Use of Bead Mixtures as a Novel Process Optimization Approach to Nanomilling of Drug Suspensions

Do Mixtures of Beads with Different Sizes Improve Wet Stirred Media Milling of Drug Suspensions?

The impacts of bead sizes and bead mixtures on breakage kinetics, the number of milling cycles applied to prevent overheating, and power consumption during the nanomilling of drug (griseofulvin) suspensions were investigated from both an experimental and theoretical perspective. Narrowly sized zirconia beads with nominal sizes of 100, 200, and 400 µm and their half-and-half binary mixtures were used at 3000 and 4000 rpm with two bead loadings of 0.35 and 0.50. Particle size evolution was measured during the 3 h milling experiments using laser diffraction. An nth-order breakage model was fitted to the experimental median particle size evolution, and various microhydrodynamic parameters were calculated. In general, the beads and their mixtures with smaller median sizes achieved faster breakage. While the microhydrodynamic model explained the impacts of process parameters, it was limited in describing bead mixtures. For additional test runs performed, the kinetics model augmented with a decision tree model using process parameters outperformed that augmented with an elastic-net regression model using the microhydrodynamic parameters. The evaluation of the process merit scores suggests that the use of bead mixtures did not lead to notable process improvement; 100 µm beads generally outperformed bead mixtures and coarser beads in terms of fast breakage, low power consumption and heat generation, and low intermittent milling cycles.

Factors affecting the preparation of nanocrystals: characterization, surface modifications and toxicity aspects

INTRODUCTION

The fabrication of well-defined nanocrystals in size and form is the focus of much investigation. In this work, we have critically reviewed several recent instances from the literature that shows how the production procedure affects the physicochemical properties of the nanocrystals.

AREAS COVERED

Scopus, MedLine, PubMed, Web of Science, and Google Scholar were searched for peer-review articles published in the past few years using different key words. Authors chose relevant publications from their files for this review. This review focuses on the range of techniques available for producing nanocrystals. We draw attention to several recent instances demonstrating the impact of various process and formulation variables that affect the nanocrystals' physicochemical properties. Moreover, various developments in the characterization techniques explored for nanocrystals concerning their size, morphology, etc. have been discussed. Last but not least, recent applications, the effect of surface modifications, and the toxicological traits of nanocrystals have also been reviewed.

EXPERT OPINION

The selection of an appropriate production method for the formation of nanocrystals, together with a deep understanding of the relationship between the drug's physicochemical properties, unique features of the various formulation alternatives, and anticipated in-vivo performance, would significantly reduce the risk of failure during human clinical trials that are inadequate.

Elaborating the crystal transformation referenced microhydrodynamic model and fracture mechanism combined molecular modelling of irbesartan nanosuspensions formation in wet media milling

In recent years, polymorphic transformation involved in media milling has become a key factor in inducing the instability of nanosuspensions (NSs). The variation trend of microhydrodynamic parameters, including milling intensity factor (F), can be observed under different milling conditions. Therefore, this study first referenced the microhydrodynamic model to explore how formulations and process parameters affect Irbesartan (IRB) form A crystallinity during wet media milling. As a result, the crystallinity of form A was affected by the intermolecular interactions between drug particles and stabilizers. The crystallinity of form A decreased with decreasing drug loading, increasing stirrer speed and bead loading, which depended on the role of F. Milling could promote the transformation from a 1H to 2H tetrazole ring with stabilizers containing -OH, and form B was changed to form A and finally to an amorphous state. Molecular modelling shows that forms A and B are ductile and fragile materials, respectively, and both present anisotropy. When milling beads hit both polymorphs paralleling to the (010) surface, the bead-bead collisions are more helpful in fracturing IRB particles. The results of this study may provide a foundation for controlling crystal transformation and obtaining ideal crystal forms.

