RESUMEN

Spray congealing technique was exploited to produce solid lipid microparticles (SLMp) loaded with a highly water-soluble drug (metoclopramide hydrochloride) dissolved in the aqueous phase of a water in oil (W/O) emulsion. The use of an emulsion as starting material for a spray congealing treatment is not so frequent. Moreover, for this application, a W/O emulsion with a drug dissolved in water is a totally novel path. A ternary diagram was built to optimize the emulsion composition, a factorial design was used to identify the factors affecting the properties of the microparticles and a Design of Experiment strategy was applied to define the impact of process conditions and formulation variables on the SLMp properties. SLMp were characterized by particle size distribution, morphology, residual moisture, drug content, release behavior, FT-IR analysis and XRPD. The obtained microparticles presented a spherical shape, particle size distribution between 54-98 µm depending on atomizing pressure used during the production step and 2-5% residual moisture 4 days after the preparation. XRPD analysis revealed that lipid polymorphic transition alfa-beta occurs depending on the presence of water. In vitro drug release tests highlighted that all the formulations had a reduced release rate compared to the drug alone. These results suggest that spray congealing of a W/O emulsion could be proposed as a good strategy to obtain SLMp with a high loading of a hydrophilic drug and able to control its release rate.

RESUMEN

The use of design space (DS) is a key milestone in the quality by design (QbD) of pharmaceutical processes. It should be considered from early laboratory development to industrial production, in order to support scientists with making decisions at each step of the product's development life. Presently, there are no available data or methodologies for developing models for the implementation of design space (DS) on laboratory-scale spray dryers. Therefore, in this work, a comparison between two different modeling approaches, thermodynamics and computational fluid dynamics (CFD), to a laboratory spray dryer model have been evaluated. The models computed the outlet temperature (Tout) of the process with a new modeling strategy that includes machine learning to improve the model prediction. The model metrics calculated indicate how the thermodynamic model fits Tout data better than CFD; indeed, the error of the CFD model increases towards higher values of Tout and feed rate (FR), with a final mean absolute error of 10.43 K, compared to the 1.74 K error of the thermodynamic model. Successively, a DS of the studied spray dryer equipment has been implemented, showing how Tout is strongly affected by FR variation, which accounts for about 40 times more than the gas flow rate (Gin) in the DS. The thermodynamic model, combined with the machine learning approach here proposed, could be used as a valid tool in the QbD development of spray-dried pharmaceutical products, starting from their early laboratory stages, replacing traditional trial-and-error methodologies, preventing process errors, and helping scientists with the following scale-up.

RESUMEN

Peppermint essential oil is encapsulated by inverse ionotropic gelation in core-shell systems, composed of alginate (ALG) alone or alginate with shellac gum (SHL) and/or carrageenan (CRG). A mixture design approach is used to evaluate the correlation between the formulation composition and some properties of the final products. Immediately after the preparation, capsules appear rounded with a smooth and homogeneous surface, having a similar particle size ranging from 3.8 mm to 4.5 mm. The drying process, carried out at 40 °C in an oven for 3 h, reduces capsules' diameters by at least 50% and has a negative impact on the shape of the systems because they lose their regular shape and their external membrane partially collapses. The peppermint essential oil content of dried capsules is between 14.84% and 33.75%. The swelling behaviour of the systems is affected by the composition of their outer shell. When the external membrane is composed of alginate and shellac gum, the capsule ability to swell is lower than that of the systems containing alginate alone. The swelling ratio reaches 31% for alginate capsules but does not exceed 21% if shellac is present. Differently, when the second polymer of the shell is carrageenan, the swelling ability increases as a function of polymer concentration and the swelling ratio reaches 360%. In the case of systems whose outer membrane is a polymeric ternary mixture, the swelling capacity increases or decreases according to the concentrations of the individual polymers. The obtained results suggest that carrageenan could be a useful excipient to increase the swelling behaviour of the systems, while shellac gum makes the system shell more hydrophobic. The use of a mixture design (i.e., the use of ternary diagrams and related calculations), in which each single component is chosen to provide specific properties to the final mixture, could be the right approach to develop improved formulations with a tailored essential oil release profile.

