AU740760B2 - Pulmonary delivery of aerosolized medicaments - Google Patents

Pulmonary delivery of aerosolized medicaments Download PDF

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Publication number
AU740760B2
AU740760B2 AU23695/99A AU2369599A AU740760B2 AU 740760 B2 AU740760 B2 AU 740760B2 AU 23695/99 A AU23695/99 A AU 23695/99A AU 2369599 A AU2369599 A AU 2369599A AU 740760 B2 AU740760 B2 AU 740760B2
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Australia
Prior art keywords
dry powder
powder composition
carrier
macromolecule
composition
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Ceased
Application number
AU23695/99A
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AU2369599A (en
Inventor
Mohammed Eljamal
Linda Foster
John S Patton
Robert M. Platz
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Novartis AG
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Inhale Therapeutics Systems Inc
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Priority claimed from AU54827/96A external-priority patent/AU702150B2/en
Application filed by Inhale Therapeutics Systems Inc filed Critical Inhale Therapeutics Systems Inc
Priority to AU23695/99A priority Critical patent/AU740760B2/en
Publication of AU2369599A publication Critical patent/AU2369599A/en
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Assigned to NEKTAR THERAPEUTICS reassignment NEKTAR THERAPEUTICS Alteration of Name(s) in Register under S187 Assignors: INHALE THERAPEUTIC SYSTEMS
Assigned to NOVARTIS AG reassignment NOVARTIS AG Alteration of Name(s) in Register under S187 Assignors: NEKTAR THERAPEUTICS
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    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00Medicinal preparations characterised by special physical form
    • A61K9/0012Galenical forms characterised by the site of application
    • A61K9/007Pulmonary tract; Aromatherapy
    • A61K9/0073Sprays or powders for inhalation; Aerolised or nebulised preparations generated by other means than thermal energy
    • A61K9/0075Sprays or powders for inhalation; Aerolised or nebulised preparations generated by other means than thermal energy for inhalation via a dry powder inhaler [DPI], e.g. comprising micronized drug mixed with lactose carrier particles
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00Medicinal preparations containing organic active ingredients
    • A61K31/70Carbohydrates; Sugars; Derivatives thereof
    • A61K31/7088Compounds having three or more nucleosides or nucleotides
    • AHUMAN NECESSITIES
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    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00Medicinal preparations containing organic active ingredients
    • A61K31/70Carbohydrates; Sugars; Derivatives thereof
    • A61K31/715Polysaccharides, i.e. having more than five saccharide radicals attached to each other by glycosidic linkages; Derivatives thereof, e.g. ethers, esters
    • A61K31/726Glycosaminoglycans, i.e. mucopolysaccharides
    • A61K31/727Heparin; Heparan
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    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
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    • A61K38/16Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof
    • A61K38/17Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans
    • A61K38/177Receptors; Cell surface antigens; Cell surface determinants
    • A61K38/1793Receptors; Cell surface antigens; Cell surface determinants for cytokines; for lymphokines; for interferons
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    • A61K38/17Peptides having more than 20 amino acids; Gastrins; Somatostatins; Melanotropins; Derivatives thereof from animals; from humans
    • A61K38/19Cytokines; Lymphokines; Interferons
    • A61K38/21Interferons [IFN]
    • A61K38/215IFN-beta
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    • A61K38/55Protease inhibitors
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    • A61K47/00Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/50Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient the non-active ingredient being chemically bound to the active ingredient, e.g. polymer-drug conjugates
    • A61K47/51Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient the non-active ingredient being chemically bound to the active ingredient, e.g. polymer-drug conjugates the non-active ingredient being a modifying agent
    • A61K47/54Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient the non-active ingredient being chemically bound to the active ingredient, e.g. polymer-drug conjugates the non-active ingredient being a modifying agent the modifying agent being an organic compound
    • A61K47/543Lipids, e.g. triglycerides; Polyamines, e.g. spermine or spermidine
    • A61K47/544Phospholipids
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    • A61K9/1617Organic compounds, e.g. phospholipids, fats
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    • A61K9/1605Excipients; Inactive ingredients
    • A61K9/1617Organic compounds, e.g. phospholipids, fats
    • A61K9/1623Sugars or sugar alcohols, e.g. lactose; Derivatives thereof; Homeopathic globules
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00Medicinal preparations characterised by special physical form
    • A61K9/14Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1605Excipients; Inactive ingredients
    • A61K9/1629Organic macromolecular compounds
    • A61K9/1652Polysaccharides, e.g. alginate, cellulose derivatives; Cyclodextrin
    • AHUMAN NECESSITIES
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    • A61K9/00Medicinal preparations characterised by special physical form
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    • A61K9/16Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1605Excipients; Inactive ingredients
    • A61K9/1629Organic macromolecular compounds
    • A61K9/1658Proteins, e.g. albumin, gelatin
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61KPREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
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    • A61K9/14Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1682Processes
    • A61K9/1688Processes resulting in pure drug agglomerate optionally containing up to 5% of excipient
    • AHUMAN NECESSITIES
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    • A61K9/1682Processes
    • A61K9/1694Processes resulting in granules or microspheres of the matrix type containing more than 5% of excipient
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M15/00Inhalators
    • A61M15/0028Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up
    • A61M15/003Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up using capsules, e.g. to be perforated or broken-up
    • A61M15/0033Details of the piercing or cutting means
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M15/00Inhalators
    • A61M15/0028Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up
    • A61M15/0045Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up using multiple prepacked dosages on a same carrier, e.g. blisters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B82NANOTECHNOLOGY
    • B82YSPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y5/00Nanobiotechnology or nanomedicine, e.g. protein engineering or drug delivery
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    • A61K9/16Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1605Excipients; Inactive ingredients
    • A61K9/1629Organic macromolecular compounds
    • A61K9/1635Organic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polyvinyl pyrrolidone, poly(meth)acrylates
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M15/00Inhalators
    • A61M15/0028Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up
    • A61M15/0045Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up using multiple prepacked dosages on a same carrier, e.g. blisters
    • A61M15/0046Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up using multiple prepacked dosages on a same carrier, e.g. blisters characterized by the type of carrier
    • A61M15/0051Inhalators using prepacked dosages, one for each application, e.g. capsules to be perforated or broken-up using multiple prepacked dosages on a same carrier, e.g. blisters characterized by the type of carrier the dosages being arranged on a tape, e.g. strips
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M15/00Inhalators
    • A61M15/0086Inhalation chambers
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61M2202/00Special media to be introduced, removed or treated
    • A61M2202/06Solids
    • A61M2202/064Powder
    • AHUMAN NECESSITIES
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    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M2205/00General characteristics of the apparatus
    • A61M2205/02General characteristics of the apparatus characterised by a particular materials
    • A61M2205/0233Conductive materials, e.g. antistatic coatings for spark prevention
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61MDEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M2205/00General characteristics of the apparatus
    • A61M2205/07General characteristics of the apparatus having air pumping means
    • A61M2205/071General characteristics of the apparatus having air pumping means hand operated
    • A61M2205/073Syringe, piston type
    • CCHEMISTRY; METALLURGY
    • C12BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12NMICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
    • C12N2799/00Uses of viruses
    • C12N2799/02Uses of viruses as vector
    • C12N2799/021Uses of viruses as vector for the expression of a heterologous nucleic acid
    • C12N2799/022Uses of viruses as vector for the expression of a heterologous nucleic acid where the vector is derived from an adenovirus

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Description

AUSTRALIA
Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): INHALE THERAPEUTIC SYSTEMS Invention Title: PULMONARY DELIVERY OF AEROSOLIZED MEDICAMENTS The following statement is a full description of this invention, including the best method of performing it known to me/us: PULMONARY DELIVERY OF AEROSOLIZED MEDICAMENTS BACKGROUND OF THE INVENTION 1. Field of the Invention.