Nanoseeded Desupersaturation and Dissolution Tests for Elucidating Supersaturation Maintenance in Amorphous Solid Dispersions

The impact of residual drug crystals that are formed during the production and storage of amorphous solid dispersions (ASDs) has been studied using micron-sized seed crystals in solvent-shift (desupersaturation) and dissolution tests. This study examines the impacts of the seed size loading on the solution-mediated precipitation from griseofulvin ASDs. Nanoparticle crystals (nanoseeds) were used as a more realistic surrogate for residual crystals compared with conventional micron-sized seeds. ASDs of griseofulvin with Soluplus (Sol), Kollidon VA64 (VA64), and hydroxypropyl methyl cellulose (HPMC) were prepared by spray-drying. Nanoseeds produced by wet media milling were used in the dissolution and desupersaturation experiments. DLS, SEM, XRPD, and DSC were used for characterization. The results from the solvent-shift tests suggest that the drug nanoseeds led to a faster and higher extent of desupersaturation than the as-received micron-sized crystals and that the higher seed loading facilitated desupersaturation. Sol was the only effective nucleation inhibitor; the overall precipitation inhibition capability was ranked: Sol > HPMC > VA64. In the dissolution tests, only the Sol-based ASDs generated significant supersaturation, which decreased upon an increase in the nanoseed loading. This study has demonstrated the importance of using drug nanocrystals in lieu of conventional coarse crystals in desupersaturation and dissolution tests in ASD development.

Predicting the Temperature Evolution during Nanomilling of Drug Suspensions via a Semi-Theoretical Lumped-Parameter Model

Although temperature can significantly affect the stability and degradation of drug nanosuspensions, temperature evolution during the production of drug nanoparticles via wet stirred media milling, also known as nanomilling, has not been studied extensively. This study aims to establish both descriptive and predictive capabilities of a semi-theoretical lumped parameter model (LPM) for temperature evolution. In the experiments, the mill was operated at various stirrer speeds, bead loadings, and bead sizes, while the temperature evolution at the mill outlet was recorded. The LPM was formulated and fitted to the experimental temperature profiles in the training runs, and its parameters, i.e., the apparent heat generation rate Q_gen and the apparent overall heat transfer coefficient times surface area UA, were estimated. For the test runs, these parameters were predicted as a function of the process parameters via a power law (PL) model and machine learning (ML) model. The LPM augmented with the PL and ML models was used to predict the temperature evolution in the test runs. The LPM predictions were also compared with those of an enthalpy balance model (EBM) developed recently. The LPM had a fitting capability with a root-mean-squared error (RMSE) lower than 0.9 °C, and a prediction capability, when augmented with the PL and ML models, with an RMSE lower than 4.1 and 2.1 °C, respectively. Overall, the LPM augmented with the PL model had both good descriptive and predictive capability, whereas the one with the ML model had a comparable predictive capability. Despite being simple, with two parameters and obviating the need for sophisticated numerical techniques for its solution, the semi-theoretical LPM generally predicts the temperature evolution similarly or slightly better than the EBM. Hence, this study has provided a validated, simple model for pharmaceutical engineers to simulate the temperature evolution during the nanomilling process, which will help to set proper process controls for thermally labile drugs.

An Enthalpy-Balance Model for Timewise Evolution of Temperature during Wet Stirred Media Milling of Drug Suspensions

PURPOSE

Nanosuspensions have been used for enhancing the bioavailability of poorly soluble drugs. This study explores the temperature evolution during their preparation in a wet stirred media mill using a coupled experimental-enthalpy balance approach.

METHODS

Milling was performed at three levels of stirrer speed, bead loading, and bead sizes. Temperatures were recorded over time, then simulated using an enthalpy balance model by fitting the fraction of power converted to heat ξ. Moreover, initial and final power, ξ, and temperature profiles at 5 different test runs were predicted by power-law (PL) and machine learning (ML) approaches.

