TAILORING DRY POWDER INHALER PERFORMANCE BY - RCPE
TAILORING DRY POWDER INHALER PERFORMANCE BY - RCPE
TAILORING DRY POWDER INHALER PERFORMANCE BY - RCPE
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Atomization and Sprays, 20(9):763–774, 2010<br />
<strong>TAILORING</strong> <strong>DRY</strong> <strong>POWDER</strong> <strong>INHALER</strong> <strong>PERFORMANCE</strong><br />
<strong>BY</strong> MODIFYING CARRIER SURFACE TOPOGRAPHY <strong>BY</strong><br />
SPRAY <strong>DRY</strong>ING<br />
Stephan G. Maas, 1 Gerhard Schaldach, 2 Peter E. Walzel, 2 &<br />
Nora A. Urbanetz 3,∗<br />
1 Institute of Pharmaceutics and Biopharmaceutics, Heinrich-Heine-University, Universitaetsstrasse<br />
1, 40225 Duesseldorf, Germany<br />
2 Department of Biochemical and Chemical Engineering, Technische Universitaet Dortmund<br />
Emil-Figge-Strasse 68, 44227 Dortmund, Germany<br />
3 Research Center Pharmaceutical Engineering GmbH, Institute of Process and Particle Technology,<br />
Graz University of Technology, Inffeldgasse 21A, 8010 Graz, Austria<br />
∗ Address all correspondence to Nora A. Urbanetz E-mail: nora.urbanetz@tugraz.at<br />
Original Manuscript Submitted: 12/07/2010; Final Draft Received: 18/11/2010<br />
In order to provide adequate performance of dry powder inhalates with respect to dosing and fine particle fraction,<br />
interparticle adhesion between drug and carrier has to be well balanced. It has to be large enough to ensure attachment<br />
of the active ingredient during powder handling and dosing, but small enough to ensure detachment of the drug from<br />
the carrier on inhalation. In this study, interparticle interactions have been modified by targeting the surface topography<br />
of the carrier or rather the contact area between drug and carrier using spray drying. Because lactose is susceptible to<br />
spray drying, resulting in partial or full amorphicity, mannitol was used here. The spray drying outlet temperature<br />
turned out to be an appropriate parameter to affect surface topography, spray drying at low temperature leading to<br />
smooth particles, and spray drying at high temperature leading to rough particle surfaces. Dosing of the inhalate was<br />
found not to be affected by surface roughness of the carrier. However, the fine particle fraction decreases with increasing<br />
surface roughness. Consequently, the use of mannitol carrier particles exhibiting different surface topographies allows<br />
for modifying interparticle interactions, thereby providing an effective tool for tailoring the performance of an inhalate.<br />
KEY WORDS: dry powder inhaler, dosing, fine particle fraction, mannitol, spray drying, surface<br />
1. INTRODUCTION<br />
The delivery of active pharmaceutical ingredients (APIs)<br />
to the lungs by inhalation allows local as well as systemic<br />
treatment of diseases, and is a very promising way<br />
of drug delivery. Pulmonary drug delivery is the most relevant<br />
route of administration in the therapy of asthma and<br />
COPD (chronical obstructive pulmonary disease) (Cazzola<br />
et al., 2007; Hanania, 2008; Miller-Larsson and Sel-<br />
roos, 2006). Local administration of the drug is advantageous<br />
because it offers the opportunity of dose reduction,<br />
and a faster onset of action is observed in comparison to<br />
systemic treatment.<br />
The European Pharmacopoeia (Ph. Eur., 2008a) lists<br />
three classes of inhaler devices, namely, nebulizers, metered<br />
dose inhalers (MDIs), and dry powder inhalers<br />
(DPIs). The related aerosolization principles are nebulization<br />
of aqueous suspensions or solutions, atomization of<br />
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764 Maas et al.<br />
suspensions or solutions by the use of liquefied propellants,<br />
or dispersion of dry powders in the inspired air, respectively.<br />
A prerequisite of the API particles intended to travel<br />
along the narrow airways and to finally reach the deep<br />
parts of the lungs, is an aerodynamic diameter in the range<br />
of 1–5 µm (Daniher and Zhu, 2008; Labiris and Dolovich,<br />
2003a). Because of their small size, these particles are<br />
quite cohesive and show poor flowing properties. Precise<br />
dosing, which is done volumetrically, however, relies on<br />
