Dispersion of fine and ultrafine powders through surface modification and rapid expansion

Enhancing flowability of fine cohesive active pharmaceutical ingredients

OBJECTIVE

The effectiveness of pharmaceutical excipients and hydrophobic nano-silica as flow aid/regulator was studied and two active pharmaceutical ingredients, i.e. paracetamol and ibuprofen were used to gauge the effectiveness. Avicel PH-101 and Avicel PH-102 were chosen as pharmaceutical excipients and Aerosil R972 Pharma was used as hydrophobic nano-silica, the API's and the excipients were micro-sized.

SIGNIFICANCE

Fine powders lead to many operational difficulties in the pharmaceutical industry which need to be alleviated. The reliability and repeatability of the Powder Flow Tester need to be established.

METHODS

Flow function, wall friction, and bulk density tests to gauge the said effect were conducted on Brookfield Powder Flow Tester. The samples for testing were prepared by blending (rigorous mixing) to ascertain the capability of inexpensive mixing in comparison to expensive blenders and machines.

RESULTS

The study undertook shows that blending (rigorous mixing) was sufficient in improving the flow of active pharmaceutical ingredient powders. Blending with excipients Avicel PH-101 and Avicel PH-102 improved the flow substantially but the maximum improvement was seen in the nano blended samples.

CONCLUSIONS

The study conducted underlined the efficacy of the blending process by showing significant improvement in flow properties. The Powder Flow Tester confirmed the anticipated results of the powder blends indicative of its reliability. Moreover, repeatable results were obtained which established the repeatability of the instrument.

Selection of Small Amounts of Glidant Capable of Improving the Tensile Strength of Ibuprofen Tablets

This study examined the selection of small amounts of excipients capable of improving the compactability of ibuprofen, thereby enabling the miniaturization of ibuprofen tablets. Various glidants in amounts of 1% of the total volume were added to dry surface-modified ibuprofen, and the tensile strengths of the resulting tablets were evaluated. The characteristics of the excipients that affected the tensile strengths of the tablets were then extracted using a tensile strength prediction model. We confirmed that the effective angle of the internal friction of the mixed powder, the coating form of the glidant, the packing fraction of the raw material, and the mixed powder affect the tensile strength of the tablet. A smooth particle layer was formed on the surface of the ibuprofen particles when a glidant with a packing fraction of <0.05 was used. In the sample with a smooth particle layer, the angle of the critical state line increased significantly and the tensile strength improved. We inferred that the smoothness of the particle layer allowed the ibuprofen particles to come into close contact with each other. Consequently, the number of junctions increased, and the frictional force between the particles improved, resulting in tablets with improved tensile strengths. In conclusion, the compactability of ibuprofen was improved by adding 1% glidant with a packing fraction of <0.05. The reduction in excipients will allow the creation of smaller tablets, making them easier to swallow. Therefore, the medication adherence of customers will be improved.

Impact of altered hydrophobicity and reduced agglomeration on dissolution of micronized poorly water-soluble drug powders after dry coating

The impact of dry coating with hydrophobic or hydrophilic nano-silica at 25-100% surface area coverage on dissolution of micronized poorly water-soluble drugs was investigated by examining their agglomeration and surface hydrophobicity. Ibuprofen (20 µm and 10 µm) and griseofulvin (10 µm) were selected having differing solubility, hydrophobicity, and surface morphology. Characterization involved particle agglomeration via two dry dispersion methods, drug dissolution using the USP IV method, cohesion reduction through shear testing, and powder wettability via the modified Washburn method. Dry coating dramatically reduced the cohesion hence agglomerate size of both the coated ibuprofen particles, but less for griseofulvin, attributed to its surface morphology. For hydrophobic silica, agglomerate size reduction outweighed the adverse impact of increased surface hydrophobicity for ibuprofen. For griseofulvin, the agglomerate reduction was much lower, not able to overcome the effect of increased drug particle hydrophobicity with hydrophobic silica coating. Hydrophilic silica coating reduced hydrophobicity for all three drug powders, leading to the synergistic improvement in the dissolution along with agglomerate size reduction. Overall, the combined effect of the drug particle surface hydrophobicity and agglomerate size, represented by specific surface area, could explain the dissolution behavior of these poorly water-soluble drugs.

