Patent Application
20240277620
The invention discloses a method for preparation of spray dried amorphous solid dispersions comprising an active agent such as an active pharmaceutical ingredient, API, and a dispersion polymer wherein the spray drying is done with a solution of the active agent and of the dispersion polymer in a solvent comprising a mixture of a C1-2 alkanol with a C1-2 carboxylic acid C1-2 alkyl ester, and optionally water.
Spray dried amorphous solid dispersions comprising an active pharmaceutical ingredient, API, and a dispersion polymer are typically produced by dissolving the dispersion polymer and the API in a volatile solvent, such as methanol or acetone followed by spray drying. In cases where the API has limited solubility, approximately <4 wt % at room temperature, in the spray drying solvent, an API suspension can be heated to a temperature either below or above the solvent's ambient pressure boiling point, this is known as “hot spray drying process”, resulting in a higher dissolved concentration of API. In some cases, even the higher temperatures do not give adequate API concentrations that are economical for a spray drying process, or cause other problems such as chemical degradation of the API, or bear the risk of incomplete API dissolution in the heat exchanger. Alternate, non-preferred volatile solvents can provide increased solubility of the API, but these solvents have other disadvantages that make them less desirable, e.g. high cost, toxicity, poor equipment compatibility, poor commercial availability, high disposal costs, challenges removing to sufficiently low levels, higher viscosity.
WO 2019/220282 A1 discloses in Example 1 spray drying of a solution of erlotinib and a dispersion polymer (PMMAMA or hydroxypropyl methylcellulose acetate succinate H grade) in methanol to provide a spray dried dispersion.
There was a need for a method for preparing spray dried solid dispersion of an active agent and dispersion polymers, which allows for dissolving the APIs in easily processable spray drying solvents at modest temperature, i.e. a temperature below the ambient pressure boiling point, at sufficiently high concentrations to enable economical throughput of spray dried amorphous solid dispersions. The amorphous solid dispersion should be stable over a longer period of time.
It was found that a mixture of a C1-2 alkanol with a C1-2 carboxylic acid C1-2 alkyl ester shows synergistic, also called non-linear, dissolution behaviour, i.e. a mixture provides for higher solubility compared to the, by linear extrapolation from the solubilities of the pure solvents, expected solubilities at the respective weight average of the individual solvents, and may be used as a mixed solvent in such spray drying method. This synergistic behaviour was not expected. Furthermore both a C1-2 alkanol and a C1-2 carboxylic acid C1-2 alkyl ester individually are regarded as poor solvents compared to solvents such as dichloromethane (DCM), tetrahydrofuran (THF) and N-methyl-2-pyrrolidone (NMP), but both are regarded as solvents well suited for spray drying, so a synergistic increase of the solubilities allows for higher concentration of active agent in the spray solution when using these two solvents as a mixture. Increased active agent solubility gives higher manufacturing throughput, and potentially better spray dried particle characteristics than what is achievable with lower solids content spray solutions.
Another advantage is that the two solvents can be mixed with water to provide a ternary mixture and this aqueous ternary mixture of the two solvents with water still provides for the synergistic increase of solubility, thereby also dispersion polymers, such as HPMC, which typically require the presence of some water in order to dissolve in an organic solvent, many be used. The synergistic behaviour of the ternary mixture was also unexpected since water alone is usual regarded being a still poorer solvent than any of the C1-2 alcohols and C1-2 carboxylic acid C1-2 alkyl esters.
Subject of the invention is a method for preparing an amorphous solid dispersion by spray drying a spray solution comprising
The solution of the active agent in the spray solution is a stable solution.
The spray solution has not more than one liquid phase.
The liquid in the spray solution may comprise in addition to the mixed solvent further solvents.
The amount of mixed solvent in the liquid of the spray solution may be at least 50 wt %, preferably at least at least 60 wt %, more preferably at least 70 wt %, even more preferably at 80 wt %, especially at least 90 wt %, more especially at least 95 wt %; with the wt % being based on the weight of the liquid of the spray solution;
The active agent is a biologically active compound. The biologically active compound may be desired to be administered to a patient in need of active agent.
