US20150017244A1 - Dry powder formulation of azole derivative for inhalation - Google Patents

Dry powder formulation of azole derivative for inhalation Download PDF

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US20150017244A1
US20150017244A1 US13/261,916 US201213261916A US2015017244A1 US 20150017244 A1 US20150017244 A1 US 20150017244A1 US 201213261916 A US201213261916 A US 201213261916A US 2015017244 A1 US2015017244 A1 US 2015017244A1
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particles
dissolution
itraconazole
spray dried
minutes
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Arthur Deboeck
Francis Vanderbist
Philippe Baudier
Thami Sebti
Christophe Duret
Karim Amighi
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GALEPHAR PHARMACEUTICAL RESEARCH Inc
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GALEPHAR PHARMACEUTICAL RESEARCH Inc
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00—Medicinal preparations containing organic active ingredients
    • A61K31/33—Heterocyclic compounds
    • A61K31/395—Heterocyclic compounds having nitrogen as a ring hetero atom, e.g. guanethidine or rifamycins
    • A61K31/495—Heterocyclic compounds having nitrogen as a ring hetero atom, e.g. guanethidine or rifamycins having six-membered rings with two or more nitrogen atoms as the only ring heteroatoms, e.g. piperazine or tetrazines
    • A61K31/496—Non-condensed piperazines containing further heterocyclic rings, e.g. rifampin, thiothixene or sparfloxacin
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/06—Organic compounds, e.g. natural or synthetic hydrocarbons, polyolefins, mineral oil, petrolatum or ozokerite
    • A61K47/08—Organic compounds, e.g. natural or synthetic hydrocarbons, polyolefins, mineral oil, petrolatum or ozokerite containing oxygen, e.g. ethers, acetals, ketones, quinones, aldehydes, peroxides
    • A61K47/14—Esters of carboxylic acids, e.g. fatty acid monoglycerides, medium-chain triglycerides, parabens or PEG fatty acid esters
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/06—Organic compounds, e.g. natural or synthetic hydrocarbons, polyolefins, mineral oil, petrolatum or ozokerite
    • A61K47/26—Carbohydrates, e.g. sugar alcohols, amino sugars, nucleic acids, mono-, di- or oligo-saccharides; Derivatives thereof, e.g. polysorbates, sorbitan fatty acid esters or glycyrrhizin
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K47/00—Medicinal preparations characterised by the non-active ingredients used, e.g. carriers or inert additives; Targeting or modifying agents chemically bound to the active ingredient
    • A61K47/06—Organic compounds, e.g. natural or synthetic hydrocarbons, polyolefins, mineral oil, petrolatum or ozokerite
    • A61K47/28—Steroids, e.g. cholesterol, bile acids or glycyrrhetinic acid
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/0012—Galenical forms characterised by the site of application
    • A61K9/007—Pulmonary tract; Aromatherapy
    • A61K9/0073—Sprays or powders for inhalation; Aerolised or nebulised preparations generated by other means than thermal energy
    • A61K9/0075—Sprays 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
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1605—Excipients; Inactive ingredients
    • A61K9/1617—Organic compounds, e.g. phospholipids, fats
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1605—Excipients; Inactive ingredients
    • A61K9/1617—Organic compounds, e.g. phospholipids, fats
    • A61K9/1623—Sugars or sugar alcohols, e.g. lactose; Derivatives thereof; Homeopathic globules
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1682—Processes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1682—Processes
    • A61K9/1688—Processes resulting in pure drug agglomerate optionally containing up to 5% of excipient
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1682—Processes
    • A61K9/1694—Processes resulting in granules or microspheres of the matrix type containing more than 5% of excipient
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P31/00—Antiinfectives, i.e. antibiotics, antiseptics, chemotherapeutics
    • A61P31/10—Antimycotics
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K2300/00—Mixtures or combinations of active ingredients, wherein at least one active ingredient is fully defined in groups A61K31/00 - A61K41/00

Definitions

  • Aspergillosis refers to the spectrum of pathologies caused by Aspergillus species which are filamentous fungi more precisely ascomycetes classified in the form subdivision of the Deuteromycotina.
  • IA Invasive aspergillosis
  • IC immunocompromised
  • the principal gateway to this pathogen (80 to 90% of IA) and are often the starting points of the invasion that can lead to disseminated state, fatal in more than 90% of cases.
  • the fungus can disseminate after invasion of the pulmonary tissue through the blood stream to reach liver, spleen, kidney, brain and other organs.
  • the invasive state is mainly reach in IC population who after conidia's inhalation has not enough immune defenses (principally macrophages) to prevent their germination and therefore hyphae proliferation (principally neutrophils) through tissues and blood capillaries in the contamination area.
  • amphotericin B is not well tolerated, shows a lot of severe adverse reactions.
  • inhaled amphotericin B was shown to be ineffective as prophylaxis in patients with prolonged neutropenia following chemotherapy or autologous bone marrow transplantation.
  • the first line therapy considered as gold standard class, are the azole derivates (itraconazole, voriconazole, posaconazole, ravuconazole).
  • current therapies oral and intravenous
  • the mortality rate goes from 50 to 90% (in regards with population's category and study.
  • oral therapies show high inter and intra-individual variation in term of bioavailability that can lead to infra therapeutic concentrations in the lung tissue. Another important factor is also to take into account in the explanation of high rate treatment failure. Indeed, for an optimal antifungal activity, minimum inhibitory concentration (MIC) in pulmonary lung epithelium and lung tissue has to be maintained. With conventional therapies (oral, IV) those concentrations may not be reach inside the fungal lesion despite high systemic concentrations.
  • MIC minimum inhibitory concentration
  • pulmonary delivery can be an interesting alternative for prophylaxis and/or treatment of invasive pulmonary aspergillosis.
  • concentration above the MIC90% could be effectively and directly maintained in the lung tissue while minimizing systemic exposure therefore side effects and metabolic interactions.
  • the poorly water soluble active ingredient has to be delivered efficiently into the lung and must be dissolved in-situ as much as possible.
  • pulmonary drug delivery has extensively been developed. Interest in this particular route of administration can be justified by the numerous problems it overcomes and the advantages it offers in particular situations. Indeed, pulmonary drug delivery can be effective both for systemic delivery and localized delivery to treat systemic or lung diseases. This non invasive route of administration avoids hepatic first-pass effect which, for example, can lead to active pharmaceutical ingredient (API) inactivation or formation of toxic metabolites. It has been demonstrated that pulmonary drug delivery required smaller doses than by oral route to achieve equivalent pulmonary therapeutic effects. This can be particularly interesting in the case of pulmonary infectious diseases treated by inhalation of anti-infectious drugs (as azole derivates) presenting systemic sides effects and metabolic interactions.
  • API active pharmaceutical ingredient
  • pulmonary drug delivery allows minimizing systemic concentration, thus side effects, while maintaining effective lung concentration directly to the site of infection.
  • the administration of the anti-infectious drug directly to the lung allows minimization of systemic concentrations therefore drug systemic side effects and metabolic interactions which are very pronounced with common antifungal drugs. Those interactions and side effects are often the reason of treatment failures in the different patient populations.
  • Inhaler devices can be classified in three different types, including liquid nebulizers, pressurized aerosol metered dose inhalers (pMDIs), and dry powder dispersions devices.
  • pMDIs pressurized aerosol metered dose inhalers
  • DPIs dry powder inhalers
  • the majors problems encountered in liquid nebulization are the drug instability during storage, the relatively long time to achieve total nebulization, risk of bacterial contamination, high cost, low efficiency and poor reproducibility.
  • pMDIs one of the principal source of administration's procedure failure is the necessity of synchronization between dose activation and breathing. For those reasons DPIs are nowadays at the top of the research interest in the pulmonary delivery field.
