1
|
Ram Munnangi S, Narala N, Lakkala P, Kumar Vemula S, Narala S, Johnson L, Karry K, Repka M. Optimization of a Twin screw melt granulation process for fixed dose combination immediate release Tablets: Differential amorphization of one drug and crystalline continuance in the other. Int J Pharm 2024; 665:124717. [PMID: 39284422 DOI: 10.1016/j.ijpharm.2024.124717] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/17/2024] [Revised: 08/27/2024] [Accepted: 09/12/2024] [Indexed: 10/11/2024]
Abstract
Interest in Twin Screw Melt Granulation (TSMG) processes is rapidly increasing, along with the search for suitable excipients. This study aims to optimize the TSMG process for immediate-release tablets containing two different drugs. The hypothesis is that one poorly water-soluble drug requires amorphous conversion for improved dissolution, while the other water-soluble drug, with a higher melting point (Tm), remains more stable in its crystalline form. Ibuprofen (IBU) and Acetaminophen (APAP) were chosen as the model drug combination to test this hypothesis. Various diluents, binders, and disintegrating agents were assessed for their impact on processability, crystallinity, disintegration, and dissolution during development. The temperatures used during processing were below the Tm of all components, except for IBU. Melted IBU acted as a granulating aid in addition to the binders in the formulation, facilitating granule formation. Physicochemical analyses by Differential Scanning Calorimetry (DSC) and X-ray Diffraction (XRD) confirmed the complete conversion of IBU into an amorphous state and the preserved crystalline nature of APAP. Saturation solubility studies showed an improvement in IBU's solubility by ∼ 32-fold in 0.1 N HCl. Poor tablet disintegration performance led to the addition of disintegrating agents, where osmotic agents (sorbitol and NaCl) were found to significantly enhance disintegration compared to super disintegrants. The optimized formulation showed an enhanced IBU release (∼20 %) compared to the physical mixture (∼12.5) in 0.1 N HCl dissolution studies.
Collapse
Affiliation(s)
- Siva Ram Munnangi
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677; Pii Centre for Pharmaceutical Technology, The University of Mississippi, University, MS 38677, USA
| | - Nagarjuna Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677
| | - Preethi Lakkala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677
| | - Sateesh Kumar Vemula
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677
| | - Sagar Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677; Pii Centre for Pharmaceutical Technology, The University of Mississippi, University, MS 38677, USA
| | | | - Krizia Karry
- BASF Corporation, Pharma Solutions, Tarrytown, NY 10591
| | - Michael Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, MS 38677; Pii Centre for Pharmaceutical Technology, The University of Mississippi, University, MS 38677, USA.
| |
Collapse
|
2
|
Paccione N, Guarnizo-Herrero V, Ramalingam M, Larrarte E, Pedraz JL. Application of 3D printing on the design and development of pharmaceutical oral dosage forms. J Control Release 2024; 373:463-480. [PMID: 39029877 DOI: 10.1016/j.jconrel.2024.07.035] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/21/2024] [Revised: 07/11/2024] [Accepted: 07/15/2024] [Indexed: 07/21/2024]
Abstract
3D printing technologies confer an unparalleled degree of control over the material distribution on the structures they produce, which has led them to become an extremely attractive research topic in pharmaceutical dosage form development, especially for the design of personalized treatments. With fine tuning in material selection and careful design, these technologies allow to tailor not only the amount of drug administered but the biopharmaceutical behaviour of the dosage forms as well. While fused deposition modelling (FDM) is still the most studied 3D printing technology in this area, others are gaining more relevance, which has led to many new and exciting dosage forms developed during 2022 and 2023. Considering that these technologies, in time, will join the current manufacturing methods and with the ever-increasing knowledge on this topic, our review aims to explore the advantages and limitations of 3D printing technologies employed in the design and development of pharmaceutical oral dosage forms, giving special focus to the most important aspects governing the resulting drug release profiles.