adequate flowability. For this reason, the micronized API<br />
particles are attached to coarser carrier particles by a mixing<br />
procedure. Usually the carrier particles have particle<br />
sizes of 50–200 µm, ensuring adequate flowability and<br />
dosing. On inhalation, the drug has to detach from the<br />
carrier in order not to impact together with the carrier on<br />
the upper airways. Therefore, interparticle forces between<br />
APIs and carrier particles are of utmost importance for<br />
the performance of the inhalate. On the one hand, these<br />
forces have to be high enough to ensure powder handling<br />
and dosing; and on the other hand, they have to be low<br />
enough to allow API detachment from the carrier surface<br />
on inhalation.<br />
Much work has been done on the modification of interparticle<br />
forces between API and carrier. According to the<br />
literature, carrier surface modification is an appropriate<br />
method to control these forces, although other parameters<br />
such as particle size and size distribution (Danjo et al.,<br />
1989; Mullins et al., 1992), shape and morphology, and<br />
chemical identity (Podczeck et al., 1996) affect interparticle<br />
interactions. The modification of surface topography<br />
targets the area of contact between the active and the carrier.<br />
Surface asperities may increase the distance and reduce<br />
the contact area between the active and the carrier,<br />
resulting in a decrease of the interparticle interactions on<br />
the one hand (Fuller and Tabor, 1975; Rabinovich et al.,<br />
2000; Rumpf, 1974; Tabor, 1977). On the other hand, surface<br />
asperities may also lead to an increase of the contact<br />
area between the active and the drug, especially when the<br />
scale of the asperities is of a similar order of magnitude<br />
as the particle size of the drug. Whether a decrease or increase<br />
of the contact area is induced depends on the size,<br />
shape, number, position, and distribution of the asperities.<br />
The prediction of the impact of surface asperities is therefore<br />
difficult (Iida et al., 1993).<br />
Most of the commercially available DPI formulations<br />
use α-lactose monohydrate carrier particles (Hersey,<br />
1975; Steckel, 2003). Hence, a lot of work has been published<br />
about the surface modification of α-lactose monohydrate.<br />
For example, surface modification was achieved<br />
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by dispersant removement (Dickhoff et al., 2006; El-<br />
Sabawi et al., 2006a,b; Iida et al., 2001, 2003a; Islam et<br />
al., 2004a,b, 2005; Zeng et al., 2001a). Iida et al. (2005)<br />
and Chan et al. (2003) worked on carrier surface covering.<br />
Another way to control carrier surface properties is<br />
the addition of micronized carrier particles or other micronized<br />
chemical compounds (Adi et al., 2006, 2007;<br />
Guchardi et al., 2008; Iida et al., 2003b, 2004a,b; Louey et<br />
al., 2003; Louey and Stewart, 2002; Podczeck, 1999; Tee<br />
et al., 2000; Zeng et al., 1998, 1999). The surface modification<br />
by milling was studied by Steckel et al. (2006),<br />
Ferrari et al. (2004), Iida et al. (2004b), and Young et<br />
al. (2002). Surface modification by varying crystallization<br />
conditions was achieved by Larhrib et al. (2003a,b) and<br />
Zeng et al. (2000a,b,c, 2001b).<br />
Although α-lactose monohydrate is commonly used as<br />
carrier in dry powder inhalates, it has several disadvantages<br />
such as incompatibility of the sugars reducing aldehyde<br />
group with APIs such as formoterol, budesonide or<br />
peptides and proteins (Steckel and Bolzen, 2004). In addition,<br />
commercially available crystals of α-lactose monohydrate<br />
may show great variability in surface properties<br />
depending on the production process (crystallisation,<br />
milling, sieving), resulting in varying adhesion forces between<br />
the drug and the carrier, and consequently varying<br />
drug detachment (Steckel et al., 2004; Young et al., 2008).<br />
Another drawback of α-lactose monohydrate is related<br />
to its different crystal faces exhibiting different physicochemical<br />
properties and affinity to attached drug particles,<br />
