1
|
Magramane S, Vlahović K, Gordon P, Kállai-Szabó N, Zelkó R, Antal I, Farkas D. Inhalation Dosage Forms: A Focus on Dry Powder Inhalers and Their Advancements. Pharmaceuticals (Basel) 2023; 16:1658. [PMID: 38139785 PMCID: PMC10747137 DOI: 10.3390/ph16121658] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/25/2023] [Revised: 11/17/2023] [Accepted: 11/24/2023] [Indexed: 12/24/2023] Open
Abstract
In this review, an extensive analysis of dry powder inhalers (DPIs) is offered, focusing on their characteristics, formulation, stability, and manufacturing. The advantages of pulmonary delivery were investigated, as well as the significance of the particle size in drug deposition. The preparation of DPI formulations was also comprehensively explored, including physico-chemical characterization of powders, powder processing techniques, and formulation considerations. In addition to manufacturing procedures, testing methods were also discussed, providing insights into the development and evaluation of DPI formulations. This review also explores the design basics and critical attributes specific to DPIs, highlighting the significance of their optimization to achieve an effective inhalation therapy. Additionally, the morphology and stability of 3 DPI capsules (Spiriva, Braltus, and Onbrez) were investigated, offering valuable insights into the properties of these formulations. Altogether, these findings contribute to a deeper understanding of DPIs and their development, performance, and optimization of inhalation dosage forms.
Collapse
Affiliation(s)
- Sabrina Magramane
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (S.M.); (K.V.); (I.A.)
| | - Kristina Vlahović
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (S.M.); (K.V.); (I.A.)
| | - Péter Gordon
- Department of Electronics Technology, Budapest University of Technology and Economics, Egry J. Str. 18, H-1111 Budapest, Hungary;
| | - Nikolett Kállai-Szabó
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (S.M.); (K.V.); (I.A.)
| | - Romána Zelkó
- Department of Pharmacy Administration, Semmelweis University, Hőgyes Str. 7–9, H-1092 Budapest, Hungary;
| | - István Antal
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (S.M.); (K.V.); (I.A.)
| | - Dóra Farkas
- Department of Pharmaceutics, Semmelweis University, Hőgyes Str. 7, H-1092 Budapest, Hungary; (S.M.); (K.V.); (I.A.)
| |
Collapse
|
2
|
Ye Y, Fan Z, Ma Y, Zhu J. Investigation on the Influence of Design Features on the Performance of Dry Powder Inhalers: Spiral Channel, Mouthpiece Dimension, and Gas Inlet. Int J Pharm 2023:123116. [PMID: 37302669 DOI: 10.1016/j.ijpharm.2023.123116] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/08/2023] [Revised: 05/28/2023] [Accepted: 06/06/2023] [Indexed: 06/13/2023]
Abstract
As inhaler design is rarely studied but critically important in pulmonary drug delivery, this study investigated the influence of inhaler designs, including a novel spiral channel, mouthpiece dimensions (diameter and length) as well as gas inlet. Experimental dispersion of a carrier-based formulation in conjugation with computational fluid dynamics (CFD) analysis, was performed to determine how the designs affect inhaler performance. Results reveal that inhalers with a narrow spiral channel could effectively increase drug-carrier detachment by introducing high velocity and strong turbulent flow in the mouthpiece, although the drug retention in the device is significantly high. It is also found that reducing mouthpiece diameter and gas inlet size could greatly improve the fine particle dose delivered to the lungs, whereas the mouthpiece length plays a trivial influence on the aerosolization performance. This study contributes toward a better understanding of inhaler designs as relevant to overall inhaler performance, and sheds light on how the designs affect device performance.