Progress of Flake Powder Metallurgy Research

This paper reviewed several recent progresses of the new powder metallurgy technology known as flake powder metallurgy (FPM) including different processing routes, conventional FPM (C-FPM), slurry blending (SB), shift-speed ball milling (SSBM), and high-shear pre-dispersion and SSBM (HSPD/SSBM). The name of FPM was derived from the use of flake metal powders obtained by low-speed ball milling (LSBM) from spherical powder. In this case, the uniformity of reinforcement distribution leads to increased strength and ductility. Powder is the basic unit in PM, especially advanced PM, and its control is key to various new PM technologies. The FPM is a typical method for finely controlling the powder shape through low-energy ball milling (LEBM) to realize the preparation of advanced material structures. The present paper represents a review of the main results of research on FPM and indicates the potential for future studies devoted to the optimization of this processing route.

Evaluation of the physical properties of dry surface-modified ibuprofen using a powder rheometer (FT4) and analysis of the influence of pharmaceutical additives on improvement of the powder flowability

In this study, we examined the characteristics of glidant that affect the improvement of the flowability of APIs by using the dry surface modification of ibuprofen. In addition, the screening method of glidant suitable for improving flowability of APIs was examined. As a result of evaluation of mixed powder with surface modification using various inorganic fine particles with different physical properties, it became clear that the packing fraction had the most influence regardless of the component. This was thought to able to coat the surface with small quantities because the smaller the packing fraction, the more it was able to dispersed from the less contacts between the glidant particles. The packing fraction of glidant was correlated with the (SE/CBD)^-1 which was calculated value from the results measured with powder rheometer. From this results, when using any excipient as a glidant for dry surface modification, it is now possible to estimate the effect of improving flowability simply by measuring with a powder rheometer. Based on this study, it is possible to select excipients suitable for improving APIs flowability and to estimate the improvement effect, and therefore, it is expected to improve the efficiency of prescription design work.

Characterization and Formulation of Isoniazid for High-Dose Dry Powder Inhalation

Tuberculosis is a major health problem and remains one of the main causes of mortality. In recent years, there has been an increased interest in the pulmonary delivery of antibiotics to treat tuberculosis. Isoniazid is one of these antibiotics. In this study, we aimed to characterize isoniazid and formulate it into a dry powder for pulmonary administration with little or no excipient, and for use in the disposable Twincer^® inhaler. Isoniazid was jet milled and spray dried with and without the excipient l-leucine. Physiochemical characterization showed that isoniazid has a low Tg of −3.99 ± 0.18 °C and starts to sublimate around 80 °C. Milling isoniazid with and without excipients did not result in a suitable formulation, as it resulted in a low and highly variable fine particle fraction. Spray drying pure isoniazid resulted in particles too large for pulmonary administration. The addition of 5% l-leucine resulted in a fraction <5 µm = 89.61% ± 1.77% from spray drying, which dispersed well from the Twincer^®. However, storage stability was poor at higher relative humidity, which likely results from dissolution-crystallization. Therefore, follow up research is needed to further optimize this spray dried formulation.

Quality by Design (QbD) based process optimisation to develop functionalised particles with modified release properties using novel dry particle coating technique

Quality by Design (QbD), a current trend employed to develop and optimise various critical pharmaceutical processes, is a systematic approach based on the ethos that quality should be designed into the product itself, not just end tested after manufacture. The present work details a step-wise application of QbD principles to optimise process parameters for production of particles with modified functionalities, using dry particle coating technology. Initial risk assessment identified speed, air pressure, processing time and batch size (independent factors) as having high-to-medium impact on the dry coating process. A design of experiments (DOE) using MODDE software employed a D-optimal design to determine the effect of variations in these factors on identified responses (content uniformity, dissolution rate, particle size and intensity of Fourier transform infrared (FTIR) C = O spectrum). Results showed that batch size had the most significant effect on dissolution rate, particle size and FTIR; with an increase in batch size enhancing dissolution rate, decreasing particle size (depicting absence of coated particles) and increasing the FTIR intensity. While content uniformity was affected by various interaction terms, with speed and batch size having the highest negative effect. Optimal design space for producing functionalised particles with optimal properties required maximum air pressure (40psi), low batch size (6g), speed between 850 to 1500 rpm and processing times between 15 to 60 minutes. The validity and predictive ability of the revised model demonstrated reliability for all experiments. Overall, QbD was demonstrated to provide an expedient and cost effective tool for developing and optimising processes in the pharmaceutical industry.

