Pharmaceutical Technology and Regulatory Affairs, University of Szeged, Szeged, Hungary
| | - Árpád Farkas
- Environmental Physiscs Department, Center for Energy Research, Budapest, Hungary
| | - Ioan Tomuță
- Department of Pharmaceutical Technology and Biopharmaceutics, Faculty of Pharmacy, 'Iuliu Hatieganu' University of Medicine and Pharmacy, Cluj-Napoca, Romania
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2
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Minootan Z, Wang H, Connaughton P, Lachacz K, Carrigy N, Ordoubadi M, Lechuga-Ballesteros D, Martin AR, Vehring R. On the Feasibility of Rugose Lipid Microparticles in Pressurized Metered Dose Inhalers with Established and New Propellants. AAPS PharmSciTech 2024; 25:82. [PMID: 38600288 DOI: 10.1208/s12249-024-02776-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/05/2023] [Accepted: 02/21/2024] [Indexed: 04/12/2024] Open
Abstract
Pressurized metered dose inhalers (pMDIs) require optimized formulations to provide stable, consistent lung delivery. This study investigates the feasibility of novel rugose lipid particles (RLPs) as potential drug carriers in pMDI formulations. The physical stability of RLPs was assessed in three different propellants: the established HFA-134a and HFA-227ea and the new low global-warming-potential (GWP) propellant HFO-1234ze. A feedstock containing DSPC and calcium chloride was prepared without pore forming agent to spray dry two RLP batches at inlet temperatures of 55 °C (RLP55) and 75 °C (RLP75). RLPs performance in pMDI formulations was compared to two reference samples that exhibit significantly different performance when suspended in propellants: well-established engineered porous particles and particles containing 80% trehalose and 20% leucine (80T20L). An accelerated stability study at 40 °C and relative humidity of 7% ± 5% was conducted over 3 months. At different time points, a shadowgraphic imaging technique was used to evaluate the colloidal stability of particles in pMDIs. Field emission electron microscopy with energy dispersive X-ray spectroscopy was used to evaluate the morphology and elemental composition of particles extracted from the pMDIs. After 2 weeks, all 80T20L formulations rapidly aggregated upon agitation and exhibited significantly inferior colloidal stability compared to the other samples. In comparison, both the RLP55 and RLP75 formulations, regardless of the propellant used, retained their rugose structure and demonstrated excellent suspension stability comparable with the engineered porous particles. The studied RLPs demonstrate great potential for use in pMDI formulations with HFA propellants and the next-generation low-GWP propellant HFO-1234ze.
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Affiliation(s)
- Zahra Minootan
- Donadeo Innovation Centre for Engineering (DICE), 9211 116 Street NW, Edmonton, Alberta, T6G1H9, Canada
| | - Hui Wang
- Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta, T6G1H9, Canada.
| | - Patrick Connaughton
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Durham, North Carolina, USA
| | - Kellisa Lachacz
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Durham, North Carolina, USA
| | - Nicholas Carrigy
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Durham, North Carolina, USA
| | - Mani Ordoubadi
- Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta, T6G1H9, Canada
| | - David Lechuga-Ballesteros
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Durham, North Carolina, USA
| | - Andrew R Martin
- Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta, T6G1H9, Canada
| | - Reinhard Vehring
- Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta, T6G1H9, Canada
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Abdelhamid M, Corzo C, Ocampo AB, Maisriemler M, Slama E, Alva C, Lochmann D, Reyer S, Freichel T, Salar-Behzadi S, Spoerk M. Mechanically promoted lipid-based filaments via composition tuning for extrusion-based 3D-printing. Int J Pharm 2023; 643:123279. [PMID: 37524255 DOI: 10.1016/j.ijpharm.2023.123279] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/29/2023] [Revised: 07/26/2023] [Accepted: 07/27/2023] [Indexed: 08/02/2023]
Abstract
Lipid excipients are favorable materials in pharmaceutical formulations owing to their natural, biodegradable, low-toxic and solubility/permeability enhancing properties. The application of these materials with advanced manufacturing platforms, particularly filament-based 3D-printing, is attractive for personalized manufacturing of thermolabile drugs. However, the filament's weak mechanical properties limit their full potential. In this study, highly flexible filaments were extruded using PG6-C16P, a lipid-based excipient belonging to the group of polyglycerol esters of fatty acids (PGFAs), based on tuning the ratio between its major and minor composition fractions. Increasing the percentage of the minor fractions in the system was found to enhance the relevant mechanical filament properties by 50-fold, guaranteeing a flawless 3D-printability. Applying a novel liquid feeding approach further improved the mechanical filament properties at lower percentage of minor fractions, whilst circumventing the issues associated with the standard extrusion approach such as low throughput. Upon drug incorporation, the filaments retained high mechanical properties with a controlled drug release pattern. This work demonstrates PG6-C16 P as an advanced lipid-based material and a competitive printing excipient that can empower filament-based 3D-printing.