Collapse
Affiliation(s)
- Yuqing Ye
- University of Western Ontario, 1151 Richmond Street, London, N6A 3K7, Canada; Suzhou Inhal Pharma Co., Ltd., 108 Yuxi Road, Suzhou, 215125, China
| | - Ziyi Fan
- University of Western Ontario, 1151 Richmond Street, London, N6A 3K7, Canada
| | - Ying Ma
- University of Western Ontario, 1151 Richmond Street, London, N6A 3K7, Canada; Suzhou Inhal Pharma Co., Ltd., 108 Yuxi Road, Suzhou, 215125, China
| | - Jesse Zhu
- University of Western Ontario, 1151 Richmond Street, London, N6A 3K7, Canada.
| |
Collapse
|
3
|
Salama R, Choi HJ, Almazi J, Traini D, Young P. Generic dry powder inhalers bioequivalence: Batch-to-batch variability insights. Drug Discov Today 2022; 27:103350. [PMID: 36096359 DOI: 10.1016/j.drudis.2022.103350] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2022] [Revised: 08/02/2022] [Accepted: 09/06/2022] [Indexed: 11/23/2022]
Abstract
Active pharmaceutical ingredient(s) [API(s)] of dry powder inhalers (DPIs) deposition and their fate in the respiratory system are influenced by a complex matrix of formulation, device, manufacturing and physiological variations. DPIs on the market have shown bioinequivalence between batches of the same product. Despite being clinically insignificant, they affect bioequivalence studies when a generic product is compared with the originator. This review discusses implications of batch-to-batch variability on bioequivalence study outcomes and shortcomings of current regulatory requirements. Possible formulation and manufacturing factors resulting in batch-to-batch variability highlight the inherent nature of this issue. Despite scholarly investigations and official regulatory guidance, there remains a need for reliable and realistic in vitro tests that accurately guide a representative reference product batch selection.
Collapse
Affiliation(s)
- Rania Salama
- Respiratory Technology Group, Woolcock Institute of Medical Research, Glebe 2037, NSW, Australia; Macquarie Medical School, Faculty of Medicine, Health and Human Sciences, Macquarie University 2109, NSW, Australia.
| | - Hong Jun Choi
- Faculty of Medicine and Health, The University of Sydney, Camperdown 2007, NSW, Australia
| | - Juhura Almazi
- Respiratory Technology Group, Woolcock Institute of Medical Research, Glebe 2037, NSW, Australia
| | - Daniela Traini
- Respiratory Technology Group, Woolcock Institute of Medical Research, Glebe 2037, NSW, Australia; Macquarie Medical School, Faculty of Medicine, Health and Human Sciences, Macquarie University 2109, NSW, Australia
| | - Paul Young
- Respiratory Technology Group, Woolcock Institute of Medical Research, Glebe 2037, NSW, Australia; Macquarie Business School, Macquarie University 2109, NSW, Australia
| |
Collapse
|
4
|
Adhikari BR, Gordon KC, Das SC. Solid state of inhalable high dose powders. Adv Drug Deliv Rev 2022; 189:114468. [PMID: 35917868 DOI: 10.1016/j.addr.2022.114468] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/16/2022] [Revised: 07/14/2022] [Accepted: 07/26/2022] [Indexed: 01/24/2023]
Abstract
High dose inhaled powders have received increased attention for treating lung infections. These powders can be prepared using techniques such as spray drying, spray-freeze drying, crystallization, and milling. The selected preparation technique is known to influence the solid state of the powders, which in turn can potentially modulate aerosolization and aerosolization stability. This review focuses on how and to what extent the change in solid state of high dose powders can influence aerosolization. It also discusses the commonly used solid state characterization techniques and the application of potential strategies to improve the physical and chemical stability of the amorphous powders for high dose delivery.
Collapse
Affiliation(s)
| | - Keith C Gordon
- The Dodd-Walls Centre for Photonic and Quantum Technologies, Department of Chemistry, University of Otago, Dunedin 9016, New Zealand
| | - Shyamal C Das
- School of Pharmacy, University of Otago, Dunedin 9054, New Zealand.