Effects of Coating Materials and Processing Conditions on Flow Enhancement of Cohesive Acetaminophen Powders by High-Shear Processing With Pharmaceutical Lubricants

This study has investigated the surface coating efficiency and powder flow improvement of a model cohesive acetaminophen powder by high-shear processing with pharmaceutical lubricants through 2 common equipment, conical comil and high-shear mixer. Effects of coating materials and processing parameters on powder flow and surface coating coverage were evaluated. Both Carr's index and shear cell data indicated that processing with the lubricants using comil or high-shear mixer substantially improved the flow of the cohesive acetaminophen powder. Flow improvement was most pronounced for those processed with 1% wt/wt magnesium stearate, from "cohesive" for the V-blended sample to "easy flowing" for the optimally coated sample. Qualitative and quantitative characterizations demonstrated a greater degree of surface coverage for high-shear mixing compared with comilling; nevertheless, flow properties of the samples at the corresponding optimized conditions were comparable between 2 techniques. Scanning electron microscopy images demonstrated different coating mechanisms with magnesium stearate or l-leucine (magnesium stearate forms a coating layer and leucine coating increases surface roughness). Furthermore, surface coating with hydrophobic magnesium stearate did not retard the dissolution kinetics of acetaminophen. Future studies are warranted to evaluate tableting behavior of such dry-coated pharmaceutical powders.

Surface modification of acetaminophen particles by atomic layer deposition

Active pharmaceutical ingredients (APIs) are predominantly organic solid powders. Due to their bulk properties many APIs require processing to improve pharmaceutical formulation and manufacturing in the preparation for various drug dosage forms. Improved powder flow and protection of the APIs are often anticipated characteristics in pharmaceutical manufacturing. In this work, we have modified acetaminophen particles with atomic layer deposition (ALD) by conformal nanometer scale coatings in a one-step coating process. According to the results, ALD, utilizing common chemistries for Al₂O₃, TiO₂ and ZnO, is shown to be a promising coating method for solid pharmaceutical powders. Acetaminophen does not undergo degradation during the ALD coating process and maintains its stable polymorphic structure. Acetaminophen with nanometer scale ALD coatings shows slowed drug release. ALD TiO₂ coated acetaminophen particles show cytocompatibility whereas those coated with thicker ZnO coatings exhibit the most cytotoxicity among the ALD materials under study when assessed in vitro by their effect on intestinal Caco-2 cells.

Functionalised particles using dry powder coating in pharmaceutical drug delivery: promises and challenges

INTRODUCTION

Production of functionalised particles using dry powder coating is a one-step, environmentally friendly process that paves the way for the development of particles with targeted properties and diverse functionalities.

AREAS COVERED

Applying the first principles in physical science for powders, fine guest particles can be homogeneously dispersed over the surface of larger host particles to develop functionalised particles. Multiple functionalities can be modified including: flowability, dispersibility, fluidisation, homogeneity, content uniformity and dissolution profile. The current publication seeks to understand the fundamental underpinning principles and science governing dry coating process, evaluate key technologies developed to produce functionalised particles along with outlining their advantages, limitations and applications and discusses in detail the resultant functionalities and their applications.

EXPERT OPINION

Dry particle coating is a promising solvent-free manufacturing technology to produce particles with targeted functionalities. Progress within this area requires the development of continuous processing devices that can overcome challenges encountered with current technologies such as heat generation and particle attrition. Growth within this field requires extensive research to further understand the impact of process design and material properties on resultant functionalities.

Rapid characterisation of the inherent dispersibility of respirable powders using dry dispersion laser diffraction

Understanding and controlling powder de-agglomeration is of great importance in the development of dry powder inhaler (DPI) products. Dry dispersion laser diffraction measures particle size readily under controlled dispersing conditions, but has not been exploited fully to characterise inherent powder dispersibility. The aim of the study was to utilise particle size-dispersing pressure titration curves to characterise powder cohesivity and ease of de-agglomeration. Seven inhaled drug/excipient powders (beclometasone dipropionate, budesonide, fluticasone propionate, lactohale 300, salbutamol base, salmeterol xinafoate and tofimilast) were subjected to a range of dispersing pressures (0.2-4.5 Bar) in the Sympatec HELOS/RODOS laser diffractometer and particle size measurements were recorded. Particle size-primary pressure data were used to determine the pressures required for complete de-agglomeration. The latter were employed as an index of the cohesive strength of the powder (critical primary pressure; CPP), and the curves were modelled empirically to derive the pressure required for 50% de-agglomeration (DA₅₀). The powders presented a range of CPP (1.0-3.5 Bar) and DA₅₀ (0.23-1.45 Bar) which appeared to be characteristic for different mechanisms of powder de-agglomeration. This approach has utility as a rapid pre-formulation tool to measure inherent powder dispersibility, in order to direct the development strategy of DPI products.