Design space approach in the optimization of the spray-drying process

Optimization of Awaze paste formulations: The effects of using spices through a mixture design approach

Previous studies have revealed the microbial quality of Awaze paste. However, limited reports describe the effect of individual spices on Awaze paste quality. A mixture design approach was used to determine the appropriate proportions, with 15 experimental points for independent variables including RP (60-90 %), GA (10-30 %), RO (5-20 %), and GI (5-10 %). The techno-functional properties, particle size, antioxidant activity (DDPH radical assay), proximate composition, iron (Fe), zinc (Zn) content, viscosity, hardness, and microbiological quality of Awaze paste were assessed. The prepared Awaze paste showed a range of characteristics, with antioxidant activity (DDPH radical assay) ranging from 11.86 % to 62.5 %, crude protein content from 6.18 % to 16.22 %, crude fat from 5.7 % to 12.6 %, crude fiber from 16.86 % to 29.06 %, total ash content from 6.32 % to 9.94 %, total carbohydrate from 41.79 % to 60.61 %, energy from 264.3 to 329.2 k cal. , iron (Fe) content from 35.59 to 108.82 mg/100g, zinc (Zn) content from 1.72 to 26.93 mg/100g, viscosity from 65.5 to 125.5 cps, hardness from 8.48 to 55.09 g, yeast and mold count from 0.83 to 2.04 log cfu/g, and total bacterial count from 1.53 to 2.61 log cfu/g. Significant differences (p < 0.05) were observed in proximate composition, techno-functional properties, particle size, antioxidant activity, physicochemical properties, and microbiological characteristics among the formulations of Awaze paste. The selected formula showed a statistically significant difference (p < 0.05) compared to the control sample. The formulation containing 74.79 % RP, 10 % GA, 10.2 % RO, and 5.0 % GI was determined to be the optimal formula with a desirability of 0.73, based on the evaluated parameters. This preferred Awaze paste had a porosity of 28.12 %, particle size of 16.49 μm, antioxidant activity of 63.63 %, crude protein content of 17.28 %, iron (Fe) content of 98.06 mg/100g, and zinc (Zn) content of 15.04 mg/100g. Therefore, this optimal blend of ingredients could be used to produce a consumer accepted Awaze paste.

Supersaturable Solid Self-microemulsifying Delivery Systems of Astaxanthin via Spray Drying: Effects of Polymers and Solid Carriers

This study aimed to develop the solid astaxanthin-encapsulated self-microemulsifying delivery system (S-AST SMEDS) spray-dried particles and investigate the effect of materials in formulations on product characteristics. The optimized liquid AST SMEDS incorporated with a polymeric precipitation inhibitor (PI) was solidified with a solid carrier by spray drying. Physicochemical properties of S-AST SMEDS spray-dried powders including morphology, particle size and distribution, flowability, solid-state characters, moisture content, yield, loading capacity of AST, and reconstitution properties were examined. Polymeric PIs seemed to have an impact on particles' size, surface smoothness, and flowability while solid carriers had an effect on the particles' moisture content and droplet size of microemulsions obtained after reconstitution. The amount of AST encapsulated in S-SMEDS powder was influenced by both polymer and solid carriers. Dissolution and short-term stability of S-AST SMEDS were also studied. Our developed spray-dried solid SMEDS particles helped enhance AST dissolution rate.

Inhalation powder development without carrier: How to engineer ultra-flying microparticles?

Particle engineering technologies have led to the commercialization of new inhaled powders like PulmoSolTM or PulmoSphereTM. Such platforms are produced by spray drying, a well-known process popular for its versatility, thanks to wide-ranging working parameters. Whereas these powders contain a high drug-loading, we have studied a low-dose case, in optimizing the production of powders with two anti-asthmatic drugs, budesonide and formoterol. Using a Design of Experiments approach, 27 powders were produced, with varying excipient mixes (cyclodextrins, raffinose and maltodextrins), solution concentrations, and spray drying parameters in order to maximize deep lung deposition, measured through fine particle fraction (next generation impactor). Based on statistical analysis, two powders made of hydropropyl-β-cyclodextrin alone or mixed with raffinose and L-leucine were selected. Indeed, the two powders demonstrated very high fine particle fraction (>55%), considerably better than commercially available products. Deep lung deposition has been correlated to very fine particle size and lower microparticles interactions shown by laser diffraction assays at different working pressures, and particle morphometry. Moreover, the two drugs would be predicted to deposit homogeneously into the lung according to impaction studies. Uniform delivery is fundamental to control symptoms of asthma. In this study, we develop carrier-free inhalation powders promoting very efficient lung deposition and demonstrate the high impact of inter-particular interactions intensity on their aerosolization behaviour.

