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

You also want an ePaper? Increase the reach of your titles

YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.

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!