thereby leading to unequal interparticle interactions<br />
between the drug and the carrier and unequal drug particle<br />
detachment from the different crystal faces.<br />
Consequently, carrier particles with equal affinity to<br />
the drug particles over the entire carrier surface are<br />
needed as, e.g., obtained in spray drying. Spray-dried particles<br />
are usually of spherical shape. They have a homogeneous<br />
surface structure, ensuring equal affinity to<br />
the active over the entire carrier surface. Additionly, they<br />
exhibit excellent flowing properties. Unfortunately, αlactose<br />
monohydrate is susceptible to mechanical treatment<br />
and spray drying, resulting in amorphicity and giving<br />
rise to stability problems (Buckton et al., 1998; Price<br />
and Young, 2004), which is a further disadvantage of αlactose<br />
monohydrate. An alternative carrier avoiding the<br />
disadvantages mentioned above is mannitol.<br />
Maas (2009) showed that fairly spherical particles exhibiting<br />
a homogeneous surface are obtained by spray<br />
drying aqueous mannitol solutions. By varying the spraydrying<br />
outlet temperature between 60 ◦ C and 120 ◦ C, he<br />
found that the surface roughness of the particles may be<br />
Atomization and Sprays
Tailoring Dry Powder Inhaler Performance 765<br />
tailored, leading to smooth particles exhibiting an indentation<br />
of their shell at low drying temperatures, and rough<br />
particles showing a hole in their shell at high outlet temperatures.<br />
Independent of the outlet temperature, particles<br />
were hollow and had almost the same particle size. Despite<br />
differences in particle surface morphologies, mannitol<br />
was crystalline and consisted of modification I. Mannitol<br />
has been discussed as an alternative to α-lactose<br />
monohydrate already (Adi et al., 2007; Harjunen et al.,<br />
2003; Saint-Lorant et al., 2007; Steckel und Bolzen, 2004;<br />
Tee et al., 2000). However, no data were reported on the<br />
influence of the surface structure of spray-dried mannitol<br />
on interparticle forces. This study is dedicated to the<br />
investigation of the impact of the surface roughness of<br />
the mannitol carrier on the performance of dry powder<br />
inhalates, such as dosing and in vitro respirable fraction.<br />
2. MATERIALS AND METHODS<br />
2.1 Materials<br />
Mannitol (Pearlitol SD 200) was kindly provided by<br />
Roquette, F-Lestrem. Salbutamol suphate was donated by<br />
Lindopharm GmbH (DE-Hilden).<br />
2.2 Micronization of Salbutamol Sulphate<br />
Salbutamol sulphate representing the active substance<br />
was micronized using the air jet mill 50 AS (Hosokawa<br />
Alpine, DE-Augsburg). The injection pressure was set<br />
to 6 bar, milling pressure to 2 bar, and the feeding rate<br />
was adjusted to 1 g/min. The obtained material exhibits<br />
a mean particle diameter of 1.82 µm (x10 = 0.65 ± 0.02<br />
µm, x50 = 1.82 ± 0.02 µm, x90 = 5.07 ± 0.22 µm). Particle<br />
size distributions were determined using laser diffraction.<br />
2.3 Spray Drying of Mannitol<br />
Aqueous mannitol solutions (15% w/w) were fed into a<br />
spray dryer (Niro Atomizer, Niro, DK-Copenhagen), with<br />
a height of 615 mm of the cylindrical part and 700 mm of<br />
the conical part. The diameter of the cylindrical part was<br />
800 mm. The feeding rate was adjusted to 14 mL/min by<br />
a flexible-tube pump, and the solution was atomized to<br />
small droplets by a rotary atomizer with a rotational speed<br />
of 27,500 rpm (4.9 bar air pressure at the turbine). The diameter<br />
of the atomizing wheel was 50 mm. It contained<br />
24 bores, which were 6 mm in height and 3 mm in width.<br />
The spray-drying outlet air temperature was varied. The<br />
obtained products were stored in desiccators containing<br />
Volume 20, Number 9, 2010<br />
silica gel until further required. Three batches (A, B, C)<br />
per outlet temperature of 60 ◦ C (mannitol 60 ◦ C), 90 ◦ C<br />
(mannitol 90 ◦ C) and 120 ◦ C (mannitol 120 ◦ C) were prepared.<br />
2.4 Preparation and Content Uniformity of<br />
Ordered Mixtures<br />
Batches of ordered mixtures of 8 g were prepared with the<br />
spray-dried particles using a carrier-to-drug ratio of 99:1.<br />
Half of the carrier material was weighed into a stainless<br />