Quality attributes of the developed banana flour: Effects of drying methods

The study aims to investigate the effects of different drying methods on the changes in functional properties, physicochemical composition, bioactive compounds, antioxidant activity, sensory attributes, and microstructural quality of the banana flours. Two local banana cultivars, Mehersagar and Sabri, were dried to produce flour using four distinct drying methods: freeze drying (FD), cabinet drying (CD), microwave oven drying (MOD), and forced air oven drying (FOD). The functional properties of the developed banana flours were observed where the findings were as water holding capacity (0.93 ± 0.06-2.74 ± 0.04 g water/g dry sample), oil absorption capacity (0.87 ± 0.06-2.22 ± 0.10 g oil/g dry sample), swelling capacity (4.62 ± 0.02-5.05 ± 0.03 g paste/g dry sample), bulk density (0.54 ± 0.04-0.81 ± 0.02 g/ml), tapped density (0.62 ± 0.04-0.93 ± 0.03 g/ml) and Carr's Index (9.38 ± 0.47-13.58 ± 0.43%). Freeze-dried Mehersagar cultivar's flour showed the leading functional properties with good flowability and cohesiveness. The physicochemical parameters of the flours also revealed significant differences (p < 0.05) in lightness (L*) (50.51 ± 1.49-72.21 ± 1.05), moisture content (3.96 ± 0.09-7.74 ± 0.13%), protein (2.72 ± 0.07-3.93 ± 0.06%), crude fat (0.11 ± 0.01-0.36 ± 0.04%), crude fiber (0.64 ± 0.03-1.22 ± 0.03%), carbohydrate (84.15 ± 0.24-88.26 ± 0.15%) and energy content (354.25 ± 0.57-370.02 ± 0.39 kcal/g). Total flavonoid content (21.44 ± 0.04-34.34 ± 0.03 mgQE/100g) and phenolic content (29.91 ± 0.01-71.46 ± 0.03 mgGAE/100g) was observed, while the highest retention of bioactive compounds was exhibited in Mehersagar cultivar's flour. In terms of appearance, fineness, taste, flavor, color, and overall acceptability, the dried banana flour of both the cultivars obtained from freeze-dried scored overall acceptability 8.04 ± 0.02 and 7.92 ± 0.17, respectively. The scanning electron microscopy analysis of the microstructure of flour granules from each sample revealed a diverse morphological configuration in particle size and shape. According to the findings of this study, the freeze-drying technology is superior to others, and the Mehersagar banana cultivar is more satisfactory in terms of quality characteristics. Moreover, the quality parameters of banana flour may facilitate the formulation of different flour-based gluten-free baked products and food supplements.

Microencapsulation of Olive Oil by Dehydration of Emulsion: Effects of the Emulsion Formulation and Dehydration Process

Microencapsulation of extra virgin olive oil has been taken into consideration. Initially, emulsions were prepared using extra virgin olive oil and aqueous solutions of different proportions of maltodextrin (MD) having dextrose equivalent (DE) 19 and whey protein isolates (WPI), such as 100% MD, 100% WPI, 25% MD + 75% WPI, 50% MD + 50% WPI and 75% MD + 25% WPI. Subsequently, emulsions were used for dehydration by either spray-drying (SD) or freeze-drying (FD) to produce olive oil microcapsules. Emulsion stability, viscosity and droplet size influenced the characteristics of the microcapsules. The highest encapsulation efficiency was achieved using 50% MD + 50% WPI in the emulsions with subsequent SD. The moisture content of the microcapsules increased with increasing proportions of MD. The size of the microcapsules increased with increasing proportions of WPI. The bulk density and tapped density were reduced with higher proportions of MD in the microcapsules. Furthermore, microcapsules with a higher proportion of MD exhibited poor flowability and high cohesiveness. Microcapsules from the higher proportion MD emulsions, followed by SD were spherical with a smooth surface; however, microcapsules with dent structures were produced from 100% WPI in the emulsions with subsequent SD. Microcapsules, produced from emulsions with a higher proportion of WPI, followed by FD were flat flakes and had irregular surfaces.

Eudragit® FS Microparticles Containing Bacteriophages, Prepared by Spray-Drying for Oral Administration

Phage therapy is recognized to be a promising alternative to fight antibiotic-resistant infections. In the quest for oral dosage forms containing bacteriophages, the utilization of colonic-release Eudragit^® derivatives has shown potential in shielding bacteriophages from the challenges encountered within the gastrointestinal tract, such as fluctuating pH levels and the presence of digestive enzymes. Consequently, this study aimed to develop targeted oral delivery systems for bacteriophages, specifically focusing on colon delivery and employing Eudragit^® FS30D as the excipient. The bacteriophage model used was LUZ19. An optimized formulation was established to not only preserve the activity of LUZ19 during the manufacturing process but also ensure its protection from highly acidic conditions. Flowability assessments were conducted for both capsule filling and tableting processes. Furthermore, the viability of the bacteriophages remained unaffected by the tableting process. Additionally, the release of LUZ19 from the developed system was evaluated using the Simulator of the Human Intestinal Microbial Ecosystem (SHIME^®) model. Finally, stability studies demonstrated that the powder remained stable for at least 6 months when stored at +5 °C.

Evaluation of Effects of Spray Drying Conditions on Physicochemical Properties of Pomegranate Juice Powder Enriched with Pomegranate Peel Phenolic Compounds: Modeling and Optimization by RSM

In this study, the effects of pomegranate peel extract concentration (2.5-10%), drying temperature (160-190 °C), and feed flow rate (0.6-1 mL/s) on the properties of pomegranate juice powder enriched with pomegranate peel phenolic compounds and produced by spray drying were investigated. The moisture content, water activity (a_w), solubility, water absorption capacity (WAC), hygroscopicity, dissolution time, total phenolic content (TPC), Carr index (CI), Hausner ratio (HR), and brightness (L*) of the samples were evaluated, and the optimal powder production conditions were obtained using response surface methodology (RSM). The results showed that the optimal conditions were found to be the phenolic extract concentration of 10%, the drying temperature of 189.9 °C, and the feed flow rate of 0.63 mL/s, considering the minimization of the moisture content, a_w, hygroscopicity, dissolution time, CI, HR, and L*, as well as the maximization of solubility, WAC, and TPC. The effect of the phenolic extract concentration was very significant (p < 0.01) on the WAC, hygroscopicity, dissolution time, TPC, CI, HR, and L* of the powder. Moreover, the effect of the drying temperature was very significant (p < 0.01) on the a_w, hygroscopicity, dissolution time, CI, and HR of the powder and significant (p < 0.05) on its moisture content. The effect of the feed flow rate was very significant (p < 0.01) on the solubility, hygroscopicity, and dissolution time of the powder and significant (p < 0.05) on its moisture content. Therefore, we found that the spray drying conditions, such as high temperature, did not negatively affect the content of phenolic compounds in pomegranate powder, and the physical properties of the resulting powder were acceptable. Thus, pomegranate powder enriched with phenolic compounds can be used as a food additive or as a dietary supplement for medicinal use.

