Abstract
Spray-drying dispersion (SDD) is a well-established manufacturing technique used to prepare amorphous solid dispersions (ASDs), allowing for poorly soluble drugs to have improved bioavailability. However, the process of spray-drying with multiple factors and numerous variables can lead to a lengthy development timeline with intense resource requirements, which becomes the main obstacle limiting spray-drying development at the preclinical stage. The purpose of this work was to identify optimized preset parameters for spray-drying to support the early development of ASDs suitable for most circumstances rather than individual optimization. First, a mini-DoE (Design of Experiment) study was designed to evaluate the critical interplay of two key variables for spray-drying using a BUCHI B-290 mini spray dryer: solid load and atomizing spray gas flow. The critical quality attributes (CQAs) of the ASDs, including yield, particle size, morphology, and in vitro release profile, were taken into account to identify the impact of the key variables. The mini-DoE results indicated that a 5% solid load (w/v %) and 35 mm height atomizing spray gas flow were the most optimized parameters. These predefined values were further verified using different formulation compositions, including various polymers (Eudragit L100-55, HPMCAS-MF, PVAP, and PVP-VA64) and drugs (G-F, GEN-A, Indomethacin, and Griseofulvin), a range of drug loading (10 to 40%), and scale (200 mg to 200 g). Using these predefined parameters, all ASD formulations resulted in good yields as well as consistent particle size distribution. This was despite the differences in the formulations, making this a valuable and rapid approach ideal for early development. This strategy of leveraging the preset spray-drying parameters was able to successfully translate into a reproducible and efficient spray-drying platform while also saving material and reducing developmental timelines in early-stage formulation development.
Graphical Abstract
Similar content being viewed by others
References
Huang Y, Dai W-G. Fundamental aspects of solid dispersion technology for poorly soluble drugs. Acta Pharm Sin B. 2014;4:18–25.
Mendonsa N, Almutairy B, Kallakunta VR, Sarabu S, Thipsay P, Bandari S, et al. Manufacturing strategies to develop amorphous solid dispersions: an overview. J Drug Deliv Sci Tec. 2019;55:101459.
Newman A, Nagapudi K, Wenslow R. Amorphous solid dispersions: a robust platform to address bioavailability challenges. Ther Deliv. 2015;6:247–61.
den Mooter GV. The use of amorphous solid dispersions: a formulation strategy to overcome poor solubility and dissolution rate. Drug Discov Today Technol. 2012;9:e79-85.
Vodak DT, Morgen M. Design and Development of HPMCAS-Based Spray-Dried Dispersions. In: Shah N, Sandhu H, Choi DS, Chokshi H, Malick AW, editors. Amorphous Solid Dispersions: Theory and Practice. Springer, New York: New York, NY; 2014. p. 303–22.
He Y, Ho C. Amorphous solid dispersions: utilization and challenges in drug discovery and development. J Pharm Sci. 2015;104:3237–58.
Schittny A, Huwyler J, Puchkov M. Mechanisms of increased bioavailability through amorphous solid dispersions: a review. Drug Deliv. 2019;27:110–27.
Williams HD, Trevaskis NL, Charman SA, Shanker RM, Charman WN, Pouton CW, et al. Strategies to address low drug solubility in discovery and development. Pharmacol Rev. 2013;65:315–499.
Kesisoglou F, Wu Y. Understanding the effect of API properties on bioavailability through absorption modeling. Aaps J. 2008;10:516–25.
Newman A, Knipp G, Zografi G. Assessing the performance of amorphous solid dispersions. J Pharm Sci. 2012;101:1355–77.
Liu X, Feng X, Williams RO, Zhang F. Characterization of amorphous solid dispersions. J Pharm Investig. 2018;48:19–41.
Jatwani S, Rana AC, Singh G, Aggarwal G. ChemInform abstract: an overview on solubility enhancement techniques for poorly soluble drugs and solid dispersion as an eminent strategic approach. Cheminform. 2013;44:no–no.
Kennedy M, Hu J, Gao P, Li L, Ali-Reynolds A, Chal B, et al. Enhanced bioavailability of a poorly soluble VR1 antagonist using an amorphous solid dispersion approach: a case study. Mol Pharm. 2008;5:981–93.
Mudie DM, Stewart AM, Biswas N, Brodeur TJ, Shepard KB, Smith A, et al. Novel high-drug-loaded amorphous dispersion tablets of posaconazole; in vivo and in vitro assessment. Mol Pharm. 2020;17:4463–72.