Collapse
Affiliation(s)
- Nicola Paccione
- TECNALIA, Basque Research and Technology Alliance (BRTA), Leonardo Da Vinci 11, 01510 Miñano, Spain; Joint Research Laboratory (JRL) on Advanced Pharma Development, A Joint Venture of TECNALIA and University of the Basque Country, Centro de investigación Lascaray ikergunea, 01006 Vitoria-Gasteiz, Spain; NanoBioCel Group, Department of Pharmacy and Food Science, Faculty of Pharmacy, University of the Basque Country (UPV/ EHU), 01006 Vitoria-Gasteiz, Spain
| | - Víctor Guarnizo-Herrero
- Department of Biomedical Sciences, Faculty of Pharmacy, University of Alcalá de Henares, Ctra Madrid-Barcelona Km 33, 600 28805 Madrid, Spain
| | - Murugan Ramalingam
- Joint Research Laboratory (JRL) on Advanced Pharma Development, A Joint Venture of TECNALIA and University of the Basque Country, Centro de investigación Lascaray ikergunea, 01006 Vitoria-Gasteiz, Spain; NanoBioCel Group, Department of Pharmacy and Food Science, Faculty of Pharmacy, University of the Basque Country (UPV/ EHU), 01006 Vitoria-Gasteiz, Spain; Bioaraba Health Research Institute, Jose Atxotegi, s/n, 01009 Vitoria-Gasteiz, Spain; Biomedical Research Networking Center in Bioengineering, Biomaterials and Nanomedicine (CIBER-BBN), Institute of Health Carlos III, 28029 Madrid, Spain.; IKERBASQUE, Basque Foundation for Science, 48013 Bilbao, Spain; School of Basic Medical Sciences, Binzhou Medical University, Yantai 264003, People's Republic of China
| | - Eider Larrarte
- TECNALIA, Basque Research and Technology Alliance (BRTA), Leonardo Da Vinci 11, 01510 Miñano, Spain; Joint Research Laboratory (JRL) on Advanced Pharma Development, A Joint Venture of TECNALIA and University of the Basque Country, Centro de investigación Lascaray ikergunea, 01006 Vitoria-Gasteiz, Spain.
| | - José Luis Pedraz
- Joint Research Laboratory (JRL) on Advanced Pharma Development, A Joint Venture of TECNALIA and University of the Basque Country, Centro de investigación Lascaray ikergunea, 01006 Vitoria-Gasteiz, Spain; NanoBioCel Group, Department of Pharmacy and Food Science, Faculty of Pharmacy, University of the Basque Country (UPV/ EHU), 01006 Vitoria-Gasteiz, Spain; Bioaraba Health Research Institute, Jose Atxotegi, s/n, 01009 Vitoria-Gasteiz, Spain; Biomedical Research Networking Center in Bioengineering, Biomaterials and Nanomedicine (CIBER-BBN), Institute of Health Carlos III, 28029 Madrid, Spain..
| |
Collapse
|
3
|
Patil H, Vemula SK, Narala S, Lakkala P, Munnangi SR, Narala N, Jara MO, Williams RO, Terefe H, Repka MA. Hot-Melt Extrusion: from Theory to Application in Pharmaceutical Formulation-Where Are We Now? AAPS PharmSciTech 2024; 25:37. [PMID: 38355916 DOI: 10.1208/s12249-024-02749-2] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/20/2023] [Accepted: 01/19/2024] [Indexed: 02/16/2024] Open
Abstract
Hot-melt extrusion (HME) is a globally recognized, robust, effective technology that enhances the bioavailability of poorly soluble active pharmaceutical ingredients and offers an efficient continuous manufacturing process. The twin-screw extruder (TSE) offers an extremely resourceful customizable mixer that is used for continuous compounding and granulation by using different combinations of conveying elements, kneading elements (forward and reverse configuration), and distributive mixing elements. TSE is thus efficiently utilized for dry, wet, or melt granulation not only to manufacture dosage forms such as tablets, capsules, or granule-filled sachets, but also for designing novel formulations such as dry powder inhalers, drying units for granules, nanoextrusion, 3D printing, complexation, and amorphous solid dispersions. Over the past decades, combined academic and pharmaceutical industry collaborations have driven novel innovations for HME technology, which has resulted in a substantial increase in published articles and patents. This article summarizes the challenges and models for executing HME scale-up. Additionally, it covers the benefits of continuous manufacturing, process analytical technology (PAT) considerations, and regulatory requirements. In summary, this well-designed review builds upon our earlier publication, probing deeper into the potential of twin-screw extruders (TSE) for various new applications.