steel vessel, then salbutamol sulphate, and finally the second<br />
half of the carrier material was added. The powder<br />
was mixed in a Turbula mixer (T2C, Bachofen AG, CH-<br />
Muttenz) at 65 rpm for 90 min and allowed to settle for<br />
2 h before further treatment. First, the content uniformity<br />
of the mixture was determined retaining 12 samples. The<br />
content of the active ingredient was analyzed by HPLC.<br />
For the subsequent aerodynamic assessment of fine particles,<br />
only ordered mixtures with content uniformities of<br />
766 Maas et al.<br />
of the cartridge was filled with powder. Each metered<br />
mass was determined by weighing the inhaler before and<br />
after the discharge.<br />
2.8 Delivered Dose<br />
The delivered dose was determined by discharging 10<br />
doses from the Novolizer multidose inhaler using the<br />
experimental setup described in the European Pharmacopoeia<br />
(Ph. Eur., 2008b). Eighty percent of the volume<br />
of the cartridge was filled with powder. In contrast<br />
to Pharmacopoeia, 10 subsequent doses were examined,<br />
each consisting of five puffs in order to ensure the<br />
proper quantification of the drug. The unit sampling apparatus<br />
was rinsed with 100.0 mL of diluted acidic acid<br />
(pH 3), which then was transferred into an Erlenmeyer<br />
flask together with the filter and ultrasonically treated<br />
(5 min) in order to dissolve the drug potentially present<br />
on the filter. The amount of active was determined by<br />
HPLC.<br />
2.9 Assessment of Fine Particles<br />
The aerodynamic assessment of fine particles (Ph. Eur.,<br />
2008c) was performed using the Apparatus E (NGI, Copley<br />
Scientific, UK-Nottingham). The following preparation<br />
steps were necessary. The small cups of the NGI<br />
were coated with 2 mL coating agent (solution of 5% of<br />
a mixture of glycerol and polyoxyethylene-20-cetylether<br />
(95:5) in isopropanol), the large cups with 4 mL. The preseparator<br />
was filled with 15 mL of diluted acetic acid.<br />
The measurements were performed using 79.3 L/min<br />
flow rate. The flow rate was measured with an electronic<br />
digital flowmeter (Model DFM, Copley Scientific, UK-<br />
Nottingham). Pumps (Typ SHC P3, Typ HC P3) and<br />
the critical flow controller (Model TPK) were also from<br />
Copley Scientific. The ordered mixture was filled in the<br />
powder container of a Novolizer (filling grade 80%),<br />
which was fixed to the throat of the impactor by a suitable<br />
adapter. Fifty doses were discharged into the impactor.<br />
The dose of active ingredient on the stages was<br />
dissolved in 20.0 mL of diluted acidic acid by gently<br />
shaking. The preseparator was rinsed with 50.0 mL of<br />
diluted acidic acid (pH 3) and diluted at the ratio 1:5.<br />
The drug was determined by HPLC. The fine particle<br />
dose is calculated as the dose of active ingredient exhibiting<br />
an aerodynamic diameter of
Tailoring Dry Powder Inhaler Performance 767<br />
TABLE 1: Particle Size Distribution of Mannitol Carrier Particles Spray Dried<br />
at 60 ◦ C, 90 ◦ C, and 120 ◦ C (Determined by laser diffraction before and after<br />
treatment with a Turbula mixer at 65 rpm for 90 min; n = 3, mean ± standard<br />
deviation).<br />
Mannitol 60 ◦ C Mannitol 90 ◦ C Mannitol 120 ◦ C<br />
Before treatment<br />
x10 / µm 3,73 ± 0,50 4,93 ± 0,35 4,89 ± 0,16<br />
x50 / µm 13,53 ± 0,28 13,59 ± 0,19 13,19 ± 0,35<br />
x90 / µm 27,77 ± 1,04 26,48 ± 1,69 23,71 ± 0,12<br />
After treatment<br />
x10 / µm 4,42 ± 0,16 4,62 ± 0,14 5,26 ± 0,14<br />
x50 / µm 13,25 ± 0,34 13,96 ± 0,70 13,08 ± 0,22<br />
x90 / µm 26,78 ± 0,69 27,71 ± 1,19 23,33 ± 0,51<br />
a<br />
b<br />
c<br />
Mannitol 60 °C<br />
20 µm<br />
Mannitol 90 °C<br />
20 µm<br />
Mannitol 120 °C<br />
20 µm<br />
d Mannitol 60 °C<br />
e<br />
f<br />
3 µm<br />
Mannitol 90 °C<br />
3 µm<br />
Mannitol 120 °C<br />
FIG. 1: Scanning electron micrographs of ordered mixtures containing active particles and mannitol carrier particles<br />
spray dried at 60 ◦ C (a,d), 90 ◦ C (b,e), and 120 ◦ C 120 ◦ C (c,f) outlet temperature; each micrograph represents a sample<br />
taken from the second of three batches.<br />
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3 µm