The present invention relates generally to methods and compositions for the dry powder formulation of pharmaceuticals, including macromolecules, for pulmonary delivery.
Over the years, certain drugs have been sold in compositions suitable for forming a drug dispersion for oral inhalation (pulmonary delivery) to treat various conditions in humans. Such pulmonary drug delivery compositions are designed to be delivered by inhalation by the patient of a drug dispersion so that the active drug within the dispersion can reach the lung. It has been found that certain drugs delivered to the lung are readily absorbed through the alveolar region directly into blood circulation. Pulmonary delivery is particularly promising for the delivery of macromolecules (proteins, polypeptides and nucleic acids) which are difficult to deliver by other routes of administration. Such pulmonary delivery can be effective both for systemic delivery and for localized delivery to treat diseases of the lungs.
Pulmonary drug delivery can itself be achieved by different approaches, including liquid nebulizers, aerosol-based metered dose inhalers (MDI's), and dry powder dispersion devices. Aerosol-based MDI's are losing favor because they rely on the use of chlorofluorocarbons (CFC's), which are being banned because of their adverse effect on the ozone layer. Dry powder dispersion devices, which do not rely on CFC aerosol technology, are promising for delivering drugs that may be readily formulated as dry powders. Many otherwise labile macromolecules may be stably stored as lyophilized or spray-dried powders by themselves or in combinazion with suitable powder carriers. The ability to deliver pharmaceutical compositions as dry powders, however, is problematic in certain respects. The dosage of many pharmaceutical compositions is often critical so it is necessary that any dry powder delivery system be able to accurately, precisely, and reliably deliver the intended amount of drug. Moreover, many pharmaceutical compositions are quite expensive. Thus, the ability to efficiently deliver the dry powders with a minimal loss of drug is critical. It is also essential that the powder be readily dispersible prior to inhalation by the patient in order to assure adequate distribution and systemic absorption.
A particularly promising approach for the pulmonary delivery of dry powder drugs utilizes a hand-held device with a hand pump for providing a source of pressurized gas. The S.pressurized gas is abruptly released through a powder 0 dispersion device, such as a venturi nozzle, and the dispersed powder made available for patient inhalation. While advantageous in many respects, such hand-held devices are problematic in a number of other respects. The particles being delivered are less than 10 Am in size, usually in the [5 range from 1Mm to 5Mm, making powder handling and dispersion more difficult than with larger particles. The problems are exacerbated by the relatively small volumes of pressurized gas, which are available using hand-actuated pumps. In particular, venturi dispersion devices are unsuitable for difficult-to-disperse powders when only small volumes of pressurized gas are available. Another requirement for hand-held and other powder delivery devices is efficiency. It is important that the concentration of drug in the bolus of gas be relatively high to reduce the number of breaths required to achieve a total dosage. The ability to achieve both adequate dispersion and small dispersed volumes is a significant technical challenge that requires in part that each unit dosage of the powdered composition be readily and reliably dispersible.
SUMMARY OF THE INVENTION According to the subject invention, dispersible dry powder pharmaceutical-based compositions are provided, including methods for their manufacture and dry powder dispersion devices.
In a first aspect, the present invention provides a spray-dried pharmaceutical-based dispersible dry powder composition for pulmonary delivery, comprising: a therapeutically effective amount of a macromolecule which retains its activity upon spray-drying, and a pharmaceutically acceptable carrier.
In a second aspect, the present invention provides a 2 unit dosage form for pulmonary delivery of a macromolecule-based composition according to the first aspect of the present invention.
oooIn a third aspect, the present invention provides a method for aerosolizing a macromolecule-based dry powder composition for subsequent inhalation by a subject, said o 25 method comprising: dispersing an amount of a dry powder composition according to the first aspect of the present invention in a gas stream to form an aerosol, and capturing the aerosol in a chamber.
In a fourth aspect, the present invention provides a method for preparing a spray-dried, macromolecule based dry powder composition according to the first aspect of the present invention, said method comprising: providing an aqueous mixture of the macromolecule and the carrier, and spray drying the mixture under conditions effective to produce a respirable dry powder.
A dispersible dry powder pharmaceutical-based composition is one having a moisture content of less than about 10% by weight water, usually below about and preferably less than about 3%w; a particle size of about 1.0-5.0 Am mass median diameter (MMD), usually 1.0-4.0 Am MMD, and preferably 1.0-3.0 Am MMD; a delivered dose of about usually preferably and most preferred and an aerosol particle size distribution of about 1.0-5.0 rm mass median aerodynamic diameter (MMAD), usually 1.5-4.5 im MMAD, and preferably 1.5-4.0 im MMAD. Such 15 compositions are of pharmaceutical grade purity.
DESCRIPTION OF SPECIFIC EMBODIMENTS The present invention is based at least in part on I the dispersibility characteristics of the pharmaceutical-based dry powder compositions produced according to the present invention. The dispersibility characteristics of the subject pharmaceutical-based compositions means that they are more suitable for use in pulmonary delivery devices than S-:compositions prepared by other methods. The compositions of 25 the invention are readily aerosolized and rapidly absorbed through the lungs of a host when delivered by a dry powder inhaler.
DEFINITIONS
In interpreting the claims to the various aspects of this invention, there are several important definitions that should be considered.
The term "dispersibility" or "dispersible" means a dry powder having a moisture content of less than about 10% by weight water, usually below about 5%w and preferably less than about 3%w; a particle size of about 1.0-5.0 Am mass median diameter (MMD), usually 1.0-4.0 jm MMD, and preferably 1.0-3.0 Aim MMD; a delivered dose of about usually preferably and most preferred and an aerosol particle size distribution of about 1.0-5.0 Am mass median aerodynamic diameter (MMAD), usually 1.5-4.5 Aim MMAD, and preferably 1.5-4.0 im MMAD.
