1
|
Block M, Sieger P, Truenkle C, Saal C, Simon R, Truebenbach I. Miniaturized screening and performance prediction of tailored subcutaneous extended-release formulations for preclinical in vivo studies. Eur J Pharm Sci 2024; 196:106733. [PMID: 38408709 DOI: 10.1016/j.ejps.2024.106733] [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: 12/04/2023] [Revised: 02/20/2024] [Accepted: 02/23/2024] [Indexed: 02/28/2024]
Abstract
Microencapsulation of active pharmaceutical ingredients (APIs) for preparation of long acting injectable (LAI) formulations is an auspicious technique to enable preclinical characterization of a broad variety of APIs, ideally independent of their physicochemical and pharmacokinetic (PK) characteristics. During early API discovery, tunable LAI formulations may enable pharmacological proof-of-concept for the given variety of candidates by tailoring the level of plasma exposure over the duration of various timespans. Although numerous reports on small scale preparation methods for LAIs utilizing copolymers of lactic and glycolic acid (PLGA) and polymers of lactic acid (PLA) highlight their potential, application in formulation screening and use in preclinical in vivo studies is yet very limited. Transfer from downscale formulation preparation to in vivo experiments is hampered in early preclinical API screening by the large number of API candidates with simultaneously very limited available amount in the lower sub-gram scale, lack of formulation stability and deficient tunability of sustained release. We hereby present a novel comprehensive platform tool for tailored extended-release formulations, aiming to support a variety of preclinical in vivo experiments with ranging required plasma exposure levels and timespans. A novel small-scale spray drying process was successfully implemented by using an air brush based instrument for preparation of PLGA and PLA based formulations. Using Design of Experiments (DoE), required API amount of 250 mg was demonstrated to suffice for identification of dominant polymer characteristics with largest impact on sustained release capability for an individual API. BI-3231, a hydrophilic and weakly acidic small compound with good water solubility and permeability, but low metabolic stability, was used as an exemplary model for one of the many candidates during API discovery. Furthermore, an in vitro to in vivo correlation (IVIVC) of API release rate was established in mice, which enabled the prediction of in vivo plasma concentration plateaus after single subcutaneous injection, using only in vitro dissolution profiles of screened formulations. By tailoring LAI formulations and their doses for acute and sub-chronic preclinical experiments, we exemplary demonstrate the practical use for BI-3231. Pharmacological proof-of-concept could be enabled whilst circumventing the need of multiple administration as result of extensive hepatic metabolism and simultaneously superseding numerous in vivo experiments for formulation tailoring.
Collapse
Affiliation(s)
- Marco Block
- Department of Drug Discovery Sciences, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riß 88397, Germany
| | - Peter Sieger
- Department of Drug Discovery Sciences, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riß 88397, Germany
| | - Cornelius Truenkle
- Department of Drug Discovery Sciences, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riß 88397, Germany
| | - Christoph Saal
- Department of Drug Discovery Sciences, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riß 88397, Germany
| | - Roman Simon
- Department of Drug Discovery Sciences, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riß 88397, Germany
| | - Ines Truebenbach
- Department of Drug Discovery Sciences, Boehringer Ingelheim Pharma GmbH & Co. KG, Biberach an der Riß 88397, Germany.
| |
Collapse
|
2
|
Barceló-Chong CM, Filipe V, Nakach M, Ré MI. How spray drying processing and solution composition can affect the mAbs stability in reconstituted solutions for subcutaneous injections. Part I: Contribution of processing stresses against composition. Int J Pharm 2024; 655:123925. [PMID: 38518870 DOI: 10.1016/j.ijpharm.2024.123925] [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: 09/04/2023] [Revised: 01/25/2024] [Accepted: 02/18/2024] [Indexed: 03/24/2024]
Abstract
Spray drying is increasingly being applied to process biopharmaceuticals, particularly monoclonal antibodies (mAbs). However, due to their protein nature, mAbs are susceptible to degradation when subjected to various stresses during a drying process. Despite extensive research in this domain, identifying the appropriate formulation composition and spray drying conditions remains a complex challenge, requiring further studies to enhance the understanding on how process and formulation parameters impact mAb stability in reconstituted solutions. This research aims to explore spray drying as technique for producing pharmaceutical mAbs-based powders intended for reconstitution and subcutaneous injection. In the initial phase of this study, using a model mAb (mAb-A), the influence of dissociated and coupled process stresses on protein stability after solution reconstitution was investigated. The findings revealed a detrimental interplay of mechanical, interfacial, and thermal/dehydration stresses on mAb-A stability, notably characterized by an increase in protein aggregation. Subsequently, in a second phase, the study delved into the impact of spray drying processing conditions, the level of excipients, and protein concentration on mAb-A aggregation in reconstituted solutions. The obtained results highlighted the critical role of formulation composition as a parameter deserving further study, specifically concerning the selection of type and concentration of stabilizers to be added in the liquid mAb-A solution to be dried.