Optimization of spray drying process parameters for the food bioactive ingredients

Spray drying (SD) is one of the most important thermal processes used to produce different powders and encapsulated materials. During this process, quality degradation might happen. The main objective of applying optimization methods in SD processes is maximizing the final nutritional quality of the product besides sensory attributes. Optimization regarding economic issues might be also performed. Applying optimization approaches in line with mathematical models to predict product changes during thermal processes such as SD can be a promising method to enhance the quality of final products. In this review, the application of the response surface methodology (RSM), as the most widely used approach, is introduced along with other optimization techniques such as factorial, Taguchi, and some artificial intelligence-based methods like artificial neural networks (ANN), genetic algorithms (GA), Fuzzy logic, and adaptive neuro-fuzzy inference system (ANFIS). Also, probabilistic methods such as Monte Carlo are briefly introduced. Some recent case studies regarding the implementation of these methods in SD processes are also exemplified and discussed.

Influence of Drying Methods on Jackfruit Drying Behavior and Dried Products Physical Characteristics

Drying processes including solar, oven, and refractance window were studied to determine their influence on the drying behavior of jackfruit slices and properties of resultant jackfruit powders. The loss of sample mass, converted to the ratio between the water content at time t and the initial water content (moisture ratio), was used as the experimental parameter for modelling drying processes. Fifteen thin layer drying models were fitted to the experimental data using nonlinear regression analysis. Based on the highest R² and lowest SEE values, the models that best fit the observed data were Modified Henderson and Pabis, Verma et al., and Hii et al. for RWD, oven, and solar drying, respectively. The effective moisture diffusivity coefficients were 5.11 × 10⁻⁹, 3.28 × 10⁻¹⁰, and 2.55 × 10⁻¹⁰ for RWD, oven and, solar drying, respectively. The solubility of freeze-dried jackfruit powder (75.7%) was not significantly different from the refractance window dried powder (73.2%) and was higher than oven-dried jackfruit powder (66.1%). Oven-dried jackfruit powder had a lower rehydration ratio and porosity. Differences in rehydration ratio and porosity under different drying methods could be explained by the microstructure. Fractal dimension (FD) and lacunarity were applied to study the structure and irregularities of jackfruit dried with the different methods. FD was significantly (P < 0.05) affected by the drying method. FD ranged from 1.809 to 1.837, while lacunarity ranged between 0.258 and 0.404.

Influence of processing conditions on quality of Indian small grey donkey milk powder by spray drying

The study was carried out to know the quality of small grey donkey milk powder by spray dryer. Donkey milk powder moisture, fat, protein, carbohydrate and ash were 4.12 (d.b), 5.97, 22.84, 4.64 and 62.43 (%). Donkey milk powder was produced at milk total solids of 20, 25 and 30% concentration at 160, 170 and 180 °C inlet air temperature using two fluid flow nozzle type atomizer of 0.84 mm diameter, pressure of 1.75 kg.cm^-2, flow rate of 0.5 L.h^-1, blower speed of 2100 rpm. L ^* , a ^* , b ^* and a_w values decreased with increasing concentrated milk feed as well as inlet air temperature. Density decreased as increase of inlet air temperature and increased as increase milk concentration. Flowability was fair according to Hausner ratio (1.25) and Carr's index (20%) values. The heat utilization efficiency increased as increase of concentration and decreased as increase of inlet air temperature. Solubility decreased as increase of concentration and inlet air temperature. Dispersibility decreased as increase of inlet air temperature and increased as increase of concentration. Wetting time increased as increase of concentration and inlet air temperature. Structure of the donkey milk powder was spherical and minerals were abundant.

Particle Design and Inhalation Delivery of Iodine for Upper Respiratory Tract Infection Therapy

Diseases caused by upper respiratory tract (URT) and pulmonary infections have been a serious threat to human health for millennia and lack of targeted effective therapeutic techniques. In this study, two kinds of cyclodextrin particles with typical particle shapes of nanocubes and microbars were synthesized through a facile process. Subsequently, the particles were used as carriers for loading and stabilizing iodine and characterizations were performed to demonstrate the loading mechanism. Next-generation impactor (NGI) experiments showed that iodine-loaded microbars (I₂@microbars) had a deposition rate of 79.75% in URT, while iodine-loaded nanocubes (I₂@nanocubes) were delivered to the deep lungs with a fine particle fraction (FPF) of 46.30%. Minimal inhibitory concentration (MIC) and minimal bactericidal concentration (MBC) indicated that the iodine-loaded nanocubes and microbars had similar bactericidal effect to povidone iodine solution. Cell viability studies and extracellular pro-inflammatory factor (TNF-α, IL-1β, IL-6) evaluations demonstrate noncytotoxic effects of the blank carriers and anti-inflammatory effects of iodine-loaded samples. The irritation of the rat pharynx by I₂@microbars was evaluated for the behavioral observations, body weight changes, histopathological studies, and TNF-α, IL-1β, and IL-6 levels in pharyngeal tissues. The results showed that I₂@microbars had no irritation to rat pharyngeal tissues at therapeutic doses. In conclusion, the present study provides novel treatment of URT infections via supramolecular cyclodextrin carriers for URT local therapy with iodine loading by a solvent-free method, which enhances the stability and reduces the inherent irritation without inhibiting their antimicrobial effects.

Optimization of drying conditions for Jackfruit pulp using Refractance Window Drying technology

Refractance window drying is a novel technology with high operational efficiency and high product quality retention compared with conventional drying methods. This study assessed the effect of refractance window dryer water temperature and pulp thickness on nutrient content and the antioxidant activity of jackfruit. Response surface methodology (RSM) was used to optimize the drying temperature and fruit pulp thickness. Optimal drying temperature and pulp thickness were found to be 93.4°C and 2.56 mm, respectively. The respective values for the response variables drying time (min), ascorbic acid (mg/100 g), antioxidant activity (mg/100 g AA equiv) and total carotenoid content (μg/g) were 60.47, 17.97, 82.34, and 13.34, respectively. Models for prediction of these values had R 2 values of .964, .980, .994, and .994, respectively, and nonsignificant lack of fit (p < .05). This indicates the suitability of the model in predicting the RWD operating conditions to produce quality dried jackfruit.