768 Maas et al.<br />
Already at this point, it has to be mentioned, the scale of<br />
the surface asperities is in the same range as the particle<br />
size of the active. This is important because the scale of<br />
the asperities in relation to the size of the drug particles is<br />
decisive for the contact area between the carrier and the<br />
active (Young et al., 2008), with smaller-scale asperities<br />
leading to a decrease of the contact area and the interparticle<br />
interactions, whereas larger-scale asperities result in<br />
an increase.<br />
3.3 Metered Mass and Uniformity of Metered<br />
Mass<br />
The metered mass is defined as the mass of the formulation<br />
metered by the built-in metering system of the inhalation<br />
device. The uniformity of the metered mass, re-<br />
mass / mg<br />
40<br />
20<br />
spectively, dosing was examined by discharging 50 doses<br />
from the Novolizer multidose inhaler using the experimental<br />
setup described in the European Pharmacopoeia<br />
monograph (Ph. Eur., 2008b). Each metered mass was<br />
determined by weighing the inhaler before and after the<br />
discharge (Fig. 2).<br />
Three batches (A, B, C) of each formulation (mannitol<br />
60 ◦ C, 90 ◦ C, 120 ◦ C) were examined, and the mean of<br />
the mass (mean mass) of the 50 doses was calculated for<br />
each batch. The mean and the standard deviation of the<br />
mean mass of the three batches (A, B, C) of each formulation<br />
(mannitol 60 ◦ C, 90 ◦ C, 120 ◦ C) were calculated. They<br />
are given in Fig. 3. There is no significant difference between<br />
the formulations, the mean of the mean mass having<br />
values of 8.0 mg for formulations containing mannitol<br />
60 ◦ C, 6.6 mg for formulations containing mannitol<br />
Mannitol<br />
120 °C<br />
Mannitol<br />
90 °C<br />
Mannitol<br />
60 °C<br />
0<br />
0 10 20 30 40 50<br />
number of the dose discharged<br />
FIG. 2: Metered mass of three batches of each formulation containing mannitol carrier particles spray dried at 60◦C, 90◦C, and 120◦C. mean of the mass / mg<br />
12,00<br />
10,00<br />
8,00<br />
6,00<br />
4,00<br />
2,00<br />
0,00<br />
Mannitol 60°C Mannitol 90°C Mannitol 120°C<br />
FIG. 3: Mean of the metered mass of 50 single doses of formulations containing mannitol carrier particles spray dried<br />
at 60◦C, 90◦C), and 120◦C; n = 3, mean ± standard deviation.<br />
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Atomization and Sprays
Tailoring Dry Powder Inhaler Performance 769<br />
90 ◦ C, and 8.9 mg for formulations containing mannitol<br />
120 ◦ C.<br />
In addition, the uniformity of dosing was evaluated by<br />
calculating the coefficient of variation of the mass of each<br />
batch (A, B, C). The mean and the standard deviation<br />
of the three coefficients of variation of each formulation<br />
(mannitol 60 ◦ C, 90 ◦ C, 120 ◦ C) were calculated. The coefficients<br />
of variation are given in Fig. 4. Despite the differences<br />
in surface topography, there is no significant difference<br />
between the formulations, the coefficient of variation<br />
showing values of 27.1% for ordered mixtures with<br />
mannitol 60 ◦ C, 36.2% for ordered mixtures with mannitol<br />
90 ◦ C, and 21.3% for ordered mixtures with mannitol<br />
120 ◦ C. Therefore, even if there was a difference of the<br />
flowability of the pure carriers prior to mixing of the carriers<br />
with the active, the attachment of the drug particles to<br />
variation coefficient of the mass / %<br />
50,0<br />
40,0<br />
30,0<br />
20,0<br />
10,0<br />
the carrier surface must have influenced the surface properties<br />
to such an extent that a similar powder flowability<br />
and dosing was finally obtained.<br />
3.4 Delivered Dose<br />
The delivered dose is defined by the dose of active delivered<br />
to the patient by the inhalation device. In this study,<br />
it was determined by discharging 10 doses from the Novolizer<br />
multidose inhaler using the experimental setup described<br />
in the European Pharmacopoeia (Ph. Eur., 2008b).<br />
In contrast to what is described in Pharmacopoeia, 10<br />
subsequent doses were examined, each consisting of five<br />
puffs in order to ensure the proper quantification of the<br />
