Patent Application
20090297565
The invention describes a method and a device for the preparation of suspensions of very fine particles and a method and a device for coating or covering such very fine particles.
Methods and devices for producing very fine particles which are then coated with protective polymers in a further process step are described.
Micronization is a process for producing particles having a size in the range of a few micrometres, usually in the range of from 1 μm to 10 μm. Micronization is often used in the pharmaceutical sector in order to improve the administration of drugs, e.g. by an increased oral bioavailability. The reduction in the particle size leads to an increase in the surface area, and in accordance with Noyes-Whitney law, the increased surface area leads to an accelerated rate of dissolution of the particles. Oral bioavailability problems can be reduced by micronizing if the rate of dissolution or the solubility are parameters which limit uptake (so-called Class II drugs according to the BCS (Biopharmaceutics Classification System)). Nevertheless, an increasing number of recently prepared compounds show even lower solubilities and associated therewith even lower rates of dissolution than the abovementioned drugs. In many cases micronizing is therefore no longer adequate to achieve a sufficiently high rate of dissolution and, resulting therefrom, a sufficiently high bioavailability.
The next step was then nanonizing of drug powders, i.e. conversion of drug microparticles into drug nanoparticles having an average particle diameter in the nanometre range (from approx. 2-3 nm to 1,000 nm). Drug nanoparticles can be prepared with the aid of so-called “bottom-up” or alternatively with “top-down” technologies. In bottom-up technologies molecules are the starting point, and particle formation is arrived at via association thereof. The conventional bottom-up technique is precipitation, in which the drug is dissolved in a solvent and the solvent is added to a non-solvent, which leads to precipitation of drug nanocrystals. This principle is utilized in the so-called “hydrosol technology” of Sucker and List (U.S. Pat. No. 5,389,382, U.S. Pat. No. 6,447,806). The particles formed are crystalline in nature, especially if they have a particle size in the upper nanometre range. The precipitation is also described in combination with specific polymers, which are used to stabilize the precipitated drug nanoparticle dispersions (WO 00 2003/080034 A3). A precipitation method which leads to precipitation of amorphous particles is also described. This product with the commercial name “Nanomorph™” was originally developed by the company Knoll in Germany (EP 1 219 292 B1). Many problems are associated with the precipitation techniques:
Continuation of the crystal growth after the precipitation is a considerable problem of the precipitation operation. Sucker et al. solve this problem by using a further process step after the precipitation, i.e. by lyophilization of the drug nanocrystal suspension. In many cases, however, not a dry product but an aqueous suspension is required. One method for maintaining the particle size achieved by the precipitation is combination of the precipitation with a heat treatment (U.S. Pat. No. 6,607,784). After the precipitation the drug suspension obtained is exposed to a second, energy-introducing step, e.g. by increasing the temperature, high-speed stirring or a homogenization process. This introduction of energy has two effects:
It was indeed possible to solve or at least minimize the problem of particle growth by the combination of precipitation and the conditioning process. However, because of the “perfection” of the drug crystals this combination is not capable of overcoming the limitation in the particle size reduction. It was therefore indeed possible to report a preserving of the particle size obtained, but no further particle size reduction.
On the basis of these considerations, there was a clear need for improved technologies for producing drug nanocrystals.
The alternatives are the “top-down” technologies, i.e. a “coarse” powder is the starting point, which is then comminuted in various ways to give various types of drug nanocrystals. A simple technique is grinding of drug microsuspensions in a ball mill. The drug powder is suspended in a surfactant solution and the suspension obtained is then introduced into a mill containing beads as grinding material. The beads are agitated by stirrers and the drug microcrystals are ground to drug nanocrystals between the grinding beads. Alternatively, instead of using a stirrer the entire grinding vessel together with balls and suspension can be agitated (U.S. Pat. No. 5,145,684). Disadvantages are associated with the use of mills for comminution of particles:
There is therefore a definitive limitation here with respect to an increase in scale (scale-up). For larger batches which exceed the filling volume of these bead mills, a bead mill which operates in a circulation method is therefore necessary. The suspension is pumped continuously through the bead mill. However, the situation is also not improved considerably as a result, since an increased batch size of course at the same time lengthens the grinding time required.