A biologically active compound may be a drug, medicament, pharmaceutical, therapeutic agent, nutraceutical, agrochemical, fertilizer, pesticide, herbicide, nutrient, or an active pharmaceutical ingredient, API; preferably an API.
The active agent may be one or more active agents; the spray dried amorphous solid dispersion may contain one or more active agents.
Preferably, the active agent has a low solubility in solvent 1 and in solvent 2, such as in methanol or in methyl acetate, especially in methanol, e.g. a low solubility of less than 3 wt %, or even less than 2 wt %, or even less than 1 wt %, or even less than 0.5 wt %, or even less than 0.25 wt %.
Preferably the solubility of said active agent in the mixed solvent is at least 1.1 fold, more preferably at least 1.25 fold, even more preferably at least 1.5 fold, even more preferably at least 1.75 fold, even more preferably at least 2 fold, especially at least 3 fold, more especially at least 4 fold, higher than the solubility of said active agent in either solvent 1 or solvent 2 alone.
Preferably the solubility of said active agent in the spray solution is at least 1.1 fold, more preferably at least 1.25 fold, even more preferably at least 1.5 fold, even more preferably at least 1.75 fold, even more preferably at least 2 fold, especially at least 3 fold, more especially at least 4 fold, higher than the solubility of said active agent in either solvent 1 or solvent 2 alone.
Preferably the concentration of said active agent dissolved in the mixed solvent is at least 1.1 fold, more preferably at least 1.25 fold, even more preferably at least 1.5 fold, even more preferably at least 1.75 fold, even more preferably at least 2 fold, especially at least 3 fold, more especially at least 4 fold, higher than the solubility of said active agent in either solvent 1 or solvent 2 alone.
Preferably the concentration of said active agent dissolved in the spray solution is at least 1.1 fold, more preferably at least 1.25 fold, even more preferably at least 1.5 fold, even more preferably at least 1.75 fold, even more preferably at least 2 fold, especially at least 3 fold, more especially at least 4 fold, higher than the solubility of said active agent in either solvent 1 or solvent 2 alone.
The active agent and the dispersion polymer are preferably homogeneously mixed in the spray dried amorphous solid dispersion.
In a spray dried amorphous solid dispersion containing the active agent and the dispersion polymer, the active agent may be homogeneously and preferably also molecularly dispersed in the dispersion polymer. The active agent and the dispersion polymer may form a solid solution in the spray dried amorphous solid dispersion.
The active agent may be amorphous or substantially amorphous in the spray dried amorphous solid dispersion; substantially means that at least 80 wt %, preferably at least 90 wt %, more preferably at least 95 wt %, even more preferably at least 98 wt %, especially at least 99% wt %, of the active agent is amorphous; the wt % being based on the total weight of active agent in the spray dried amorphous solid dispersion. The amorphous nature of active agent may be evidenced by a lack of sharp Bragg diffraction peaks in the x-ray pattern when spray dried amorphous solid dispersion is analyzed by a powder X-Ray Diffraction, PXRD. Possible parameters and settings for a x-ray diffractometer are equipment with a Cu-Kalpha source, setting in modified parallel beam geometry between 3 and 40° 2Theta and a scan rate of 2°/min with a 0.0° step size. Another evidence for the amorphous nature of active agent in the spray dried amorphous solid dispersion may be a single glass transition temperature, Tg. A single Tg is also evidence of a homogeneous mixture of amorphous active agent and dispersion polymer. Samples as such without any further sample preparation may be used for the determination of the Tg, the determination may run for example in modulated mode at a scan rate of 2.5° C./min, modulation of ±1.5° C./min, and a scan range from 0 to 180° C. The amorphous nature of the active agent shows a Tg which is equal to the Tg of neat dispersion polymer or which is between the Tg of the dispersion polymer and the Tg of the active agent. The Tg of the spray dried amorphous solid dispersion is often similar to the weighted average of the Tg of the active agent and the Tg of the dispersion polymer.
Any of the lower limits may be combined with any of the upper limits of active agent in the spray solution.
In one embodiment, the mixed solvent is not methanol/ethyl-acetate.
The ratio (w:w) of solvent 1: solvent 2 may be from 10:90 to 90:10, preferably from 20:80 to 80:20, more preferably from 30:70 to 70:30.