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Affiliation(s)
- Moaaz Abdelhamid
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Graz, Austria
| | - Carolina Corzo
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | | | | | - Eyke Slama
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Carolina Alva
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | | | | | | | - Sharareh Salar-Behzadi
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; University of Graz, Institute of Pharmaceutical Sciences, Department of Pharmaceutical, Technology and Biopharmacy, Graz, Austria.
| | - Martin Spoerk
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Graz, Austria
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Corzo C, Crvenjak D, Sotirov K, Afonso Urich J, Öhlinger K, Meindl C, Lochmann D, Reyer S, Fröhlich E, Zimmer A, Salar-Behzadi S. Lipid-based particle engineering via spray-drying for targeted delivery of antibiotics to the lung. Int J Pharm 2023; 642:123201. [PMID: 37406948 DOI: 10.1016/j.ijpharm.2023.123201] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2023] [Revised: 06/29/2023] [Accepted: 07/01/2023] [Indexed: 07/07/2023]
Abstract
Pulmonary delivery of antibiotics for the treatment of tuberculosis provides several benefits compared to conventional oral and parenteral administration. API-loaded particles delivered directly to alveolar macrophages, where Mycobacterium tuberculosis resides, can reduce the required dose and decrease the severe side effects of conventional treatment. In this work, lipid-microparticles loaded with rifampicin were engineered via spray-drying to be administered as a carrier-free dry powder for inhalation. Although, it is well-known that spray-drying of lipid-based excipients is strongly limited, a completely lipid-based formulation using diglycerol full ester of behenic acid was produced. The solid state of the lipid, providing high melting temperature, absence of polymorphism and monophasic crystallization, led to high yield of spray-dried particles (83%). Inhalable particles of mass median aerodynamic diameter of 2.36 µm, median geometric size of 2.05 µm, and negative surface (-50.03 mV) were engineered. Such attributes were defined for deep lung deposition and targeted delivery of antibiotics to alveolar macrophages. Superior aerodynamic performance as carrier-free DPI was associated to a high fine particle fraction of 79.5 %. No in vitro cytotoxic effects were found after exposing epithelial cell lines and alveolar macrophages. In vitro uptake of particles into alveolar macrophages indicated the efficiency of their targeted delivery. The use of highly processable and safe lipid-based excipients for particle engineering via spray-drying can extend the availability of materials for functionalized applications for pulmonary delivery.
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Affiliation(s)
- Carolina Corzo
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; Institute of Pharmaceutical Sciences, Department of Pharmaceutical Technology & Biopharmacy, University of Graz, Graz, Austria
| | - Djana Crvenjak
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; Institute of Pharmaceutical Sciences, Department of Pharmaceutical Technology & Biopharmacy, University of Graz, Graz, Austria
| | - Kamen Sotirov
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; Institute of Pharmaceutical Sciences, Department of Pharmaceutical Technology & Biopharmacy, University of Graz, Graz, Austria
| | | | - Kristin Öhlinger
- Center for Medical Research, Medical University of Graz, Graz, Austria
| | - Claudia Meindl
- Center for Medical Research, Medical University of Graz, Graz, Austria
| | | | | | - Eleonore Fröhlich
- Center for Medical Research, Medical University of Graz, Graz, Austria
| | - Andreas Zimmer
- Institute of Pharmaceutical Sciences, Department of Pharmaceutical Technology & Biopharmacy, University of Graz, Graz, Austria
| | - Sharareh Salar-Behzadi
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria; Institute of Pharmaceutical Sciences, Department of Pharmaceutical Technology & Biopharmacy, University of Graz, Graz, Austria.