The term "powder" means a composition that consists of finely dispersed solid particles that are free flowing and capable of being readily dispersed in an inhalation device and subsequently inhaled by a subject so that the particles reach the lungs to permit penetration into the alveoli. Thus, the powder is said to be "respirable." Preferably the average particle size is less than about 10 microns (im) in diameter with a relatively uniform spheroidal shape distribution. More preferably the diameter is less than about 7.5 jm and most preferably less than about 5.0 jm. Usually the particle size distribution is between about 0.1 jm and about 5 jm in diameter, particularly about 0.3 Am to about 5 jim.
The term "dry" means that the composition has a moisture content such that the particles are readily dispersible in an inhalation device to form an aerosol. This moisture content is generally below about 10% by weight water, usually below about 5%w and preferably less than about 25 3%w.
The term "therapeutically effective amount" is the amount present in the composition that is needed to provide the desired level of drug in the subject to be treated to give the anticipated physiological response. This amount is determined for each drug on a case-by-case basis. Guidelines are given hereafter.
-The term "physiologically effective amount" is that amount delivered to a subject to give the desired palliative or curative effect. This amount is specific for each drug and its ultimate approved dosage level. Guidelines are given hereafter.
The term "pharmaceutically acceptable carrier" means that the carrier can be taken into the lungs with no significant adverse toxicological effects on the lungs.
COMPOSITIONS OF THE INVENTION In general, the compositions of this invention are suitable for pulmonary delivery because of their dispersibility characteristics. Such compositions were not previously known in the art. In the dry state, the pharmaceutical may be in crystalline or amorphous form. Some examples of pharmaceutical compositions suitable for formulation into dispersible dry powders are listed in Table 1. These include macromolecule and non-macromolecule-based pharmaceuticals, usually macromolecules, with insulin, interleukin-1 receptor, parathyroid hormone (PTH-34), alpha-i antitrypsin, calcitonin, low molecular weight heparin, heparin, interferon, and nucleic acids being preferred.
SA therapeutically effective amount of active pharmaceutical will vary in the composition depending on the biological activity of-the drug employed and.the amount needed S in a unit dosage form. Because the subject compounds are S dispersible, it is highly preferred that they be manufactured in a unit dosage form in a manner that allows for ready .2 manipulation by the formulator and by the consumer. This generally means that a unit dosage will be between about mg and 15 mg of total material in the dry powder composition, preferably between about 2 mg and 10 mg. Generally, the amount of drug in the composition will vary from about 0.05%w to about 99.0%w. Most preferably the composition will be about 0.2% to about 97.0%w drug.
The amount of the pharmaceutically acceptable carrier is that amount needed to provide the necessary stability, dispersibility, consistency and bulking characteristics to ensure a uniform pulmonary delivery of the composition to a subject in need thereof. Numerically the amount may be from about 0.05%w to about 99.95%w, depending on the activity of the drug being employed. Preferably about to about 95%w will be used.
The carrier may be one or a combination of two or more pharmaceutical excipients, but will generally be substantially free of any "penetration enhancers." Penetration enhancers are surface active compounds which promote penetration of a drug through a mucosal membrane or lining and are proposed for use in intranasal, intrarectal, and intravaginal drug formulations. Exemplary penetration enhancers include bile salts, taurocholate, glycocholate, and deoxycholate; fusidates, e.g., taurodehydrofusidate; and biocompatible detergents, e.g., Tweens, Laureth-9, and the like. The use of penetration enhancers in formulations for the lungs, however, is generally undesirable because the epithelial blood barrier in the lung can be adversely affected by such surface active compounds.
20 The dry powder compositions of the present invention are readily absorbed in the lungs without the need to employ penetration enhancers.
.The types of pharmaceutical excipients that are useful as carriers in this invention include stabilizers such 2: :25 as human serum albumin (HSA), bulking agents such as carbohydrates, amino acids and polypeptides; pH adjusters or buffers; salts such as sodium chloride; and the like. These carriers may be in a crystalline or amorphous form or may be a mixture of the two.
It has been found that kSA is particularly valuable as a carrier in that it provides improved dispersibility.
Bulking agents that are particularly valuable include compatible carbohydrates, polypeptides, amino acids or combinations thereof. Suitable carbohydrates include monosaccharides such as galactose, D-mannose, sorbose, and the like; disaccharides, such as lactose, trehalose, and the like; cyclodextrins, such as 2-hydroxypropyl-3-cyclodextrin; and trisaccharides, such as raffinose, and polysaccharides such as maltodextrins, dextrans, and the like; alditols, such as mannitol, xylitol, and the like. A preferred group of carbohydrates includes lactose, trehalose, raffinose maltodextrins, and mannitol. Suitable polypeptides include aspartame. Amino acids include alanine and glycine, with glycine being preferred.
Additives, which are minor components of the composition of this invention, may be included for conformational stability during spray drying and for improving dispersibility of the powder. These additives include hydrophobic amino acids such as tryptophan, tyrosine, leucine, phenylalanine, and the like.
Suitable pH adjusters or buffers include organic salts prepared from organic acids and bases, such as sodium citrate, sodium ascorbate, and the like; sodium citrate is preferred.
The unit dosage form, method of treatment, and process of preparation of this invention are described S hereafter.
Unit Dosage Form.
The composition of this invention (as discussed hereinbefore) is placed within a suitable dosage receptacle in an amount sufficient' to provide a subject with drug for a unit dosage treatment. The dosage receptacle is one that fits within a suitable inhalation device to allow for the aerosolization of the interferon-based dry powder composition by dispersion into a gas stream to form an aerosol and then capturing the aerosol so produced in a chamber having a mouthpiece attached for subsequent inhalation by a subject in need of treatment. Such a dosage receptacle includes any container enclosing the composition known in the 8 art such as gelatin or plastic capsules with a removable portion that allows a stream of gas air) -o be directed into the container to disperse the dry powder composition.
Such containers are exemplified by those shown in U.S. Patents 4,227,522 issued October 14, 1980; 4,192,309 issued March 11, 1980; and 4,105,027 issued August 8, 1978. Suitable containers also include those used in conjunction with Glaxo's Ventolin Rotohaler brand powder inhaler or Fison's Spinhaler brand powder inhaler. Another suitable unit-dose container which provides a superior moisture barrier is formed from an aluminum foil plastic laminate. The pharmaceutical-based powder is filled by weight or by volume into the depression in the formable foil and hermetically sealed with a covering foil-plastic laminate. Such a container for use with a powder 'i"i inhalation device is described in U.S. Patent 4,778,054 and is used with Glaxo's Diskhaler® Patents 4,627,432; 4,811,731; and 5,035,237). All of these references are incorporated herein by reference.
