A range
of tablet excipients were evaluated for their influence
on the physical form and chemical stability of levothyroxine sodium
pentahydrate (LSP; C15H10I4NNaO4·5H2O). LSP–excipient binary powder
blends were stored under two conditions: (a) in hermetically sealed
containers at 40 °C and (b) at 40 °C/75% RH. By use of synchrotron
X-ray diffractometry, the disappearance of LSP could be quantified
and the appearance of crystalline levothyroxine (free acid) could
be identified. Under hermetically sealed conditions (40 °C) hygroscopic
excipients such as povidone induced partial dehydration of LSP to
form levothyroxine sodium monohydrate. When stored at 40 °C/75%
RH, acidic excipients induced measurable disproportionation of LSP
resulting in the formation of levothyroxine (free acid). HPLC analyses
of drug–excipient mixtures revealed that lactose monohydrate,
microcrystalline cellulose, and croscarmellose sodium caused pronounced
chemical decomposition of LSP. On the other hand, magnesium stearate,
sodium stearyl fumarate, and alkaline pH modifiers did not affect
the physical and chemical stability of the API following storage at
40 °C/75% RH. HPLC, being a solution based technique, revealed
chemical decomposition of the API, but the technique was insensitive
to physical transformations. Excipient properties such as hygroscopicity
and microenvironmental acidity were identified to be critical determinants
of both physical and chemical stability of LSP in a drug product.
For drugs exhibiting both physical and chemical transformations, simultaneous
solid-state and solution based analyses will enable comprehensive
stability evaluation.