Quantitative investigation of particle formation of a model pharmaceutical formulation using single droplet evaporation experiments and X-ray tomography

Molecular structure of ketoprofen-polyvinylpyrrolidone solid dispersions prepared by different amorphization methods

Amorphous solid dispersions (ASDs) are a widely studied formulation approach for improving the bioavailability of poorly water-soluble pharmaceuticals. Yet, a complete understanding remains lacking for how specific processing methods may influence ASDs' molecular structure. We prepare ketoprofen/polyvinylpyrrolidone (KTP/PVP) ASDs, ranging from 0-75 wt% KTP, using five different amorphization techniques: melt quenching, rotary evaporation with vacuum drying, spray drying, and acoustic levitation with either a premixed solution or in situ mixing of separate co-sprayed solutions. The co-spray levitation approach enables on-demand compositional changes in a containerless processing environment, while requiring minimal pharmaceutical material (∼1 mg). The structure of all ASDs are then compared using high-energy X-ray total scattering. X-ray pair distribution functions are similar for most ASDs of a given composition (Rx = 0.4-2.5%), which is consistent with them having similar intramolecular structure. More notably, differences in the X-ray structure factors for the various amorphization routes indicate differing extents of molecular mixing, a direct indication of their relative stability against crystallization. Melt quenching, spray drying, and levitation of premixed solutions exhibit some degree of molecular mixing, while the co-sprayed levitation samples have molecular arrangements like those of KTP/PVP physical mixtures. These findings illustrate how X-ray total scattering can be used to benchmark amorphous forms prepared by different techniques.

The effect of the molecular structure of hydroxypropyl methylcellulose on the states of water, wettability, and swelling properties of cryogels prepared with and without CaO2

Hydroxypropyl methylcellulose (HPMC) belongs to the cellulose ether family that has hydroxyl groups substituted by hydrophobic methyl groups (DS) and hydrophilic hydroxypropyl groups (MS). Herein, the interactions between water molecules and cryogels prepared with HPMC in the presence and absence of a linear nonionic surfactant, as well as CaO₂ microparticles, which react with water producing O₂, were systematically investigated by sorption experiments and Time-Domain Nuclear Magnetic Resonance. Regardless of the DS and MS, most water molecules presented transverse relaxation time t2 typical of intermediate water and a small population of more tightly bound water. HPMC cryogels with the highest DS of 1.9 presented the slowest swelling rate of 0.519 ± 0.053 g_water/(g.s) and the highest contact angle values 85.250^o ± 0.004^o, providing the best conditions for a slow reaction between CaO₂ and water. The presence of surfactant favored hydrophobic interactions that allowed the polar head of the surfactant to be exposed to the medium, resulting in a higher swelling rate and lower contact angle values. The HPMC with the highest MS presented the fastest swelling rate and the lowest contact angle. These findings are relevant for the formulations and reactions, where tuning the swelling kinetics is crucial for the final application.

Internal microstructure of spray dried particles affects viral vector activity in dry vaccines

To maintain the activity of sensitive biologics during encapsulation by spray drying, a better understanding of deactivation pathways in dried particles is necessary. The effect of solid-air interfaces within dried particles on viral deactivation was examined with three binary excipient blends, mannitol/dextran (MD), xylitol/dextran (XD), and lactose/trehalose (LT). Particles encapsulating human serotype 5 adenovirus viral vector (AdHu5) were produced via both spray drying and acoustic levitation. The particles' internal microstructure was directly visualized, and the location of a viral vector analogue was spatially mapped within the particles by volume imaging using focused ion beam sectioning and scanning electron microscopy. The majority of the viral vector analogue was found at, or near, the solid-air interfaces. Peclet number and crystallization kinetics governed the internal microstructure of the particles: XD particles with minimal internal voids retained the highest viral activity, followed by MD particles with a few large voids, and finally LT particles with numerous internal voids exhibited the lowest viral activity. Overall, AdHu5 activity decreased as the total solid-air interfacial area increased (as quantified by nitrogen sorption). Along with processing losses, this work highlights the importance of surface area within particles as an indicator of activity losses for dried biologics.

Acoustic levitation and rotation of thin films and their application for room temperature protein crystallography

Acoustic levitation has attracted attention in terms of chemical and biochemical analysis in combination with various analytical methods because of its unique container-less environment for samples that is not reliant on specific material characteristics. However, loading samples with very high viscosity is difficult. To expand the scope, we propose the use of polymer thin films as sample holders, whereby the sample is dispensed on a film that is subsequently loaded onto an acoustic levitator. When applied for protein crystallography experiments, rotation controllability and positional stability are important prerequisites. We therefore study the acoustic levitation and rotation of thin films with an aspect ratio (the diameter-to-thickness ratio) of 80–240, which is an order of magnitude larger than those reported previously. For films with empirically optimized shapes, we find that it is possible to control the rotation speed in the range of 1–4 rotations per second while maintaining a positional stability of 12 ± 5 µm. The acoustic radiation force acting on the films is found to be a factor of 26–30 higher than that for same-volume water droplets. We propose use cases of the developed films for protein crystallography experiments and demonstrate data collections for large single crystal samples at room temperature.