Method of Treating a Disease State.
Conditions that may be treated by the .compositions of this invention are described in Table 1.
The physiologically effective amount needed to treat a particular condition or disease state will depend on the individual, the condition, length of treatment, the regularity of treatment, the type of drug, and other factors, but can be determined by one of ordinary skill in the medicinal arts.
It is presently believed that the effective absorption by a host of dry powder composition according to the present invention results from a rapid dissolution in the ultra-thin fluid layer of the alveolar lining of the lung. The particles of the present invention thus have a mean size which is from 10 to 50 times larger than *:he lung fluid layer, making it unexpected that the particles are dissolved and the drug systemically absorbed in a rapid manner for either local lung or systemic treatment. An understanding of the precise mechanism, however, is not necessa:ry for practicing the present invention as described herein.
The aerosolized pharmaceutical-based dry powders of this invention are particularly useful in place of parenteral delivery. Thus, the methods and compositions of the present invention will be particularly valuable in chronic treatment protocols where a patient can self-medicate. The patient can S achieve a desired dosage by inhaling an appropriate amount of drug, as just described. The efficiency of systemic delivery via the method as just described will typically be in the S range from about 15% to Method for Aerosolizing the Powder.
A further detailed description of this method is found in Australian patent 662,919 and Australian patent application number 17449/95, both of which are incorporated herein by reference. Australian patent 662,919 corresponds S to US application 07/910,048 and Australian patent application number 17449/95 corresponds to US application 08/907,472.
Preparing the Compositions.
Spray drying is a process in which a homogeneous aqueous mixture of drug and the carrier is introduced -ia a nozzle a two fluid nozzle), spinning disc or an equivalent device into a hot gas stream to atomize the solution to form fine droplets. The aqueous mixture may be a solution, suspension, slurry, or the like, but needs to be homogeneous to ensure uniform distribution of the components in the mixture and ultimately the powdered composition.
Preferably the aqueous mixture is a solution. The solvent, generally water, rapidly evaporates from the droplets producing a fine dry powder having particles.1 to 5 Am in diameter. Surprisingly, the drug is not degraded when it is exposed to the hot drying gas, and the resulting drug-containing spray-dried powders can be prepared having sufficient purity for pharmaceutical use. An acceptable purity is defined as less than 5% degradation products and contaminates, preferably less than 3% and most preferably less than 1%.
The spray drying is done under conditions that result in substantially amorphous powder of homogeneous constitution having a particle size that is respirable, a low moisture content and flow characteristics that allow for ready aerosolization. Preferably the particle size of the resulting 25 powder is such that more than about 98% of the mass is in particles having a diameter of about 10 pm o less with about 90% of the mass being in particles having a diameter less than 5 Am. Alternatively, about 95% of the mass will have particles with a diameter of less than 10 pm with about 80% of the mass of the particles having a diameter of less than 5 Am.
The solutions may then be sprayed dried in conventional spray drying equipment from commercial suppliers, such as Buchi, Niro, Yamato Chemical Co., Okawara Kakoki Co., and the like, resulting in a substantially amorphous particulate product.
For the spraying process, such spraying methods as rotary atomization, pressure atomization and two-fluid Satomization can be used. Examples of the devices used in these processes include "Parubisu [phonetic rendering] Mini-Spray GA-32" and "Parubisu Spray Drier DL-41", manufactured by Yamato Chemical Co., or "Spray Drier CL-8," "Spray Drier "Spray Drier FL-12," "Spray Drier FL-16" or "Spray Drier FL-20," manufactured by Okawara Kakoki Co., can be used for the method of spraying using rotary-disk atomizer.
While no special restrictions are placed on the nozzle of the atomizer used in the process of spraying, it is recommended to use a nozzle which can produce a spray-dry composition with a grain diameter suitable for nasal, pharyngeal or pulmonary administration. For example, nozzle types and the like, manufactured by Yamato Chemical Co., can be used for the above-mentioned spray-drier, manufactured by the same company. In addition, disks type "MC-50," "MC-65" or "MC-85," manufactured by Okawara Kakoki Co., can be used as rotary disks of the spray-drier atomizer, manufactured by the same company.
While no particular restrictions are placed on the gas used to dry the sprayed material, it is recommended to use air, nitrogen gas or an inert gas. The temperature of the inlet of the gas used to dry the sprayed materials such that it does not cause heat deactivation of the sprayed material.
The range of temperatures may vary between about 500C to about 200 0 C, preferably between about 50 0 C and 100 0 C. The temperature of the outlet gas used to dry the sprayed material, may vary between about O°C and about 1500, preferably between 0 C and 90 0 C, and even more preferably S between 0oC and 60 0 C. The fact that inlet and outlet temperatures above about 55°C can be used is surprising in view of the fact that most macromolecule-based drugs deactivate at that temperature, with nearly complete deactivation occurring at about 70 0
C.
The dispersible pharmaceutical-based dry powders of the present invention may optionally be combined with pharmaceutical carriers or excipients which are suitable for respiratory and pulmonary administration. Such carriers may serve simply as bulking agents when it is desired to reduce the interferon concentration in the powder which is being delivered to a patient, but may also serve to enhance the stability of the interferon compositions and to improve the dispersibility of the powder within a powder dispersion device in order to provide more efficient and reproducible delivery of the interferon and to improve handling characteristics of the interferon such as flowability and consistency to facilitate manufacturing and powder filling.
Such carrier materials may be combined with the drug prior to spray drying, by adding the carrier material to the purified bulk solution. In that way, the carrier particles will be formed simultaneously with the drug particles to produce a homogeneous powder. Alternatively, the carriers may be separately prepared in a dry powder form and combined with the dry powder drug by blending. The powder carriers will usually be crystalline (to avoid water absorption), but might in some cases be amorphous or mixtures of crystalline and amorphous. The size of the carrier particles may be selected to improve the flowability of the drug powder, typically being in the range from 25 Am to 100 Am. A preferred carrier material is crystalline lactose having a size in the above-stated range.
Alternatively, dry powder compositions may be prepared by other processes such as lyophilization and jet milling as disclosed in WO 91/16038.
o.
