The shelf life of ASDs: 2. Predicting the shelf life at storage conditions

Amorphous solid dispersions (ASDs) are a widely used formulation technology for poorly water-soluble active pharmaceutical ingredients (API). Depending on the API-polymer combination and API load in the ASD, the amorphous API might be thermodynamically metastable and crystallize over time. The crystallization onset is one critical factor that can define the shelf life of the ASD. Thus, for ASD formulations, long-term stability against crystallization of the API is of particular interest. This work presents a method for predicting the long-term physical stability of ASDs (crystallization onset time). The new approach combines the Johnson-Mehl-Avrami-Kolmogorov (JMAK) equation with classical nucleation theory. The shelf life predicted using the new approach depends on supersaturation (determined with PC-SAFT), viscosity (determined with WLF equation or Arrhenius equation) and two specific model parameters k' and B. The latter were fitted to a few fast crystallization-kinetics measurements above the glass transition of the ASD. An additional crystallization-kinetics measurement below the glass-transition temperature of the ASD was used to determine the Arrhenius parameters. Once all parameters are determined for a given API/polymer combination and manufacturing method, they are valid for any API load, temperature, and RH. The proposed approach allows predicting the shelf life (crystallization onset) of a potential ASD in early stage of development within a few days. It was successfully verified for ASDs stored at 25 °C and 10% RH or 60% RH.

The Shelf Life of ASDs: 1. Measuring the Crystallization Kinetics at Humid Conditions

Amorphous solid dispersions (ASDs), where an active pharmaceutical ingredient (API) is dissolved in a polymer, are a favored formulation technique to achieve sufficient bioavailability of poorly water-soluble APIs. The shelf life of such ASDs is often limited by API crystallization. Crystallization depends strongly on the storage conditions (relative humidity and temperature) and the polymer selected for generating the ASD. Determining the crystallization kinetics of ASDs under various conditions requires suitable analytical methods. In this work, two different analytical methods were compared and cross-validated: The first builds on water-sorption measurements combined with thermodynamic predictions ( Eur. J. Pharm. Biopharm. 2018, 127, 183-193, DOI: 10.1016/j.toxrep.2018.11.002), whereas the second applies Raman spectroscopy. Using the two independent methods, factors influencing the crystallization kinetics of ASDs containing the API griseofulvin were investigated quantitatively. It was found that crystallization kinetics increases with increasing temperature and relative humidity. Additionally, the influence of different polymers (poly(vinylpyrrolidone-co-vinyl acetate) and Soluplus) on crystallization kinetics were investigated. The experimentally obtained crystallization kinetics were described using the Johnson-Mehl-Avrami-Kolmogorov model and are the basis for future shelf life predictions at desired storage conditions.

Influence of Process Temperature and Residence Time on the Manufacturing of Amorphous Solid Dispersions in Hot Melt Extrusion

The manufacturing of amorphous solid dispersions via hot melt extrusion is a topic of high interest in pharmaceutical development. By this technique, the drug is dissolved in the molten polymer above solubility temperature within the process time. In this study an experimental framework is proposed determining the minimum required process temperature and the residence time using particularly low quantities of material. Drug/polymer mixtures in different ratios were processed in a micro scale extruder while the process temperature and residence time were varied systematically. The phase situation was assessed by the turbidity of the final extrudate. Four different drug/polymer mixtures were investigated in three drug/polymer ratios. The minimum required process temperature was close to solubility temperature for each specific formulation. Moreover, an influence of residence time on the phase situation was found. About 3 minutes were required in order to dissolve the drug in the polymer at these process conditions.

Viscosity of ASDs at humid conditions

Many amorphous solid dispersions (ASDs) are thermodynamically unstable. Thus, the active pharmaceutical ingredient (API) might crystallize over time. The crystallization kinetics and therewith the long-term stability of ASDs depends on the storage conditions temperature and relative humidity (RH) as they determine the molecular mobility of the API in the polymer. To quantify the molecular mobility, the rheological behavior of two different ASDs with ibuprofen and either poly(vinyl acetate) or poly(vinylpyrrolidone-co-vinyl acetate) was analyzed as function of temperature and relative humidity by means of an oscillatory rheometer. The plasticizing effect of ibuprofen and absorbed water on the zero-shear viscosity of the polymer could be fully explained by the reduction of the glass-transition temperature of the mixture compared to the one of the pure polymer. Moreover, this work proposes an approach to predict the zero-shear viscosity of an ASD based on only the temperature dependence of the zero-shear viscosity of the pure polymer as well as the predicted water content in the ASD at certain RH using the Perturbed-Chain Statistical Associating Fluid Theory (PC-SAFT).

Selecting Excipients Forming Therapeutic Deep Eutectic Systems-A Mechanistic Approach

The majority of all newly identified active pharmaceutical ingredients (APIs) have a low solubility in water (partly smaller than marble). In order to enhance their solubility and bioavailability, the formulation of these APIs, as part of therapeutic deep eutectic systems (THEDES), has been recently shown to be a promising approach. By choosing the right excipient, the melting point of the API/excipient mixture can be lowered below body temperature or even room temperature, resulting in a liquid formulation. To date, because of a lack of mechanistic understanding of how THEDES are formed, the identification of suitable excipients for a given API is almost exclusively based on heuristic decisions and trial-and-error-based approaches. This is both very time-consuming and expensive. The purpose of this work is to reduce the experimental effort to identify suitable excipients for a given API solely based on the melting properties (melting temperature and melting enthalpy) of the API and excipient and accounting for intermolecular interactions via a predictive thermodynamic model [in this case, UNIFAC(Do)]. Lidocaine, ibuprofen, and phenylacetic acid were considered as model APIs, whereas thymol, vanillin, lauric acid, para-toluic acid, benzoic acid, and cinnamic acid were considered as model excipients. The formation of THEDES from these components was predicted and confirmed using differential scanning calorimetry. The results indicate that the experimental effort for the identification of suitable API/excipient combinations can be drastically reduced by thermodynamic modeling, leading to more efficient and tailor-made formulations in the future.