Peptide Isolation via Spray Drying: Particle Formation, Process Design and Implementation for the Production of Spray Dried Glucagon

PURPOSE

Spray drying plays an important role in the pharmaceutical industry for product development of sensitive bio-pharmaceutical formulations. Process design, implementation and optimisation require in-depth knowledge of process-product interactions. Here, an integrated approach for the rapid, early-stage spray drying process development of trehalose and glucagon on lab-scale is presented.

METHODS

Single droplet drying experiments were used to investigate the particle formation process. Process implementation was supported using in-line process analytical technology within a data acquisition framework recording temperature, humidity, pressure and feed rate. During process implementation, off-line product characterisation provided additional information on key product properties related to residual moisture, solid state structure, particle size/morphology and peptide fibrillation/degradation.

RESULTS

A psychrometric process model allowed the identification of feasible operating conditions for spray drying trehalose, achieving high yields of up to 84.67%, and significantly reduced levels of residual moisture and particle agglomeration compared to product obtained during non-optimal drying. The process was further translated to produce powders of glucagon and glucagon-trehalose formulations with yields of >83.24%. Extensive peptide aggregation or degradation was not observed.

CONCLUSIONS

The presented data-driven process development concept can be applied to address future isolation problems on lab-scale and facilitate a systematic implementation of spray drying for the manufacturing of sensitive bio-pharmaceutical formulations.

Drying Kinetics and Particle Formation from Dilute Colloidal Suspensions in Aerosol Droplets

Industrial processes such as spray drying of pharmaceutical and food products often involve the drying of aerosol droplets containing colloidal suspensions into powdered microparticles of desired properties. The morphology and surface properties of the final dry products/microparticles obtained after the drying process are strongly influenced by the parameters of the initial aerosol droplet composition and the drying conditions. In particular, the final dry microparticle morphology can be dependent on the dimensionless Péclet number (Pe), which expresses the relative competition between the diffusion of the dispersed particles within the droplet and the rate of solvent loss via evaporation. In this work, we examine how control over the gas phase drying conditions and initial aerosol droplet composition can be used to influence the aerosol droplet drying kinetics in the gas phase for a range of Péclet numbers. We used a single-particle levitation instrument, the electrodynamic balance, to measure the drying kinetics of colloidal silica droplets (0.10-0.60% v/v) under controlled gas phase drying conditions of temperature (263-326 K) and relative humidity (0-90%) and obtained Péclet numbers ranging from 4.05 to 184.5. We demonstrate that, for aerosol droplets with initially dilute feed colloid concentrations and within the constant evaporation regime, the starting composition does not strongly influence the solvent evaporation rate with the included nanoparticles (NPs) acting as spectators. However, the gas phase drying conditions, temperature, and relative humidity, directly influence the droplet temperature via evaporative cooling as well as the droplet drying kinetics and the final dry microparticle properties. With a priori knowledge of the droplet drying kinetics from the single droplet measurements, we further demonstrate the possibility of tailoring the morphology of the dried microparticles. Dried silica microparticles collected at Pe = 23.8 had dense spherical morphologies, while those at the highest Pe = 180.0 had crumpled surface morphologies with a transition in morphology between these limiting Pe values. Our results extend the fundamental understanding of the mechanisms controlling the drying of aerosol droplets in colloidal suspensions across a wide range of application areas extending from spray drying to the drying of respiratory fluid droplets containing bacteria and viruses and the drying of atmospheric aerosol droplets.

A micro-XRT image analysis and machine learning methodology for the characterisation of multi-particulate capsule formulations

The application of X-ray microtomography for quantitative structural analysis of pharmaceutical multi-particulate systems was demonstrated for commercial capsules, each containing approximately 300 formulated ibuprofen pellets. The implementation of a marker-supported watershed transformation enabled the reliable segmentation of the pellet population for the 3D analysis of individual pellets. Isolated translation- and rotation-invariant object cross-sections expanded the applicability to additional 2D image analysis techniques. The full structural characterisation gave access to over 200 features quantifying aspects of the pellets' size, shape, porosity, surface and orientation. The extracted features were assessed using a ReliefF feature selection method and a supervised Support Vector Machine learning algorithm to build a model for the detection of broken pellets within each capsule. Data of three features from distinct structure-related categories were used to build classification models with an accuracy of more than 99.55% and a minimum precision of 86.20% validated with a test dataset of 886 pellets. This approach to extract quantitative information on particle quality attributes combined with advanced data analysis strategies has clear potential to directly inform manufacturing processes, accelerating development and optimisation.

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Coupling micro-XRT analysis with feature selection and machine learning for advanced pharmaceutical product characterisation.

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Information on particle 3D-orientation were utilised to extract translation- and rotation-invariant object cross-sections.

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Successful extraction of over 200 quantitative pellet descriptors linked to size, shape, porosity, surface and orientation.

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Sensitivity analysis and ReliefF feature selection approach to identify predictive features for pellet classification.

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Feature-based binary SVM classification model for the detection of broken pellets within the formulated system.

WITHDRAWN: A micro-XRT Image Analysis and Machine Learning Methodology for the Characterisation of Multi-Particulate Capsule Formulations

The Publisher regrets that this article is an accidental duplication of a published article,https://doi.org/10.1016/j.ijpx.2020.100041. The duplicate article has therefore been withdrawn. The full Elsevier Policy on Article Withdrawal can be found at https://www.elsevier.com/about/our-business/policies/article-withdrawal.