Collapse
Affiliation(s)
- Hemlata Patil
- Department of Product Development, Catalent Pharma Solutions, 14 Schoolhouse Road, Somerset, New Jersey, 08873, USA
| | - Sateesh Kumar Vemula
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
- Department of Pharmaceutics, School of Pharmaceutical Sciences, Lovely Professional University, Phagwara, Punjab, 144001, India
| | - Sagar Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Preethi Lakkala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Siva Ram Munnangi
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Nagarjuna Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA
| | - Miguel O Jara
- Molecular Pharmaceutics and Drug Delivery Division, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, Austin, Texas, 78712, USA
| | - Robert O Williams
- Molecular Pharmaceutics and Drug Delivery Division, College of Pharmacy, The University of Texas at Austin, 2409 University Avenue, Austin, Texas, 78712, USA
| | - Hibreniguss Terefe
- Department of Product Development, Catalent Pharma Solutions, 14 Schoolhouse Road, Somerset, New Jersey, 08873, USA
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Oxford, Mississippi, 38677, USA.
- Pii Center for Pharmaceutical Technology, The University of Mississippi, University, Oxford, Mississippi, 38677, USA.
| |
Collapse
|
4
|
Mandati P, Nyavanandi D, Narala S, Alzahrani A, Vemula SK, Repka MA. A Comparative Assessment of Cocrystal and Amorphous Solid Dispersion Printlets Developed by Hot Melt Extrusion Paired Fused Deposition Modeling for Dissolution Enhancement and Stability of Ibuprofen. AAPS PharmSciTech 2023; 24:203. [PMID: 37783961 DOI: 10.1208/s12249-023-02666-w] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/14/2023] [Accepted: 09/20/2023] [Indexed: 10/04/2023] Open
Abstract
The primary focus of the research is to study the role of cocrystal and amorphous solid dispersion approaches for enhancing solubility and preserving the stability of a poorly soluble drug, i.e., ibuprofen (IBP). First, the solvent-assisted grinding approach determined the optimum molar ratio of the drug and the coformer (nicotinamide (NIC)). Later, the polymeric filaments of cocrystals and amorphous solid dispersions were developed using the hot melt extrusion (HME) process, and the printlets were fabricated using the fused deposition modeling (FDM) additive manufacturing process. In addition, the obtained filaments were also milled and compressed into tablets as reference samples. The formation of cocrystals and amorphous solid dispersions was evaluated and confirmed using differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR), and powder X-ray diffraction (PXRD) analysis. The drug release profiles of 3D printlets with 50% infill were found to be faster and are in line with the release profiles of compressed tablets. In addition, the 3D-printed cocrystal formulation was stable for 6 months at accelerated conditions. However, the 3D printlets of amorphous solid dispersions and compressed tablets failed to retain stability attributed to the recrystallization of the drug and loss in tablet mechanical properties. This shows the suitability of a cocrystal platform as a novel approach for developing stable formulations of poorly soluble drug substances over amorphous solid dispersions.
Collapse
Affiliation(s)
- Preethi Mandati
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Mississippi, 38677, USA
| | - Dinesh Nyavanandi
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Mississippi, 38677, USA
| | - Sagar Narala
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Mississippi, 38677, USA
| | - Abdullah Alzahrani
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Mississippi, 38677, USA
| | - Sateesh Kumar Vemula
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Mississippi, 38677, USA
| | - Michael A Repka
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, University, Mississippi, 38677, USA.
- Pii Center for Pharmaceutical Technology, The University of Mississippi, University, Mississippi, 38677, USA.
| |
Collapse
|