13 TABLE 1 SELECTED MACROMOLECULE
DRUGS
FOR SYSTEMIC APPLICATIONS
DRUG
Calcitonin Erthropoetin (EPO) Factor IX Granulocyte Colony Stimulating Factor (G-CSF) Granulocyte Macrophage Colony Stimulating Factor (GM-CSF) Growth Hormone Heparin Heparin (Low Molecular Weight) Insulin Interferon Alpha Interferon Beta Interferon Gamma Interleukin-2 Luteinizing Hormone Releasing Hormone (LHRH) Somatostatin Analog Vasopressin Analog Follicle Stimulating Hormone (FSH) Amylin Ciliary Neurotrophic Factor Growth Hormone Releasing Factor (GRF) Insulin-Like Growth Factor Insulinotropin Interferon Beta Interferon Gamma Interleukin-1 Receptor Antagonist Interleukin-3 Interleukin-4
INDICATIONS
Osteoporosis Prophylaxis Paget's Disease Hypercalcemia Anemia Hemophilia B Neutropenia Bone Marrow Engraftment/Transplant Failure Short Stature Renal Failure Blood Clotting Blood Clotting Type I and Type II Diabetes Hepatitis B and C Hairy Cell Leukemia Kaposi's Sarcoma Multiple Sclerosis Chronic Granulomatous Disease Renal Cancer Prostate Cancer Endometriosis Gastrointestinal Cancers Diabetes Insipidus Bed Wetting Fertility Type I Diabetes Lou Gehrig's Disease Short Stature Osteoporosis Nutritional Support Type II Diabetes Hepatitis B and C Rheumatoid Arthritis Rheumatoid Arthritis Adjuvant to Chemotherapy Immunodeficiency Disease
S
S
S.
S
14 TABLE 1 Continued SELECTED MACROMOLECULE DRUGS FOR SYSTEMIC APPLICATIONS is .3 0
DRUG
Macrophage Colony Stimulating Factor (M-CSF) Nerve Growth Factor Parathyroid Hormone Somatostatin Analog Thymosin Alpha 1 lIb/Illa Inhibitor Alpha-i Antitrypsin Anti-RSV Antibody Cystic Fibrosis Transmembrane Regulator (CFTR) Gene Deoxyribonuclease (DNase) Hepauin Bactericidal/Permeability Increasing Protein (BPI) Anti-CMV Antibody Interleukin-1 Receptor
INDICATIONS
Fungal Disease Cancer Hypercholesterolemia Peripheral Neuropathies Osteoporosis Refractory Diarrheas Hepatitis B and C Unstable Angina Cystic Fibrosis Respiratory Syncytial Virus Cystic Fibrosis Chronic Bronchitis Asthma Adult Respiratory Distress Syndrome (ARDS) Cytomegalovirus Asthma SELECTED NON-MACROMOLECULE DRUGS FOR SYSTEMIC AND LOCAL LUNG APPLICATIONS
DRUG
Pentamidine isethiouate Albuterol sulfate Metaproterenol sulfate Beclomethasone diprepionate Triamcinolone acetamide Budesomide acetonide Ipratropiumn bromide Flunisolide Cromolyn sodium Ergotamine Tartrate
INDICATIONS
Pncumocystis carini pneumonia Bronchospasm Bronchial asthma Migraines The following examples are offered by way of illustration and not limitation.
EXPERIMENTAL
According the subject invention, the following dispersible dry powder formulations were prepared as described. All compositions produced according to the present invention meet the strict specifications for content and purity required of pharmaceutical products.
EXAMPLE I 20.0% INSULIN FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk crystalline human zinc insulin, was obtained from Eli Lilly and Company, Indianapolis, IN. A 20% insulin formulation was achieved by combining 1.5 mg insulin per mL deionized water with 4.96 mg/mL USP mannitol and 1.04 mg/mL citrate buffer (sodium citrate dihydrate USP and citric acid monohydrate USP) for a total solids concentration of 7.5 mg/mL at pH 6.7 0.3.
B. Spray Drying.
A dry powder of the 20% insulin formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-8 0
C
Inlet temperature 120-1220C Feed rate 5.3 mL/min Outlet temperature 80-81 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 80 0 C for about 10 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The above 20% insulin dry powder composition contained 66.1% mannitol and 13.9% citrate. The composition was found to contain 1.1 to 2.0% moisture as measured by a columbic Karl Fischer method using a Mitsubishi CA-06 Moisture Meter.
The particle size distribution of the composition was measured by liquid centrifugal sedimentation in a Horiba CAPA-700 Particle Size Analyzer following dispers:ion of the powder on Sedisperse A-11 (Micrometrics, Norcross, GA) and was determined to be 1.3 Am to 1.5 Am MMD.
The delivered dose of the insulin powder composition was measured by collecting the aerosol powder produced by a dry powder dispersion device, similar to devices described in co-pending U.S. Application Serial Numbers 07/910,048; 08/313,707; 08/309,691 and PCT/US92/05621, the disclosures of which are hereby incorporated by reference, on a filter placed over the device mouthpiece. The delivered dose of the insulin powder composition was determined to be 563 16 pg or 60 to 64% of the total powder (5.0 mg) loaded into the device.
The aerosol particle size distribution, measured using a cascade impactor (California Measurements IMPAQ-6), was determined to be 2.0 Am MMAD, with 86% to 90% of the particles 5.0 Am in diameter.
The insulin content of the powder, measured by reverse phase HPLC (rpHPLC) was determined to be 197 ig/mg powder, accounting for 99% of the expected insulin. No 2 5 degradation peaks were detected in the chromatogram.
EXAMPLE II PARATHYROID HORMONE FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk 34 amino acid active fragment of parathyroid hormone, PTH was obtained from BACHEM CALIFORNIA, Torrance, CA. A 5.0% PTH (1-34) formulation was achieved by combining 0.375 mg PTH (1-34) per 1.0 mL deionized water with 6.06 mg/mL mannitol USP and 1.04 mg/mL citrate buffer (sodium citrate dihydrate USP and citric acid monohydrate USP) for a total solids concentration of 7.48 mg/mL at pH 6.3.
B. Spray Drying.
A dry powder of the 5.0% PTH (1-34) formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-8 0
C
Inlet temperature 122-124o
C
Feed rate 5.2 mL/min Outlet temperature 73-74 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 80 0 C for about 5 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 5.0% PTH (1-34) dry powder composition contained 81.0% mannitol and 13.9% citrate. The formulation contained 0.5% moisture.
The particle size distribution of the composition was determined to be 2.4 .m and 2.7 Mm MMD in separate measurements.
25 The delivered dose of the PTH (1-34) powder was determined to be 161 Ag or 64.5% and 175 Mg or 69.2% in separate measurements.
The PTH (1-34) content of the powder, measured by rpHPLC was determined to be 48.5 Ag/mg powder, accounting for 97% of the expected value. No degradation peaks were detected in the chromatogram.
a EXAMPLE III 0.7% INTERLEUKIN-1 RECEPTOR FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk interleukin-1 receptor, IL-i receptor, was obtained from Immunex Corporation, Seattle, WA. A 0.7% IL-1 receptor formulation was achieved by combining 0.053 mg IL-1 receptor per 1.0 mL deionized water with 7.07 mg/mL raffinose (Pfanstiehl, Waukegan, IL) and 0.373 mg/mL Tris buffer at pH 7.18.
