25.09.2012 Views

TAILORING DRY POWDER INHALER PERFORMANCE BY - RCPE

TAILORING DRY POWDER INHALER PERFORMANCE BY - RCPE

TAILORING DRY POWDER INHALER PERFORMANCE BY - RCPE

SHOW MORE
SHOW LESS

Create successful ePaper yourself

Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.

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 />

1044–5110/10/$35.00 c○ 2010 by Begell House, Inc. 763<br />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz


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 />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

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 />

Volume 20, Number 9, 2010<br />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

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 />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

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 />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

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 />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

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 />

Volume 20, Number 9, 2010<br />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

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 />

REFERENCES<br />

Adi, H., Larson, I., Chiou, H., Young, P., Traini, D., and Stewart,<br />

P., Agglomerate strength and dispersion of salmeterol xinafoate<br />

from powder mixtures for inhalation, Pharm. Res.,<br />

vol. 23, pp. 2556–2565 2006.<br />

Adi, H., Larson, I., and Stewart, P. J., Adhesion and redistribution<br />

of salmeterol xinafoate particles in sugar-based mixtures<br />

for inhalation, Int. J. Pharm., vol. 337, pp. 229–238, 2007.<br />

Buckton, G., Yonemochi, E., Hammond, J., and Moffat, A., The<br />

use of near infra-red spectroscopy to detect changes in the<br />

form of amorphous and crystalline lactose, Int. J. Pharm.,<br />

168, pp. 231–241, 1998.<br />

Cazzola, M., Donner, C. F., and Hanania, N. A., One hundred<br />

years of chronic obstructive pulmonary disease (COPD),<br />

Resp. Med., vol. 101, pp. 1049–1065, 2007.<br />

Chan, L. W., Lim, L. T., and Heng, P. W. S., Immobilization<br />

of fine particles on lactose carrier by precision coating and<br />

its effect on the performance of dry powder formulations, J.<br />

Pharm. Sci., vol. 92, pp. 975–984, 2003.<br />

Daniher, D. I. and Zhu, J., Dry powder platform for pulmonary<br />

drug delivery, Particuology, vol. 6, pp. 225–238, 2008.<br />

Danjo, K., Kinoshita, K., Kitagawa, K., Iida, K., Sunada, H.,<br />

and Otsuka, A., Effect of particle-shape on the compaction<br />

and flow properties of powders, Chem. Pharm. Bull., vol. 37,<br />

pp. 3070–3073, 1989.<br />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

Dickhoff, B. H. J., de Boer, A. H., Lambregts, D., and Frijlink,<br />

H. W., The effect of carrier surface treatment on drug<br />

particle detachment from crystalline carriers in adhesive mixtures<br />

for inhalation, Int. J. Pharm., vol. 327, pp. 17–25, 2006.<br />

El-Sabawi, D., Edge, S., Price, R., and Young, P. M., Continued<br />

investigation into the influence of loaded dose on the performance<br />

of dry powder inhalers: Surface smoothing effects,<br />

Drug Dev. Ind. Pharm., vol. 32, pp. 1135–1138, 2006a.<br />

El-Sabawi, D., Price, R., Edge, S., and Young, P. M., Novel temperature<br />

controlled surface dissolution of excipient particles<br />

for carrier based dry powder inhaler formulations, Drug Dev.<br />

Ind. Pharm., vol. 32, pp. 243–251, 2006b.<br />

Ferrari, F., Cocconi, D., Bettini, R., Giordano, F., Santi, P., Tobyn,<br />

M., Price, R., Young, P., Caramella, C., and Colombo, P.,<br />

The surface roughness of lactose particles can be modulated<br />

by wet-smoothing using a high-shear mixer, AAPS Pharmscitech,<br />

vol. 5, no. 4, pp. 1–6, 2004.<br />

Fuller, K. N. G. and Tabor, D., Effect of surface-roughness on<br />

adhesion of elastic solids, Proc. R. Soc. London Ser. A, vol.<br />

345, pp. 327–342, 1975.<br />

Guchardi, R., Frei, M., John, E., and Kaerger, J. S., Influence<br />

of fine lactose and magnesium stearate on low dose dry powder<br />

inhaler formulations, Int. J. Pharm., vol. 348, pp. 10–17,<br />

2008.<br />

Hanania, N. A., Targeting airway inflammation in asthma—<br />

Current and future therapies, Chest, vol. 133, pp. 989–998,<br />

2008.<br />

Harjunen, P., Lankinen, T., Salonen, H., Lehto, V. P., and Jarvinen,<br />

K., Effects of carriers and storage of formulation on the<br />

lung deposition of a hydrophobic and hydrophilic drug from<br />