Chiang P-C, Cui Y, Ran Y, Lubach J, Chou K-J, Bao L, et al. In vitro and in vivo evaluation of amorphous solid dispersions generated by different bench-scale processes, using Griseofulvin as a model compound. Aaps J. 2013;15:608–17.
Zhang D, Lee Y-C, Shabani Z, Lamm CF, Zhu W, Li Y, et al. Processing impact on performance of solid dispersions. Pharm. 2018;10:142.
Hu Q, Choi DS, Chokshi H, Shah N, Sandhu H. Highly efficient miniaturized coprecipitation screening (MiCoS) for amorphous solid dispersion formulation development. Int J Pharm. 2013;450:53–62.
Chiang P-C, Ran Y, Chou K-J, Cui Y, Sambrone A, Chan C, et al. Evaluation of drug load and polymer by using a 96-well plate vacuum dry system for amorphous solid dispersion drug delivery. AAPS PharmSciTech. 2012;13:713–22.
Santos D, Maurício AC, Sencadas V, Santos JD, Fernandes MH, Gomes PS. Spray drying: an overview. 2018.
Sosnik A, Seremeta KP. Advantages and challenges of the spray-drying technology for the production of pure drug particles and drug-loaded polymeric carriers. Adv Colloid Interfac. 2015;223:40–54.
Maury M, Murphy K, Kumar S, Shi L, Lee G. Effects of process variables on the powder yield of spray-dried trehalose on a laboratory spray-dryer. Eur J Pharm Biopharm. 2005;59:565–73.
Di L, Fish PV, Mano T. Bridging solubility between drug discovery and development. Drug Discov Today. 2012;17:486–95.
Thackaberry EA. Oral formulation roadmap from early drug discovery to development. 2017;89–114.
Patel BB, Patel JK, Chakraborty S, Shukla D. Revealing facts behind spray dried solid dispersion technology used for solubility enhancement. Saudi Pharm J. 2015;23:352–65.
Ousset A, Chirico R, Robin F, Schubert MA, Somville P, Dodou K. A Novel protocol using small-scale spray-drying for the efficient screening of solid dispersions in early drug development and formulation, as a straight pathway from screening to manufacturing stages. Pharm. 2018;11:81.
Ormes JD, Zhang D, Chen AM, Hou S, Krueger D, Nelson T, et al. Design of experiments utilization to map the processing capabilities of a micro-spray dryer: particle design and throughput optimization in support of drug discovery. Pharm Dev Technol. 2012;18:121–9.
Pohlen M, Lavrič Z, Prestidge C, Dreu R. Preparation, physicochemical characterisation and DoE optimisation of a spray-dried dry emulsion platform for delivery of a poorly soluble drug, Simvastatin. AAPS PharmSciTech. 2020;21:119.
Ousset A, Bassand C, Chavez P-F, Meeus J, Robin F, Schubert MA, et al. Development of a small-scale spray-drying approach for amorphous solid dispersions (ASDs) screening in early drug development. Pharm Dev Technol. 2018;24:1–47.
Jermain SV, Lowinger MB, Ellenberger DJ, Miller DA, Su Y, Williams RO. In vitro and in vivo behaviors of KinetiSol and spray-dried amorphous solid dispersions of a weakly basic drug and ionic polymer. Mol Pharm. 2020;17:2789–808.
Parrott N, Hainzl D, Scheubel E, Krimmer S, Boetsch C, Guerini E, et al. Physiologically based absorption modelling to predict the impact of drug properties on pharmacokinetics of bitopertin. Aaps J. 2014;16:1077–84.
Cui Y, Chiang P-C, Choo EF, Boggs J, Rudolph J, Grina J, et al. Systemic in vitro and in vivo evaluation for determining the feasibility of making an amorphous solid dispersion of a B-Raf (rapidly accelerated fibrosarcoma) inhibitor. Int J Pharm. 2013;454:241–8.
Bao L, An L, Ran Y. Solubilization of a poorly soluble B-Raf (rapidly accelerated fibrosarcoma) inhibitor: from theory to application. J Pharm Sci. 2018;107:327–33.
Monschke M, Kayser K, Wagner KG. Influence of particle size and drug load on amorphous solid dispersions containing pH-dependent soluble polymers and the weak base ketoconazole. AAPS PharmSciTech. 2021;22:44.
Kemp IC, Hartwig T, Herdman R, Hamilton P, Bisten A, Bermingham S. Spray drying with a two-fluid nozzle to produce fine particles: atomisation, scale-up and modelling. Dry Technol. 2015;34:1243–52.