A review on the modernization of pharmaceutical development and manufacturing - Trends, perspectives, and the role of mathematical modeling

Recently, the pharmaceutical industry has been facing several challenges associated to the use of outdated development and manufacturing technologies. The return on investment on research and development has been shrinking, and, at the same time, an alarming number of shortages and recalls for quality concerns has been registered. The pharmaceutical industry has been responding to these issues through a technological modernization of development and manufacturing, under the support of initiatives and activities such as quality-by-design (QbD), process analytical technology, and pharmaceutical emerging technology. In this review, we analyze this modernization trend, with emphasis on the role that mathematical modeling plays within it. We begin by outlining the main socio-economic trends of the pharmaceutical industry, and by highlighting the life-cycle stages of a pharmaceutical product in which technological modernization can help both achieve consistently high product quality and increase return on investment. Then, we review the historical evolution of the pharmaceutical regulatory framework, and we discuss the current state of implementation and future trends of QbD. The pharmaceutical emerging technology is reviewed afterwards, and a discussion on the evolution of QbD into the more effective quality-by-control (QbC) paradigm is presented. Further, we illustrate how mathematical modeling can support the implementation of QbD and QbC across all stages of the pharmaceutical life-cycle. In this respect, we review academic and industrial applications demonstrating the impact of mathematical modeling on three key activities within pharmaceutical development and manufacturing, namely design space description, process monitoring, and active process control. Finally, we discuss some future research opportunities on the use of mathematical modeling in industrial pharmaceutical environments.

Thermodynamic Balance vs. Computational Fluid Dynamics Approach for the Outlet Temperature Estimation of a Benchtop Spray Dryer

The use of design space (DS) is a key milestone in the quality by design (QbD) of pharmaceutical processes. It should be considered from early laboratory development to industrial production, in order to support scientists with making decisions at each step of the product’s development life. Presently, there are no available data or methodologies for developing models for the implementation of design space (DS) on laboratory-scale spray dryers. Therefore, in this work, a comparison between two different modeling approaches, thermodynamics and computational fluid dynamics (CFD), to a laboratory spray dryer model have been evaluated. The models computed the outlet temperature (Tout) of the process with a new modeling strategy that includes machine learning to improve the model prediction. The model metrics calculated indicate how the thermodynamic model fits Tout data better than CFD; indeed, the error of the CFD model increases towards higher values of Tout and feed rate (FR), with a final mean absolute error of 10.43 K, compared to the 1.74 K error of the thermodynamic model. Successively, a DS of the studied spray dryer equipment has been implemented, showing how Tout is strongly affected by FR variation, which accounts for about 40 times more than the gas flow rate (Gin) in the DS. The thermodynamic model, combined with the machine learning approach here proposed, could be used as a valid tool in the QbD development of spray-dried pharmaceutical products, starting from their early laboratory stages, replacing traditional trial-and-error methodologies, preventing process errors, and helping scientists with the following scale-up.

Formulation and Evaluation of Chitosan/NaCl/Maltodextrin Microparticles as a Saltiness Enhancer: Study on the Optimization of Excipients for the Spray-Drying Process

Spray-dried chitosan/NaCl/maltodextrin microparticles have the potential to be used to enhance saltiness; however, its notable hygroscopicity results in handling and storage problems, thus limiting its application. In the present study, we attempted to introduce maltodextrin, microcrystalline cellulose (MCC), and waxy starch (WS) as excipients into the spray drying formulation of microparticles to reduce the cohesiveness and caking behavior and improve the yield simultaneously by ameliorating the moisture absorption tendency. The prepared microparticles showed a spherical appearance and had particle sizes ranging from 6.29 to 7.64 μm, while the sizes of the NaCl crystals embedded in the microparticles were 0.36 to 1.24 μm. The crystalline reflections of WS and MCC were retained in the microparticles after the spray-drying process. The handling properties were assessed to be acceptable. The formulation with only maltodextrin as the excipient showed a high moisture absorption rate of 2.83 g/100 g·h and a caking strength of 3.27 kg. The addition of MCC and WS significantly reduced the hygroscopic rate and caking strength. The spray-dried products provided better saltiness perception than native NaCl; as such, they may be promising for seasoning dry food products to achieve sodium intake reduction in the food industry.

Enhanced rehydration behaviors of micellar casein powder: The effects of high hydrostatic pressure treatments on micelle structures

Natural micellar casein is generally dried into powdered forms for commercial transportation and storage. However, the poor rehydration ability of micellar casein powder critically limited the potential applications due to its dense cross-linked structures caused by colloidal calcium phosphate (CCP). In this study, micellar casein solutions were exposed to a high hydrostatic pressure (HHP) ranging from 100 to 500 MPa and were then freeze dried to produce powders. The effects on the casein micelle structures and the rehydration characteristics including wetting, dispersion and dissolving were comprehensively investigated. The results showed that HHP could induce smaller micelle sizes and significantly increase the free calcium in the reconstituted solution. It demonstrated that the majority of CCP bridges in casein micelles were dissociated, which produced porous powders with loose structures and thus significantly improved rehydration behaviors. 300 MPa was the pressure level that caused the quickest dispersion process and best solubility. Consequently, HHP has potential to be a novel physical technique to potentially modify the protein higher-order structures as well as improve the corresponding functionalities.