  • the problem to be solved is to provide patients with antifungal inhaled compositions that offer a high lung deposition and allow an adequate dissolution profile of the poorly water soluble active ingredient in-situ, therefore allowing an optimized efficacy of the drug product.
  • the inhaled compositions should present an acceptable safety profile, should be stable, should be easy to administer in a reproducible and precise way.
  • the manufacturing process of said composition should be short, simple, cheap, ecological, reliable, and environmentally friendly (no USP class 1 or 2 solvents)
  • an important characteristic that the formulation must possess is an improved and optimal in vitro dissolution profile (compared to the unformulated drug).
  • the manufacturing process must present the flexibility of controlling the dissolution rate of the active ingredient to obtain an optimal pharmacokinetic profile thus providing an optimal therapeutic response.
  • An optimal pharmacokinetic profile corresponds to a maximization of lung time residence while minimizing systemic absorption and elimination.
  • Azole compounds are poorly water-soluble substances (e.g. solubility of itraconazole pH 7 ⁇ 1 ⁇ g/ml) and inhalation of an insoluble powder can lead to (i) poor tolerance and/or (ii) lack of efficacy.
  • the low wetability of poorly water soluble active ingredients can cause irritation and inflammation to the pulmonary mucosa after inhalation.
  • Improvement of its dissolution rate and wettability are here necessary to avoid excessive elimination of the undissolved fraction of the drug by alveolar macrophages in the lower airways and mucociliary clearance in the upper airways.
  • acceleration of the dissolution rate of the active ingredient has preferably to be limited to a certain extend because a too fast dissolution rate would result in an excessive absorption of the dissolved fraction to the systemic compartment and thus possibly to adverse event.
  • a need that the invention must satisfy is the possibility to modify the dry powder composition to improve and/or modulate its dissolution rate while keeping good powder flowability and high dispersibility properties.
  • the dissolution rate of the active ingredient must be kept in a determined ranged and it should be possible to make vary the dissolution profile (greater or less amount of dissolved active substance at the same time point within the dissolution range) in order to make vary the in-situ dissolution rate therefore the therapeutic and side effects.
  • antifungal azole compound after oral inhalation has to reach the site of infection.
  • the dry powder should present an optimized aerodynamic behavior. That means than the dry powder must reach the potential conidia's deposition site where fungus can grow and invade peripheral tissue area.
  • a determinate fraction of the generated particles have to present an aerodynamic diameter range similar than those of fungal conidia (between 1.9 and 6 ⁇ m) to provide to the lung an appropriated antifungal dose.
  • the generated particles from an inhaler device in breath condition must present a high percentage of particles having an aerodynamic diameter less than 6 ⁇ m. This percentage will directly influence the dose really reaching the lungs.
  • the aerodynamic behavior of particles is determined by their size and composition. As described above, the formulation must present an optimized dissolution profile to obtain an optimal pharmacokinetic profile in vivo. Once an optimized composition has been developed, it should be possible to modify its aerodynamic behavior in order to modulate powder fine particle fraction to reach a suitable dose deposition that would play correctly its fungal activity (depending on its dissolution rate profile).
  • powder for use in dry powder inhaler must display good flowability, low agglomeration tendency for an easy processing at industrial scale.
  • the manufacturing process must be simple, continuous and designed to be realized in one or two step to obtain the final dry product.
  • This invention allows producing a dry powder with a high percentage of particles presenting the same aerodynamic diameter that inhaled conidia.
  • This fraction of particles presents an improved and/or controlled dissolution profile compared to unformulated drug.
  • This release profile can be modified by only using endogenous or GRAS substances and low toxicity potential solvents. The whole process is a one or two step procedures.
  • the problem to be solved is to provide patients with antifungal inhaled compositions that offer a high lung deposition and at the same time allow an adequate dissolution profile of the poorly water soluble active ingredient in-situ, therefore allowing an optimized efficacy of the drug product.
  • the inhaled compositions should present an acceptable safety profile, should be stable, should be easy to administer in a reproducible and precise way.
  • the manufacturing process of said composition should be short, simple, cheap, ecological, reliable, and environmentally friendly (no USP class 1 or 2 solvents)
  • PCT International Pub. No. WO 2009/106333 A1 describes a new nanosuspension of antifungal azole derivates with improved purity profile. This high purity profile is guaranty by a high quality production process minimizing contamination of the formulation which could come from equipments. This assured minimum toxicity that can be caused by inorganic insoluble impurity.
  • Canadian Pub. No. 2014401 A1 relates to pharmaceutical compositions for treating invasive fungal infections by inhalation. It describes dry powder for inhalation wherein the micronized active ingredient is blended with an acceptable carrier. Those compositions allow deep penetration of the active ingredient to the lung but do not promote dissolution rate.
  • U.S. Pat. No. 6,645,528 B1 discloses a method of fabrication of porous drug matrices presenting a faster dissolution rate than bulk material and no porous drug matrices of the same drug.
  • This matricial product could be administrated by inhalation as a dry powder.
  • the active ingredient is dissolved in a volatile solvent to form drug solution.
  • a pore forming agent is combined to the drug solution to form an emulsion, suspension or second solution.
  • the volatile solvent and pore forming agent are then removed (preferably by spray drying) to yield the porous matrix of drug.
  • the pore forming agent can be a volatile liquid or a volatile solid preferably a volatile salt that are immiscible with the volatile solvent.
  • U.S. Pat. No. 7,521,068 B2 describes formulations and associated manufacturing procedure for nanoparticulate dispersion aerosol, dry powder nanoparticulate aerosol formulation, and propellant based aerosol formulations preparation.
  • the aqueous dispersion or dry powder describe therein contained insoluble drug particles (including azole derivates) having a surface modifier on their surface.
  • insoluble drug particles including azole derivates
  • surfaced modifier include various polymers, low molecular weight oligomers, natural products and surfactant.
  • the dry powder formulation is obtained by drying an aqueous nanosuspension. Prior drying, the aqueous dispersion of drug and surface modifier can contain a dissolved diluent such as sugars.
  • this invention presents some disadvantages. Indeed, it was correctly emphasized on the advantage that size reduction has on dissolution rate improvement since there is proportionality between the solid API dissolution rate and its surface area available for dissolution as described by the Nernst-Brunner/Noyes-Whitney equation. But it is not possible with this manufacturing process to modify dissolution rate of the solid nanoparticle present in the formulation.
  • the dissolution rate of the solid API after inhalation would be inherent to nanoparticles dissolution rate which can lead to excessive absorption in the systemic compartment therefore enhancing the probability adverse reactions, drug-drug and metabolic interactions which could induce treatment failure.
  • Nanoparticles dissolution velocity is generally tremendous fast and this invention do not clearly establish the possibility to delay, decrease or control dissolution rate of the active ingredient. Additionally, a surface modifier is necessary for nanosuspension stabilization and it will result in surface wetting enhancement of particles and consequently to their dissolution rate. Moreover, diluents and excipient that can be added prior the drying step of the aqueous nanosuspension are limited to hydrophilic components and cannot be hydrophobic due to the aqueous nature of the described dispersants. Once this diluent will be after inhalation in contact with the aqueous pulmonary surfactant its dissolution will be fast and it would not be possible to modify nanoparticles dissolution rate therefore their systemic absorption leading to an excessive elimination.
  • PCT International Pub. No. WO 2004/060903 A2 discloses effective lung concentration and residence time specifically for amphotericin B after inhalation to treat or to give a prophylaxis against fungal infection.
  • toxicity related to this formulation type which is a serious limitation for pulmonary administration that cannot be accepted (Spickard and Hirschmann, Archives of Internal Medicine 1994, 154(6), 686).