Collapse
Affiliation(s)
| | - Vasco Filipe
- Sanofi R&D, 1, Impasse des Ateliers, 94403 Vitry sur Seine, France
| | - Mostafa Nakach
- Sanofi R&D, 1, Impasse des Ateliers, 94403 Vitry sur Seine, France
| | - Maria Inês Ré
- IMT Mines Albi, RAPSODEE UMR CNRS 5302, Albi, France
| |
Collapse
|
3
|
Klimša V, Mašková L, Kašpar O, Ruphuy G, Štěpánek F. Rapid screening of ternary amorphous formulations by a spray drying robot. Int J Pharm 2024; 651:123739. [PMID: 38145780 DOI: 10.1016/j.ijpharm.2023.123739] [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: 10/30/2023] [Revised: 12/13/2023] [Accepted: 12/22/2023] [Indexed: 12/27/2023]
Abstract
Spray drying is commonly used for producing amorphous solid dispersions to improve drug solubility. The development of such formulations typically relies on comprehensive excipient and composition screening, which requires the preparation of many spray-dried powder samples. This is both labour-intensive and time-consuming when carried out manually. In the present work, the formulation screening task was automated by coupling a laboratory spray dryer operated in a semi-continuous mode with custom-made add-ons, allowing for rapid, computer-controlled production of formulation samples with systematically varying composition. The practical use of the spray drying robot in formulation development was demonstrated on a case study of poorly water-soluble model drugs simvastatin and ezetimibe. Six different polymers and several drug:polymer ratios were screened for the enhancement of dissolution properties. From a pool of 28 spray-dried samples, ternary compositions containing Eudragit L100-55 were identified as the most suitable ones for further processing and characterisation. The ability to populate the formulation design space rapidly and automatically made it possible to construct maps of physico-chemical properties such as glass transition temperature or dissolution rate. The spray drying robot thus enables the acceleration of early formulation development and a deeper understanding of composition-property relationships for multi-component spray dried powders.
Collapse
Affiliation(s)
- Vojtěch Klimša
- Department of Chemical Engineering, University of Chemistry and Technology Prague, Technická 3, 166 28 Prague, Czech Republic; Levare s.r.o., Jičínská 226/17, 130 00 Prague, Czech Republic
| | - Lucie Mašková
- Department of Chemical Engineering, University of Chemistry and Technology Prague, Technická 3, 166 28 Prague, Czech Republic
| | - Ondřej Kašpar
- Department of Chemical Engineering, University of Chemistry and Technology Prague, Technická 3, 166 28 Prague, Czech Republic
| | - Gabriela Ruphuy
- Department of Chemical Engineering, University of Chemistry and Technology Prague, Technická 3, 166 28 Prague, Czech Republic; Levare s.r.o., Jičínská 226/17, 130 00 Prague, Czech Republic
| | - František Štěpánek
- Department of Chemical Engineering, University of Chemistry and Technology Prague, Technická 3, 166 28 Prague, Czech Republic.
| |
Collapse
|
4
|
Nano-Dry-Melting: A Novel Technology for Manufacturing of Pharmaceutical Amorphous Solid Dispersions. Pharmaceutics 2022; 14:pharmaceutics14102145. [PMID: 36297580 PMCID: PMC9608596 DOI: 10.3390/pharmaceutics14102145] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2022] [Revised: 09/19/2022] [Accepted: 09/23/2022] [Indexed: 11/07/2022] Open
Abstract
Amorphous solid dispersions (ASD) are one of the most prominent formulation approaches to overcome bioavailability issues that are often presented by new poorly soluble drug candidates. State-of-the art manufacturing techniques include hot melt extrusion and solvent-based methods like spray drying. The high thermal and mechanical shear stress during hot melt extrusion, or the use of an organic solvent during solvent-based methods, are examples of clear drawbacks for those methods, limiting their applicability for certain systems. In this work a novel process technology is introduced, called Nano-Dry-Melting (NDM), which can provide an alternative option for ASD manufacturing. NDM consists of a comminution step in which the drug is ground to nanosize and a drying step provides a complete amorphization of the system at temperatures below the melting point. Two drug–polymer systems were prepared using NDM with a wet media mill and a spray dryer and analyzed regarding their degree of crystallinity using XRD analysis. Feasibility studies were performed with indomethacin and PVP. Furthermore, a “proof-of-concept” study was conducted with niclosamide. The experiments successfully led to amorphous samples at temperatures of about 50 K below the melting point within seconds of heat exposition. With this novel, solvent-free and therefore “green” production technology it is feasible to manufacture ASDs even with those drug candidates that cannot be processed by conventional process technologies.