An alternative is the use of the high pressure homogenization technique. In this, the powder is dispersed in the surfactant solution and the suspension obtained is then subjected to a high pressure homogenization process, e.g. by using a piston-gap homogenizer (U.S. Pat. No. 5,858,410) or utilizing the jet stream principle (realized with the Microfluidizer U.S. Pat. No. 5,091,187). The comminution principle of the Microfluidizer comprises frontal collision of two flows, which collide with one another at high speed. A great disadvantage of this method is the relative large number of cycles required to obtain drug nanoparticles. The 50-100 homogenization cycles required, mentioned in the example (U.S. Pat. No. 5,091,187), are not particularly production-friendly. In addition, the Microfluidizer principle is less effective compared with the piston-gap method, and especially in the case of very hard crystals it leads to an undesirable content of microparticles in the nanosuspension. The piston-gap homogenization of suspensions of a drug in water leads to drug nanocrystals having an average particle size in the range of from approx. 200 nm to 1,000 nm. Cavitation was described in this context as the comminution principle (U.S. Pat. No. 5,858,410). An effective particle comminution in non-aqueous media or in mixtures of water and water-miscible liquids has since also been described. Examples of non-aqueous media are liquid polyethylene glycols (PEG) (e.g. PEG 400 or PEG 600) or oils (e.g. medium-chain triglycerides (MCT)). The advantage of these nanosuspensions is that they can be filled directly into hard or soft gelatine capsules. Homogenization in aqueous mixtures, such as e.g. water/ethanol mixtures, leads to suspensions which can easily be spray dried. Homogenization in water/glycerol mixtures leads directly to isotonic products for parenteral administration. The particle size which can be achieved in high pressure homogenization depends on the homogenization pressure and the softness or hardness of the substance to be processed. For relatively soft drugs, diameters of between 200 nm and 300 have been published (e.g. Paclitaxel (B. Böhm, Dissertation, FU Berlin, 1999)). In the case of relatively hard active compounds, the diameters would rather be in the range of from 700 nm to 1,000 nm (e.g. M. Grau, Dissertation, FU Berlin, 2000). For the latter group of drugs in particular, more efficient comminution methods are particularly desirable. The particle sizes cited above were obtained by homogenization under a pressure of 1,500 bar. It is known from the literature that smaller particle sizes can be obtained by an increase in the homogenization pressure, e.g. from 500 bar to 1,500 bar. Hard crystalline substances were consequently homogenized under pressures of up to 4,000 bar. In spite of more than twice the homogenization pressure, however, the resulting particle sizes remain practically unchanged (Fichera, M. A., Wissing, S. A., Müller, R. H., Effect of 4000 bar homogenisation pressure on particle diminution on drug suspensions, Int. Meeting on Pharm., Biopharm. and Pharm. Technology, Nuremberg, 679-680, 2004). One explanation for this is the increasing crystallinity of the particles during the homogenization process. At the start, the particles break at weak points, that is to say in particular at defects or in amorphous regions. As the comminution progresses, however, the number of these defects or amorphous regions decreases constantly, and the smaller particles produced become increasingly more perfect. At a certain point in the homogenization operation only almost perfect crystals remain. Further comminution, e.g. by doubling the homogenization pressure, is no longer possible, since the force required for this increases in a non-linear manner with ever more perfect crystals. This is an exponential increase. If the steep part of the curve has already been reached, even doubling of the homogenization pressure has only a slight influence on the size. It is clear from this that in high pressure homogenization a maximum dispersivity can be achieved under pressures in the range of 1,500 bar. In order to achieve a further particle size reduction for a particular drug, greatly improved comminution techniques must be used.
Summarizing, it can be said: The problems associated with the production of drug nanocrystals by precipitation, such as difficulties in maintaining the particle size and the associated specific methods required (e.g. lyophilization), lead to the fact that it has hitherto been possible to find scarcely any or only few uses for these products on the market. It was possible to solve or minimize a potential problem, namely the subsequent particle growth occurring after the precipitation, by using the principle of subsequent heat treatment, e.g. by introduction of energy, which leads to preservation of the particle size achieved by the precipitation (e.g. U.S. Pat. No. 6,607,784).
Technologies which can be used for drugs which are poorly soluble in all media are the ball mill techniques and the high pressure homogenization technologies. Problems associated with the ball mills are the long grinding times and a potential contamination of the product. It has been possible to overcome these limitations by using piston-gap homogenizers. However, there continues to be a need for improved homogenization technologies, since the non-linear relationship between the pressure and the crystal size which can be achieved, as a function of the crystallinity, limits the minimum particle size which can be achieved.
There is therefore a clear need for novel production methods which:
The object of this invention is therefore to provide a method for producing coated particles, in particular nanoparticles, which dissolve rapidly, transport drugs to the site of action in a targeted manner and at the same time protect them from premature breakdown by influences such as gastric acid, enzymes or other adverse factors. The method includes production of the particles with a minimum possible size and subsequent coating of these particles with protective polymers.
The object according to the invention of producing the particles to be coated is achieved by a method for the preparation of suspensions of very fine particles, which is characterized in that a liquid stream of a particle-free liquid 1 containing the active compound in dissolved form is brought together with a second liquid stream of a liquid 2 in a high-energy zone or at the earliest 2 seconds before reaching the high-energy zone, wherein the two liquids are miscible with one another and the active compound dissolved in liquid 1 is insoluble or less soluble in liquid 2 and precipitates as particles in the or within a maximum of 2 seconds before reaching the high-energy zone on mixing of the two liquids.
The particles produced in this way by way of example are then introduced into an aqueous external phase which contains the coating or covering materials in dissolved form, and the mixture is then subjected to a drying step, as a result of which these materials precipitate on the particles as a closed coating. The particles enveloped in this way are protected from harmful influences and, in contrast to non-enveloped particles, have modified release kinetics.