| |
Collapse
|
5
|
Zhang X, Zhou Y, Wang G, Zhao Z, Jiang Z, Cui Y, Yue X, Huang Z, Huang Y, Pan X, Wu C. Co-spray-dried poly-L-lysine with L-leucine as dry powder inhalations for the treatment of pulmonary infection: Moisture-resistance and desirable aerosolization performance. Int J Pharm 2022; 624:122011. [PMID: 35820517 DOI: 10.1016/j.ijpharm.2022.122011] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/10/2022] [Revised: 06/26/2022] [Accepted: 07/06/2022] [Indexed: 10/17/2022]
Abstract
Poly-L-lysine (PLL) is a promising candidate for the treatment of pulmonary infection with lower occurrence of drug-resistance due to its unique antibacterial mechanisms. Dry powder inhalations (DPIs) are considered as the first choice for formulating PLL to treat pulmonary infection on account of direct delivery and satisfactory stability. However, hygroscopicity of PLL limited its therapeutic effect on pulmonary infection when PLL developed into DPIs. The hygroscopicity caused two obstacles including the low drug deposition in the lower respiratory tract and undesirable aerosolization performance deterioration. In this study, PLL was co-spray-dried with L-leucine (LL) to achieve moisture-resistance and desirable aerosolization performance. The ratio of PLL and LL was optimized to obtain particles with different morphology, hygroscopicity and aerodynamic properties. The obtained PLL DPIs were suitable for inhalation with a corrugated surface formed by hydrophobic LL. The anti-hygroscopicity, aerosolization performance and rheological properties of P2 DPIs were optimal when PLL:LL = 85:15. The DPIs particles were stable after being stored at high relative humidity (60 ± 5%), and their superiority in treating pulmonary infections was also proved by in vitro and in vivo experiments. The established PLL DPIs were proved to be a feasible and desirable approach to treat pulmonary infections.
Collapse
Affiliation(s)
- Xuejuan Zhang
- College of Pharmacy, Jinan University, Guangzhou 510632, Guangdong, PR China.
| | - Yue Zhou
- College of Pharmacy, Jinan University, Guangzhou 510632, Guangdong, PR China.
| | - Guanlin Wang
- School of Pharmaceutical Sciences, Sun Yat-Sen University, Guangzhou 510006, Guangdong, PR China.
| | - Ziyu Zhao
- Pharmacy Department, Guangzhou Red Cross Hospital, Guangzhou 510006, Guangdong, PR China.
| | - Zhongxiang Jiang
- Department of Pulmonary and Critical Care Medicine, Chongqing General Hospital, Chongqing 401147, PR China.
| | - Yingtong Cui
- School of Pharmaceutical Sciences, Sun Yat-Sen University, Guangzhou 510006, Guangdong, PR China.
| | - Xiao Yue
- College of Pharmacy, Jinan University, Guangzhou 510632, Guangdong, PR China
| | - Zhengwei Huang
- College of Pharmacy, Jinan University, Guangzhou 510632, Guangdong, PR China.
| | - Ying Huang
- College of Pharmacy, Jinan University, Guangzhou 510632, Guangdong, PR China.
| | - Xin Pan
- School of Pharmaceutical Sciences, Sun Yat-Sen University, Guangzhou 510006, Guangdong, PR China.
| | - Chuanbin Wu
- College of Pharmacy, Jinan University, Guangzhou 510632, Guangdong, PR China.