a DPI, Int. J. Pharm., vol. 263, pp. 151–163, 2003.<br />

Hersey, J. A., Ordered mixing—New concept in powder mixing<br />

practice, Powder Technol., vol. 11, pp. 41–44, 1975.<br />

Iida, K., Hayakawa, Y., Okamoto, H., Danjo, K., and Leuenberger,<br />

H., Evaluation of flow properties of dry powder inhalation<br />

of salbutamol sulfate with lactose carrier, Chem.<br />

Pharm. Bull., vol. 49, pp. 1326–1330, 2001.<br />

Iida, K., Hayakawa, Y., Okamoto, H., Danjo, K., and Leuenberger,<br />

H., Preparation of dry powder inhalation by surface<br />

treatment of lactose carrier particles, Chem. Pharm. Bull.,<br />

vol. 51, pp. 1–5, 2003a.<br />

Iida, K., Hayakawa, Y., Okamoto, H., Danjo, K., and Luenberger,<br />

H., Effect of surface covering of lactose carrier particles<br />

on dry powder inhalation properties of salbutamol sulfate,<br />

Chem. Pharm. Bull., vol. 51, pp. 1455–1457, 2003b.<br />

Iida, K., Hayakawa, Y., Okamoto, H., Danjo, K., and Luenberger,<br />

H., Influence of storage humidity on the in vitro inhalation<br />

properties of salbutamol sulfate dry powder with surface<br />

covered lactose carrier, Chem. Pharm. Bull., vol. 52, pp.<br />

444–446, 2004a.<br />

Iida, K., Inagaki, Y., Todo, H., Okamoto, H., Danjo, K., and Lu-<br />

Atomization and Sprays


Tailoring Dry Powder Inhaler Performance 773<br />

enberger, H., Effects of surface processing of lactose carrier<br />

particles on dry powder inhalation properties of salbutamol<br />

sulfate, Chem. Pharm. Bull., vol. 52, pp. 938–942, 2004b.<br />

Iida, K., Otsuka, A., Danjo, K., and Sunada, H., Measurement<br />

of the adhesive force between particles and a substrate<br />

by means of the impact separation method—Effect of<br />

the surface-roughness and type of material of the substrate,<br />

Chem. Pharm. Bull., vol. 41, pp. 1621–1625, 1993.<br />

Iida, K., Todo, H., Okamoto, H., Danjo, K., and Leuenberger,<br />

H., Preparation of dry powder inhalation with lactose<br />

carrier particles surface-coated using a Wurster fluidized bed,<br />

Chem. Pharm. Bull., vol. 53, pp. 431–434, 2005.<br />

Islam, N., Stewart, P., Larson, I., and Hartley, P., Effect of carrier<br />

size on the dispersion of salmeterol xinafoate from interactive<br />

mixtures, J. Pharm. Sci., vol. 93, pp. 1030–1038, 2004a.<br />

Islam, N., Stewart, P., Larson, I., and Hartley, P., Lactose surface<br />

modification by decantation: Are drug-fine lactose ratios<br />

the key to better dispersion of salmeterol xinafoate from<br />

lactose-interactive mixtures?, Pharm. Res., vol. 21, pp. 492–<br />

499, 2004b.<br />

Islam, N., Stewart, P., Larson, I., and Hartley, P., Surface roughness<br />

contribution to the adhesion force distribution of salmeterol<br />

xinafoate on lactose carriers by atomic force microscopy,<br />

J. Pharm. Sci., vol. 94, pp. 1500–1511, 2005.<br />

Labiris, N. R. and Dolovich, M. B., Pulmonary drug delivery.<br />

Part I: Physiological factors affecting therapeutic effectiveness<br />

of aerosolized medications, Br. J. Clin. Pharmacol., vol.<br />

56, 588–599, 2003a.<br />

Larhrib, H., Martin, G. P., Marriott, C., and Prime, D., The influence<br />

of carrier and drug morphology on drug delivery from<br />

dry powder formulations, Int. J. Pharm., vol. 257, pp. 283–<br />

296, 2003a.<br />

Larhrib, H., Martin, G. P., Prime, D., and Marriott, C., Characterisation<br />

and deposition studies of engineered lactose crystals<br />

with potential for use as a carrier for aerosolised salbutamol<br />

sulfate from dry powder inhalers, Eur. J. Pharm. Sci.,<br />

vol. 19, pp. 211–221, 2003b.<br />

Louey, M. D., Razia, S., and Stewart, P. J., Influence of physicochemical<br />

carrier properties on the in vitro aerosol deposition<br />

from interactive mixtures, Int. J. Pharm., vol. 252, pp. 87–98,<br />

2003.<br />

Louey, M. D. and Stewart, P. J., Particle interactions involved<br />

in aerosol dispersion of ternary interactive mixtures, Pharm.<br />

Res., vol. 19, pp. 1524–1531, 2002.<br />

Maas, S. G., Optimierung trägerbasierter Pulverinhalate durch<br />

Modifikation der Trägeroberfläche mittels Sprühtrocknung,<br />

PhD Thesis, Heinrich-Heine-Universität Düsseldorf, 2009.<br />

Miller-Larsson, A. and Selroos, O., Advances in asthma and<br />

COPD treatment: Combination therapy with inhaled corticosteroids<br />

and long-acting beta(2)-agonists, Curr. Pharm. Des.,<br />

vol. 12, pp. 3261–3279, 2006.<br />

Volume 20, Number 9, 2010<br />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