Collapse
|
5
|
Fernández-Paz E, Fernández-Paz C, Barrios-Esteban S, Santalices I, Csaba N, Remuñán-López C. Dry powders containing chitosan-based nanocapsules for pulmonary administration: Adjustment of spray-drying process and in vitro evaluation in A549 cells. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117149] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/08/2023]
|
6
|
Poozesh S, Mahdi Jafari S. Are traditional small-scale screening methods reliable to predict pharmaceutical spray drying? Pharm Dev Technol 2019; 24:915-925. [PMID: 31057007 DOI: 10.1080/10837450.2019.1616208] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
Abstract
Driven by the new trend to build quality into products and reducing empiricism, small-scale screening techniques have been frequently used to evaluate, thermodynamic of drug solubility in the polymer, and drug-polymer kinetic amorphous miscibility. In this paper, these methods have been overviewed to shed light on their liabilities in predicting spray-dried amorphous solid dispersions' (ASDs) properties. By scrutinizing relevant open literature, several inconsistencies have been recognized, deemed to be due to the inability of conventional miniaturized means to simulate the spray drying process operations/constraints in formulating active pharmaceutical ingredients (APIs). Given the complex interplay of thermodynamics of mixing, heat and mass transfer, and fluid dynamics in this process, scaling rules have been introduced to remedy arisen issues in conventional miniaturized tools. Accordingly, spray drying process is analyzed considering the fundamental physical transformations involved, i.e. atomization and drying. Each transformation is explored from a scaling perspective with an emphasis on key response factors, and ways to retain them for each transformation across scales. Prospective bifurcated developments may improve the odds of successful formulations/process conditions later on during development stages.
Collapse
Affiliation(s)
- Sadegh Poozesh
- a Mechanical Engineering Department , Tuskegee University , Tuskegee , AL , US
| | - Seid Mahdi Jafari
- b Food Materials and Process Design Engineering Department , Gorgan University of Agricultural Sciences and Natural Resources , Gorgan , Iran
| |
Collapse
|
7
|
Ousset A, Chirico R, Robin F, Schubert MA, Somville P, Dodou K. A Novel Protocol Using Small-Scale Spray-Drying for the Efficient Screening of Solid Dispersions in Early Drug Development and Formulation, as a Straight Pathway from Screening to Manufacturing Stages. Pharmaceuticals (Basel) 2018; 11:ph11030081. [PMID: 30150516 PMCID: PMC6160943 DOI: 10.3390/ph11030081] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/23/2018] [Revised: 08/17/2018] [Accepted: 08/23/2018] [Indexed: 12/28/2022] Open
Abstract
This work describes a novel screening strategy that implements small-scale spray-drying in early development of binary amorphous solid dispersions (ASDs). The proposed methodology consists of a three-stage decision protocol in which small batches (20–100 mg) of spray-dried solid dispersions (SDSDs) are evaluated in terms of drug–polymer miscibility, physical stability and dissolution performance in bio-predictive conditions. The objectives are to select the adequate carrier and drug-loading (DL) for the manufacturing of robust SDSD; and the appropriate stabilizer dissolved in the liquid vehicle of SDSD suspensions, which constitutes the common dosage form used during non-clinical studies. This methodology was verified with CDP146, a poorly water soluble (<2 µg/mL) API combined with four enteric polymers and four stabilizers. CDP146/HPMCAS-LF 40:60 (w/w) and 10% (w/v) PVPVA were identified as the lead SDSD and the best performing stabilizer, respectively. Lead SDSD suspensions (1–50 mg/mL) were found to preserve complete amorphous state during 8 h and maintain supersaturation in simulated rat intestinal fluids during the absorption window. Therefore, the implementation of spray-drying as a small-scale screening approach allowed maximizing screening effectiveness with respect to very limited API amounts (735 mg) and time resources (9 days), while removing transfer steps between screening and manufacturing phases.
Collapse
Affiliation(s)
- Aymeric Ousset
- School of Pharmacy and Pharmaceutical Sciences, Faculty of Health Sciences and Wellbeing, University of Sunderland, Sunderland SR13SD, UK.
| | - Rosanna Chirico
- UCB Pharma S.A., Product Development, B-1420 Braine l'Alleud, Belgium.
| | - Florent Robin
- UCB Pharma S.A., Product Development, B-1420 Braine l'Alleud, Belgium.
| | | | - Pascal Somville
- UCB Pharma S.A., Product Development, B-1420 Braine l'Alleud, Belgium.
| | - Kalliopi Dodou
- School of Pharmacy and Pharmaceutical Sciences, Faculty of Health Sciences and Wellbeing, University of Sunderland, Sunderland SR13SD, UK.
| |
Collapse
|