drug. The dose of active delivered was determined by<br />
HPLC (Fig. 5).<br />
0,0<br />
Mannitol 60°C Mannitol 90°C Mannitol 120°C<br />
FIG. 4: Variation coefficient of the metered mass of 50 single doses of formulations containing mannitol carrier<br />
particles spray dried at 60◦C, 90◦C, and 120◦C; n = 3, mean ± standard deviation.<br />
delivered dose / µg<br />
0<br />
0<br />
0<br />
0 1 2 3 4 5 6 7 8 9 10<br />
number of the dose discharged<br />
FIG. 5: Delivered dose of three batches of each formulation containing mannitol carrier particles spray dried at 60◦C, 90◦C, and 120◦C. Volume 20, Number 9, 2010<br />
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Mannitol<br />
120 °C<br />
Mannitol<br />
90 °C<br />
Mannitol<br />
60 °C
770 Maas et al.<br />
Three batches (A, B, C) of each formulation (mannitol<br />
60 ◦ C, 90 ◦ C, 120 ◦ C) were examined, and the coefficient<br />
of variation of the dose of each batch was calculated in<br />
order to get a measure of the uniformity of the delivered<br />
dose. The mean and the standard deviation of the three<br />
coefficients of variation of each formulation were calculated<br />
(mannitol 60 ◦ C, 90 ◦ C, 120 ◦ C). They are given in<br />
Fig. 6. There is no significant difference between the formulations,<br />
the mean of the coefficients of variation having<br />
values of 33.6% for formulations containing mannitol<br />
60 ◦ C, 37.8% for formulations containing mannitol 90 ◦ C,<br />
and 18.0% for formulations containing mannitol 120 ◦ C.<br />
Because the coefficients of variation of the delivered<br />
dose are not substantially higher than the coefficients of<br />
variation of the metered mass of the formulations metered<br />
by the built-in metering device of the inhaler, the<br />
poor uniformity of the delivered dose may be attributed<br />
to the inadequate flowability and dosing of the formulations,<br />
which, in turn, results from the small particle size<br />
of the carrier obtained by the laboratory spray dryer. In order<br />
to prepare particle sizes of the carrier between 50 and<br />
200 µm, which are normally used in commercially available<br />
products, larger spray dryers will be used. In contrast,<br />
there is no hint that the poor uniformity of the delivered<br />
dose may have been caused by an arbitrary amount of the<br />
formulation being retained on the walls of the inhaler on<br />
actuation.<br />
3.5 Retained Dose<br />
By relating the delivered dose of active to the metered<br />
mass of the drug (which is calculated from the metered<br />
variation<br />
coefficient or the delivered dose / %<br />
55,0<br />
50,0<br />
45,0<br />
40,0<br />
35,0<br />
30,0<br />
25,0<br />
20,0<br />
15,0<br />
10,0<br />
5,0<br />
0,0<br />
mass of the formulation by multiplying the respective<br />
value with the amount of drug present in the formulation),<br />
a measure of the fraction of drug, which is delivered to the<br />
patient, vice versa retained in the inhaler and the mouthpiece<br />
adapter, was obtained. The amount of drug delivered<br />
is 77% for formulations containing mannitol 60 ◦ C<br />
and mannitol 90 ◦ C, and 78 % for formulations containing<br />
mannitol 120 ◦ C, indicating that the amount retained<br />
also is independent on the surface topography of the carrier<br />
(Fig. 7).<br />
3.6 Fine Particle Fraction<br />
The FPF is defined as the fraction of the active with an<br />
aerodynamic particle diameter ≤5 µm devided by the total<br />
amount of the active found in the impactor, and is an<br />
indicator for the fraction of the active reaching the lower<br />
part of the lungs in relation to the total amount of drug<br />
delivered to the patient. The experiments were carried out<br />
using the experimental setup described in the European<br />
Pharmacopoeia (Ph. Eur. 2008c). Fifty puffs equivalent to<br />
approximately 4 mg of drug were delivered from the Novolizer<br />
device to the NGI. The amount of drug on each<br />
stage was measured using HPLC.<br />
Three batches (A, B, C) of each formulation (mannitol<br />
60 ◦ C, 90 ◦ C, 120 ◦ C) were examined, and the mean and<br />
standard deviation of the FPF of the three batches were<br />
calculated. Figure 8 shows that the FPF decreases from<br />
formulations containing mannitol spray dried at 60 ◦ C<br />