Mullins, M. E., Michaels, L. P., Menon, V., Locke, B., and<br />

Ranade, M. B., Effect of geometry on particle adhesion,<br />

Aerosol Sci. Technol., vol. 17, 105–118, 1992.<br />

Ph. Eur., Preparations for inhalation, in European Pharmacopoeia,<br />

6th ed., Council of Europe, Strasbourg, pp. 739–743,<br />

2008a.<br />

Ph. Eur., Preparations for inhalation: Uniformity of delivered<br />

dose, in European Pharmacopoeia, 6th ed., Council of Europe,<br />

Strasbourg, p. 742, 2008b.<br />

Ph. Eur., Preparations for inhalation: Aerodynamic assessment<br />

of fine particles, in European Pharmacopoeia, 6th ed., Council<br />

of Europe, Strasbourg, pp. 287–300, 2008c.<br />

Podczeck, F., The influence of particle size distribution and surface<br />

roughness of carrier particles on the in vitro properties<br />

of dry powder inhalations, Aerosol Sci. Technol., vol. 31, pp.<br />

301–321, 1999.<br />

Podczeck, F., Newton, J. M., and James, M. B., The influence of<br />

chemical structure on the friction properties between particles<br />

and compacted powder surfaces, J. Mater. Sci., vol. 31, pp.<br />

2213–2219, 1996.<br />

Price, R. and Young, P. M., Visualization of the crystallization<br />

of lactose from the amorphous state, J. Pharm. Sci., vol. 93,<br />

pp. 155–164, 2004.<br />

Rabinovich, Y. I., Adler, J. J., Ata, A., Singh, R. K., and<br />

Moudgil, B. M., Adhesion between nanoscale rough surfaces—I.<br />

Role of asperity geometry, J. Colloid Interface Sci.,<br />

vol. 232, pp. 10–16, 2000.<br />

Rumpf, H., Die Wissenschaft des Agglomerierens, Chem. Ing.<br />

Tech., vol. 46, pp. 1–11, 1974.<br />

Saint-Lorant, G., Leterme, P., Gayot, A., and Flament, M. P., Influence<br />

of carrier on the performance of dry powder inhalers,<br />

Int. J. Pharm., vol. 334, pp. 85–91, 2007.<br />

Steckel, H. and Bolzen, N., Alternative sugars as potential carriers<br />

for dry powder inhalations, Int. J. Pharm., vol. 270, pp.<br />

297–306, 2004.<br />

Steckel, H., Markefka, P., Tewierik, H., and Kammelar, R.,<br />

Functionality testing of inhalation grade lactose, Eur. J.<br />

Pharm. Biopharm., vol. 57, pp. 495–505, 2004.<br />

Steckel, H., Inhalationspulver—Neuere Entwicklungen bei Pulverinhalatoren,<br />

Pharm. Zeit. PZ Prisma, vol. 10, pp. 145–<br />

157, 2003.<br />

Steckel, H., Markefka, P., teWierik, H., and Kammelar, R., Effect<br />

of milling and sieving on functionality of dry powder inhalation<br />

products, Int. J. Pharm., vol. 309, pp. 51–59, 2006.<br />

Tabor, D., Surface forces and surface interactions, J. Colloid Interface<br />

Sci., vol. 58, pp. 2–13, 1977.<br />

Tee, S. K., Marriott, C., Zeng, X. M., and Martin, G. P., The use<br />