B. Snray Drying.
A dry powder of the 0.7% IL-1 receptor formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-8 0
C
Inlet temperature 135-137 0
C
Feed rate 4.9 mL/min Outlet temperature 92-93 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 90 0 C for about 15 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 0.7% IL-1 receptor dry powder composition contained 94.3% raffinose and 5.0% Tris. The formulation contained 1.84 0.25% moisture.
The particle size distribution of the composition was determined to be 1.95 Am MMD with 100% of the particles 5.0 pm.
The delivered dose of the IL-I receptor powder was determined to be 22.3 2.0 gg or 53.4 4.7%.
The aerosol particle size distribution, was determined to be 3.2 gm MMAD, with 77% of the particles gm in diameter.
The IL-1 receptor content of the powder as measured by rpHPLC was determined to be 8.4 Lg/mg, accounting for 120% of the expected IL-1 receptor. No degradation peaks were detected in the chromatogram.
EXAMPLE IV INTERLEUKIN-1 RECEPTOR FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk interleukin-1 receptor, IL-1 receptor, was obtained from Immunex Corporation, Seattle, WA. A 5.0% IL-1 receptor formulation was achieved by combining 0.375 mg IL-1 receptor per 1.0 mL deionized water with 6.77 mg/mL raffinose and 0.351 mg/mL Tris buffer at pH 7.35.
B. SDray Dryinc.
A dry powder of the 5.0% IL-1 receptor formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: 25 Temperature of aqueous mixture 2-8 0
C
Inlet temperature 138oC Feed rate 4.9 mL/min Outlet temperature 91 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 90 0 C for about 15 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 5.0% IL-1 receptor dry powder composition contained 90.3% raffinose and 4.7% Tris. The formulation contained 1.75 0.26% moisture.
The particle size distribution of the composition was determined to be 2.74 gm MMD with 97% of the particles Am.
The delivered dose of the IL-1 receptor powder was determined to be 123.4 24.5 Ag or 49.3 9.8%.
The aerosol particle size distribution, was determined to be 4.1 Mm MMAD, with 64% of the particles Mm in diameter.
The IL-1 receptor content of the powder as measured by rpHPLC was determined to be 52.7 1.8 Mg/mg, accounting for 105% of the expected IL-1 receptor. No degradation peaks were detected in the chromatogram.
EXAMPLE V 26.7% HUMAN CALCITONIN FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk human calcitonin was obtained from Ciba-Geigy.
A 26.7% human calcitonin formulation was achieved by combining 1.9 mg human calcitonin per 1.0 mL deionized water with 4.3 mg/mL mannitol and 0.9 mg/mL citrate buffer at pH 3.85.
SB. Spray Drying.
A dry powder of the 26.7% human calcitonin formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 4 0
C
Inlet temperature 1190C Feed rate 5.5 mL/min Outlet temperature 780C ".35 Atomizer coolant temperature 0-5 0
C
Cyclone coolant temperature 25-30 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 80 0 C for about 10 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 26.7% human calcitonin dry powder composition contained 60% mannitol and 13.3% citrate. The formulation contained 0.71% moisture.
The particle size distribution of the composition was determined to be 1.33 0.63 /m MMD.
The delivered dose of the human calcitonin powder was determined to be 76.8 6.7%.
The human calcitonin content of the powder as measured by rpHPLC was determined to be 272.0 Ag/mg, accounting for 102 1.7% of the expected human calcitonin.
No degradation peaks were detected in the chromatogram.
EXAMPLE VI ALPHA-1 ANTITRYPSIN FORMULATION FOR PULMONARY DELIVERY
S
S. A. Formulation.
Bulk alpha-i antitrypsin, A1A, was obtained from .Armour Pharmaceutical Company, Kankakee, IL. A 90% A1A formulation was achieved by combining 4.89 mg A1A per 1.0 mL deionized water with 0.54 mg/mL citrate buffer at pH B. Spray Drying.
A dry powder of the 90% A1A formulation described above was produced by spray drying the aqueous mixture using a 35 Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 4 0
C
Inlet temperature 98-101 0
C
Feed rate 5.0 mL/min Outlet temperature 65 0
C
Atomizer coolant temperature 2-8 0
C
Cyclone coolant temperature 30 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 690C for about 10 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 90% A1A dry powder composition contained 10.0% citrate. The formulation contained 4.79% moisture.
The particle size distribution of the composition was determined to be 1.71 0.87 Am MMD.
The delivered dose of the 90% A1A powder was determined to be 67.0 The aerosol particle size distribution, was determined to be 1.0 Am MMAD, with 90% of the particles Am in diameter.
The A1A content of the powder as measured by rpHPLC was determined to be 80% of the expected value. No degradation peaks were detected in the chromatogram. The ^5 activity after spray drying was determined to be 74 1% EXAMPLE VII 0.3% BETA INTERFERON FORMULATION FOR PULMONARY DELIVERY CONTAINING HUMAN SERUM ALBUMIN A. Formulation.
Bulk beta interferon, IFN-0, was obtained from Toray Industries, Inc., Tokyo, Japan. A 0.3% IFN-0 formulation was achieved by combining 0.025 mg IFN-3 per 1.0 mL deionized water with 5.54 mg/mL human serum albumin (HSA), 2.3 mg/mL citrate buffer and 0.345 mg/mL of NaC1 at pH B. SDray Drying.
A dry powder of the 0.3% IFN-0 formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-8 0
C
Inlet temperature 93 0
C
Feed rate 2.7 mL/min Outlet temperature 62oC C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 0.3% IFN-0 dry powder composition contained 66.0% HSA, 27.4% citrate, 4.1% NaCl. The formulation contained 4.22% moisture.
The particle size distribution of the composition was determined to be 1.62 Am MMD with 94.8% of the particles Am.
The delivered dose of the 0.3% IFN-0 powder was determined to be 9.9 Ag/mg or 66.0 The aerosol particle size distribution, was S determined to be 2.0 Am MMAD, with 85% of the particles m in diameter.
25 The IFN-0 activity of the powder as measured by IFN-0 enzyme immunoassay (Toray-Fuji Bionics) and was determined to be 109 8% of the expected activity.
EXAMPLE VIII 0.3% BETA INTERFERON FORMULATION FOR PULMONARY DELIVERY CONTAINING RAFFINOSE A. Formulation.
35 Bulk beta interferon, IFN-0, was obtained from Toray Industries, Inc., Tokyo, Japan. A 0.3% IFN-3 formulation was achieved by combining 0.025 mg IFN-0 per 1.0 mL deionized water with 4.7 mg/mL raffinose, 1.0 mg/mL human serum albumin (HSA), 2.3 mg/mL citrate buffer and 0.3 mg/mL of NaC1 at pH B. Spray Drying.