The size-reducing process comprises dissolving of the active compound in a solvent, mixing of the solvent with a non-solvent and carrying out of a precipitation in a zone of high energy. Thereafter, the suspension obtained is subjected to a film coating process (coating process) with polymers or macromolecules. The film coating process can be used in particular for nanoparticles, but of course also for microparticles, without organic solvents having to be used. The process can be carried out in non-organic solvents, in particular in water or aqueous media.
The present invention opens up the possibility of obtaining very fine or ultrafine drug particles or polymer particles having an average diameter of less than 1,000 nm, preferably of less than 300 nm, particularly preferably of less than 200 nm and specifically of less than 100 nm down to approx. 5 to 10 nm. Various methods have been described to date for preparation of suspensions via precipitation, the size which can be achieved depending exclusively on the precipitation conditions (e.g. mixing rate, nature of the stabilizer) (see U.S. Pat. No. 5,389,382 and US-A-2005 0 139 144). It has also been described that the precipitated product can be treated in a second subsequent step after precipitation has been concluded. The precipitated product is treated with high energy in order to maintain the particle size achieved and to prevent further growth of the suspension such as occurs when the suspensions are stored for days (see US-A-2002 0 127 278). The same process can also be used to modify the crystalline character of the material, i.e. to convert amorphous or partly crystalline regions into completely crystalline material. In contrast to merely maintaining the particle size achieved by precipitation, this invention prevents a growth of the crystals during the precipitation process by expending energy. The method is used, not after the complete precipitation process, as described in US-A-2002 0 127 278, but already during the precipitation. Surprisingly, it has additionally been discovered that a prevention of the crystal growth leads to crystals which can be comminuted still further relatively easily by further expenditure of energy (Example 1).
Carrying out the precipitation in a zone of high energy requires a particular design of the apparatus. This design can also be achieved by a modification of already existing apparatuses, in that various modified parts are added in order to feed in the liquid phase which is processed in the high-energy zone.
The film coating process can be carried out in various ways. Either the desired polymers are already dissolved in the external phase before production of the particles, or particles of the desired size are first produced, in order for these then to be dispersed in a polymer solution and thereafter for a film formation to be achieved by withdrawal of the solvent or modification of the properties of the solvent. The withdrawal of the solvent or the film formation can be carried out by spray drying, evaporation methods, solvent diffusion methods, lyophilization or in the course of the use of further processes, such as, for example, fluidized bed granulation or suspension spray application (suspension layering).
The aim of this invention was to develop a process for producing coated particles, in particular nanoparticles, which dissolve rapidly in order to transport these drugs to the intestinal tract and at the same time to protect them from the acidic pH of the stomach. The process includes, for example, production of nanoparticles with a minimum possible size and subsequent coating of these particles with protective polymers.
The size-reducing process comprises dissolving of the active compound in a solvent, mixing of the solvent with a non-solvent and carrying out a precipitation in a zone of high energy. Thereafter, the suspension obtained is subjected to a film coating process (coating process) with polymers or macromolecules. The film coating process can be used in particular for nanoparticles, but of course also for microparticles, without organic solvents having to be used.
The process can be carried out in non-organic solvents, in particular in water or aqueous media.
The present invention opens up the possibility of obtaining very fine or ultrafine drug particles or polymer particles having an average diameter of less than 1,000 nm, preferably of less than 300 nm, particularly preferably of less than 200 nm and specifically of less than 100 nm down to approx. 5 to 10 nm.
Various methods have been described to date for preparation of suspensions via precipitation, the size which can be achieved depending exclusively on the precipitation conditions (e.g. mixing rate, nature of the stabilizer) (see U.S. Pat. No. 5,389,382, US-A-2005 0 139 144). It has also been described that the precipitated product can be treated in a second subsequent step after precipitation has been concluded. The precipitated product is treated with high energy in order to maintain the particle size achieved and to prevent further growth of the suspension such as occurs when the suspensions are stored for days (US-A-2002 0 127 278). The same process can also be used to modify the crystalline character of the material, i.e. to convert amorphous or partly crystalline regions into completely crystalline material. In contrast to merely maintaining the particle size achieved by precipitation, this invention prevents a growth of the crystals during the precipitation process by expending energy. The method is used, not after the complete precipitation process, as described in (US-A-2002 0 127 278), but already during the precipitation. Surprisingly, it has additionally been discovered that a prevention of the crystal growth leads to crystals which can be comminuted still further relatively easily by further expenditure of energy (Example 1).
Carrying out the precipitation in a zone of high energy requires a particular design of the apparatus. This design can also be achieved by a modification of already existing apparatuses, in that various modified parts are added in order to feed in the liquid phase which is processed in the high-energy zone.
The film coating process can be carried out in various ways. Either the desired polymers are already dissolved in the external phase before production of the particles, or particles of the desired size are first produced, in order for these then to be dispersed in a polymer solution and thereafter for a film formation to be achieved by withdrawal of the solvent or modification of the properties of the solvent. The withdrawal of the solvent or the film formation can be carried out by spray drying, evaporation methods, solvent diffusion methods, lyophilization or in the course of the use of further processes, such as, for example, fluidized bed granulation or suspension spray application (suspension layering).