of different sugars as fine and coarse carriers for aerosolised<br />

salbutamol sulphate, Int. J. Pharm., vol. 208, pp. 111–123,<br />

2000.


774 Maas et al.<br />

Young, P. M., Cocconi, D., Colombo, P., Bettini, R., Price, R.,<br />

Steele, D. F., and Tobyn, M. J., Characterization of a surface<br />

modified dry powder inhalation carrier prepared by ”particle<br />

smoothing, J. Pharm. Pharmacol., vol. 54, pp. 1339–1344,<br />

2002.<br />

Young, P. M., Roberts, D., Chiou, H., Rae, W., Chan, H.-K.,<br />

and Traini, D., Composite carriers improve the aerosolisation<br />

efficiency of drugs for respiratory delivery, J. Aerosol Sci.,<br />

vol. 39, pp. 82–93, 2008.<br />

Zeng, X. M., Martin, G. P., Marriott, C., and Pritchard, J.,<br />

The effects of carrier size and morphology on the dispersion<br />

of salbutamol sulphate after aerosolization at different<br />

flow rates, J. Pharm. Pharmacol., vol. 52, pp. 1211–1221,<br />

2000a.<br />

Zeng, X. M., Martin, G. P., Marriott, C., and Pritchard, J., The<br />

influence of carrier morphology on drug delivery by dry powder<br />

inhalers, Int. J. Pharm., vol. 200, pp. 93–106, 2000b.<br />

Zeng, X. M., Martin, G. P., Marriott, C., and Pritchard, J., The<br />

influence of crystallization conditions on the morphology of<br />

Begell House Digital Library, http://dl.begellhouse.com Downloaded 2011-3-4 from IP 129.27.117.213 by Technische Universitaet Graz<br />

lactose intended for use as a carrier for dry powder aerosols,<br />

J. Pharm. Pharmacol., vol. 52, pp. 633–643, 2000c.<br />

Zeng, X. M., Martin, G. P., Marriott, C., and Pritchard, J., Lactose<br />

as a carrier in dry powder formulations: The influence of<br />

surface characteristics on drug delivery, J. Pharm. Sci., vol.<br />

90, pp. 1424–1434, 2001a.<br />

Zeng, X. M., Martin, G. P., Marriott, C., and Pritchard, J., The<br />

use of lactose recrystallised from carbopol gels as a carrier for<br />

aerosolised salbutamol sulphate, Eur. J. Pharm. Biopharm.,<br />

vol. 51, pp. 55–62, 2001b.<br />

Zeng, X. M., Martin, G. P., Tee, S. K., and Marriott, C., The role<br />

of fine particle lactose on the dispersion and deaggregation of<br />

salbutamol sulphate in an air stream in vitro, Int. J. Pharm.,<br />

vol. 176, pp. 99–110, 1998.<br />

Zeng, X. M., Martin, G. P., Tee, S. K., bu Ghoush, A., and Marriott,<br />

C., Effects of particle size and adding sequence of fine<br />

lactose on the deposition of salbutamol sulphate from a dry<br />

powder formulation, Int. J. Pharm., vol. 182, pp. 133–144,<br />

1999.<br />

Atomization and Sprays

Hooray! Your file is uploaded and ready to be published.

Saved successfully!

Ooh no, something went wrong!