A dry powder of the 0.3% IFN-0 formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-80C Inlet temperature 1450C Feed rate 5.0 mL/min Outlet temperature 87oC Once the aqueous mixture was consumed, the outlet temperature was maintained at 97 0 C for about 5 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 0.3% IFN-0 dry powder composition contained 56.4% raffinose, 11.9% HSA, 27.4% citrate, NaCI. The formulation contained 0.69% moisture.
The particle size distribution of the composition was determined to be 2.06 Am MMD with 88.9% of the particles 5 Am.
S" The delivered dose.of the 0.3% IFN-j powder was determined to be 10.2 Ag/mg or 68.0 The aerosol particle size distribution, was determined to be 2.5 pm MMAD, with 84% of the particles .m in diameter.
The IFN-3 activity of the powder as measured by IFN-0 enzyme immunoassay (Toray-Fuji Bionics) and was determined to be 109 8% of the expected activity.
ooo EXAMPLE IX 93% LOW MOLECULAR WEIGHT HEPARIN FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk low molecular weight heparin sodium salt (Av.
Mol. Wt.: Approx. 6000) from porcine intestinal mucosa, heparin (LMW), was obtained from Sigma Chemical, St. Louis, MO.. A 93% heparin (LMW) formulation was achieved by combining 6.9 mg heparin (LMW) per 1.0 mL deionized water with mg/mL HSA at pH 6.9.
B. Spray Drying.
A dry powder of the 93% heparin (LMW) formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-80C Inlet temperature 140 0
C
Feed rate 3.8 mL/min Outlet temperature 850C Atomizer coolant temperature 2-8 0
C
Cyclone coolant temperature 20 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 80 0 C for about 10 minutes by 25 slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 93% heparin (LMW) dry powder composition contained 7.0% HSA.
The delivered dose of the 93% heparin (LMW) powder 35 was determined to be 60.0 The aerosol particle size distribution, was determined to be 3.5 Am MMAD, with 70% of the particles pm in diameter.
f, t 26 EXAMPLE X 97% UNFRACTIONATED HEPARIN FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk unfractionated heparin sodium salt from porcine intestinal mucosa, heparin, was obtained from Sigma Chemical, St. Louis, MO. A 97% heparin formulation was achieved by combining 7.0 mg heparin per 1.0 mL deionized water with 0.25 mg/mL HSA at pH 6.55.
B. Spray Drying.
A dry powder of the 97% heparin formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-8 0
C
Inlet temperature 150 0
C
Feed rate 4.0 mL/min Outlet temperature 850C Atomizer coolant temperature 2-8 0
C
Cyclone coolant temperature 20 0
C
Once the aqueous mixture was consumed, the outlet S temperature was maintained at 80 0 C for about 10 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
S
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 97% heparin dry powder composition contained 3.0% HSA. The formulation contained 5.11% moisture.
The particle size distribution of the composition was determined to be 2.0 to 2.5 Am MMD.
35 The delivered dose of the 97% heparin powder was determined to be 79.0 The aerosol particle size distribution, was determined to be 3.2 Am MMAD, with 70% of the particles Am in diameter.
EXAMPLE XI LIPID VECTOR GENE FORMULATION FOR PULMONARY
DELIVERY
A. Formulation.
Bulk pCMV0 DNA:Lipid vector was obtained from Genzyme Corporation, Cambridge, MA. A 0.71% DNA:Lipid vector formulation was achieved by combining 0.005:0.03 mg DNA:Lipid vector per 1.0 mL deionized water with 5.3 mg/mL glycine
(J.T.
Baker) 0.3 mg/mL HSA at pH 6.4.
B. Spray Drying.
A dry powder of the DNA:Lipid vector formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: Temperature of aqueous mixture 2-80C Inlet temperature 120 0
C
Feed rate 3.8 mL/min Outlet temperature 71oC Atomizer coolant temperature 2-8 0
C
S25 Cyclone coolant temperature 2-8 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 65 0 C for about 5 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above 0.71% DNA:Lipid vector dry powder composition contained 93.97% glycine, and 5.32% HSA.
The particle size distribution of the composition was determined to be 2.0 Am MMD.
The delivered dose of the 97% heparin (HMW) powder was determined to be 64.0 The aerosol particle size distribution, was determined to be 2.4 Am MMAD, with 75% of the particles Am in diameter.
Activity after spray drying was determined to be 160% of the expected value.
EXAMPLE XII ADENOVIRAL VECTOR GENE FORMULATION FOR PULMONARY DELIVERY A. Formulation.
Bulk pCMV3 DNA:Adenovirous vector was obtained from Genzyme Corporation, Cambridge, MA. A DNA:adenovirous vector formulation was achieved by combining 108 PFU/mL DNA:Lipid vector per 1.0 mL deionized water with 6.1 mg/mL glycine J.T.
Baker) 2.5 mg/mL HSA, 1.9 mg/mL phosphate buffer at pH 7.4.
B. Spray Drying.
A dry powder of the DNA:Lipid vector formulation described above was produced by spray drying the aqueous mixture using a Buchi Laboratory Spray Dryer under the following conditions: 25 Temperature of aqueous mixture 2-80C Inlet temperature 105 0
C
Feed rate 2.9 mL/min Outlet temperature 72oC Atomizer coolant temperature 2-8 0
C
Cyclone coolant temperature 20 0
C
Once the aqueous mixture was consumed, the outlet temperature was maintained at 70 0 C for about 10 minutes by slowly decreasing the inlet temperature to provide a secondary drying.
C. Characterization.
The following characterization of the dry powder formulation described above was carried out using the methods described in Example I unless indicated otherwise.
The above DNA:adenovirous vector dry powder composition contained 58% glycine, and 24% HSA and 18% phosphate buffer.
The particle size distribution of the composition was determined to be 2.3 im MMD.
The delivered dose of the 97% heparin (HMW) powder was determined to be 51.0 The aerosol particle size distribution, was determined to be 1.8 Am MMAD, with 80% of the particles Aim in diameter.
Activity after spray drying was determined to be 76% of the expected value.
All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
The invention now being fully described, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from 25 the spirit or scope of the appended claims.
ae *ooze* *o 29A It is to be understood that a reference herein to a prior art document does not constitute an admission that the document forms part of the common general knowledge in the art in Australia or in any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprising", or grammatical variations thereof, is used in the sense of "including", i.e. the features specified may be associated with further features in various embodiments of the invention.
oo o•*

Claims (40)

1. A spray-dried pharmaceutical-based dispersible dry powder composition for pulmonary delivery, comprising: a therapeutically effective amount of a macromolecule which retains its activity upon spray-drying, and a pharmaceutically acceptable carrier.
2. The dry powder composition of claim 1, comprising particles having a uniform distribution of macromolecule and carrier.
3. The dry powder composition of claim i, wherein of the mass of the composition comprises particles 15 having a particle size below 10 microns.