A precipitation step carried out in the conventional manner leads within 1 to 10 seconds to a product having an average particle diameter in the size range of from approx. 500 nm to a few micrometres, and crystal growth typically rapidly leads to a precipitate in the micrometre range. Processing of this material by means of high pressure homogenization can preserve the precipitated particle size and prevent further crystal growth, but does not substantially reduce the particle size (US-A-2002 0 127 278). It is therefore particularly important that in the present invention the comminution process starts immediately or within milliseconds to seconds after the crystallization process. In this phase the particles are still in the lower nanometre range (e.g. below 500 nm). In addition, it can be assumed that the orientation method of the molecules which form the crystal is not yet concluded completely, since the crystallization has just begun.
Just as in the case of lipids, arrangement of the molecules requires time for an optimized arrangement within the crystal structure. In the case of lipids, such as e.g. adeps solidus (hard fat), it takes approximately 6 seconds to arrive at the more ordered beta modification from the alpha modification. Apart from highly purified fats, fats are chemically inhomogeneous, that is to say they are composed of very different molecules. These molecules of spatially different structure require more time to orientate themselves compared with chemically uniform compounds. This can be compared to the construction of a wall from uniform bricks, which can be constructed relatively rapidly compared with a wall of very different stones. The conclusion drawn from this theoretical consideration is that the crystal formation process of a chemically uniform drug should proceed very rapidly. Surprisingly, it has been found that precipitation in the range of high energy or followed by the immediate expenditure of high energy (e.g. above the power density of 105 W/m3) leads to prednisolone nanocrystals having an average diameter of 133.6 nm (determined by photon correlation spectroscopy (PCS)) (Example 2). The achievement of such a size using the high pressure homogenization technique has not yet been reported to date.
The suspension obtained by this procedure was processed further under the action of further energy. Circulation of the suspension up to a total time of 5 minutes in the homogenizer led to a PCS diameter of 26.6 nm. Surprisingly, the structure of the particles which were precipitated out under the influence of high energy appears to be transformed into a more fragile form. The particle diameter decreased here to a size (Example 3) which as yet has never been reported for a high pressure homogenization process corresponding to U.S. Pat. No. 5,091,187 or U.S. Pat. No. 5,858,410.
According to the Kelvin equation, the vapour pressure of drops of liquid in a gas phase increases with increasing curvature of the drops, i.e. with decreasing drop size. Equivalent to this, the solution pressure of solid particles in a liquid increases with decreasing particle size, i.e. the saturation solubility increases (K. Peters, Dissertation, FU Berlin, 1999). Model calculations have been performed for the increase in the vapour/solution pressure as a function of the size of the spherical drops/particles (S. Anger, Dissertation, FU Berlin, 2004). An exponential relationship was obtained here. The calculations showed no or only a very small increase for sizes of about 1 μm. However, a remarkable increase was found when the size was reduced from 1 μm (1,000 nm) to 100 nm. Due to the exponential character of the relationship between size and solution pressure, a significant increase in the solution pressure was found at particle sizes below 100 nm, which was particularly pronounced below 50 nm, and an extremely high increase was found at particle sizes of below 25 nm. On the basis of this, the saturation solubility will have a particularly pronounced increase if the size is below 50 nm. In Example 4 the prednisolone particles were homogenized in the continuous process for 10 minutes. After 6 minutes the PCS diameter was 22.1 nm, after 7 minutes 21.4 nm, and after 8 minutes the nanocrystals were dissolved and a clear solution was obtained. This highly supersaturated solution was stable for approximately 1 hour before precipitation with the formation of large crystals occurred.
A similar effect was observed in the precipitation of budesonide, which led to the formation of crystals having a diameter of LD 50% of 7.339 μm (volume distribution, determined by laser diffractometry, LD) (Example 5). The precipitation according to the invention using the jet stream principle (corresponding to the construction in
In order to be able to subject the crystallizing particles to a comminuting force immediately, it is necessary for the precipitation to take place directly in the dissipation zone of the energy-supplying apparatus, e.g. ultrasonic probe (
Depending on the speed of the in situ formation of particles during the precipitation operation, it may be more advantageous either to precipitate the particles directly in the homogenization zone or to bring the particles into the homogenization zone with a short delay, so that at least the formation of the core is concluded. Further precipitation and crystal growth could otherwise occur if the particles have already left the homogenization zone. In order to be able to control the delay time between the start of the crystallization and the homogenization, a device has been developed with which the required delay can be established via the pumping speed and a variable distance between the “site of mixing” and “the zone of introduction of power”, to obtain the desired target size of the crystals. It is not desirable to generate the smallest possible crystals in every case.
In order to achieve this, specific homogenization chambers have been designed for this process (
To avoid energy “impinging” on the particles just forming by precipitation in too early a phase, a delay can be incorporated in that mixing of the solvent and the non-solvent takes place with a delay of from one millisecond to a maximum of two minutes before the dissipation zone of the ultrasonic apparatus, of the homogenizer, of the colloid mill or of comparable comminution apparatuses is reached. The time of the delay of entry in the homogenization zone can be adapted by varying the flow rate of the liquid streams and by varying the distance x (e.g.
