Spray drying is a well-established manufacturing technique which can be used to formulate amorphous solid dispersions (ASDs) which is an effective strategy to deliver poorly water soluble drugs (PWSDs). However, the inherently complex nature of the spray drying process coupled with specific characteristics of ASDs makes it an interesting area to explore. Numerous diverse factors interact in an inter-dependent manner to determine the final product properties. This review discusses the basic background of ASDs, various formulation and process variables influencing the critical quality attributes (CQAs) of the ASDs and aspects of downstream processing. Also various aspects of spray drying such as instrumentation, thermodynamics, drying kinetics, particle formation process and scale-up challenges are included. Recent advances in the spray-based drying techniques are mentioned along with some future avenues where major research thrust is needed.
Predensification and compression are unit operations imperative to the manufacture of tablets and capsules. Such stress-inducing steps can cause destabilization of solid dispersions which can alter their molecular arrangement and ultimately affect dissolution rate and bioavailability. In this study, itraconazole-Soluplus solid dispersions with 50% (w/w) drug loading prepared by hot-melt extrusion (HME) were investigated. Compression was performed at both pharmaceutically relevant and extreme compression pressures and dwell times. The starting materials, powder, and compressed solid dispersions were analyzed using modulated differential scanning calorimetry (MDSC), X-ray diffraction (XRD), small- and wide-angle X-ray scattering (SWAXS), attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR), and broadband dielectric spectroscopy (BDS). MDSC analysis revealed that compression promotes phase separation of solid dispersions as indicated by an increase in glass transition width, occurrence of a peak in the nonreversing heat flow signal, and an increase in the net heat of fusion indicating crystallinity in the systems. SWAXS analysis ruled out the presence of mesophases. BDS measurements elucidated an increase in the Soluplus-rich regions of the solid dispersion upon compression. FTIR indicated changes in the spatiotemporal architecture of the solid dispersions mediated via disruption in hydrogen bonding and ultimately altered dynamics. These changes can have significant consequences on the final stability and performance of the solid dispersions.
The structural and physical stability of solid dispersions have not been adequately explored during spray drying manufacturing processes. In this study a wide range of compositions of naproxen/PVP-VA 64 (poly(1-vinylpyrrolidone-co-vinyl acetate)) and miconazole/PVP-VA 64 solid dispersions prepared by different laboratory spray dryers were collected from various selected locations and used to investigate the drug-polymer mixing across spray dryers. Spray-dried dispersions with 30% (w/w) naproxen collected from the transport tube of the Pro-C-epT Microspray dryer showed the narrowest glass transition width, which apparently indicates the highest degree of drug-polymer mixing compared to the other locations. The intensity of the naproxen-PVP-VA 64 interaction peak at 1654 cm(-1) of IR spectra differs for solid dispersions (SDs) from the collector and transport tube of Pro-C-epT Microspray dryer with a higher intensity for the latter. Samples with 50% (w/w) naproxen loading collected from the cyclone and the cyclone steel part of the Buchi mini spray dryer showed a melting endotherm (Tm at 112.2 ± 0.8 °C and ΔHf between 0.7 and 1.8 J/g), whereas samples from the cyclone tube to the drying chamber were devoid of crystalline material. The variations in drug-polymer mixing extend to miconazole/PVP-VA solid dispersions where 20% drug loading showed location-dependent drug-polymer mixing. This study clearly showed that the variation in drug-polymer miscibility and solid form of the drug in solid dispersions can occur across spray dryer in small-scale manufacturing processes. The optimization of formulation parameters and spray drying process parameters is imperative to diminish these variations to enhance homogeneity of solid dispersions in laboratory scale spray dryers. The same problem can occur in geometrically large spray drying manufacturing equipment, and the robustness of the processes should be carefully assessed.
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