The combined amount of solvent 1 and solvent 2 in the mixed solvent may be at least 70 wt %, preferably at least at least 80 wt %;
In one embodiment, the mixed solvent consists of a mixture of solvent 1 and solvent 2; preferably, solvent 1 consists of only one of the possible individual solvents 1 and solvent 2 consists of only one of the possible individual solvents 2;
The mixed solvent may further comprise water.
The amount of water is chosen to be such that the spray solution has not more than one liquid phase.
When the mixed solvent comprises water, then the mixed solvent comprises not more than 30 wt %, preferably not more than 27.5 wt %, more preferably not more than 25 wt %, even more preferably not more than 22.5 wt %, especially not more than 20 wt %;
When the mixed solvent comprises water, then the mixed solvent may comprise at least 0.5 wt %, preferably at least 1 wt %, more preferably at least 2 wt %; even more preferably at least 5 wt %, of water, with the wt % being based on the weight of the mixed solvent.
In one embodiment, the mixed solvent consists of a mixture of solvent 1 and solvent 2 and water;
In one embodiment, the mixed solvent consists of a mixture of solvent 1 and solvent 2; preferably, solvent 1 consists of only one of the possible individual solvents 1 and solvent 2 consists of only one of the possible individual solvents 2.
In one embodiment, solvent 1 consists of only one of the possible individual solvents 1 and solvent 2 consists of only one of the possible individual solvents 2.
Preferred embodiments of HPMCAS are
When the dispersion polymer is HPMC, preferably the mixed solvent further comprises water; with the amount of water and all its embodiments as stated herein, for example from 10 to 30 wt %, or from 15 to 30 wt %, or from 20 to 30 wt %, with the wt % being based on the weight of the mixed solvent.
The dispersion polymer and the mixed solvent are chosen such that the dispersion polymer dissolves in the mixed solvent.
For example amounts of dispersion polymer in the spray solution may be from 0.5 wt % to 25 wt %, preferably from 1 wt % to 20 wt %, more preferably from 2.5 wt % to 15 wt %, even more preferably from 3 wt % to 10 wt %, with the wt % being based on the weight of the spray solution.
Amounts of dispersion polymer and of active agent in the spray solution are chosen such that a predefined amount of dispersion polymer and of active agent in the spray dried amorphous solid dispersion are provided.
The spray dried amorphous solid dispersion may comprise from 1 to 99 wt %, preferably from 10 to 95 wt %, more preferably from 10 to 80 wt %, even more preferably from 20 to 60 wt %, of active agent, the wt % being based on the weight of the spray dried amorphous solid dispersion.
The spray dried amorphous solid dispersion may comprise from 1 to 99 wt %, preferably from 20 to 90 wt %, more preferably from 40 to 80 wt %, of the dispersion polymer, the wt % being based on the weight of the spray dried amorphous solid dispersion.
Preferably, the combined content of active agent and dispersion polymer in spray dried amorphous solid dispersion is from 65 to 100 wt %, more preferably from 67.5 to 100 wt %, even more preferably from 80 to 100 wt %; especially from 90 to 100 wt %; more especially from 95 to 100 wt %; the wt % being based on the weight of the spray dried amorphous solid dispersion.
In one embodiment, the spray dried amorphous solid dispersion consists of active agent and dispersion polymer.
Relative amounts (w:w) of active agent to dispersion polymer in spray dried amorphous solid dispersion may be from 50:1 to 1:50, preferably from 25:1 to 1:25, more preferably from 10:1 to 1:10, even more preferably from 5:1 to 1:5.
An embodiment of the invention is a method for preparing an amorphous solid dispersion by spray drying a spray solution comprising
An embodiment of the invention is a method for preparing an amorphous solid dispersion by spray drying a spray solution comprising
An embodiment of the invention is a method for preparing an amorphous solid dispersion by spray drying a spray solution comprising
The spray solution may be fed into the spray dryer with a temperature of the spray solution up to the boiling point of the spray solution at ambient pressure; preferably with a temperature of from 4° C. to the boiling point of the spray solution at ambient pressure, preferably from 4° C. to a temperature below the boiling point of the spray solution at ambient pressure. In the context of this invention the term “the spray solution may be fed into the spray dryer with a temperature of the spray solution” means that “the spray solution is spray dried with a temperature of the spray solution”.