  • amphotericin B was shown to be ineffective as prophylaxis in patients with prolonged neutropenia following chemotherapy or autologus bone marrow transplantation.
  • Formulations described therein are lipid complex based formulations of amphotericin B that can be disadvantageous for the azole derivates because of their poor solubility.
  • azole derivates are included but no examples of this pharmaceutical class were provided. No specific manufacturing procedure was underlined to allow optimization of those concentration and residence time. Lipid/phospholipid based formulations production methods are described but those process are specific to amhpotericin B (complex formation) and could not be applied to different compounds such as azole derivates.
  • compositions are constituted of one or more respirable aggregates comprising one or more poorly water soluble active agent. After inhalation those composition allow to reach a maximum lung concentration of at least 0.25 ⁇ g/g that can be kept for a certain period.
  • the inventors describe a series of methods that can be use to prepare those respirable aggregates. Those methods comprise Ultra rapid freezing (U.S. Pat. Appl. Pub. No. 2004/0137070), Spray freezing into liquid (U.S. Pat. No. 6,862,890), Evaporative precipitation into aqueous solution (U.S. Pat. No.
  • Solubilisation of drugs in co-solvents or micellar-solutions is other possibilities to improved and/or modify dissolution rate of poorly soluble active ingredients.
  • those kinds of formulations are also designed to be administrated by nebulization and not as a dry powder for inhalation.
  • Complexation with cyclodextrin is another strategy to improve dissolution rate of poorly soluble substance when formulated as dry powder for inhalation.
  • cyclodextrin have shown after inhalation to induce inflammatory reaction signs and its safety profile is, nowadays, not clear enough.
  • Polymeric surfactants such as co-polymers of polyoxyethylene and polyoxypropylene have been used in several DPI formulations presenting an improved in vitro dissolution rate (McConville et al., 2006). Those polymers have been noted to produce slight alveolitis after 2 weeks of exposure in inhalation toxicity study Formation of salt forms with enhanced dissolution profiles and formation of solid dispersion are also common techniques in formulation field to improve dissolution rate of poorly soluble
  • Another possibility to improve dissolution rate of a drug is the modification of the physical form of the dry active ingredient. Both nanonizing dry crystalline particles and formation of amorphous dry form of the drug induce an improvement of substance's dissolution rate. However, drying particles generally induce their aggregation and then a loss of dissolution rate improvement due to the decrease in the total surface area available to the dissolution medium. Moreover there is here a need to form particles with a determinate aerodynamic diameter to reach after inhalation the site of infection of the Aspergillus colonization site (regarding their aerodynamic diameter).
  • Dispersing those nanosize crystalline and/or amorphous particles in acceptable excipient for inhalation is an interesting approach to form particles with appropriated aerodynamic diameter and to keep dissolution rate improvement of generated dry particles once deposited on the pulmonary mucosa.
  • the nature of the matricial agent should have the properties to enhance or delayed dissolution rate of the active ingredient (compared to another formulation). All excipients and solvent in use have to be physiologically tolerated or recognized as save to minimize potential toxicity after inhalation or during production and reduce hazardous environmental contaminations.
  • the present invention provides a one or two step procedure to produce this type of dry powder using only safe and authorized excipient/solvent.
  • This dry powder presents good flowability.
  • the produced dry powders present appropriated aerodynamic features (regarding inhaled conidia) once emitted from a dry powder inhaler device.
  • the concept of formulation allows improvement and/or modification/control . . . of the poorly soluble active ingredient dissolution rate to obtain a formulation that will minimize systemic absorption while maximizing its residence time in the lung and hence its efficacy.
  • the subject matter of the present invention is spray-dried particles (X) for a inhalation composition
  • a inhalation composition comprising (a) between 5 and 50% by weight of at least one azole derivative in amorphous state and (b) at least one matricial agent to the composition selected from a group consisting of polyol such as sorbitol, mannitol and xylitol; a monosaccharides such as glucose and arabinose; disaccharide such as lactose, maltose, saccharose and dextrose; cholesterol, and any mixture thereof.
  • said matricial agent is mannitol or cholesterol.
  • the weight ratio of azole derivative(s)/matricial agent(s) is between 0.5/99.5 and 40/60, preferably between 1/99 and 35/65, more preferably between 10/90 and 35/65.
  • Said azole derivative do not comprise a compound of the group consisting of omeprazole, esomeprazole, lansaprazole, pantoprazole and rabeprazole.
  • said particles further comprise a surfactant and preferably comprise between 0.1 and 5% by weight of the surfactant.
  • said surfactant is selected from lecithin, phospholipids derivatives such as phosphatic acids, phosphatidyl choline (saturated and unsaturated), phoshpatidyl ethanol amine, phosphatidyl glycerol, phosphatidyl serine, phosphatidyl inositol, dioleoylphosphatidylcholine, dimyristoyl phosphatidylcholine, dipalmitoylphosphatidylcholine, distearoyl phosphatidylcholine, diarachidoyl phoshatidylcholine, dibenoyl phosphatidylcholine, ditricosanoyl phosphatidylcholine, dilignoceroylphatidylcholine, dimiristoylphosphatidylethanol
  • the subject matter of the present invention is also a spray dried-powder composition for inhalation comprising the particles (X), wherein said composition comprises at least 50% of the matricial agent and provides a dissolution rate of said azole derivative of at least, 5% within 10 minutes, 10% within 20 minutes and 40% within 60 minutes when tested in the dissolution apparatus type 2 of the United States Pharmacopoeia at 50 rotation per minute, 37° C. in 900 milliliters of an aqueous dissolution medium adjusted at pH 1.2 and containing 0.3% of sodium laurylsulfate.
  • Said composition preferably provides a Fine Particle Fraction of the azole derivative of at least 35% of the total nominal dose of the azole in the powder following the method “preparations for inhalation: assessment of fines particles” using the Multi-stage Liquid Impinger, Apparatus C—chapter 2.9.18 of the European Pharmacopoeia.
  • said composition further comprises another type of particles (Y) which contain (a) between 5 and 50% by weight of at least one azole derivative in amorphous state (b) at least one matricial agent, and (c) a surfactant Said particles (Y) preferably contain between 0.5 and 5% by weight of the surfactant(s).
  • said composition further comprises another type of particles (Z) which further contain up to 20% by weight of nanoparticles of the azole derivative in crystalline structure having a mean size between 0.1 and 1 ⁇ m.
  • said composition provides a dissolution rate of the azole derivative of 5 to 50% within 5 minutes, 10 to 60% within 10 minutes, 15 to 90% within 20 minutes and 40 to 100% after 60 minutes.
  • the azole derivative(s) is selected from miconazole, fluconazole, itraconazole, posaconazole, voriconazole, isoconazole, ketoconazole, oxiconazole, bifonazole, fenticonazole, tioconazole, terconazole, sulconazole, ravuconazole, econazole, terconazole, preferably, itraconazole.
  • the subject matter of the present invention is also a method for preparing said spray dried particles and composition which comprises the following steps of:
  • said method further comprises the steps of:
  • the subject matter of the present invention is also a liquid composition
  • a liquid composition comprising:
  • said liquid composition further comprises at least one surfactant and/or nanoparticles of at least one azole derivative having a mean size between 0.1 and 1 ⁇ m.
  • FIG. 1 is the MDSC heating curves of spray dried itraconazole.
  • FIG. 2 is in vitro dissolution profile of micronized crystalline bulk itraconazole, pure amorphous itraconazole and a spray dried powder formulation according to the present invention (example 1B) comprising hydrophilic matricial and itraconazole.
  • FIG. 4 is in vitro dissolution profile of bulk crystalline itraconazole and the spray dried formulations according to present invention (examples 2A to 2D).