(mannitol 60) to formulations containing mannitol spray<br />
dried at 90 ◦ C (mannitol 90) and finally to formulations<br />
containing mannitol spray dried at 120 ◦ C (mannitol 120)<br />
Mannitol 60 °C Mannitol 90 °C Mannitol 120 °C<br />
FIG. 6: Coefficient of variation of 10 doses of formulations containing mannitol carrier particles spray dried at 60 ◦ C,<br />
90 ◦ C, and 120 ◦ C); n = 3, mean ± standard deviation.<br />
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Atomization and Sprays
Tailoring Dry Powder Inhaler Performance 771<br />
fraction of the drug delivered / %<br />
100<br />
80<br />
60<br />
40<br />
20<br />
0<br />
Mannitol 60 °C Mannitol 90 °C Mannitol 120 °C<br />
FIG. 7: Fraction of the drug delivered (equal to delivered dose in relation to the metered dose) of formulations<br />
containing mannitol carrier particles spray dried at 60 ◦ C, 90 ◦ C, and 120 ◦ C; n = 3, mean ± standard deviation.<br />
fine particle fraction / %<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
Mannitol 60 °C Mannitol 90 °C Mannitol 120 °C<br />
FIG. 8: Fine particle fraction of formulations containing mannitol carrier particles spray dried at 60◦C, 90◦C, and<br />
120◦C; n = 3, mean ± standard deviation.<br />
indicating that drug detachment is enhanced from smooth<br />
carrier particles but impeded from rough carrier particles.<br />
Bearing in mind that the drug particles and the asperities<br />
on the surface of the carrier (Fig. 1) are of similar size<br />
range, drug detachment from the rough surface is disfavored<br />
due to the higher contact area between the drug and<br />
the carrier when the drug is embedded in the cavities of<br />
the carrier surface.<br />
4. CONCLUSION<br />
Modifying the surface topography of mannitol carriers intended<br />
for the use in dry powder inhalers is successful by<br />
spray drying aqueous mannitol solutions. By varying the<br />
spray-drying air outlet temperature, the surface roughness<br />
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of the particles can be modified, with low outlet temperatures<br />
leading to smooth surfaces, high outlet temperatures<br />
leading to rough ones. Despite the differences of the<br />
carrier surface topography, the mass of ordered mixtures<br />
of mannitol carriers and the active salbutamol sulphate,<br />
which is metered by the built-in metering system of a<br />
multidose dry powder inhaler, is not affected. This is attributed<br />
to the prescence of the active at the carrier surface<br />
affecting surface topography to such an extent that, despite<br />
the initially different surface topography of the carrier<br />
itself, the surface properties of the mixtures with the<br />
active will be similar. In contrast, the FPF determined in<br />
vitro, and supposed to correlate with the respirable fraction<br />
in vivo, depends strongly on the surface roughness of<br />
the carrier used. Ordered mixtures containing the active
772 Maas et al.<br />
salbutamol sulphate and spray-dried mannitol particles of<br />
a smooth surface exhibit a higher FPF than those containing<br />
mannitol particles of a rough surface. It is assumed<br />
that the rough carrier surface, the asperities of which are<br />
of the same scale as the particle size of the active, builds<br />
up a higher contact area with the drug, thereby increasing<br />
interparticle interactions and decreasing drug detachment.<br />
Consequently, the use of mannitol carriers exhibiting different<br />
surface topographies allows the modification of interparticle<br />
interactions between the carrier and the drug<br />
in a manner that ensures drug attachment to the carrier on<br />
handling, processing, and dosing on the one hand, but adequate<br />
drug detachment on inhalation on the other hand.<br />
Finally, tailoring of interparticle interactions provides a<br />
tool promising adequate performance of the inhalate, irrespective<br />
of the drug substance, to be transferred into the<br />
aerosol.<br />
ACKNOWLEDGMENTS<br />
This work is supported by the DFG (Deutsche Forschungsgemeinschaft),<br />
SPP 1423. The authors are also<br />
grateful to Lindopharm, D-Hilden, for financial support.<br />
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