Elversson J, Millqvist-Fureby A, Alderborn G, Elofsson U. Droplet and particle size relationship and shell thickness of inhalable lactose particles during spray drying. J Pharm Sci. 2003;92:900–10.
Kanojia G, Willems G-J, Frijlink HW, Kersten GFA, Soema PC, Amorij J-P. A Design of Experiment approach to predict product and process parameters for a spray dried influenza vaccine. Int J Pharm. 2016;511:1098–111.
Buchi B-290 manual [Internet]. Available from: https://assets.buchi.com/image/upload/v1605800030/pdf/Operation-Manuals/OM_093001_B-290_en.pdf.
Lu Z, Yang Y, Covington R-A, Bi Y (Vivian), Dürig T, Ilies MA, et al. Supersaturated controlled release matrix using amorphous dispersions of glipizide. Int J Pharm. 2016;511:957–68.
Qian F, Wang J, Hartley R, Tao J, Haddadin R, Mathias N, et al. Solution behavior of PVP-VA and HPMC-AS-based amorphous solid dispersions and their bioavailability implications. Pharm Res. 2012;29:2766–76.
Fryer RM, Patel M, Zhang X, Baum-Kroker KS, Muthukumarana A, Linehan B, et al. Physical properties and effect in a battery of safety pharmacology models for three structurally distinct enteric polymers employed as spray-dried dispersion carriers. Front Pharmacol. 2016;7:368.
Ueda H, Hirakawa Y, Tanaka H, Miyano T, Sugita K. Applicability of an experimental grade of hydroxypropyl methylcellulose acetate succinate as a carrier for formation of solid dispersion with indomethacin. Pharm. 2021;13:353.
Murdande SB, Pikal MJ, Shanker RM, Bogner RH. Solubility advantage of amorphous pharmaceuticals: II. Application of quantitative thermodynamic relationships for prediction of solubility enhancement in structurally diverse insoluble pharmaceuticals. Pharm Res. 2010;27:2704–14.
Paudel A, Worku ZA, Meeus J, Guns S, den Mooter GV. Manufacturing of solid dispersions of poorly water soluble drugs by spray drying: formulation and process considerations. Int J Pharm. 2013;453:253–84.
Ogawa N, Hiramatsu T, Suzuki R, Okamoto R, Shibagaki K, Fujita K, et al. Improvement in the water solubility of drugs with a solid dispersion system by spray drying and hot-melt extrusion with using the amphiphilic polyvinyl caprolactam-polyvinyl acetate-polyethylene glycol graft copolymer and d-mannitol. Eur J Pharm Sci. 2018;111:205–14.
Que C, Lou X, Zemlyanov DY, Mo H, Indulkar AS, Gao Y, et al. Insights into the dissolution behavior of Ledipasvir-Copovidone amorphous solid dispersions: role of drug loading and intermolecular interactions. Mol Pharm. 2019;16:5054–67.
Mudie DM, Buchanan S, Stewart AM, Smith A, Shepard KB, Biswas N, et al. A novel architecture for achieving high drug loading in amorphous spray dried dispersion tablets. Int J Pharm X. 2020;2:100042.
Acknowledgements
The authors would like to thank Edward Yost, Evelyn Yanez, Nivedita Shetty, Steven Castleberry, Wei Zhang, Jonathan Hau, Wei Jia, and Yingqing Ran for their support throughout this project.
Funding
This research was funded by Genentech Inc.
Author information
Authors and Affiliations
Contributions
Marika Nespi: conceptualization, analysis, investigation, methodology, validation, and writing.
Robert Kuhn: analysis, investigation, validation, and writing.
Chun-Wan Yen: conceptualization, analysis, methodology, validation, supervision, and writing.
Joseph W. Lubach: investigation, review and editing.
Dennis Leung: supervision, resources, review and editing.
Corresponding author
Ethics declarations
Conflict of Interest
The authors declare no competing interests.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Supplementary Information
Below is the link to the electronic supplementary material.
Rights and permissions
About this article
Cite this article
Nespi, M., Kuhn, R., Yen, CW. et al. Optimization of Spray-Drying Parameters for Formulation Development at Preclinical Scale. AAPS PharmSciTech 23, 28 (2022). https://doi.org/10.1208/s12249-021-02160-1
Received:
Accepted:
Published:
DOI: https://doi.org/10.1208/s12249-021-02160-1