  • FIG. 5 is the SEM photographs of spray dried powder formulations according to the present invention (examples 3A to 3E) and a spray dried itraconazole (example 3F) at magnification ⁇ 1000.
  • FIG. 6 is the MDSC heating curves of spray dried powder formulations according to the present invention (examples 3A to 3E), spray dried itraconazole (example 3F) and spray dried mannitol.
  • FIG. 8 is in vitro dissolution profile of micronized crystalline bulk itraconazole, spray dried amorphous itraconazole (example 3F) and spray dried powder formulations according to the present invention (examples 3A to 3E).
  • FIG. 9 is in vitro dissolution profile of spray dried powder formulations according to the present invention (examples 3A to 3E) with Curve A defining the dissolution rate of 5% within 10 minutes, 10% within 20 minutes and 40% within 60 minutes.
  • FIG. 10 is in vitro dissolution profile of spray dried powder formulations according to the present invention (examples 3A to 3E) with Curves B and B′ defining the dissolution rate of 5% within 5 minutes, 10% within 10 minutes, 15% within 20 minutes and 40% within 60 minutes, and the one of 50% within 5 minutes, 60% within 10 minutes, 90% within 20 minutes and 100% within 60 minutes, respectively.
  • FIG. 11 is in vitro dissolution profile of micronized crystalline bulk itraconazole and a spray dried powder formulation according to the present invention comprising Itraconazole, cholesterol and phospholipon (example 4).
  • FIG. 12 is in vitro dissolution profile of micronized crystalline bulk itraconazole and spray dried powder formulations comprising itraconazole and mannitol according to the present invention, i.e., particles not containing crystalline nanoparticles of itraconazole (example 5A) and particles containing crystalline nanoparticles of itraconazole (example 5B).
  • This invention is related to a dry powder formulation for inhalation of azole derivatives with the proviso that said azole derivative is not a compound of the group consisting of the family of omeprazole, esomeprazole, lansaprazole, pantoprazole and rabeprazole and a process to provide it.
  • Azole derivatives can be selected from the group consisting of miconazole, fluconazole, itraconazole, posaconazole, voriconazole, isoconazole, ketoconazole, oxiconazole, bifonazole, fenticonazole, tioconazole, tereonazole, sulconazole, ravuconazole, econazole, terconazole.
  • the dry powder of the invention can present high dispersibility capabilities to maximize, after inhalation from an inhaler device, the proportion of particles presenting an appropriated aerodynamic diameter range.
  • Appropriated aerodynamic range refers to aerodynamic diameter that presents inhaled conidia. Generated particles from an inhaler device in breath conditions must present the same aerodynamic range that inhaled aspergillus conidia (1.9-6 ⁇ m) to reach potential infections sites for an optimal treatment targeting and effectiveness.
  • the dry powder composition is based on the use of exclusively physiological component excipients, safe, generally recognized as save (GRAS) excipients, FDA authorized excipients for inhalation therapy to guaranty a good safety profile after inhalation and to be compatible with the lung membrane to avoid hyper-responsiveness, cough, airway spasticity or inflammation.
  • GRAS physiological component excipients
  • FDA authorized excipients for inhalation therapy to guaranty a good safety profile after inhalation and to be compatible with the lung membrane to avoid hyper-responsiveness, cough, airway spasticity or inflammation.
  • the manufacturing process requires one or two step(s) to obtain the final dry product and all techniques used are made for an easy scaling up to industrial batch size production.
  • the dry powder in itself is designed to possess enhanced flow properties for an easy processing at industrial scale.
  • the dry powder is specifically designed for oral inhalation to treat or give prophylaxis against pulmonary invasive aspergillosis.
  • the azole derivatives are in form that allows that dissolution rate can be improved at different extent and/or modified by varying the composition of the dry powder. The improvement can be controlled by modifying the dry powder composition and/or the active pharmaceutical ingredient (API) physical state or by combining prior administration different embodiments of the invention.
  • the dry powder is constituted of matricial microparticles.
  • the matricial microparticles are constituted of safe, physiological component or inhalation FDA authorized excipient wherein the active ingredient is dispersed in a modified physical state. After inhalation of those microparticles, after matrix dissolution or erosion, the active ingredient will expose a higher surface area to the pulmonary mucosa than the same dose of pure spray dried active ingredient microparticles, resulting in an improved dissolution rate.
  • the nature of the matricial agent directly influences the dissolution profile of the active ingredient.
  • the matricial agent can be (i) hydrophilic to directly release the active ingredient when in contact with the pulmonary mucosa (ii) hydrophobic to delay the release of the active ingredient (iii) a mixture of hydrophilic and hydrophobic (in different proportion) agent to obtain an intermediate release profile.
  • Matricial agents are physiological component excipients, GRAS excipients; FDA authorized excipients for inhalation therapy to avoid as far as possible pulmonary or systemic toxicity.
  • the matricial agents can be combined together to confer to the dry powder desired flow, aerodynamic and dissolution characteristics. The matricial agent is necessary in the composition.
  • Matricial agent can be selected from the group consisting of sugar alcohols, polyols such as sorbitol, mannitol and xylitol, and crystalline sugars, including monosaccharides (glucose, arabinose) and disaccharides (lactose, maltose, saccharose, dextrose) and cholesterol.
  • polyols such as sorbitol, mannitol and xylitol
  • crystalline sugars including monosaccharides (glucose, arabinose) and disaccharides (lactose, maltose, saccharose, dextrose) and cholesterol.
  • the API is in majority in amorphous state.
  • the proportion of amorphous active ingredient (in percentage of the total amount of active ingredient from the invention is from 51% to 100%, preferably between 70% and 100%, even more preferably 100%.
  • One way to obtain an amorphous compound is to spray dry it from a solution because the rapid solvent evaporation during the drying process do not let enough time to solid particles to recrystallize.
  • azole compounds and particularly itraconazole are only sparingly soluble in chloride solvent such as dichloromethane and chloroform which are, due to their high toxicity, not recommended for the preparation of pharmaceutical formulations.
  • This invention provides methods to obtain an amorphous product by spray drying the API from a solution using only a class 3 solvent. Those solvents are considered as low toxic potential solvents and then offer a better safety profile in case of residuals inhalation.
  • This category of solvent includes acetic acid, Heptane, Acetone, Isobutyl acetate, Anisole, Isopropyl acetate, 1-Butanol, Methyl acetate, 2-Butanol, 3-Methyl-1-butanol, Butyl acetate, Methylethylketone, tert-Butylmethyl ether, Methylisobutylketone, Cumene, 2-Methyl-1-propanol, Dimethyl sulfoxide, Pentane, Ethanol, 1-Pentanol, Ethyl acetate, 1-Propanol, Ethyl ether, 2-Propanol, Ethyl formate, Propyl acetate, formic acid or the mixture thereof,
  • An acid can be added into—a preheated organic class 3 solvent under magnetic stirring in order to enhance the solubility of poorly soluble azole compound such as itraconazole.
  • An organic solution comprising azole compound(s) can also be heated to high temperature under magnetic stifling to obtain enhanced solubility of the azole compound(s).
  • Those options only allow the dissolution of hydrophobic excipients in the solution.
  • a determinate quantity of water can be added to one of those solutions type in order to allow dissolving both poorly soluble active ingredients, hydrophilic and hydrophobic excipients. This can be particularly interesting in order to modify active ingredient's dissolution rate, particle size, aerodynamic behavior and flow properties.
  • Preferential ratio of water to organic solvent are from 0 to 50%, preferably between 0% to 30%, more preferably between 10% and 30% and even more preferably between 20% and 30%.
  • amorphous compounds present the advantage to possess higher solubility than the same crystalline compound.