Engineered-inhaled particles: Influence of carbohydrates excipients nature on powder properties and behavior

Pulmonary drug administration has long been used for local or systemic treatment due to several advantages. Dry powder inhalers emerge as the most promising due to efficiency, ecologic, and drug stability concerns. Coarse lactose-carrier is still the gold standard when inhalation powders are developed. Despite some efforts to produce new types of powders, the lung drug deposition is still poorly controlled, which will ultimately impact therapeutic effectiveness. In this study, we developed "engineered-inhalation powders" using the spray-drying technique. Multiple carbohydrates excipients were binary mixed and combined with two active pharmaceutical ingredients for asthma therapy (budesonide and formoterol). Particle morphology, from spherical to deflated shapes, was characterized by the number and the depth of dimples measured from SEM images. We define a new characteristic deflation ratio ξ as the product between the number of dimples and their depth. Six different powders having opposite morphologies have been selected and we have demonstrated a linear correlation between the fine particle fraction and the deflation ratio of produced powders. Overall, we showed first that the morphology of inhalable powder can be finely tuned by spray-drying technique when excipients varied. Secondly, we developed stable inhalation powders that simultaneously induced high fine particle fractions (>40%) for two drugs due to their deflated surface. The stability has been evaluated for up to 2 months at room temperature.

Lipid-microparticles for pulmonary delivery of active pharmaceutical ingredients: Impact of lipid crystallization on spray-drying processability

Spray-drying is an extensively used technology for engineering inhalable particles. Important technical hurdles are however experienced when lipid-based excipients (LBEs) are spray-dried. Stickiness, extensive wall deposition, or simply inability to yield a solid product have been associated to the low melting points of LBEs. In this work, solutions containing polyglycerol esters of behenic acid (PGFA-behenates), or other high melting point LBEs, were spray-dried to produce ibuprofen (IBU)-loaded inhalable lipid-microparticles. Prior to spray-drying, rational boundaries for the outlet temperature of the process were defined using LBE-IBU phase diagrams. Despite spray-drying the solutions at outlet temperatures below the boundaries, process performance and yield among LBEs were entirely different. Lipid crystallization into polymorphs or multi-phases negatively impacted the yield (10-47%), associated to liquid fractions unable to recrystallize at the surrounding gas temperature in the spray-dryer. The highest yields (76-82%), ascribed to PGFA-behenates, resulted from monophasic crystallization and absence of polymorphism. Lipid-microparticles, composed of a PGFA-behenate, were characterized by a volume mean diameter of 6.586 µm, tap density of 0.389 g/cm³ and corrugated surface. Application as carrier-free dry powder for inhalation resulted in high emitted fraction (90.9%), median mass aerodynamic diameter of 3.568 µm, fine particle fraction of 45.6% and modified release in simulated lung fluid.

Comprehensive Understanding of Roller Milling on the Physicochemical Properties of Red Lentil and Yellow Pea Flours

The development of convenience foods by incorporating nutrient-rich pulses such as peas and lentils will tremendously alter the future of pulse and cereal industries. However, these pulses should be size-reduced before being incorporated into many food products. Therefore, an attempt was made to adapt roller mill settings to produce de-husked yellow pea and red lentil flours. The milling flowsheets unique to yellow peas and red lentils were developed in producing small, medium, and large flours with maximum yield and flour quality. This study also investigated the differences in chemical composition, physical characteristics, and particle size distributions of the resultant six flour fractions. The kernel dimensions and physicochemical properties of the whole yellow pea and red lentils were also studied to develop customized mill settings. Overall, the mill settings had a significant effect on the physical properties of different particle-sized flours. The geometric mean diameters of different particle-sized red lentil flours were 56.05 μm (small), 67.01 μm (medium), and 97.17 μm (large), while for yellow pea flours they were 41.38 μm (small), 60.81 μm (medium), and 98.31 μm (large). The particle size distribution of all the flour types showed a bimodal distribution, except for the small-sized yellow pea flour. For both the pulse types, slightly more than 50% flour was approximately sizing 50 μm, 75 μm, and 100 μm for small, medium, and large settings, respectively. The chemical composition of the flour types remained practically the same for different-sized flours, fulfilling the objective of this current study. The damaged starch values for red lentil and yellow pea flour types increased with a decrease in flour particle size. Based on the Hausner’s ratios, the flowability of large-sized flour of red lentils could be described as passable; however, all the remaining five flour types were indicated as either poor or very poor. The findings of this study assist the millers to adapt yellow pea and red lentil milling technologies with minor modifications to the existing facilities. The study also helps in boosting the production of various baking products using pulse and wheat flour blends to enhance their nutritional quality.

Engineering Advances in Spray Drying for Pharmaceuticals

Spray drying is a versatile technology that has been applied widely in the chemical, food, and, most recently, pharmaceutical industries. This review focuses on engineering advances and the most significant applications of spray drying for pharmaceuticals. An in-depth view of the process and its use is provided for amorphous solid dispersions, a major, growing drug-delivery approach. Enhanced understanding of the relationship of spray-drying process parameters to final product quality attributes has made robust product development possible to address a wide range of pharmaceutical problem statements. Formulation and process optimization have leveraged the knowledge gained as the technology has matured, enabling improved process development from early feasibility screening through commercial applications. Spray drying's use for approved small-molecule oral products is highlighted, as are emerging applications specific to delivery of biologics and non-oral delivery of dry powders. Based on the changing landscape of the industry, significant future opportunities exist for pharmaceutical spray drying.

Complete Cocrystal Formation during Resonant Acoustic Wet Granulation: Effect of Granulation Liquids

The manufacturing of solid pharmaceutical dosage forms composed of cocrystals requires numerous processes during which there is risk of dissociation into parent molecules. Resonant acoustic wet granulation (RAG) was devised in an effort to complete theophylline–citric acid (THPCIT) cocrystal formation during the granulation process, thereby reducing the number of operations. In addition, the influence of granulation liquid was investigated. A mixture of anhydrous THP (drug), anhydrous CIT (coformer), and hydroxypropyl cellulose (granulating agent) was processed by RAG with water or ethanol as a granulation liquid. The purposes were to (i) form granules using RAG as a breakthrough method; (ii) accomplish the cocrystallization during the integrated unit operation; and (iii) characterize the final solid product (i.e., tablet). The RAG procedure achieved complete cocrystal formation (>99%) and adequately sized granules (d50: >250 μm). The granulation using water (GW) facilitated formation of cocrystal hydrate which were then transformed into anhydrous cocrystal after drying, while the granulation using ethanol (GE) resulted in the formation of anhydrous cocrystal before and after drying. The dissolution of the highly dense GW tablet, which was compressed from granules including fine powder due to the dehydration, was slower than that of the GE tablet.

