Classifications

• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
  • A61P11/00—Drugs for disorders of the respiratory system
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07J—STEROIDS
  • C07J31/00—Normal steroids containing one or more sulfur atoms not belonging to a hetero ring
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
  • A61P11/00—Drugs for disorders of the respiratory system
  • A61P11/02—Nasal agents, e.g. decongestants
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
  • A61P17/00—Drugs for dermatological disorders
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
  • A61P17/00—Drugs for dermatological disorders
  • A61P17/06—Antipsoriatics
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
  • A61P29/00—Non-central analgesic, antipyretic or antiinflammatory agents, e.g. antirheumatic agents; Non-steroidal antiinflammatory drugs [NSAID]
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07J—STEROIDS
  • C07J31/00—Normal steroids containing one or more sulfur atoms not belonging to a hetero ring
  • C07J31/006—Normal steroids containing one or more sulfur atoms not belonging to a hetero ring not covered by C07J31/003
• • 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
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07B—GENERAL METHODS OF ORGANIC CHEMISTRY; APPARATUS THEREFOR
  • C07B2200/00—Indexing scheme relating to specific properties of organic compounds
  • C07B2200/13—Crystalline forms, e.g. polymorphs
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
  • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]

Definitions

• the present invention relates to a novel crystallisation process for preparing fluticasone propionate as crystalline form 1 polymorph with controlled particle size and suitable for micronisation.
• Fluticasone propionate is a corticosteroid acting as a potent anti-inflammatory and which is used as crystalline form 1 in the treatment of rhinitis, eczema, psoriasis, asthma and COPD. It has the chemical name S-(fluoromethyl)-6a,9-difluoro-1 i -17-dihydroxy-16a- methyl-3-oxoandrosta-1 ,4-diene-17 -carbothioate, 17-propionate and the following chemical structure:
• WO 00/3881 1 discloses the crystallisation of fluticasone propionate dissolved in acetone by mixing with water in the presence of ultrasound radiation.
• WO 01/32125 discloses the crystallisation of fluticasone propionate by admitting a stream of solution of fluticasone propionate in acetone and a stream of water as anti-solvent tangentially into a cylindrical mixing chamber having an axial outlet port such that said streams are intimately mixed through formation of a vortex.
• these processes are not easily scalable and use complex apparatus and technologies (such as use of ultrasound).
• crystalline form 1 of fluticasone propionate can be obtained by dissolving the crude product as obtained in e.g. GB 2088877 in ethyl acetate and then re-crystallising.
• a method for preparing fluticasone propionate as crystalline polymorphic form 1 by mixing a solution of fluticasone propionate in a non-solvating organic liquid solvent such as methyl acetate, ethyl acetate or pentanone, with a non-solvating organic liquid anti-solvent such as toluene, isooctane or hexane thereby causing fluticasone propionate as crystalline form 1 to crystallise out of the solution has been described in WO 03/066653. However, it has been found that these crystallisation processes do not offer control and flexibility in terms of output particle size distribution for fluticasone propionate.
• fluticasone propionate is usually subjected to micronisation prior to formulation to enable production of appropriately sized respirable particles. It is however well known from the literature that there is a link between the particle size of ingoing material and the size of micronized product, hence it is of key importance to precisely control the particle size of the material that is fed into the microniser to ensure reliable and effective drug delivery to the lung.
• the present invention represents a solution to the above mentioned problems.
• the present invention is indeed directed to a new crystallisation process for preparing fluticasone propionate as crystalline form 1 which is scalable, reproducible and does not involve complex apparatus.
• the crystallisation process according to the present invention also enables more flexibility and precise control of product particle size distribution through variations in solvent composition. Finally the crystallisation process according to the present invention shows lower product loss in the micronisation chamber compared to a traditional anti-solvent crystallisation.
• the present invention is thus directed to a process for preparing fluticasone propionate as crystalline form 1 , which comprises the step of dissolving fluticasone propionate in acetone or in a mixture of acetone and water and then adding this solution to water or to a mixture of water and acetone, thereby causing fluticasone propionate to crystallise out of the solution as crystalline form 1.
• the water or water/acetone mixture in which the fluticasone propionate solution is added may also be referred as the "non-solvent" or the "non-solvating mixture” respectively.