  • amorphous compounds often recrystallize to lower energy crystalline state presenting lower solubility than the initial product.
  • This invention provides formulations wherein an active compound is in an amorphous state and formulated so that its dissolution occurs before complete drug recrystallization leading to an improved dissolution rate product.
  • the improvements and enlargement of surface area of dry powder formulation arrived at local site of a patient can be obtained by spray drying a solution of an active ingredient together with a hydrophilic maticial agent which provides particles comprising the active ingredient in amorphous state dispersing in the matricial agent.
  • Such improvements in surface area can—accelerate the active ingredient dissolution rate preventing from excessive recrystallization prior dissolution.
  • Recrystallization of amorphous drugs also may happen during storage leading to a decrease of the dissolution performance product.
  • One aspect of the present invention provide a stable amorphous product when formulate as a solid dispersion of the active ingredient in a matricial agent.
  • the amount of azole derivates that can be incorporated in the matricial agent(s) is from 0.5 to 40%, preferably from 1 to 35%, more preferably from 10 to 35% by weight.
  • the amount of the azole derivative added in the liquid composition is between 0.1% and 5%, preferably between 0.5% and 2% by weight of the azole derivative to the volume of the liquid composition (g/100 mL).
  • a surfactant can be added in the matrix of particles comprised in a dry powder formulation according to the present invention in order to improve the dissolution rate enhancement of the active ingredient.
  • a surfactant is an amphiphilic compound with both hydrophilic and hydrophobic characteristics.
  • the surfactant(s) can be selected from the group consisting of physiological component, GRAS (generally recognized as save) excipients, FDA authorized excipients for inhalation therapy to avoid any pulmonary or systemic toxicity.
  • GRAS generally recognized as save
  • the quantity of added surfactant could influence azole compound dissolution rate improvement.
  • the preferred amount of surfactant is comprised between 0.1 and 5% by weight in the dry powder composition.
  • Preferentially surfactant can be phospholipids, lecithin, lipids or GRAS modified vitamins, or combination of such surfactant.
  • Phospholipids that may use comprise phosphatic acids, phosphatidyl choline (saturated and unsaturated), phoshpatidyl ethanol amine, phosphatidyl glycerol, phosphatidyl serine, phosphatidyl inositol.
  • Examples of such phospholipids include, dioleoylphosphatidylcholine, dimyristoyl phosphatidylcholine (DMPC), dipalmitoylphosphatidylcholine (DPPC), distearoyl phosphatidylcholine (DSPC), diarachidoyl phoshatidylcholine (DAPC), dibenoyl phosphatidylcholine (DBPC), ditricosanoyl phosphatidylcholine (DTPC), dilignoceroylphatidylcholine (DLPC), dimiristoylphosphatidylethanolamine (DMPE), dipalmitoylphosphatidylethanoalamine (DPPE), pipalmitoleoylphasphatidylethanolamine, distearoylphosphatidylethanolamine (DSPE), dimyristoylphosphatidylglycerol (DMPG), dipalmitoylphosphatidyl glyce
  • a too high quantity of surfactant in the formulation can induce an important particle size increase during spray drying. Due to their low melting point, surfactants could soft or melt during spray drying increasing particle size. Dilution of the surfactant in the matricial agent can mask this effect resulting in production of smaller particles with appropriate characteristics.
  • One particular embodiment of the invention consists to obtain the active ingredient in the form of crystalline nanoparticles by a method described in the art.
  • nanoparticles used to describe the present invention has a meaning of solid discrete particles ranging in size from 1 nm to 1000 nm.
  • the presence of the crystalline nanoparticles of azole derivative in a spray dried particle and the weight ratio of the crystalline nanoparticles comprised in the particle can be determined by using powder X-ray diffraction, and differential scanning calorimetry concomitantly with HPLC drug quantification.
  • nanoparticles are then dispersed in a matricial agent to confer to the formulation appropriated particle size, flow properties, dissolution rate and aerodynamic behavior.
  • the dissolution rate of those nanoparticles is instantaneous (within 5 minutes) with a very pronounced burst effect that cannot be delayed due to inherent dissolution rate of the nanoparticles.
  • the production of this formulation types includes two steps in the manufacturing procedure.
  • the first step being the production of drug nanoparticles and the second step being the drying procedure.
  • the nanoparticles could be produced by a method described in the art.
  • nanoparticles are produced by high pressure homogenization.
  • the matricial agent can be added prior the size reduction step or before the spray drying procedure.
  • the active ingredient is dispersed in the matricial agent both in form of crystalline nanoparticles and amorphous compound.
  • This embodiment can be the result of the spray drying of both matricial agent and the active ingredient in solution together with nanoparticles of the active in.
  • the dry powder formulation according to the present invention is manufactured by a simple blend of the nanoparticles of the active ingredient, which are obtained by spray drying of a suspension comprising its crystalline nanoparticles and a matricial agent or by mechanical milling of the crystalline active ingredient, and an amorphous matricial formulation obtained by spray drying of the active ingredient in solution.
  • This blend powder will be filled in capsule, blister or multidose device.
  • the desired result is to confer to the formulation a controlled dissolution profile by optimizing the proportion of nanoparticles/amorphous compound in the formulation.
  • This dissolution profile could not be reach with only the nanoparticles in the formulations.
  • the modification of the proportion nanoparticles/amorphous allow varying dissolution profile.
  • the ratio (w/w) of amorphous matricial particles/nanocrystalline matricial composition is comprised between 100/0 to 80/20.
  • the active ingredient is dispersed as nanoparticles or microparticles in a matrix of the same active ingredient.
  • the active ingredient matricial being in amorphous state
  • Nanosuspension could be concomitantly spray dried with a solution of active ingredient containing a matrix former.
  • the differences that exist between amorphous and nanoparticles dissolution rate could allow modifying dissolution rate of the formulation.
  • the API in solution could either be used as matrix former encapsulating the nanoparticles. This could provide formulation presenting an interesting dissolution rate and optimal aerodynamic characteristics.
  • the starting material is constituted of crystalline micronized itraconazole (ITZ) with a volume mean diameter of 3.5 ⁇ m and 90% of particles below 6.2 ⁇ m.
  • ITZ crystalline micronized itraconazole
  • Example 1A Pure amorphous itraconazole (Example 1A) and a hydrophilic matricial formulation of itraconazole dry powder (Example 1B; invention) were produced at laboratory scale by spray-drying using a Büchi Mini Spray Dryer B-191a (Büchi laboratory-Techniques, Switzerland).
  • feed stock solutions Two feed stock solutions were prepared then separately spray-dried in the following conditions: spraying air flow, 800 l/h; drying air flow, 35 m 3 /h; solution feed rate, 2.7 g/min; nozzle size, 0.5 mm; Inlet temperature, 90° C.; resulting outlet temperature of 53° C.
  • Table 1 The composition of the feedstock solutions is summarized in Table 1. Each component were dissolved under magnetic stifling (600 rpm) in a hydro-alcoholic solution (20 water-80 isopropanol) heated at 70° c. During spray drying the solutions were kept at a temperature between 60 and 70° C.
  • Example 1 liquid Isopropanol Water composition Itraconazole (g) Mannitol (g) (ml) (ml) Example 1A 0.56 — 80 20 (Comparative: Cex) Example 1B 0.56 1 80 20 (Invention: INV)
  • Crystallinity profile of the dried samples was evaluated using MDSC (modulate temperature differential scanning calorimetry) and PXRD (powder x-ray diffraction). Those two techniques are complementary and provide a maximum of information on sample's polymorphism.