| |
Collapse
|
6
|
Mannitol Polymorphs as Carrier in DPIs Formulations: Isolation Characterization and Performance. Pharmaceutics 2021; 13:pharmaceutics13081113. [PMID: 34452073 PMCID: PMC8401007 DOI: 10.3390/pharmaceutics13081113] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/11/2021] [Revised: 07/16/2021] [Accepted: 07/19/2021] [Indexed: 12/28/2022] Open
Abstract
The search for best performing carriers for dry powder inhalers is getting a great deal of interest to overcome the limitations posed by lactose. The aerosolization of adhesive mixtures between a carrier and a micronized drug is strongly influenced by the carrier solid-state properties. This work aimed at crystallizing kinetically stable D-mannitol polymorphs and at investigating their aerosolization performance when used in adhesive mixtures with two model drugs (salbutamol sulphate, SS, and budesonide, BUD) using a median and median/high resistance inhaler. A further goal was to assess in vitro the cytocompatibility of the produced polymer-doped mannitol polymorphs toward two lung epithelial cell lines. Kinetically stable (up to 12 months under accelerate conditions) α, and δ mannitol forms were crystallized in the presence of 2% w/w PVA and 1% w/w PVP respectively. These solid phases were compared with the β form and lactose as references. The solid-state properties of crystallized mannitol significantly affected aerosolization behavior, with the δ form affording the worst fine particle fraction with both the hydrophilic (9.3 and 6.5%) and the lipophilic (19.6 and 32%) model drugs, while α and β forms behaved in the same manner (11–13% for SS; 53–58% for BUD) and better than lactose (8 and 13% for SS; 26 and 39% for BUD). Recrystallized mannitol, but also PVA and PVP, proved to be safe excipients toward lung cell lines. We concluded that, also for mannitol, the physicochemical properties stemming from different crystal structures represent a tool for modulating carrier-drug interaction and, in turn, aerosolization performance.
Collapse
|
7
|
Spherical agglomerates of lactose as potential carriers for inhalation. Eur J Pharm Biopharm 2020; 159:11-20. [PMID: 33358941 DOI: 10.1016/j.ejpb.2020.12.015] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/06/2020] [Revised: 12/02/2020] [Accepted: 12/15/2020] [Indexed: 11/21/2022]
Abstract
We report here on spherical lactose agglomerates as potential carriers for inhalation applications. Micromeritic properties of three spherical lactose agglomerates (SA-A, SA-B, SA-C) and a standard lactose inhalation grade carrier (Lactohale 100; LH100) were evaluated and compared. Ordered mixtures with micronized salbutamol sulfate as the model active pharmaceutical ingredient (API) and lactose carriers at two drug loadings (2 wt%, 5 wt%) were prepared, and in-vitro aerosolization performance was assessed. The spherical crystallization process led to particles with tailored micromeritic properties. These had larger specific surface area and greater fine fraction < 10 µm, compared to LH100, due to their coarse morphology. Their properties were reflected in the flowability parameters, where two types of spherical agglomerates of lactose showed more cohesive behavior compared to the other lactose grades. Blend uniformity showed improved homogeneous distribution of the API at higher drug load. In-vitro aerosolization tests showed that the spherical agglomerates of lactose enhanced the dose of API, compared to LH100. SA-B and SA-C showed significantly higher fine particle fractions at low drug load compared to the others, whereas overall, the largest fine particle fraction was for SA-B at high drug load. The carrier material attributes related to particle size, specific surface area, compressibility, flowability (cohesion, flow function), and air permeability were critical for aerosolization performance.
Collapse
|
8
|
Aloum F, Al Ayoub Y, Mohammad M, Obeed M, Paluch K, Assi K. Ex vivo and in vitro evaluation of the influence of the inhaler device and formulation on lung deposition of budesonide. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.06.037] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
|
9
|
Paul M, Lau R. Potentials and challenges of Levodopa particle formulation for treatment of Parkinson’s disease through intranasal and pulmonary delivery. ADV POWDER TECHNOL 2020. [DOI: 10.1016/j.apt.2020.03.028] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022]
|
10
|
Della Bella A, Müller M, Danani A, Soldati L, Bettini R. Effect of Lactose Pseudopolymorphic Transition on the Aerosolization Performance of Drug/Carrier Mixtures. Pharmaceutics 2019; 11:pharmaceutics11110576. [PMID: 31689975 PMCID: PMC6920796 DOI: 10.3390/pharmaceutics11110576] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/05/2019] [Revised: 10/18/2019] [Accepted: 11/01/2019] [Indexed: 02/04/2023] Open
Abstract
Physico-chemical properties of lactose are key factors in adhesive mixtures used as dry powder inhaler (DPI). Despite the abundant literature on this topic, the effect of the polymorphism and pseudo-polymorphism of lactose has been seldom investigated and discussed although often lactose used in DPI is subjected to unit operations, which may alter its solid-state properties. Here, we studied the aerosolization performance of salbutamol sulphate (SS) or budesonide (BUD) formulations by investigating the effect of lactose pseudopolymorphism in ternary (coarse lactose/fine lactose/drug) and binary (coarse lactose/drug) mixtures. An improvement of the aerosolization performance of SS formulations with the increase of the amount of fine micronized lactose up to 30% (fine particle fraction (FPF) = 57%) was observed. Micronized lactose contained hygroscopic anhydrous α-lactose, which converted to α-lactose monohydrate at ambient conditions. This implied that the positive effect of fines on the aerosolization performance decreased and eventually disappeared with the formulation aging. Positive effect on SS deposition was observed also with binary mixtures with anhydrous lactose, whereas the opposite occurred with budesonide-containing formulations. The collected data demonstrated the crucial role of the carrier crystal form on the positive effect of fines on the deposition.