• fluticasone propionate is dissolved in acetone containing 0 to 10% water, and the resulting solution is added to water containing 0 to 35% acetone.
• fluticasone propionate is dissolved in acetone, and the resulting solution is added to water containing 0 to 30 % acetone.
• a solution is prepared through dissolving fluticasone propionate in acetone or an acetone/water mixture with concentrations between 30 and 50 grams per litre of solvent.
• said solution is prepared through dissolving fluticasone propionate in acetone or an acetone/water mixture with concentrations between 35 and 45 grams per litre of solvent.
• fluticasone propionate is dissolved in 1 volume of acetone or acetone/water mixture and this solution is then added to a volume of water or water/acetone mixture comprised between 0.65 and 1 .35.
• 1 volume of the fluticasone propionate solution is added to a volume of water or water/acetone mixture comprised between 0.8 and 1 .2. More preferably, 1 volume of the acetone/ fluticasone propionate solution is added to a volume of water or water/acetone mixture of about 1 .
• the addition takes place at a temperature comprised between 10°C and 40°C.
• the addition takes place at ambient temperature.
• the addition takes place over a period comprised between 10 minutes and 6 hours.
• the addition takes place over a period comprised between 30 minutes and 2 hours. More preferably, the addition takes place over a period of about 1 hour.
• the addition of the fluticasone propionate solution occurs via a pump in the form of pulsed aliquots.
• the fluticasone propionate solution into the non- solvent or non-solvating mixture, nucleation and growth of fluticasone propionate occur.
• the slurry formed is stirred over a period comprised between 0 and 12 hours, followed by filtration and drying.
• the slurry is stirred over a period of comprised between 1 hour and 10 hours. More preferably, the slurry is stirred over a period comprised between 4 hours and 8 hours. Still more preferably, the slurry is stirred over a period of about 1 hour.
• the process according to the present invention is particularly advantageous since it allows good flexibility and control of the physical properties of the fluticasone propionate obtained, in particular the size and shape of the particles obtained.
• This is exemplified in Figure 1 , showing the dependence of particle size on solvent composition when fluticasone propionate is crystallised using the process described in the present invention.
• the specific reverse anti-solvent crystallization process according to the present invention allows the crystallization of fluticasone propionate with different particle sizes through variations in solvent composition and also delivers fluticasone propionate particles which do not exhibit the agglomeration which is typical of conventional anti-solvent crystallization, as described for example by Murnane et al. in Cryst. Growth Des. 2008, 8, 2753-2764 and as illustrated in Figure 2.
• fluticasone propionate In addition to influencing the efficacious delivery of intra-nasal and pulmonary drug formulations, control of physical properties of fluticasone propionate is also important since these properties influence bulk density, flow and downstream processing characteristics of the product.
• the process according to the present invention yields particles that are 5-200 ⁇ in length with a width of 3-30 ⁇ .
• the fluticasone propionate particles obtained by the process according to the present invention thus have the most appropriate design, in particular for micronisation and formulation with lactose as a dry powder and administration with a dry powder inhaler such as the device described in e.g. WO 2005/002654.
• the particles of fluticasone propionate obtainable from the herein described crystallisation process thus constitute another object of the present invention.
• An additional and significant advantage of the particles resulting from the process according to the present invention is the increased yield in micronized fluticasone propionate due to lower loss of product in the jet milling chamber, compared to micronisation input obtained from a conventional anti-solvent process
• Fluticasone propionate may be prepared according to any of the processes known from the literature such as e.g the process described in GB 2088877. Alternatively, fluticasone propionate is also commercially available for a number of suppliers, e.g. Hovione, Sterling or NewChem.
• the particles of fluticasone propionate as obtained from the crystallisation process according to the present invention may be micronized to a controlled size and formulated with lactose so as to form a dry powder blend.
• Fluticasone propionate as obtained from the process according to the present invention is particularly suitable for micronisation and administration by inhalation from a dry powder inhaler. Typically, it is administered in the form of a dry powder as a mixture with lactose.
• the particles of fluticasone propionate as obtained from the process according to the present invention are micronized by jet miling, and subsequently blended with lactose.
• the lactose used according to the present invention may be anhydrous or in the form of the monohydrate.
• a-lactose monohydrate is used.
• the blend thus obtained is then suitable for filling into a dry powder inhaler.