The spray drying may be done with an inlet temperature of from 60 to 165° C., preferably from 80 to 140° C.
The spray drying may be done with an outlet temperature equal to or less than the boiling point of the mixed solvent, such as with an outlet temperature from 20° C. to a temperature of 10° C. below the boiling point of the mixed solvent.
The spray drying may be done with any inert gas commonly used for spray drying, such as nitrogen.
The spray solution may further comprise a dissolved surfactant.
The surfactant may be for example a fatty acid and alkyl sulfonate, docusate sodium (for example available from Mallinckrodt Spec. Chern., St. Louis, Mo.), polyoxyethylene sorbitan fatty acid esters (for example Tween®, available from ICI Americas Inc, Wilmington, Del., or Liposorb® P-20, available from Lipochem Inc, Patterson, N.J., or Capmul® POE-0, available from Abitec Corp., Janesville, Wis.), natural surfactants such as sodium taurocholic acid, 1-palmitoyl-2-oleoyl-sn-glycero-3-phosphocholine, lecithin, other phospholipids and mono- and diglycerides, vitamin E TPGS, PEO-PPO-PEO triblock copolymers (for example known under the tradename pluronics), or PEO (PEO are also called PEG, polyethyleneglycols (PEG)).
The amount of surfactant in the spray solution may be such that an amount of surfactant in the spray dried amorphous solid dispersion of up to 10 wt % or up to 5 wt % is provided, the wt % being based on the weight of the spray dried amorphous solid dispersion.
The spray solution may further comprises pharmaceutically acceptable excipients, such as fillers, disintegrating agents, pigments, binders, lubricants, flavorants, and so forth which can be used for customary purposes and in typical amounts known to the person skilled on the art.
The spray dried amorphous solid dispersion may comprise residual mixed solvent, that is residual solvent 1 or residual solvent 2 or both, the total content of residual solvent in the spray dried amorphous solid dispersion may be 5′000 ppm or less, preferably 3′000 ppm or less, more preferably 500 ppm or less, even more preferably of 100 ppm or less, the ppm being based on the weight of the spray dried amorphous solid dispersion.
Any residual content of solvent in the spray dried amorphous solid dispersion may be reduced to a desired predefined and final content of solvent by submitting the spray dried amorphous solid dispersion after the spray drying to a second drying. Secondary drying may be done using a tray dryer or any agitated dryer known to the skilled person for drying solids.
Mixed solvents were prepared by premixing individual solvents by weight. Solvent ratios are the weight percent of each component.
Saturated solutions were made by adding excess crystalline API to 2 mL individual solvent or mixed solvent and stirring for 24 h at 25° C. Each sample was then filtered through a 1 micrometer glass filter. An aliquot of 50 microliter was run on the TA Inc. Discovery TGA, TA Instruments, New Castle, DE 19720, US, isothermally at 90° C. for 10 min to remove solvent and measure the mass of the API in solution.
Results are given in the tables. The mg/ml values are the measured values, the wt % values are calculated from density estimates of the mixed solvent.
Table 1 shows the saturation concentration of Sulfasalazine in MeOAc/MeOH.
Table 3 shows the saturation concentration of Nilotinib in MeOAc/MeOH.
Table 5 shows the saturation concentration of Gefitinib in MeOAc/MeOH.
Table 2 shows the saturation concentration of Sulfasalazine in EtOAc/EtOH.
Table 4 shows the saturation concentration of Nilotinib in EtOAc/EtOH.
Table 6 shows the saturation concentration of Gefitinib in EtOAc/EtOH.
Table 7 shows the saturation concentration of Gefitinib in MeOAc/EtOH.
Table 8 shows the saturation concentration of Gefitinib in EtOAc/MeOH.
Table 9 shows the saturation concentration of Gefitinib in EtFormate/MeOH.
Table 10 shows the saturation concentration of Gefitinib in MeOAc/MeOH with 2000 water, the wt %0 being based on the weight of mixed solvent, that is on the combined weight of solvent 1, solvent 2 and water.