  • MDSC experiments were conducted using a Q 2000 DSC (TA Instruments) equipped with cooling system. MDSC differs from standard DSC in the possibility to apply two simultaneous heating rates to the sample, a sinusoidal modulation is added to the linear heating ramp. The total measured heat flow corresponds to the standard heat flow in classic DSC. MDSC heating conditions offers the possibility to make the deconvolution of reversing and non reversing heat flow in which particular thermal event can be singularly detected. Crystallizations phenomena were then observed in the non-reversing heat flow, glass transitions were observed in the reversing heat flow while melting were observed in total heat flow All samples were analyzed in the same following conditions. A 2-3 mg sample was exactly weighted in a low mass aluminum hermetic pan.
  • a 5 C.°/min temperature rate with a modulation of +/ ⁇ 0.8° C. every 60 seconds was applied to the sample from 25° C. to 185° C.
  • the instrument was calibrated for temperature using indium as a standard.
  • the heat flow and heat capacity signals were calibrated using a standard sapphire sample.
  • the Universal Analysis 2000 software was used to integrate each thermal event.
  • PXRD is a powerful tool widely used to evaluate the crystalline form of various compounds. It can help to determine the structural physical state of a product. At a given crystalline lattice, will correspond a given PXRD spectra and inversely a given chaotic system (as amorphous state) would not provide any diffraction peak. This will therefore help to evaluate the polymorphic form obtained after spray drying and in a second time to estimate the proportion of amorphous phase within a sample.
  • the diffractometer (Siemens D5000, Germany) equipped with a mounting said reflection Bragg-Brentano, connected to the monochromator and a channel program Diffracplus.
  • the measures are determined to 40 KV, 40 mA in 2theta an angular range from 2° to 60° in steps of 0.02° through a counting speed of 1.2 s per step and a rotation speed of ‘sample of 15 rpm.
  • Each sample was stored in a hermetic plastic container and placed at 8, 25, 40° C. They were analyzed directly after spray drying, and after 2 months storage at the different temperatures.
  • PDRX confirmed amorphous state of itraconazole in Examples 1A and 1B. At T 0 month no diffraction's peak appeared on diffractogram of Example 1A. Approximated calculated amorphous phase in this sample was equal to 100%. This traduced the lack of any crystalline structure in the sample.
  • Example 1B's diffractogram exhibited some diffractions peaks. However none of those peaks corresponded to crystalline itraconazole. Diffraction profiles of both ⁇ , ⁇ and ⁇ mannitol were present. Total approximated amount of amorphous phase within the sample was equal to 52%. This value was higher than actual content of itraconazole in the sample. This came probably from the proportion of mannitol that was amorphous after spray drying. When stored at 8° C., 25° C. and 40° C. only small variations in the approximated amorphous phase in the sample was observed (see Table 2). Contrary to Example 1A, no recrystallization evidences of itraconazole were present at its characteristics diffractions angles. Dispersing amorphous itraconazole in mannitol (by spray drying a solution containing both components) yielded to the stabilization of the amorphous API.
  • Aerodynamic behavior of generated particles after dose actuation from a dry powder inhaler was assed using a multistage liquid impinger (MsLI).
  • the dry powder inhaler used was an Axahaler® (SMB laboratories).
  • a flow rate (adjusted to a pressure drop of 4 kPa) of 100 L/min during 2.4 sec was applied through the device for each actuation.
  • the device was filled with HPMC no 3 capsules loaded with an approximate quantity of dry powder corresponding to 2.5 mg of itraconazole.
  • One test was realized with three discharges. After the three dose actuations the total deposited dry powder was quantified for each part of the impactor with a suitable and validated HPLC method. Each test was replicated three times.
  • FPD fine particle dose
  • MsLI aerodynamic assessment of fine particle, apparatus C
  • the expressed results have been weighted to a constant itraconazole nominal dose of 2.5 mg.
  • the fine particle fraction (FPF) is the FPD expressed in % of the nominal dose.
  • a Malvern Spraytec® laser diffraction equipment was used to measure particle size distribution (PSD) during the aerodynamic fine particle assessment test.
  • PSD particle size distribution
  • the laser beam was directly placed between the throat and the impactor to measure the PSD of generated dry powder cloud, which was then split along its aerodynamic diameter in the MsLI during simulated inhalation conditions.
  • the average PSD was measured from three replicates of each sample. Results were expressed in terms of D[4,3], d(0.5) and d(0,9) which are, respectively, the volume mean diameter and the size in microns at which 50% and 90% of the particles are smaller than the rest of the distribution. Results are expressed in Table 3.
  • Dissolution tests were performed using USP 33 type 2 paddle apparatus (Distek Dissolution System 2100C, Distek Inc., USA).
  • the dissolution media was constituted of desionized water set at pH 1.2 (HCl 0.063N) containing 0.3% of sodium lauryl sulfate. This dissolution allowed maintaining SINK conditions throughout the test.
  • the medium was heated to 37° C. and kept at this temperature during the test.
  • the paddle speed was set at 50 rpm and the dissolution vessel was filled with 900 ml of dissolution media.
  • Itraconazole was quantified at pre-determined intervals (0, 2, 5, 10, 20, 30, 60, and 120 minutes) using a suitable validated HPLC method. Five milliliters of dissolution media was removed from the dissolution vessel and directly replaced by fresh dissolution medium. These five milliliters were directly filtered through 0.2 ⁇ m diameter filters to avoid quantification of undissolved particles at the determinate time interval. The cumulative amount of drug release was calculated and expressed in percentage of initial drug load and plotted versus time. Each test was replicated three times.
  • Dissolution profiles are shown in FIG. 2 .
  • Comparison of the dissolution curves of crystalline micronized (bulk ITZ) and pure amorphous ITZ (Example 1A) suggested no difference in the drug release curves. This observation was interesting, since amorphous ITZ would be expected to have a faster dissolution profile compared to the crystalline ITZ. This may come from the fact that the highly hydrophobic nature of the drug substance could lead to poor wetability by the aqueous dissolution media impeding drug dissolution improvement.
  • Example 1B shows that the formulation of Example 1B according to the present invention wherein ITZ is dispersed in mannitol microparticles provided a significant improvement of the dissolution rate of ITZ, i.e., 11.4% at 10 min, 15.2% at 20 min and 46.7% at 60 min, compared to bulk micronized crystalline ITZ and pure amorphous ITZ.
  • the increase in surface area available to the dissolution media of amorphous ITZ when dispersed in mannitol microparticles could explain this significant acceleration ( FIG. 2 ) of dissolution rate.
  • Mannitol being dissolved quasi instantly, it was supposed that remaining ITZ particles exposed a higher surface area to the dissolution media that pure spray dried amorphous particles. Mannitol formed spherical matrix wherein amorphous ITZ is dispersed. Once the mannitol is dissolved, porous amorphous ITZ particles are released in the dissolution vessel whit, due to numerous pores formed by the mannitol dissolution. The increased surface area available to the dissolution media increases dissolution rate and prevents excessive re-crystallization which enhance solubility therefore dissolution rate.
  • the purpose of this example was to demonstrate the ability of the invention to modify aerodynamic behavior of the dry powder without modifying its dissolution rate by modifying excipient/API ratio and the total solute in the liquid composition for spray drying.
  • Example 2 Liquid composition Composition (for 100 ml)
  • Example 2A Itraconazole 0.56 g Mannitol 1 g
  • Example 2B Itraconazole 0.234 g Mannitol 1.326 g
  • Example 2C Itraconazole 0.28 g Mannitol 0.5 g
  • Example 2D Itraconazole 0.84 g Mannitol 1.5 g
  • the diffractograms of the four fourmulation presented some diffraction's peaks. However none of those diffraction's peaks corresponded to crystalline itraconaozole. That means that itraconazole, in those formulations, was in an amorphous state. Mannitol was in majority in crystalline state. Its three different polymorphic forms ( ⁇ , ⁇ and ⁇ ) were present in all samples but in different proportions, the ⁇ form being in majority.