The Lab-Scale Microfluidizer HC-2000 (Microfluidics Inc., USA) has been adapted for this process in that a hose with a 0.45 g cannula has been placed in the inflow reservoir in order to add the solvent liquid stream in a controlled manner. The pumping rate here was 10 ml/min. The non-solvent was added to the inflow reservoir (corresponding to
The pumping speed of the liquids through the homogenizer was approx. 200 ml/min. On the intake side of the pump the flow rate of the product is up to 0.1 m/s for low-viscosity liquids (Müller, R. H., Böhm, B. (ed.), Dispersion Techniques for Laboratory and Industrial Scale Processing, Wissenschaftliche Verlagsgesellschaft Stuttgart, 113 S., 2001, p. 77). Taking into account the low viscosity of water and ethanol and the short distance between the reservoir and the pump, the liquids thus reach the pump after approximately less than 200 ms. According to the manufacturers of the apparatus, the diameter of the intake tube is relatively large in order to render possible the lowest possible flow resistance (Müller, R. H., Böhm, B. (ed.), Dispersion Techniques for Laboratory and Industrial Scale Processing, Wissenschaftliche Verlagsgesell-schaft Stuttgart, 113 S., 2001, p. 77). By the modification of the apparatus in accordance with
This construction can also be utilized to precipitate particles directly in the collision zone (
For oral administration, the drug nanocrystals often require a polymer coating, especially if the drugs are acid-labile drugs which could be destroyed during unprotected passage through the stomach. Further reasons for polymer coatings are targeted administration of the drug (drug targeting) or a desired controlled release. So that the abovementioned advantageous properties of individual drug nanocrystals do not have to be dispensed with, the possibility of coating individual nanocrystals, as implemented in this patent, is particularly desirable.
In this context the use of organic solvents is undesirable for any process, whether for toxicological, ecological or economic reasons. For this reason a process has been developed in which the (nano)crystals prepared are preferably coated with polymers without the use of organic solvents.
Acidic polymers which are present in protonated form at the acidic pH of the stomach and are insoluble are often used for the preparation of enteric-coated drug forms. When the pH then increases on transition to the intestine, salts of these polymers form.
The deprotonated polymers have a better solubility and release the enclosed drug.
In order to apply these polymers to the medicament forms they are as a rule dissolved in organic solvents or used in the form of aqueous dispersions (O/W emulsions). Generally, the use of organic solvents is not advantageous, and in the specific case they cannot be used at all since many water-insoluble active compounds are in some cases even very readily soluble in organic solvents. Aqueous dispersions likewise cannot be used for coating nanocrystals since these on the one hand have too large a particle size/drop size compared with the drug nanocrystals and on the other hand often react in a very unstable manner during mixing.
For these reasons aqueous polymer solutions were used as the coating material in the present invention, the pH-dependent solubility of polymers having been utilized.
Aqueous solutions of enteric film-forming agents have already been known for a relatively long time (Bianchini, R., Resciniti, M., Vecchio, C. Technology evaluation of aqueous enteric coating systems with and without insoluble additives, Drug Dev Ind Pharm 17, 1779-1794, 1991; company information Röhm, Pharmapolymere, Magensaftresistente Überzüge, 2003). However, these polymer solutions have hitherto been employed only to coat conventional medicament forms, such as e.g. tablets and pellets, with an enteric film-forming agent. If conventional bases, such as sodium hydroxide or potassium hydroxide, are used, however, enteric properties can be achieved only by applying large amounts. This is not practicable technically for nanoparticles/nanocrystals (e.g. to high a dilution of the nanosuspension, which is difficult to concentrate again; reduction in the zeta potential by addition of electrolyte with subsequent aggregation of crystals). A solution approach, namely the use of volatile bases, such as ammonium bicarbonate, is described by Hasan Rafati in the patent GB2353215. However, this patent includes only the solution layering technique (specifically in the coating pan method) and also gives only examples for enteric-coated acetylsalicylic acid tablets.
In contrast, the present invention describes the use of aqueous polymer solutions both as the dispersion medium during the production of nanocrystals and for coating nanoparticles, specifically drug nanocrystals.
In principle, a distinction may be made between two versions in the coating of the drug nanocrystals. In the first version the particles to be coated are produced directly in the polymer solution. In this context either the methods described above can be used, or the drug nanocrystals can be produced by another method and manner. Possible methods are described, for example, in the patent of R. H. Müller et al. (WO 0103670) but without going into detail of a film coating process (coating) of individual nanocrystals.
In a further version of the patent, the drug nanocrystals are already produced before the addition to the polymer solution, and are dispersed in the polymer solution only subsequently in the form of a nanosuspension or a powder with the aid of mixing apparatuses of low power density (for example toothed disc mixer, blade stirrer).
The coated nanoparticles then have, depending on the method used and the starting size, a particle size in the range of from a few 100 nm up to 100 μm, preferably below 50 μm, ideally below 5 μm, the drug crystals having a particle size in the nanometre range.