71.4 g of 50/50 (w/w) methanol/methyl acetate was weighed into a flask. 1.01 g of gefitinib was added to the mixed solvent and stirred with a magnetic stir bar at 20° C. until completely dissolved. 3.00 g of PVPVA64 was added and the mixture was stirred for at least 30 min until the polymer was dissolved.
Then the solution was spray dried using a custom built spray dryer. The solution was pumped into a lab-scale 0.3 m diameter stainless steel spray drying chamber using head pressure on the tank of 120 psi. The spray solution was atomized using the nozzle:
Heated nitrogen gas (125 to 130° C. inlet, 48 to 52° C. outlet, 500 g/min) was used to dry the particles. The resulting ASD was collected using a cyclone to separate the solid particles from the gas stream.
The collected ASD was placed in a tray dryer at 40° C./15% RH for secondary drying in order to remove residual solvent. The ASD was dried for 24 h on the tray dryer. The residual amount of MeOH determined by GC was less than 50 ppm after the tray dryer.
71.5 g of 50/50 (w/w) methanol/methyl acetate was weighed into a flask. 1.00 g of gefitinib was added to the mixed solvent and stirred with a magnetic stir bar at 20° C. until completely dissolved. 3.01 g of Eudragit L100 was added and the mixture was stirred for at least 30 min until the polymer was dissolved.
Then the solution was spray dried using a custom built spray dryer. The solution was pumped into a lab-scale 0.3 m diameter stainless steel spray drying chamber using head pressure on the tank of 120 psi. The spray solution was atomized using a the nozzle:
Heated nitrogen gas (125 to 130° C. inlet, 48 to 52° C. outlet, 500 g/min) was used to dry the particles. The resulting ASD was collected using a cyclone to separate the solid particles from the gas stream.
The collected ASD was placed in a tray dryer at 40° C./15% RH for secondary drying in order to remove residual solvent. The ASD was dried for 24 h on the tray dryer. The residual amount of MeOH determined by GC was less than 60 ppm after the tray dryer.
71.5 g of 50/50 (w/w) methanol/methyl acetate was weighed into a flask. 1.00 g of gefitinib was added to the mixed solvent and stirred with a magnetic stir bar at 20° C. until completely dissolved. 3.00 g of HPMCAS-MG was added and the mixture was stirred for at least 30 min until the polymer was dissolved.
Then the solution was spray dried using a custom built spray dryer. The solution was pumped into a lab-scale 0.3 m diameter stainless steel spray drying chamber using head pressure on the tank of 120 psi. The spray solution was atomized using the nozzle:
Heated nitrogen gas (125 to 130° C. inlet, 48 to 52° C. outlet, 500 g/min) was used to dry the particles. The resulting ASD was collected using a cyclone to separate the solid particles from the gas stream.
The collected ASD was placed in a tray dryer at 40° C./15% RH for secondary drying in order to remove residual solvent. The ASD was dried for 24 h on the tray dryer. The residual amount of MeOH was less than 30 ppm determined by GC after the tray dryer.
74.8 g of 40/40/20 (w/w/w) methanol/methyl acetate/water was weighed into a flask. 1.00 g of gefitinib was added to the mixed solvent and stirred with a magnetic stir bar at 24° C. until completely dissolved. 3.00 g of HPMC E3 was added, and the mixture was stirred for at least 30 min until the polymer was dissolved.
Then the solution was spray dried using a custom built spray dryer. The solution was pumped into a lab-scale 0.3 m diameter stainless steel spray drying chamber using head pressure on the tank of 120 psi. The spray solution was atomized using the nozzle:
Heated nitrogen gas (145 to 150° C. inlet, 48 to 53° C. outlet, 500 g/min) was used to dry the particles. The resulting ASD was collected using a cyclone to separate the solid particles from the gas stream.
The collected ASD was placed in a tray dryer at 40° C./15% RH for secondary drying in order to remove residual solvent. The ASD was dried for 24 h on the tray dryer. The residual amount of MeOH was less than 10 ppm determined by GC after the tray dryer.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21179384.9 | Jun 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/065542 | 6/8/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63209468 | Jun 2021 | US | |
| 63208643 | Jun 2021 | US |