Collapse
Affiliation(s)
| | - Michele Müller
- Micro-Sphere S.A., Ponte Cremenaga, 6996 Monteggio, Switzerland.
| | - Andrea Danani
- Istituto Delle Molle di Studi Sull'Intelligenza Artificiale, Scuola Universitaria Professionale Della Svizzera Italiana, 6928 Manno, Switzerland.
| | - Luciano Soldati
- Micro-Sphere S.A., Ponte Cremenaga, 6996 Monteggio, Switzerland.
| | - Ruggero Bettini
- Food and Drug Department, University of Parma, 43124 Parma, Italy.
| |
Collapse
|
11
|
Benassi A, Perazzi I, Bosi R, Cottini C, Bettini R. Quantifying the loading capacity of a carrier-based DPI formulation and its dependence on the blending process. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.08.109] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
|
12
|
Zellnitz S, Roblegg E, Pinto J, Fröhlich E. Delivery of Dry Powders to the Lungs: Influence of Particle Attributes from a Biological and Technological Point of View. Curr Drug Deliv 2019; 16:180-194. [PMID: 30360739 DOI: 10.2174/1567201815666181024143249] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/03/2018] [Revised: 09/21/2018] [Accepted: 10/18/2018] [Indexed: 12/19/2022]
Abstract
Dry powder inhalers are medical devices used to deliver powder formulations of active pharmaceutical ingredients via oral inhalation to the lungs. Drug particles, from a biological perspective, should reach the targeted site, dissolve and permeate through the epithelial cell layer in order to deliver a therapeutic effect. However, drug particle attributes that lead to a biological activity are not always consistent with the technical requirements necessary for formulation design. For example, small cohesive drug particles may interact with neighbouring particles, resulting in large aggregates or even agglomerates that show poor flowability, solubility and permeability. To circumvent these hurdles, most dry powder inhalers currently on the market are carrier-based formulations. These formulations comprise drug particles, which are blended with larger carrier particles that need to detach again from the carrier during inhalation. Apart from blending process parameters, inhaler type used and patient's inspiratory force, drug detachment strongly depends on the drug and carrier particle characteristics such as size, shape, solid-state and morphology as well as their interdependency. This review discusses critical particle characteristics. We consider size of the drug (1-5 µm in order to reach the lung), solid-state (crystalline to guarantee stability versus amorphous to improve dissolution), shape (spherical drug particles to avoid macrophage clearance) and surface morphology of the carrier (regular shaped smooth or nano-rough carrier surfaces for improved drug detachment.) that need to be considered in dry powder inhaler development taking into account the lung as biological barrier.
Collapse
Affiliation(s)
- Sarah Zellnitz
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria
| | - Eva Roblegg
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria.,Department of Pharmaceutical Technology and Biopharmacy, Institute of Pharmaceutical Sciences, University of Graz, Graz, Austria
| | - Joana Pinto
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria.,Department of Pharmaceutical Technology and Biopharmacy, Institute of Pharmaceutical Sciences, University of Graz, Graz, Austria
| | - Eleonore Fröhlich
- Research Center Pharmaceutical Engineering GmbH, Graz, Austria.,Center for Medical Research, Medical University of Graz, Graz, Austria
| |
Collapse
|