Surface Composition and Aerosolization Stability of an Inhalable Combinational Powder Formulation Spray Dried Using a Three-Fluid Nozzle

Abstract

Purpose

This study aims to understand the impact of spray drying nozzles on particle surface composition and aerosol stability.

Methods

The combination formulations of colistin and azithromycin were formulated by 2-fluid nozzle (2 N) or 3-fluid (3 N) spray drying in a molar ratio of 1:1. A 3-factor, 2-level (23) factorial design was selected to investigate effects of flow rate, inlet temperature and feed concentration on yield of spray drying and the performance of the spray dried formulations for the 3 N.

Results

FPF values for the 2 N formulation (72.9 ± 1.9% for azithromycin & 73.4 ± 0.8% for colistin) were higher than those for the 3 N formulation (56.5 ± 3.8% for azithromycin & 55.1 ± 1.6% for colistin) when stored at 20% RH for 1 day, which could be attributed to smaller physical size for the 2 N. There was no change in FPF for both drugs in the 2 N formulation after storage at 75% RH for 90 days; however, there was a slight increase in FPF for colistin in the 3 N formulation at the same storage conditions. Surface enrichment of hydrophobic azithromycin was measured by X-ray photoelectron spectroscopy for both 2 N and 3 N formulations and interactions were studied using FTIR.

Conclusions

The 3-fluid nozzle provides flexibility in choosing different solvents and has the capability to spray dry at higher feed solid concentrations. This study highlights the impact of hydrophobic azithromycin enrichment on particle surface irrespective of the nozzle type, on the prevention of moisture-induced deterioration of FPF for hygroscopic colistin.

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Abbreviations

2 N:

Two-fluid nozzle

3 N:

Three-fluid nozzle

ColAz (1-1):

Co-spray dried colistin and azithromycin at a molar ratio of 1:1

DOE:

Design of experiments

DPI:

Dry powder inhaler

DVS:

Dynamic vapor sorption

ED:

Emitted dose

FPF:

Fine particle fraction

FTIR:

Fourier-transform infrared spectroscopy

GSD:

Geometric standard deviation

MMAD:

Median mass aerodynamic diameter

NGI:

Next generation Impactor

PXRD:

Powder X-ray diffractometer

RH:

Relative humidity

SD:

Spray drying

SEM:

Scanning electron microscopy

XPS:

X-ray photoelectron spectroscopy

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Correspondence to Qi (Tony) Zhou.

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Shetty, N., Zhang, Y., Park, H. et al. Surface Composition and Aerosolization Stability of an Inhalable Combinational Powder Formulation Spray Dried Using a Three-Fluid Nozzle. Pharm Res 37, 219 (2020). https://doi.org/10.1007/s11095-020-02937-2

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Key words

  • aerosol performance
  • dry powder inhaler
  • spray drying
  • surface composition
  • three-fluid nozzle