Effective microencapsulation of Enterococcus faecium in biopolymeric matrices using spray drying

The objective of this work was to evaluate the potential of whey protein concentrate (WPC), native agave fructans (NAF), and their mixture (WPC-NAF, 1:1 w/w) as wall materials and evaluate the physicochemical properties and stability of encapsulated Enterococcus faecium during the spray drying, storage, and passage through the simulated gastrointestinal tests. The encapsulated microorganisms with WPC-NAF by spray drying showed greater viability (9.26 log CFU/g) and a higher microencapsulation yield (88.43%). They also had a smaller reduction in the cell count (0.61 log cycles), while the microcapsules produced with NAF had the greatest reduction in viability during the simulated gastrointestinal tests. Similarly, probiotics encapsulated with WPC-NAF revealed a higher survival rate (> 8 log CFU/g) when stored at a water activity of 0.328. The thermal analysis showed that the addition of NAF to the WPC produced a slight shift in the Tg towards temperatures higher than that shown by NAF. Therefore, this study provides evidence that the spray drying process was appropriate to encapsulate the probiotic strain Enterococcus faecium and that the mixture WPC-NAF protected it from adverse drying conditions and improved the viability of Enterococcus faecium during storage and simulated gastrointestinal tests, demonstrating that the combination of NAF and WPC as encapsulating material is adequate in the production of more stable microcapsules with potential application in various foods.Key Points• E. faecium was successfully encapsulated in WPC and NAF.• WPC-NAF offered protection to E. faecium in the gastrointestinal tests and during storage.• Aw around 0.328 positively influenced the viability of the microorganism during storage. Graphical abstract.

The current state of Bayesian methods in nonclinical pharmaceutical statistics: Survey results and recommendations from the DIA/ASA-BIOP Nonclinical Bayesian Working Group

The use of Bayesian methods to support pharmaceutical product development has grown in recent years. In clinical statistics, the drive to provide faster access for patients to medical treatments has led to a heightened focus by industry and regulatory authorities on innovative clinical trial designs, including those that apply Bayesian methods. In nonclinical statistics, Bayesian applications have also made advances. However, they have been embraced far more slowly in the nonclinical area than in the clinical counterpart. In this article, we explore some of the reasons for this slower rate of adoption. We also present the results of a survey conducted for the purpose of understanding the current state of Bayesian application in nonclinical areas and for identifying areas of priority for the DIA/ASA-BIOP Nonclinical Bayesian Working Group. The survey explored current usage, hurdles, perceptions, and training needs for Bayesian methods among nonclinical statisticians. Based on the survey results, a set of recommendations is provided to help guide the future advancement of Bayesian applications in nonclinical pharmaceutical statistics.

Formulation of Curcumin-β-cyclodextrin-polyvinylpyrrolidone supramolecular inclusion complex: experimental, molecular docking, and preclinical anti-inflammatory assessment

This research planned to ameliorate an aqueous solubility and dissolution of Curcumin (CUR) by the formulation of inclusion complex with β-cyclodextrin (β-CD) and polyvinylpyrrolidone (PVP). The phase solubility study was performed to assess the solubility of CUR. The prepared CUR complex assessed for dissolution study, physicochemical evaluation, in-vitro antioxidant activity, molecular modeling, and anti-inflammatory assessment. The pivotal findings of phase-solubility studies demonstrate apparent stability constant (Kc) and complexation efficiency (CE) values for CUR-β-CD and CUR-β-CD-PVP complex was 175.4 M ^-1, 1.15% and 833.3.2 M ^-1 and 5.21%, respectively. The characterization results revealed amorphization of crystalline state (CUR) into amorphous state. The maximum drug release found with the ternary CUR complex (F7), i.e. 45.41 ± 3.78% in 6 h study. The chemical shift in the NMR supports that the aromatic ring of CUR is completely complexed inside the β-CD cavity. The antioxidant activity of pure CUR was found to be 58.02 ± 2.21% and CUR ternary complex (F7) showed significantly higher activity to 96.02 ± 2.46%. The in-vivo effect of CUR complex (F7) was also found significantly higher than that of pure CUR. The molecular modeling study depicted that PVP increased the stability of the ternary complex by forming the link between CUR and β-CD. Thus, the ternary inclusion complex of CUR-β-CD-PVP could contribute as an innovative outcome in the enhancement of solubility and in-vivo activity.

Formulation of amorphous ternary solid dispersions of dapagliflozin using PEG 6000 and Poloxamer 188: solid-state characterization, ex vivo study, and molecular simulation assessment

The present study was designed to prepare dapagliflozin (DFG) loaded ternary solid dispersions (SDs) using the carrier blend polyethylene glycol 6000 (PEG 6000) and poloxamer 188 (PLX 188). The prepared DFG-SDs were evaluated for solubility study, physicochemical characterization and molecular simulation study. The prepared DFG-SDs showed significant higher solubility and dissolution vis-a-vis pure DFG and DFG physical mixture. The composition DFG:PEG:PLX (1:2.25:0.75 mM) showed the highest solubility (0.476 ± 0.016 mg/mL). The physicochemical characterization confirms the polymorphic transition of DFG from crystalline state to stable amorphous form. The prepared DFG-SDs showed a significantly higher dissolution (64.78 ± 2.34% to 78.41 ± 2.39%) than pure DFG (15.70 ± 3.54%). DFG-SD2 showed a significantly enhanced drug permeation (p<.05) (58.76 ± 4.65 µg/cm) as compared to pure DFG (14.97 ± 3.32 µg/cm). The molecular docking study result revealed a good hydrophobic interaction of DFG with the used carrier due to the lowest energy pose. The interaction occurs between the methylene bridges and the central hydrophobic chain of polyoxypropylene of the polymer. Therefore, DFG-SDs prepared by microwave irradiation method using hydrophilic carrier blend might be a promising strategy for improving the solubility and in vitro dissolution performance.