RESUMEN

Encapsulation of essential oils represents a good strategy to protect and to transform them in free-flowing particles. Core-shell systems containing peppermint essential oil have been obtained by inverse ionotropic gelation. An O/W emulsion composed of essential oil (O) and aqueous CaCl2 solution enriched with hydroxyethylcellulose (W) was dripped in an alginate solution added of a secondary excipient (maltodextrin or shellac gum) at two concentrations. The qualitative/quantitative modifications of capsule shell composition had a limited impact on the essential oil content (it was more than 50% w/w), while they affected other dried capsule properties like dimensions, shell thickness, hardness and swelling behavior. Neither the type nor the amount of secondary excipient influenced wet capsule particle size (about 4 mm). After drying, particle size decreased (it was about 2 mm) and while shellac gum amount did not affect dried capsule dimensions, an increase in maltodextrin amount corresponded to an increase in their diameters. Capsule hardness diminished by increasing the amount of secondary excipient in the formulations. In addition, the amount of maltodextrin included in the formulations affected the swelling behavior of the dried capsules in water and this leads considering maltodextrin a useful excipient to modulate swelling according to the needs of the different applications.

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RESUMEN

The purpose of the present work was to prepare multiparticulate drug delivery systems for oral administration of a poorly soluble drug such as itraconazole. Multiparticulate systems were prepared by extrusion/spheronization technique using a mix of crospovidone, low viscosity hypromellose, microcrystalline cellulose, micronized drug and water. In order to improve the release performance of the multiparticulate systems, the micronized drug was suspended in water with polysorbate 20 and nanonized by a high-pressure homogenization. The suspension of drug nanoparticles was then spray-dried for enabling an easy handling of the drug and for preventing the over-wetting of the powders during extrusion/spheronization processing. Both multiparticulate units prepared with micronized or nanonized drug showed acceptable disintegrating properties. The nanosizing of micronized drug powder provided a significant improvement of drug dissolution rates of the multiparticulates.

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Itraconazole (ITZ) nanocrystal-containing powders were prepared through the combined use of high pressure homogenization (HPH) and spray drying (SD). These powders were intended as base materials for the preparation of extemporary oral suspensions of the drug. The role and the effect of stabilizers on the size of re-dispersed particles were studied using a mixture design and a Scheffé model relating the dried nanosuspension composition to the mean particle diameters. The homogenization process required a surface active agent (Tween 20) to obtain the efficient comminution of itraconazole micronized powder. SD was carried out on ITZ nanosuspensions after addition of a cellulose derivative (Methocel(®) E5) that allowed the prompt re-dispersion of nanoparticles under "in use" conditions. The powders obtained by drying of homogenized systems showed in vitro dissolution profile faster than that of the micronized drug, suggesting a potential ameliorated GI absorption of itraconazole released from the nanosuspensions.

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The work is aimed at investigating the polymorphism and the phase transition kinetics of binary lipid mixtures with potential application in controlled drug delivery. The lipid systems, constituted of glyceryl tristearate (GTS) added with different amounts (1.0-7.5% w/w) of a medium-chain liquid triglyceride (C10-C12 acyl derivative - MCT), were studied by differential scanning calorimetry, by X-ray diffraction and hot-stage microscopy. The liquid lipid, although present in small amount, modified the thermal profile and the diffraction pattern of the systems, indicating that it promoted the formation of the GTS stable polymorph, ß, during the re-solidification of the melted mixture. This promotion effect of MCT was concentration-dependent and evident for systems containing MCT>2.5%. Also the kinetics of transformation of GTS polymorphs was affected by the percentage of the liquid component. The α → ß-transition was a biphasic process which for GTS-MCT mixture (99:1) superimposed that of pure GTS, while followed a different trend for systems containing percentages of MCT higher than 2.5.

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