RESULTS

Heat generation was higher at the higher stirrer speed and bead loading/size, which was explained by the higher power consumption. Despite its simplicity with a single fitting parameter ξ, the enthalpy balance model fitted the temperature evolution well with root mean squared error (RMSE) of 0.40-2.34°C. PL and ML approaches provided decent predictions of the temperature profiles in the test runs, with RMSE of 0.93-4.17 and 1.00-2.17°C, respectively.

CONCLUSIONS

We established the impact of milling parameters on heat generation-power and demonstrated the simulation-prediction capability of an enthalpy balance model when coupled to the PL-ML approaches.

Analysis of heat generation during the production of drug nanosuspensions in a wet stirred media mill

Although heat is generated during the wet stirred media milling of drug suspensions, leading to notable temperature rise, a comprehensive analysis of heat generation does not exist. Hence, we investigated the impact of stirrer speed, bead loading, and bead size at three levels on the evolution of suspension temperature at the mill outlet during the milling of fenofibrate. The particle sizes and viscosities of the milled suspensions and power were measured. Our results suggest that stirrer speed had the most significant impact on the temperature increase, followed by bead loading and bead size. Both the time when the temperature reached 22 °C and the temperature at 5 min of milling were strongly correlated with the power. Assessing the impacts of the process parameters on the temperature rise, cycle time, power, and median particle size holistically, an optimal milling process was identified: 3000 rpm with 50% loading of 200 or 400 µm beads. A power number correlation was established to calculate power at any milling condition which determines the heat generation rate. Overall, this study indicated the importance of developing a good understanding of heat generation during nanomilling for development of a robust milling process especially for thermally labile drugs.

Review of nanosuspension formulation and process analysis in wet media milling using microhydrodynamic model and emerging characterization methods

Wet media milling is a popular technology used to prepare nanosuspensions. However, the theories and methods to guide the research on the formulation and process affecting wet media milling remain limited. The research on wet media milling follows a "black box" approach to a certain extent. This review focuses on exploring the formulation and process parameters factors in wet media milling. The formulation factors include the concentration, hydrophilicity/hydrophobicity, and structure of the drug and stabilizer, whereas the milling process parameters include the milling speed, milling time, and material, size, and filling volume of milling beads. Contrary to other reviews, this review attempts to quantify and visualize these factors by combining a microhydrodynamic model with emerging characterization methods to provide a scientific basis for the selection of nanosuspension formulations and process parameters, as opposed to the conventional trial-and-error approach.

Exploring the influence factors and improvement strategies of drug polymorphic transformation combined kinetic and thermodynamic perspectives during the formation of nanosuspensions

Nanosuspensions can effectively increase saturation solubility and improve the bioavailability of poorly water-soluble drugs attributed to high loading and surface-to-volume ratio. Wet media milling has been regarded as a scalable method to prepare nanosuspensions because of its simple operation and easy scale-up. In recent years, besides particle aggregation and Ostwald ripening, polymorphic transformation induced by processing has become a critical factor leading to the instability of nanosuspensions. Therefore, this review aims to discuss the influence factors comprehensively and put forward the corresponding improvement strategies of polymorphic transformation during the formation of nanosuspensions. In addition, this review also demonstrates the implication of molecular simulation in polymorphic transformation. The competition between shear-induced amorphization and thermally activated crystallization is the global mechanism of polymorphic transformation during media milling. The factors affecting the polymorphic transformation and corresponding improvement strategies are summarized from formulation and process parameters perspectives during the formation of nanosuspensions. The development of analytical techniques has promoted the qualitative and quantitative characterization of polymorphic transformation, and some techniques can in-situ monitor dynamic transformation. The microhydrodynamic model can be referenced to study the stress intensities by analyzing formulation and process parameters during wet media milling. Molecular simulation can be used to explore the possible polymorphic transformation based on the crystal structure and energy. This review is helpful to improve the stability of nanosuspensions by regulating polymorphic transformation, providing quality assurance for nanosuspension-based products.