Spray drying and storage of probiotic-enriched almond milk: probiotic survival and physicochemical properties

BACKGROUND

The combination of the nutritional profile of almond milk with the benefits of probiotic bacteria is an interesting development to meet the demand for sustainable and health-promoting food. Almond milk inoculated with probiotic Lactobacillus plantarum (ATCC8014) was spray dried and the almond, its milk, and powders were characterized physicochemically. Samples were characterized in terms of bacterial survival before and after atomization. Bacterial viability and total fatty acid changes were studied during 8 months' storage at 4 and 22 °C.

RESULTS

Results showed adequate physicochemical properties and an optimal bacterial survival rate, maintaining almost the same values before and after the spray-drying operation. A decrease was observed in the cell viability for samples stored at 4 °C. However, the cell count was maintained above the minimum level suggested (10⁷ living cells) to allow potential probiotic functionality for 8 months. On the other hand, the count cell of powders stored at 22 °C was below the minimum level required after 6 months. The fatty acids profile was not significantly (P > 0.05) affected by storage time and temperature.

CONCLUSION

A new almond-based-product with probiotics was developed to meet consumer demands. Almond nutrients were recovered from almond milk powder and were found to be a good source of K and high in Mg and in monounsaturated fat. The viability of bacteria was assured during 8 months of storage at 4 °C and up to 6 months for samples stored at 22 °C. © 2020 Society of Chemical Industry.

Cross-Linked Microencapsulation of CO2 Supercritical Extracted Oleoresins from Sea Buckthorn: Evidence of Targeted Functionality and Stability

Oleoresin supercritical extracts from sea buckthorn were microencapsulated in whey proteins isolate and casein, in two states: native (N) and cross-linked mediated by transglutaminase (TG). The encapsulation efficiency showed values higher than 92% for total carotenoids and lycopene. Phytochemicals content was 352.90 ± 1.02 mg/g dry weight (DW) for total carotenoids in TG and 302.98 ± 2.30 mg/g DW in N, with antioxidant activity of 703.13 ± 23.60 mMol Trolox/g DW and 608.74 ± 7.12 mMol Trolox/g DW, respectively. Both powders had an inhibitory effect on α-glucosidase, of about 40% for N and 35% for TG. The presence of spherosomes was highlighted, with sizes ranging between 15.23-73.41 µm and an agglutination tendency in N, and lower sizes, up to 35 µm in TG. The in vitro digestibility revealed a prolonged release in an intestinal environment, up to 65% for TG. Moisture sorption isotherms were studied at 20 °C and the shape of curves corresponds to sigmoidal type II model. The presence of cross-linked mediated aggregates in TG powders improved stability and flowability. Our results can be used as evidence that cross-linked aggregates mediated by transglutaminase applied for microencapsulation of oleoresins have the potential to become new delivery systems, for carotenoids and lycopene, being valuable in terms of their attractive color and biological and bioaccessibility properties.

Quality by design thinking in the development of long-acting injectable PLGA/PLA-based microspheres for peptide and protein drug delivery

Adopting the Quality by Design (QbD) approach in the drug development process has transformed from "nice-to-do" into a crucial and required part of the development, ensuring the quality of pharmaceutical products throughout their whole life cycles. This review is discussing the implementation of the QbD thinking into the production of long-acting injectable (LAI) PLGA/PLA-based microspheres for the therapeutic peptide and protein drug delivery. Various key elements of the QbD approaches are initially elaborated using Bydureon®, a commercial product of LAI PLGA/PLA-based microspheres, as a classical example. Subsequently, the factors influencing the release patterns and the stability of the peptide and protein drugs are discussed. This is followed by a summary of the state-of-the-art of manufacturing LAI PLGA/PLA-based microspheres and the related critical process parameters (CPPs). Finally, a landscape of generic product development of LAI PLGA/PLA-based microspheres is reviewed including some major challenges in the field.

Influence of Composition and Spray-Drying Process Parameters on Carrier-Free DPI Properties and Behaviors in the Lung: A review

Although dry powder inhalers (DPIs) have attracted great interest compared to nebulizers and metered-dose inhalers (MDIs), drug deposition in the deep lung is still insufficient to enhance therapeutic activity. Indeed, it is estimated that only 10–15% of the drug reaches the deep lung while 20% of the drug is lost in the oropharyngeal sphere and 65% is not released from the carrier. The potentiality of the powders to disperse in the air during the patient’s inhalation, the aerosolization, should be optimized. To do so, new strategies, in addition to classical lactose-carrier, have emerged. The lung deposition of carrier-free particles, mainly produced by spray drying, is higher due to non-interparticulate forces between the carrier and drug, as well as better powder uniformity and aerosolization. Moreover, the association of two or three active ingredients within the same powder seems easier. This review is focused on a new type of carrier-free particles which are characterized by a sugar-based core encompassed by a corrugated shell layer produced by spray drying. All excipients used to produce such particles are dissected and their physico-chemical properties (Péclet number, glass transition temperature) are put in relation with the lung deposition ability of powders. The importance of spray-drying parameters on powders’ properties and behaviors is also evaluated. Special attention is given to the relation between the morphology (characterized by a corrugated surface) and lung deposition performance. The understanding of the closed relation between particle material composition and spray-drying process parameters, impacting the final powder properties, could help in the development of promising DPI systems suitable for local or systemic drug delivery.

