The importance of providing safe and effective delayed-and extended-release oral formulations that can replace products requiring multiple administrations has been continually cited as an area in need of improvement for pharmaceutical companies. Such controlled release challenges become especially critical when they must be adapted for paediatrics, those suffering from dysphagia, or patients with specific dosage administration limitations. More often than not, lack of palatability and taste-masking compound this formulation challenge. Many particulate approaches show promise, but can be fraught with broad particle size distributions, initial drug burst, poor drug entrapment efficiency, low drug loading, and limited scalability. Here, we summarize the key factors that drive formulation development of format-flexible controlled-release oral powders, and the manufacturing aspects involved with some of the foremost marketed products, including next-generation singlestep layered powder manufacturing (below). Keywords: powder, particle, microsphere, taste-masking, paediatric, controlled-release
The dosage form problemThe importance of providing safe, effective, and proven medicines for populations with dysphagia, such as children, geriatrics, and those suffering from debilitating illnesses, has been continually cited as an area in need of improvement for pharmaceutical companies and the providers who administer their product (Bergstrom D. et al., 2004;Bhardwaj S. and Hayward M., 1996;Cram A. et al., 2013;Dickens D.S. et al., 2008;Engelen L. et al., 2005;Imai E. et al., 1995;Ivanovska V. et al., 2014;Lopez F.L. et al., 2015;Matsui D., 2007;Milne C.P. and Bruss J.B., 2008;Rocca J.G. and Park K., 2004;Sugao H., 1997;Tyle P., 1993). The widespread lack of dispersed format oral products, however, forces clinicians and pharmacists to use alternative solutions to treat their patients that are not always backed by supporting bioavailability, stability, and safety studies. Tablets are sometimes administered extemporaneously by crushing the dosage form and mixing with food or drink. Not only are these delivery methods inconsistent, they often lead to dosing errors, decreased bioavailability or efficacy, and non-adherence because of foul-tasting active pharmaceutical ingredients (APIs) (Jayanthi B. and Manna P., 2011;Osterberg L. and Blaschke T., 2005;Sansom L., 1999;Schier J. et al., 2003).Due to taste and efficacy concerns, The Institute for Safe Medical Practices (ISMP) has issued a "Do Not Crush" list, which highlights over 400 dosage forms that cannot be compounded due to special controlled-release properties, taste-masking, or API protection (Bergstrom D. et al., 2004;Bhardwaj S. and Hayward M., 1996;Dickens D.S. et al., 2008;Engelen L. et al., 2005;Imai E. et al., 1995;Matsui D., 2007;Milne C.P. and Bruss J.B., 2008;Rocca J.G. and Park K., 2004;Sugao H., 1997;Tyle P., 1993). Lack of titratable and palatable formulations affects over half of the global population (under 18 and over 65 years of age) and can subject ...