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Steiner D, Schumann LV, Bunjes H. Processing of Lipid Nanodispersions into Solid Powders by Spray Drying. Pharmaceutics 2022; 14:pharmaceutics14112464. [PMID: 36432654 PMCID: PMC9696983 DOI: 10.3390/pharmaceutics14112464] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2022] [Revised: 11/04/2022] [Accepted: 11/10/2022] [Indexed: 11/17/2022] Open
Abstract
Spray drying is a promising technology for drying lipid nanodispersions. These formulations can serve as carrier systems for poorly water-soluble active pharmaceutical ingredients (APIs) that are loaded into the lipid matrix to improve their bioavailability. Once the API-loaded nanocarriers have been further processed into solid dosage forms, they could be administered orally, which is usually preferred by patients. Various solid lipids as well as oils were used in this study to prepare lipid nanodispersions, and it was shown that their nanoparticulate properties could be maintained when lactose in combination with SDS was used as matrix material in the spray-drying process. In addition, for lipid nanoemulsions loaded with fenofibrate, a good redispersibility with particle sizes below 300 nm at a lipid content of 26.8 wt.% in the powders was observed. More detailed investigations on the influence of the drying temperature yielded good results when the inlet temperature of the drying air was set at 110 °C or above, enabling the lactose to form an amorphous matrix around the embedded lipid particles. A tristearin suspension was developed as a probe to measure the temperature exposure of the lipid particles during the drying process. The results with this approach indicate that the actual temperature the particles were exposed to during the drying process could be higher than the outlet temperature.
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Affiliation(s)
- Denise Steiner
- Institut für Pharmazeutische Technologie und Biopharmazie, Technische Universität Braunschweig, Mendelssohnstraße 1, 38106 Braunschweig, Germany
- Zentrum für Pharmaverfahrenstechnik (PVZ), Technische Universität Braunschweig, Franz-Liszt-Straße 35a, 38106 Braunschweig, Germany
- Correspondence:
| | - Leonie V. Schumann
- Institut für Pharmazeutische Technologie und Biopharmazie, Technische Universität Braunschweig, Mendelssohnstraße 1, 38106 Braunschweig, Germany
| | - Heike Bunjes
- Institut für Pharmazeutische Technologie und Biopharmazie, Technische Universität Braunschweig, Mendelssohnstraße 1, 38106 Braunschweig, Germany
- Zentrum für Pharmaverfahrenstechnik (PVZ), Technische Universität Braunschweig, Franz-Liszt-Straße 35a, 38106 Braunschweig, Germany
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Wang H, Connaughton P, Lachacz K, Carrigy N, Ordoubadi M, Lechuga-Ballesteros D, Vehring R. Inhalable Microparticle Platform Based on a Novel Shell-Forming Lipid Excipient and its Feasibility for Respirable Delivery of Biologics. Eur J Pharm Biopharm 2022; 177:308-322. [PMID: 35905804 DOI: 10.1016/j.ejpb.2022.07.013] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/01/2022] [Revised: 07/18/2022] [Accepted: 07/24/2022] [Indexed: 11/04/2022]
Abstract
Administration of biologics such as proteins, vaccines, and phages via the respiratory route is becoming increasingly popular. Inhalable powder formulations for the successful delivery of biologics must first ensure both powder dispersibility and physicochemical stability. A lipid-based inhalable microparticle platform combining the stability advantages offered by dry powder formulations and high dispersibility afforded by a rugose morphology was spray dried and tested. A new simplified spray drying method requiring no organic solvents or complicated feedstock preparation processes was introduced for the manufacture of the microparticles. Trehalose was selected to form the amorphous particle core, because of its well-known ability to stabilize biologics, and also because of its ability to serve as a surrogate for small molecule actives. Phospholipid distearoyl phosphatidylcholine (DSPC), the lipid component in this formulation, was used as a shell former to improve powder dispersibility. Effectiveness of the lipid excipient in modifying trehalose particle morphology and enhancing powder dispersibility was evaluated at different lipid mass fractions (5%, 10%, 25%, 50%) and compared with that of several previously published shell-forming excipients at their effective mass fractions, i.e., 5% trileucine, 20% leucine, and 40% pullulan. A strong dependence of particle morphology on the lipid mass fraction was observed. Particles transitioned from typical smooth spherical trehalose particles without lipid to highly rugose microparticles