  • Powder flowability was evaluated by Carr's compressibility index (CI) as described in Example 1.
  • CI Carr's compressibility index
  • a Carr's index values of above 40% are generally related to poor powder flowability whereas value under 20% are related to extremely good powder flowability.
  • the four present a CI value ranging from 20.9% to 28.8%. Those values indicate good powder flowability for both formulations.
  • Particle size distribution of powders was evaluated by laser scattering using a Malvern Mastersizer 2000® (Malvern instrument) via a Sirocco 2000® (Malvern instrument) dry feeder dispersion unit. Particle size measurement was done on a sample of +/ ⁇ 50 mg at a pressure of 4 Bar with a feed rate vibration set at 40%. Those conditions allow to measure particle size distribution of practically, totally desagglomerated powder due to very drastic dispersion conditions. Particle refractive index with a real part equaling 1.48 and imaginary part of 0.1 were chosen. Those values ensure low weighted residual ( ⁇ 2%) which traduces result's integrity.
  • Results were expressed in terms of D[4,3], d(0.5) and d(0,9) which are, respectively, the volume mean diameter and the size in microns at which 50% and 90% of the particles are smaller than the rest of the distribution. Results are expressed in Table 5.
  • Aerodynamic behavior of generated particles was evaluated by impaction test as described in Example 1.
  • the fine particle fraction is the FPD expressed in % of the nominal dose (FPF) having an aerodynamic diameter inferior to 5 ⁇ m.
  • the emitted doses have been calculated and correspond to the recovered dose from the induction port and five stages of the MsLI during the tests.
  • the emitted dose is express in percentage of the nominal dose and corresponds to the percent of the nominal dose that effectively leaved the device and capsule. Results are expressed in Table 6 and represented in FIG. 3 .
  • Example 2A 0.74 ⁇ 0.01 1.00 ⁇ 0.04 1.78 ⁇ 0.09 2.22 ⁇ 0.11 2.75 ⁇ 0.39 3.38 ⁇ 0.28
  • Example 2B (INV) 0.73 ⁇ 0.03 1.2 ⁇ 0.46 1.89 ⁇ 10.49 2.99 ⁇ 0.11 6.45 ⁇ 1.78 14.91 ⁇ 9.94
  • Example 2C (INV) 0.76 ⁇ 0.03 1.54 ⁇ 0.18 3.08 ⁇ 0.75 2.70 ⁇ .05 4.60 ⁇ 0.62 7.12 ⁇ 2.20
  • Example 2D 0.76 ⁇ 0.03 1.54 ⁇ 0.18
  • the 2B and 2C formulations have higher FPF than formulations 2A and 2D. This is directly related to higher emitted dose for those two formulations (2B and 2C). Because of extremely fine granulometry, despite lower deagglomeration tendency and slightly larger particle size those two formulations penetrated deeper in the impactor than formulation 2A and 2D which result in higher FPF.
  • Example 2 Dissolution tests were conducted as described in Example 1. Obtained dissolution profiles are shown in FIG. 4 . The four formulations exhibited different and faster dissolution's rate than bulk micronized crystalline itraconazole ( FIG. 4 ). The dissolution profiles of Examples 2A, 2B, 2C and 2D were similar.
  • the purpose of this example was to show the ability of the invention to modify dissolution rate's acceleration of a formulation while keeping good flow properties and aerodynamic characteristics.
  • Determination of drug content was used in order to compare expected and actual drug content. For that a determined quantity of dry powder was dissolved in a dilution phase and sonicated during 20 min Those solutions were analyzed by HPLC-UV from which the drug content (wt %) was determined. Average content (wt %) and standard deviations were calculated from five analysis. Itraconazole content measurements results for the different formulations are summarized in Table 8. The measured values were very close to the expected one with relative errors ranged between ⁇ 3.9% and 3.0%. Lower itraconazole content as well as introduction of phospholipids in the formulations induced a reduction of this relative error.
  • the active ingredient seemed to be uniformly distributed within particles since samples have been selected randomly and that variation coefficient for all five test samples were not greater than 3.25%. Those exact ITZ contents values were used during aerodynamic particle size analysis to determine exact nominal doses. No ITZ degradation seemed to occur during the spray drying process. The relative error between the measured and expected ITZ content for pure spray dried itraconazole (Example 3F) was equal to 0.7%.
  • Example 3A (INV) 34.5 ⁇ 0.6 1.64 35.9 ⁇ 3.9
  • Example 3B (INV) 9.99 ⁇ 0.3 3.25 10 ⁇ 0.1
  • Example 3C (INV) 35.6 ⁇ 0.7 1.82 35.8 ⁇ 0.6
  • Example 3D (INV) 33.6 ⁇ 0.7 2.01 34.65 ⁇ 3.1
  • Example 3E (INV) 10.2 ⁇ 0.2 1.98 9.9 3.0
  • mannitol was the major component and was therefore subject to forming matricial particles within which were dispersed the ITZ and, if applicable, the PL.
  • the morphological evaluation showed that very small spherical particles ( ⁇ 1-2 ⁇ m with presence of submicron size particles) with smooth surfaces were formed from the spray dried solution containing mannitol and itraconazole without PL (Examples 3A and 3B; FIG. 5 ). No morphological differences were observed between these formulations despite the different proportions of amorphous content and mannitol polymorphs. However Example 3B seems to be constituted of slightly larger spherical particles.
  • the residual moisture and solvent content of the different dry powders was assessed using thermogravimetric analysis (TGA) with a Q500 apparatus (TA instruments, New Castle, USA) and Universal Analysis 2000 version 4.4A software (TA Instruments, Zellik, Belgium).
  • TGA thermogravimetric analysis
  • the residual water and solvent content was calculated as the weight loss between 25° C. and 125° C. and expressed as a percentage of the initial sample mass. Run were set from 25° C. to 300° C. at a heating rate of 10° C./min on sample mass of about 10 mg and performed in triplicate. Weight loss measured during heating the samples between 25° C. and 125° C. were very low ( ⁇ 0.5%) for each formulations.
  • Example 3F amorphous glassy state after the spray drying process
  • CI Carr's index compressibility index
  • Particle size analyses were conducted using two different methods.
  • the first method (using a Malvern Mastersizer2000®) provided size results corresponding to totally individualized particles.
  • the second method using a Malvern Spraytec®) allowed evaluating the size of particles in a deagglomeration rate that is produced after dispersion form an inhaler device.
  • Aerodynamic fine particle assessment was done as described in Example 2. Results are shown in Table 10. For all formulation the FPF was calculated to be up to 40% and even up to 60% for the Examples 3B and 3E. In other words, more than 40% of loaded formulations into the device would be deposited in the potential deposition site of inhaled fungal spores after emission from the device. Deposition pattern are exposed in FIG. 7 .
  • Dissolution tests were conducted in the conditions described in Example 1. Every formulations presented different and faster dissolution rate than amorphous spray dried itraconazole (Example 3F) and crystalline bulk ITZ ( FIG. 8 ). As shown in FIG. 9 , all dissolution rates of ITZ according to the present invention, 3A to 3E, are at least 5% within 10 minute, 10% within 20 minutes and 40% within 60 minutes when tested in the dissolution apparatus type 2 of the United States Pharmacopoeia at 50 rotation per minute, 37 ⁇ C.
  • the dissolution rates of ITZ according to 3A to 3E are also included in an area between curves B and B′, which defines the dissolution rate of 5% within 5 minute, 10% within 10 minute, 15% within 20 minutes and 40% within 60 minutes, and the one of 50% within 5 minute, 60% within 10 minute, 90% within 20 minutes and 100% within 60 minutes, respectively, when tested in the dissolution apparatus type 2 of the United States Pharmacopoeia at 50 rotation per minute, 37° C. in 9000 milliliters of an aqueous dissolution medium adjusted at pH 1.2 and containing 0.3% of sodium laurylsulfate.