Stability of bifidobacteria entrapped in goat's whey freeze concentrate and inulin as wall materials and powder properties

Goat's whey was submitted to two cycles of block freeze concentration process, resulting in concentrate 1 and concentrate 2. Concentrate 1 was added with 5 g of inulin and both concentrates were inoculated with Bifidobacterium animalis ssp. lactis BB-12, the concentrates were then denoted as feed solutions 1 and 2, respectively. Feed solutions were spray-dried, resulting in powder 1 and 2. The stability of the bifidobacteria entrapped within the powders was evaluated for both spray-dried powders stored at 4 °C and 25 °C for 60 days. The spray-dried powders were also evaluated in relation to their physical and thermal properties. It was noted that Bifidobacteria displayed increased stability at refrigeration temperature. Analysis of physical properties indicated that the addition of inulin resulted in increased water solubility. However, both spray-dried powders displayed less flowability, as well as a yellow-greenish color. By evaluating the spray-dried powders thermal properties, it was possible to confirm that goat whey concentrates behave as excellent wall materials.

In Situ Hydrogel-Forming/Nitric Oxide-Releasing Wound Dressing for Enhanced Antibacterial Activity and Healing in Mice with Infected Wounds

The eradication of bacteria from wound sites and promotion of healing are essential for treating infected wounds. Nitric oxide (NO) is desirable for these purposes due to its ability to accelerate wound healing and its broad-spectrum antibacterial effects. We developed an in situ hydrogel-forming/NO-releasing powder dressing (NO/GP), which is a powder during storage and forms a hydrogel when applied to wounds, as a novel NO-releasing formulation to treat infected wounds. An NO/GP fine powder (51.5 μm) was fabricated by blending and micronizing S-nitrosoglutathione (GSNO), alginate, pectin, and polyethylene glycol (PEG). NO/GP remained stable for more than four months when stored at 4 or 37 °C. When applied to wounds, NO/GP absorbed wound fluid and immediately converted to a hydrogel. Additionally, wound fluid triggered a NO release from NO/GP for more than 18 h. The rheological properties of hydrogel-transformed NO/GP indicated that NO/GP possesses similar adhesive properties to marketed products (Vaseline). NO/GP resulted in a 6-log reduction in colony forming units (CFUs) of methicillin resistant Staphylococcus aureus (MRSA) and Pseudomonas aeruginosa, which are representative drug-resistant gram-positive and -negative bacteria, respectively. The promotion of wound healing by NO/GP was demonstrated in mice with full-thickness wounds challenged with MRSA and P. aeruginosa. Thus, NO/GP is a promising formulation for the treatment of infected wounds.

Product Development, Manufacturing, and Packaging of Solid Dosage Forms Under QbD and PAT Paradigm: DOE Case Studies for Industrial Applications

An integrated approach based on QbD and PAT provides a systematic and innovative framework for product development, manufacturing, and quality risk management. In this context, the significance of the outcome of design of experiments (DOEs) to the selection of the product design, robust commercial manufacturing process, design space, and overall control strategy remains vital for the success of a drug product throughout its life cycle. This paper aims at discussing selected recent DOE case studies conducted during QbD-based and integrated QbD/PAT-based development of solid oral formulations and process improvement studies. The main focus of this paper is to highlight the rationales and importance of design selection during development and applications of mathematical models and statistical tools in analyzing DOE and PAT data for developing a design space, control strategy, and improved process monitoring. A total of 25 case studies (includes 9 PAT application studies) have been discussed in this paper which cover 11 manufacturing processes commonly utilized for solid dosage forms. Two case studies relevant to selection of packaging design for solid dosage forms are also briefly discussed to complete the scope. Overall, for a successful modern QbD approach, it is highly important that DOEs are conducted and analyzed in a logical sequence which involves designs that are phase-appropriate and quality-driven and facilitate both statistical and chemometric thinking at each development stage. This approach can result into higher regulatory flexibility along with lower economic burden during life cycle of a product, irrespective of regulatory path used (NDA or ANDA).

Global Sensitivity Analysis of a Spray Drying Process

Spray drying is a key unit operation used to achieve particulate products of required properties. Despite its widespread use, the product and process design, as well as the process control remain highly empirical and depend on trial and error experiments. Studying the effect of operational parameters experimentally is tedious, time consuming, and expensive. In this paper, we carry out a model-based global sensitivity analysis (GSA) of the process. Such an exercise allows us to quantify the impact of different process parameters, many of which interact with each other, on the product properties and conditions that have an impact on the functionality of the final drug product. Moreover, classical sensitivity analysis using the Sobol-based sensitivity indices was supplemented by a polynomial chaos-based sensitivity analysis, which proved to be an efficient method to reduce the computational cost of the GSA. The results obtained demonstrate the different response dependencies of the studied variables, which helps to identify possible control strategies that can result in major robustness for the spray drying process.

Scale-up of pharmaceutical spray drying using scale-up rules: A review

Spray drying is one of the widely used manufacturing processes in pharmaceutical industry. While there are voluminous experimental studies pertaining to the impact of various process-formulation parameters on the quality attributes of spray dried powders such as particle size, morphology, density, and crystallinity, there is scant information available in the literature regarding process scale-up. Here, we first analyze salient features of scale-up attempts in literature. Then, spray drying process is analyzed considering the fundamental physical transformations involved, i.e., atomization, drying, and gas-solid separation. Each transformation is scrutinized from a scale-up perspective with non-dimensional parameters & multi-scale analysis, and comprehensively discussed in engineering context. Successful scale-up entails similar key response variables from each transformation across various scales. These variables are identified as droplet size distribution, outlet temperature, relative humidity, separator pressure loss coefficient, and collection efficiency. Instead of trial-and-error-based approaches, this review paper advocates the use of mechanistic models and scale-up rules for establishing design spaces for the process variables involved in each transformation of spray drying. While presenting a roadmap for process development and scale-up, the paper demonstrates how to bridge the current gap in spray drying scale-up via a rational understanding of the fundamental transformations.