In the case of acidic polymers (for example polymethacrylates, cellulose acetate phthalate, hydroxypropylmethylcellulose phthalate, HPMCAS), an aqueous polymer solution is obtained, for example, by addition of sufficient amounts of volatile bases, such as e.g. ammonium bicarbonate. By addition of this base, the pH is shifted into a range in which the polymer is soluble (
Typical surfactants or stabilizing substances which can be added to the solvent are e.g. compounds from the series of polyoxyethylene/polyoxypropylene block copolymers (poloxamers), ethylenediamine/polyethylene oxide/polypropylene oxide block polymers (poloxamines), ethoxylated mono- and diglycerides, ethoxylated lipids and lipiods, ethoxylated fatty alcohols and alkylphenols, ethoxylated fatty acid esters, polyglycerol ethers and esters, lecithins, esters and ethers of sugars or sugar alcohols with fatty acids or fatty alcohols, such as e.g. ethoxylated sorbitan fatty acid esters, in particular polysorbates (e.g. polysorbate 80 or Tween 80), polyglycerol methylglucose distearate (Tego Care 450), sorbitan fatty acid esters (e.g. Span 85), phospholipids and sphingolipids, sterols, esters or ethers thereof and mixtures of these compounds. In addition, egg lecithin, soya lecithin or hydrogenated lecithins, mixtures thereof or mixtures of one or both lecithins with one or more phospholipid components, cholesterol, cholesterol palmitate, stigmasterol or other sterols are also possible for addition to the solution.
Under certain circumstances it may be necessary to add further substances to the solution in order to influence the properties of the solution itself or the properties of the dry powder prepared from the solution. Possible substances for this are, inter alia: diacetyl phosphate, phosphatidyl-glycerol, saturated or unsaturated fatty acids, sodium cholate, peptisators or amino acids, and cellulose ethers and esters, polyvinyl derivatives, alginates, xanthans, pectins, polyacrylates, poloxamers and poloxamines, polyvinyl alcohol, polyvinylpyrrolidone or glucose, mannose, trehalose, mannitol and sorbitol, fructose, sodium citrate, sodium hydrogen phosphate, sodium dihydrogen phosphate, sodium chloride, potassium chloride or glycerol. If necessary, dyestuffs, either in dissolved form or in insoluble form as pigments, can also be added to the solvent.
After the particles to be coated have been produced or dispersed completely in the polymer solution, film formation around these particles can be initiated by increasing the temperature of the system or by various drying methods. In this context the film formation process can be realized in various ways.
One possible method is spray drying, in which the process temperature is to be chosen as a function of the heat sensitivity of the drug and the properties of the polymer. In the case of the thermolabile drug omeprazole, a product temperature of from 50 to 60° C. should not be exceeded.
During the spray drying process, the ammonium salt of the enteric polymer/macromolecule which is formed when the polymer dissolves dissociates into the free acid and ammonia and water, the ammonia formed evaporating immediately (
Examples of spray dryers which can be used are apparatuses from the companies Niro, Nubilosa, Caldyn, Büchi, APV, Trema etc.
In the case of active compounds which are not heat-sensitive, the base dispersion formed can be heated, while stirring, as a rule temperatures above 60° C. being preferred. Ammonia, carbon dioxide and water are formed here, ammonia and CO2 escaping and the polymer separating out on the surface of the nanocrystals via phase separation due to the lowered pH. In an appropriate process procedure, individual encapsulated nanocrystals are formed. By addition of electrolytes, the process can also be controlled via lowering of the zeta potential such that encapsulated nanocrystals join together to form large aggregates. The latter may be advantageous during further processing (e.g. these particle aggregates are easier to separate off).
A further approach to film formation is the addition of acids to nanosuspensions if the active compounds to be encapsulated are sufficiently stable to acids for the process time and the polymers are employed, for example, to coat the drug nanocrystals only for an improved “drug targeting”.
A further approach to film formation is the use of drying methods via emulsion processes. In this context, the base dispersion is dispersed as the internal phase in a non-aqueous phase by conventional dispersing methods (e.g. blade stirrers, rotor-stator systems, toothed discs, homogenization by high pressure, with the aid of ultrasound). A w/o system is formed, the water drops containing the nanoparticles and dissolved polymer. Water is withdrawn in the next step, which can take place in various ways, e.g.:
During withdrawal of the water polymer is deposited on the surface of the nanoparticles, the viscosity increases, as the temperature increases evaporation of ammonia and carbon dioxide occurs again and an enteric coating is formed. In the preferred version, the polymer particles obtained are characterized in that as a rule they have included more than one nanoparticle.
The base dispersion prepared can also be further processed directly in a granulation process. In principle the same process as in the evaporation methods proceeds, but with the difference that further inert auxiliaries from a conventional granulation process are also present (e.g. lactose crystals). Deposition on nanoparticles and lactose crystals takes place in parallel, so that a mixture of encapsulated nanoparticles and encapsulated auxiliaries is prepared.
The granules obtained can either be filled into capsules, or alternatively tablets can be pressed. A further possibility is filling into sachets, e.g. for redispersing in drinks for administration. Extrusion of the granules to matrix pellets is furthermore possible.
In a further version, the suspension with still dissolved polymer/macromolecule which is obtained after the homogenization is sprayed directly, after addition of plasticizer, on to e.g. sugar pellets (non-pareilles). During the drying process a solid polymer shell is formed, this containing firmly included nanoparticles. The drying process is carried out at temperatures above 60° C., so that ammonia and carbon dioxide escape again.