  • Example 3C contained 1% (w/w) of phospholipids (expressed by weight of itraconazole) whereas Example 3D contained 10% (w/w).
  • Example 3E containing also 10% (w/w) of phospholipids expressed by weigh of itraconazole exhibited a similar dissolution profile than Example 3D, which also contained 10% (w/w) of phospholipids.
  • the total amount of phospholipids in the final dry form was much lower for Example 3E (0.99% for Example 3E) this formulation did not show a different dissolution profile than Example 3D which contained a higher total quantity of phospholipids in the final dry form (3.47%).
  • the purpose of this example was to show the ability of the invention to produce matricial dry powders with high fine particle fractions, improved wettability, different dissolution profile and good flow properties using high potentially healty safe hydrophobic matrix forming agents.
  • the formulation was prepared at laboratory scale by spray-drying using a Büchi Mini Spray Dryer B-191a (Büchi laboratory-Techniques, Switzerland).
  • a determined quantity of itraconazole, cholesterol and hydrogenated soy-lecithin with more than 90% of hydrogenated phosphatidylcholine (Phospholipon 90H) (see Table 12) were dissolved in 100 ml of isopropanol heated at 70° C. under magnetic stiffing (600 rpm).
  • the solution was spray-dried in the following conditions: spraying air flow, 800 l/h heated at 50° C.; drying air flow, 35 m 3 /h; solution feed rate, 2.7 g/min; nozzle size, 0.5 mm; Inlet temperature, 70° C.; resulting outlet temperature, 45° C.
  • Example 4 Liquid composition Composition (g/100 ml)
  • Example 4 Itraconazole 0.525 g (INV) Cholesterol 1.5 g Phospholipon 90H 0.0525 g
  • Example 4 Device 0.73 ⁇ 0.05 Throat (mg) 0.15 ⁇ 0.03 Stage 1 (mg) 0.26 ⁇ 0.14 Stage 2 (mg) 0.17 ⁇ .08 Stage 3 (mg) 0.31 ⁇ 0.03 Stage 4 (mg) 0.50 ⁇ 0.05 Stage 5 (mg) 0.28 ⁇ 0.03 Mean FPD (mg) 1.1 ⁇ 0.1 Mean FPF (%) 44 ⁇ 4
  • Dissolution test were performed as described in Example 1 but the dissolution media was constituted of desionized water set at pH 1.2 (HCl 0.063N) containing 1% of sodium lauryl sulfate ( FIG. 11 ).
  • Formulation 4 presented a faster dissolution rate than crystalline micronized bulk itraconazole.
  • hydrophobic GRAS matrix former directly modified the release profile of the dispersed API while providing good aerodynamic characteristics and flow properties.
  • the purpose of this example is to show the influence of API's physical state (amorphous Vs crystalline nanoparticles) in the formulation.
  • API's physical state amorphous Vs crystalline nanoparticles
  • the formulations 5A and 5B were obtained by spray drying a solution or a nanosuspension, respectively, using a Büchi Mini Spray Dryer B-191a (Büchi laboratory-Techniques, Switzerland).
  • Example 5A the dry powder was produced by spray drying a feed stock solution of both excipient and API.
  • 0.10 g of itraconazole, 0.9 g of mannitol and 0.01 g of TPGS 1000 were dissolved in 100 ml of an hydro-alcoholic solution (20 water: 80 isopropanol) heated at 70° C. under magnetic stifling (600 rpm).
  • This solution was spray-dried in the following conditions: spraying air flow, 800 l/h; drying air flow, 35 m 3 /h; solution feed rate, 2.7 g/min; nozzle size, 0.5 mm; Inlet temperature, 90° C.; resulting outlet temperature of 53° C.
  • Example 5B the dry powder was produced by spray drying a feed stock solution of excipients in which was re-suspended a determined volume of API nanosuspension added prior spray drying. This procedure was composed of two steps. The first one consisted in size reduction of a micronized API suspension to a nanosize range suspension. The second one consisted to re-suspend a determined quantity of the produced nanoparticles in a feed stock solution containing the matricial agent in order to spray-dry it.
  • the nanosuspension was prepared as following. In 75 ml of a hydro-alcoholic solution (isopropanol 25: water 50) 75 mg of TPGS 1000 were dissolved under magnetic stirring (600 rp). 750 mg of micronized itraconazole were suspended in this solution using a CAT high speed homogenizer X620 (HSH) (CAT M. Zipperer, Staufen, Germany) at 24,000 rpm during 5 min. The suspension was then circulated in a high pressure homogenizer EmulsiFlex C5 (Avestin Inc., Ottawa, Canada) at 24000 PSI until the particles presented a d(0,5) under 300 nm and a d(0,9) under 2.5 ⁇ m.
  • HSH high speed homogenizer X620
  • Particle size distribution analysis of the homogenized suspension was done by laser diffraction with a wet sampling system (Mastersizer, Hydro 2000, Malvern instruments, UK). For measurements samples were dispersed in deionized water saturated in itraconazole containing 2% of poloxamer 407 to avoid particle dissolution and aggregation. A refractive index of 1.61 and an absorption index of 0.01 were used for measurements. The high pressure homogenization was done using a heat exchanger, placed ahead of the homogenizing valve to maintain sample temperature below 10° C.
  • composition of final dry products is shown in Table 15.
  • Example 5A Itraconazole 9.9% (INV) Mannitol 89.1% TPGS 1000 0.9%
  • Example 5B Itraconazole 9.9% (INV) Mannitol 89.1% TPGS 1000 0.9%
  • Formulation 5B seemed to present lower deagglomeration efficiency than formulation 5A in simulated breath condition. However, despite this presence of severe agglomerates formulation 5B presented the higher fine particle fraction determined as described in Example 1 (see Table 17).
  • Example 5A Example 5B Device (mg) 0.27 ⁇ 0.01 0.44 ⁇ 0.02 Throat (mg) 0.49 ⁇ 0.02 0.28 ⁇ 0.01 Stage 1 (mg) 0.24 ⁇ 0.01 0.13 ⁇ 0.03 Stage 2 (mg) 0.37 ⁇ 0.01 0.25 ⁇ 0.04 Stage 3 (mg) 0.62 ⁇ 0.01 0.68 ⁇ 0.03 Stage 4 (mg) 0.31 ⁇ 0.0 0.47 ⁇ 0.02 Stage 5 (mg) 0.04 ⁇ 0.0 0.08 ⁇ 0.0 Mean FPD (mg) 0.95 +/ ⁇ 0.1 1.19 +/ ⁇ 0.03 Mean FPF (%) 38 +/ ⁇ 4 48 +/ ⁇ 1.2
  • Dissolution tests were conducted using the method described in Example 1. The two formulations presented different dissolution rates. Formulation 5B exhibited a faster dissolution rate than formulation 5A but the two formulations presented faster dissolution rate than bulk itraconazole.
  • the invention can also consist in a blend of crystalline nanoparticles matricial formulation and the amorphous matricial formulations to vary the dissolution profile of the active ingredient in the desire range.
  • the blend can be realized before or during capsule filling.
  • the burst effect that would be provided by the nanoparticles will induce a determined concentration of ITZ that could be enhanced at a desired velocity by dissolution of the amorphous matricial formulation for which the dissolution rate could be optimized.
  • the proportion of matrixial nanoparticle formulation in the final blend will determine to which extend the burst effect (rapid initial dissolution of the drug) would be pronounced.

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