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The use of amorphous drug delivery systems is an attractive approach to improve the bioavailability of low molecular weight drug candidates that suffer from poor aqueous solubility. However, the pharmaceutical performance of many neat amorphous drugs is compromised by their tendency for recrystallization during storage and lumping upon dissolution, which may be improved by the application of coatings on amorphous surfaces. In this study, hot melt coating (HMC) as a solvent-free coating method was utilized to coat amorphous carvedilol (CRV) particles with tripalmitin containing 10% (w/w) and 20% (w/w) of polysorbate 65 (PS65) in a fluid bed coater. Lipid coated amorphous particles were assessed in terms of their physical stability during storage and their drug release during dynamic in vitro lipolysis. The release of CRV during in vitro lipolysis was shown to be mainly dependent on the PS65 concentration in the coating layer, with a PS65 concentration of 20% (w/w) resulting in an immediate release profile. The physical stability of the amorphous CRV core, however, was negatively affected by the lipid coating, resulting in the recrystallization of CRV at the interface between the crystalline lipid layer and the amorphous drug core. Our study demonstrated the feasibility of lipid spray coating of amorphous CRV as a strategy to modify the drug release from amorphous systems but at the same time highlights the importance of surface-mediated processes for the physical stability of the amorphous form.

In this study, surface diffusion of L-aspartic acid−carvedilol (ASP-CAR) co-amorphous systems at different ASP concentrations is measured and correlated with their physical stability. ASP-CAR films at ASP concentrations of 1−5% (w/w) were prepared by a newly developed method based on a vacuum compression molding process. Surface diffusion measurements were conducted on these systems based on the surface grating decay method using atomic force microscopy (AFM). The results demonstrate that a small amount of ASP (i.e., ≤ 5% w/w) in the co-amorphous systems could significantly slow down the grating decay process compared with that of pure amorphous CAR, indicating a reduced surface diffusion of CAR molecules. The decay time gradually increased in co-amorphous systems with increasing ASP concentration from 1 to 5% (w/w), with the longest observed decay time of around 800 h for the 5%ASP-CAR system, which was more than 200 times longer compared to the decay time of pure amorphous CAR (approximately 3 h). A good correlation between the decay constants of the pure amorphous CAR and co-amorphous films at ASP concentrations of 1−5% (w/w) and the physical stability of corresponding amorphous powder samples was found. Overall, this study provides a new method to prepare co-amorphous films for surface property measurements and reveals the impact of surface diffusion on the physical stability of co-amorphous systems.

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