4. The dry powder composition of claim i, comprising particles of a size ranging from 1.0-5.0 microns mass e median diameter (MMD).
5. The dry powder composition of claim i, comprising particles of a size ranging from 1.0-4.0 microns mass median diameter (MMD). 25 6. The dry powder composition of claim 1, comprising particles having an aerosol particle size distribution ego• from 1.0-5.0 microns mass median aerodynamic diameter (MMAD)
7. The dry powder composition of claim i, comprising particles having an aerosol particle size distribution from 1.5-4.0 microns mass median aerodynamic diameter (MMAD).
8. The dry powder composition of claim 1, characterized by a delivered dose of greater than
9. The dry powder composition of claim 1, characterized by a delivered dose of greater than The dry powder composition of claim 1, having a homogeneous constitution.
11. The dry powder composition of claim 1, comprising less than 5% macromolecule degradation products.
12. The dry powder composition of claim 1, wherein said composition is substantially free from surface active 15 compounds.
13. The dry powder composition of claim 1, which, when pulmonarily administered to a subject, rapidly dissolves in the fluid layer of the alveolar lining of the lung.
14. The dry powder composition of claim 1, wherein ::::said carrier is selected from the group consisting of carbohydrates, amino acids, polypeptides, pH adjusters, 25 and salts.
15. The dry powder composition of claim 14, wherein said carrier is selected from the group consisting of galactose, D-mannose, sorbose, lactose, trehalose, 2- hydroxypropyl-p-cyclodextrin, raffinose, mannitol, and xylitol.
16. The dry powder composition of claim 14, wherein said carrier is an amino acid.
17. The dry powder composition of claim 16, wherein said amino acid carrier comprises a hydrophobic amino acid.
18. The dry powder composition of claim 17, wherein said amino acid carrier is selected from the group consisting of tryptophan, tryrosine, leucine, and phenylalanine.
19. The dry powder composition of claim 18, wherein said amino acid carrier comprises leucine. The dry powder composition of claim 1, wherein 15 the macromolecule is selected from the group consisting of insulin, interleukin 1 receptor, parathyroid hormone, alpha-i antitrypsin, low molecular weight heparin, and nucleic acids.
21. An aerosolized dry powder composition of claim 1.
22. A unit dosage form for pulmonary delivery of a macromolecule-based composition, comprising a unit dosage receptacle containing the dry powder composition according- 25 to any one of claims 1-20. t 23. A method for aerosolizing a macromolecule-based .dry powder composition for subsequent inhalation by a subject, said method comprising: dispersing an amount of a dry powder composition according to any one of claims 1-20, 21 in a gas stream to form an aerosol, and capturing the aerosol in a chamber.
24. A method for preparing a spray-dried, macromolecule based dry powder composition according to any one of claims 1-20, said method comprising: providing an aqueous mixture of the macromolecule and the carrier, and spray drying the mixture under conditions effective to produce a respirable dry powder. The method of claim 24, wherein said aqueous mixture of the macromolecule and the carrier is a homogeneous aqueous mixture.
26. The method of claim 24, wherein said aqueous mixture of the macromolecule and the carrier is a 15 solution.
27. The method of claim 24, wherein the respirable o**o dry powder produced in said spray-drying step comprises individual particles in which the carrier and the macromolecule are uniformly mixed. 9**9*9
28. The method of claim 24, wherein the spray-dried respirable powder produced in said spray-drying step, when administered pulmonarily to a patient in need thereof,- is 25 systemically absorbed in a rapid manner.
29. The method of claim 24, wherein said aqueous mixture is substantially free from surface active compounds. The method of claim 24, wherein said carrier is selected from the group consisting of carbohydrates, amino acids, polypeptides, pH adjusters, and salts. 6 I 34
31. The method of claim 24, wherein said carrier is selected from the group consisting of galactose, D-mannose, sorbose, lactose, trehalose, 2-hydroxypropyl-P- cyclodextrin, raffinose, mannitol, and xylitol.
32. The method of claim 24, wherein said carrier is an amino acid.
33. The method of claim 24, wherein said amino acid carrier comprises a hydrophobic amino acid.
34. The method of claim 24, wherein said amino acid carrier is selected from the group consisting of tryptophan, tryrosine, leucine, and phenylalanine.
35. The method of claim 24, wherein said amino acid carrier comprises leucine. S
36. The method of claim 24, wherein said carrier .e comprises a carbohydrate in combination with an amino acid.
37. The method of claim 24, wherein said carrier comprises a carbohydrate in combination with a 25 polypeptide.
38. The method of claim 24, wherein the macromolecule is selected from the group consisting of insulin, interleukin 1 receptor, parathyroid hormone, alpha-1 antitrypsin, low molecular weight heparin, and nucleic acids.
39. A composition according to any one of claims 1-20 having a moisture content below about 5% by weight. A spray-dried powder for pulmonary delivery produced according to the method of claim 24.
41. The dry powder composition of claim 1, wherein said composition, when administered by inhalation, is systemically absorbed in a rapid manner.
42. The dry powder composition of claim 1, comprising particles having a diameter less than 10 microns.
43. The dry powder of claim 1, wherein said macromolecule is selected from the group consisting of proteins, polypeptides and nucleic acids. 15 44. The dry powder of claim 43, wherein said macromolecule is a protein.
45. The dry powder of claim 43, wherein said macromolecule is a polypeptide. S S46. The dry powder of claim 43, wherein said S macromolecule is a nucleic acid.
47. The dry powder of claim 1, wherein said carrier •.mc 25 is selected from the group consisting of monosaccharides, *o disaccharides, trisaccharides, alditols, polypeptides, amino acids, and pH adjusters.
48. The dry powder of claim 47, wherein said carrier is selected from the group consisting of monosaccharides, disaccharides, trisaccharides, and alditols.
49. A composition substantially as herein described with reference to any one of Examples I to XII. The method of claim 23 or 24 substantially as herein described with reference to any one of Examples I to XII. Dated this 3rd day of September 2001 INHALE THERAPEUTIC SYSTEMS By its Patent Attorneys GRIFFITH HACK 000 0 0000
AU23695/99A 1995-04-14 1999-04-09 Pulmonary delivery of aerosolized medicaments Ceased AU740760B2 (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5260306A (en) * 1981-07-24 1993-11-09 Fisons Plc Inhalation pharmaceuticals
US5384133A (en) * 1986-08-11 1995-01-24 Innovata Biomed Limited Pharmaceutical formulations comprising microcapsules

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5260306A (en) * 1981-07-24 1993-11-09 Fisons Plc Inhalation pharmaceuticals
US5384133A (en) * 1986-08-11 1995-01-24 Innovata Biomed Limited Pharmaceutical formulations comprising microcapsules

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