at higher lipid mass fractions (> 5%). In vitro aerosol performance testing demonstrated a significant improvement of powder dispersibility even at lipid mass fractions as low as 5%. Powder formulations with excellent aerosol performance comparable to those modified with leucine and trileucine were achieved at higher lipid mass fractions (> 25%). A model biologic-containing formulation with 35% myoglobin, 35% glass stabilizer (trehalose), and 30% lipid shell former was shown to produce highly rugose particle structure as designed and excellent aerosol performance for efficient pulmonary delivery. A short-term stability at 40 °C proved that this protein-containing formulation had good thermal stability as designed. The results demonstrated great potential for the new lipid microparticle as a platform for the delivery of both small-molecule APIs and large-molecule biologics to the lung.
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Affiliation(s)
- Hui Wang
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - Patrick Connaughton
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Kellisa Lachacz
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Nicholas Carrigy
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Mani Ordoubadi
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - David Lechuga-Ballesteros
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Reinhard Vehring
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
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Wang H, Ordoubadi M, Connaughton P, Lachacz K, Carrigy N, Tavernini S, Martin AR, Finlay WH, Lechuga-Ballesteros D, Vehring R. Spray Dried Rugose Lipid Particle Platform for Respiratory Drug Delivery. Pharm Res 2022; 39:805-823. [PMID: 35364777 DOI: 10.1007/s11095-022-03242-w] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2022] [Accepted: 03/21/2022] [Indexed: 01/13/2023]
Abstract
PURPOSE To develop a new lipid-based particle formulation platform for respiratory drug delivery applications. To find processing conditions for high surface rugosity and manufacturability. To assess the applicability of the new formulation method to different lipids. METHODS A new spray drying method with a simplified aqueous suspension feedstock preparation process was developed for the manufacture of rugose lipid particles of 1,2-distearoyl-sn-glycero-3-phosphocholine (DSPC). A study covering a wide range of feedstock temperatures and outlet temperatures was conducted to optimize the processing conditions. Aerosol performance was characterized in vitro and in silico to assess the feasibility of their use in respiratory drug delivery applications. The applicability of the new spray drying method to longer-chain phospholipids with adjusted spray drying temperatures was also evaluated. RESULTS Highly rugose DSPC lipid particles were produced via spray drying with good manufacturability. A feedstock temperature close to, and an outlet temperature lower than, the main phase transition were identified as critical in producing particles with highly rugose surface features. High emitted dose and total lung dose showed promising aerosol performance of the produced particles for use as a drug loading platform for respiratory drug delivery. Two types of longer-chain lipid particles with higher main phase transition temperatures, 1,2-diarachidoyl-sn-glycero-3-phosphocholine (DAPC) and 1,2-dibehenoyl-sn-glycero-3-phosphocholine (22:0 PC), yielded similar rugose morphologies when spray dried at correspondingly higher processing temperatures. CONCLUSIONS Rugose lipid particles produced via spray drying from an aqueous suspension feedstock are promising as a formulation platform for respiratory drug delivery applications. The new technique can potentially produce rugose particles using various other lipids.
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Affiliation(s)
- Hui Wang
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - Mani Ordoubadi
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - Patrick Connaughton
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Kellisa Lachacz
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Nicholas Carrigy
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Scott Tavernini
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - Andrew R Martin
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - Warren H Finlay
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada
| | - David Lechuga-Ballesteros
- Inhalation Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, South San Francisco, CA, USA
| | - Reinhard Vehring
- Department of Mechanical Engineering, University of Alberta, Alberta, Canada.
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