Due to the film formation of the polymer on the surface of the drug particles, the properties of the coated drug nanocrystals are changed significantly. Depending on the polymer used e.g. a delayed release, an increased mucoadhesiveness or also a protection of sensitive drugs from the influence of gastric juice can be achieved. Needless to say, for enteric properties it is necessary for the base used for adjustment of the pH to be volatile under the process conditions, i.e. not to be present, for example, in the dry form in the end product.
If non-volatile bases are used, such as e.g. sodium hydroxide, precipitation of the acidic polymers occurs only after contact with acid, and as a result acid can initially penetrate and damage the sensitive drug. If volatile bases are used, such as e.g. ammonium bicarbonate, the base content escapes completely during the drying process since the ammonium salts of the acidic polymers liberate ammonia and are then present in the protonated, i.e. acid-insoluble form again. The polymer films formed are therefore already solid and acid-resistant before the action of an acid (
Prednisolone was precipitated in the conventional manner, that is to say by addition of a solvent to a non-solvent. 275 mg of prednisolone were dissolved in 10 ml of 90% (v/v) ethanol and this solution was poured into 90 ml of distilled water, while stirring with a magnetic stirrer. Determination of the particle size directly after the precipitation gave a diameter LD 50% of 2.185 μm, LD 95% of 5.108 μm, LD 99% of 6.414 μm and a diameter of LD 100% of 8.944 μm (volume distribution, laser diffractometry, Coulter LS 230, Beckman-Coulter, USA).
Prednisolone was dissolved in 10 ml of 90% (v/v) ethanol analogously to Example 1. 10 ml of this prednisolone solution were then pumped with the aid of an infuser (Braun Melsungen, Germany) into an apparatus which is described in
A precipitation was carried out analogously to Example 2, and after 5 minutes a sample of the precipitated product was taken and analyzed with the aid of photon correlation spectroscopy. The average particle diameter (z-average) was 27 nm at a polydispersity index (PI) of 0.460.
A precipitation was carried out analogously to Example 2, the homogenization time being 10 min. After 6 minutes a sample of the precipitate was taken and analyzed with the aid of photon correlation spectroscopy. The average particle diameter (z-average) was 22 nm at a polydispersity index (PI) of 0.854. A sample taken after 7 minutes had a PCS diameter of 22 nm at a PI of 0.441. After 8 minutes the prednisolone crystals dissolved due to the increased solution pressure at this small size. The milky suspension changed into a clear solution. After one hour the highly supersaturated solution started to crystallize out in the form of long, macroscopically visible needles.
Budesonide was precipitated in the conventional manner by addition of a solvent to a non-solvent. For this, 275 mg of budesonide were dissolved in 10 ml of 90% (v/v) ethanol and this solution was poured into 90 ml of distilled water, while stirring with a magnetic stirrer. Determination of the particle size directly after the precipitation gave a diameter LD 50% of 7.339 μm and LD 90% of 10.920 μm (volume distribution, laser diffractometry, Coulter LS 230, Beckman-Coulter, USA).
Budesonide was dissolved in 10 ml of 90% (v/v) ethanol analogously to Example 1. 10 ml of this prednisolon solution were then pumped with the aid of an infuser (Braun Melsungen, Germany) into an apparatus which is described in
An ethanolic budesonide solution corresponding to Example 6 was prepared, and a portion of this solution was added to distilled water, which was directly in the reservoir tank of a Micron LAB 40 (APV Homogenizer Systems, Unna, Germany). The budesonide precipitated out and 2 seconds after the precipitation energy was expended in the form of a homogenization step in order to investigate the effect of a delayed use of energy. A homogenization cycle was carried out under 1,500 bar. The diameter, determined by laser diffractometry, was LD 50% 2.651 μm and LD 90% 5.693 μm (volume distribution, laser diffractometry, Coulter LS 230, Beckman-Coulter, USA).
The precipitation product prepared for Example 5 was subjected to a jet stream method, the homogenization taking place as described in Example 6. An LD 50% of 2.157 μm was measured as the particle size. If the inventive method is used, as described in Example 6, 1.858 μm is obtained.
The pharmaceutical active compound hydrocortisone acetate was comminuted according to the invention in an aqueous polymer solution by high pressure homogenization. For this, 1.0 g of ammonium bicarbonate was first added to 92.0 g of water and 5.0 g of hydroxypropylmethylcellulose phthalate 55 (HPMCP 55) were dissolved in this solution. A liberation of carbon dioxide thereby occurred. The pH of the resulting polymer solution was then adjusted to 7.5 by further addition of ammonium bicarbonate. 1 g of poloxamer 188 was dissolved in this solution and 1.0 g of micronized hydrocortisone acetate was dispersed with an Ultra-Turrax (Janke & Kunkel, Germany) at 9,500 revolutions per minute. The mixture was then homogenized with a Micron LAB 40 high pressure homogenizer (APV Homogenisers, Unna, Germany). At the start 2 cycles were carried out under 150 bar, then 2 cycles under 500 bar and further homogenization was subsequently carried out under 1,500 bar. After 20 homogenization cycles at room temperature (RT) under a pressure of 1,500 bar, an average particle diameter of 951 nm and a polydispersity index (PI) of 0.216 were obtained with the aid of photon correlation spectroscopy (PCS).
The pharmaceutical active compound hydrocortisone acetate was comminuted according to the invention in an aqueous polymer solution by high pressure homogenization. For this, 2.5 g of ammonium bicarbonate were first added to 91.5 g of water and 4.0 g of Eudragit S 100 (pulverulent) were dissolved in this solution. A liberation of carbon dioxide thereby occurred. The pH of the resulting polymer solution was then adjusted to 7.5 by further addition of ammonium bicarbonate. 1.0 g of poloxamer 188 was dissolved in this solution and 1.0 g of micronized hydrocortisone acetate was dispersed with an Ultra-Turrax (Janke & Kunkel, Germany) at 9,500 revolutions per minute. The mixture was then homogenized with a Micron LAB 40 high pressure homogenizer (APV Homogenisers, Unna, Germany). At the start 2 cycles were carried out under 150 bar, then 2 cycles under 500 bar and further homogenization was subsequently carried out under 1,500 bar. After 20 homogenization cycles at room temperature (RT) under a pressure of 1,500 bar, an average particle diameter of 787 nm and a polydispersity index (PI) of 0.273 were obtained with the aid of photon correlation spectroscopy (PCS).
The pharmaceutical active compound omeprazole was likewise comminuted according to the invention in an aqueous polymer solution by high pressure homogenization. For this, 1.0 g of ammonium bicarbonate was first added to 92.0 g of water and 5.0 g of hydroxypropylmethylcellulose phthalate 55 (HPMCP 55) were dissolved in this solution. A liberation of carbon dioxide thereby occurred. The pH of the resulting polymer solution was then adjusted to 7.5 by further addition of ammonium bicarbonate. 1.0 g of poloxamer 188 was dissolved in this solution and 1.0 g of micronized omeprazole was dispersed with an Ultra-Turrax (Janke & Kunkel, Germany) at 9,500 revolutions per minute. The mixture was then homogenized with a Micron LAB 40 high pressure homogenizer (APV Homogenisers, Unna, Germany). At the start 2 cycles were carried out under 150 bar, then 2 cycles under 500 bar and further homogenization was subsequently carried out under 1,500 bar. After 20 homogenization cycles at 5° C. under a pressure of 1,500 bar, an average particle diameter of 945 nm and a polydispersity index (PI) of 0.289 were obtained with the aid of photon correlation spectroscopy (PCS).
The pharmaceutical active compound omeprazole was likewise comminuted according to the invention in an aqueous polymer solution by high pressure homogenization. For this, 2.5 g of ammonium bicarbonate were first added to 91.5 g of water and 4.0 g of Eudragit S 100 (pulverulent) were dissolved in this solution. A liberation of carbon dioxide thereby occurred. The pH of the resulting polymer solution was then adjusted to 7.5 by further addition of ammonium bicarbonate. 1.0 g of poloxamer 188 was dissolved in this solution and 1.0 g of micronized omeprazole was dispersed with an Ultra-Turrax (Janke & Kunkel, Germany) at 9,500 revolutions per minute. The mixture was then homogenized with a Micron LAB 40 high pressure homogenizer (APV Homogenisers, Unna, Germany). At the start 2 cycles were carried out under 150 bar, then 2 cycles under 500 bar and further homogenization was subsequently carried out under 1,500 bar. After 20 homogenization cycles at 5° C. under a pressure of 1,500 bar, an average particle diameter of 921 nm and a polydispersity index (PI) of 0.370 were obtained with the aid of photon correlation spectroscopy (PCS).
The suspension prepared for Example 9 was then spray dried with a Mini Spray Dryer, model 190 spray dryer (Büchi, Switzerland). The spray drying conditions were: volume flow 700 l/min, pump setting 5, aspiration 8, heating rate: 5, inlet temperature: 120° C., outlet temperature: 55 to 60° C. The powder obtained in this manner was then examined under a light microscope. A uniformly round appearance, only few aggregates and a particle size in the range of from 1 to 5 μm was found at 1,000-fold magnification. Macroscopically, the product is a white, loose powder with good flowability.
The powder prepared in Example 13 was subjected to a release test in order to demonstrate the reduced release in an acidic medium. For this, the powder was first stirred at 50 revolutions per minute in 750 ml of 0.1 N HCl for one hour at 37° C. and samples were taken with the aid of a 0.2 μm filter syringe at suitable intervals of time. The drug content was then determined with the aid of an HPLC installation. Only 20% of the total drug content was released within the first hour. A further 250 ml of phosphate buffer were then added to the release medium and the pH was therefore increased to pH 6.8. This increase in pH resulted in the intended dissolution of the enteric polymer. The total residual content of drug was released within 30 minutes after addition of the phosphate buffer.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2005-053-862.2 | Nov 2005 | DE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP06/09930 | 10/13/2006 | WO | 00 | 8/19/2008 |