• the dosage unit is determined by a pre-filled capsule, blister or pocket or by a system that uses a gravimetrically fed dosing chamber.
• Units in accordance with the invention are typically arranged to administer a metered dose or "puff" containing from 50 to 500 ⁇ g of fluticasone propionate as obtained from the process according to the present invention.
• the overall daily dose will typically be in the range of 50 ⁇ g to 2 mg which may be administered in a single dose or, more usually, as divided doses throughout the day.
• the fluticasone propionate obtained from the process according to the present invention may be administered alone or in combination with one or more other drugs.
• Suitable examples of other therapeutic agents which may be used in combination with fluticasone propionate include, but are by no means limited to ⁇ 2 agonists, preferably long-acting ⁇ 2 agonists, and M3 muscarinic antagonists, preferably long-acting M3 muscarinic antagonists.
• Suitable ⁇ 2 agonists include in particular salbutamol, terbutaline, bambuterol, fenoterol, salmeterol, formoterol, tulobuterol and their salts.
• the ⁇ 2 agonist is selected from salmeterol or formoterol and their salts. More preferably, the ⁇ 2 agonist is salmeterol xinafoate.
• M3 muscarinic antagonists examples include in particular ipratropium, oxitropium, tiotropium and their salts.
• M3 muscarinic antagonist is tiotropium bromide.
• fluticasone propionate as obtained from the process according to the present invention is administered by inhalation as a dry powder either alone or in combination with salmeterol xinafoate.
• Figure 1/10 Effect of acetone % in the anti-solvent mixture on the volume median diameter D[v, 0.5] for a reverse anti-solvent process.
• Figure 4/10 PXRD patterns for Example 2 product (top line) and reference fluticasone propionate form 1 pattern for comparison (bottom line).
• FIG. 6/10 PXRD pattern for example 3 product (top line) and reference fluticasone propionate form 1 pattern for comparison (bottom line).
• Figure 8/10 PXRD pattern for example 4 product (top line) and reference fluticasone propionate form 1 pattern for comparison (bottom line).
• 0 Crystals of fluticasone propionate obtained from example b.
• Example 1 Re-crystallisation of fluticasone propionate using a standard anti- solvent process 1 .0g of fluticasone propionate [S-(fluoromethyl)-6a,9-difluoro-1 1 -1 7-dihydroxy-1 6a- methyl-3-oxoandrosta-1 ,4-diene-1 7 -carbothioate, 17-propionate] obtained from a commercial source was mixed with 25ml_ acetone. The mixture was heated to 40 Q C, and then cooled to 20 Q C. 25ml_ water was added to the solution at approximatively 20 Q C. Crystallisation of the product was observed during the addition. The slurry was filtered under vacuum, and the isolated solid was dried in an oven at 50 Q C under 0.9 bar vacuum, yielding fluticasone propionate Form 1 . Crystals obtained from this experiment are shown in Figure 2.
• the powder X-ray diffraction pattern was determined using a Bruker-AXS Ltd. D4 powder X-ray diffractometer fitted with an automatic sample changer, a theta-theta goniometer, automatic beam divergence slit, and a PSD Vantec-1 detector.
• the sample was prepared for analysis by mounting on a low background cavity silicon wafer specimen mount. The peaks obtained were aligned against a silicon reference standard.
• Example 4 Re-crystallisation of fluticasone propionate using the reverse anti- solvent process of the present invention 9g of fluticasone propionate [S-(fluoromethyl)-6a,9-difluoro-1 i -17-dihydroxy-16a-methyl- 3-oxoandrosta-1 ,4-diene-17 -carbothioate, 17-propionate] obtained from a commercial source was mixed with 270ml_ acetone. The mixture was heated to 40°C, and then cooled to 10°C. The chilled solution was added to a separate agitated vessel containing 175ml_ water and 75ml_ acetone at 10°C over a period of 6 hours. Crystallisation of the product was observed during the addition.
• Example 7 Re-crystallisation of fluticasone propionate using the reverse antisolvent process of the present invention
• 2.50Kg of fluticasone propionate [S-(fluoromethyl)-6a,9-difluoro-1 1 ⁇ -17-dihydroxy- 16a- 25 methyl-3-oxoandrosta-1 ,4-diene-17 -carbothioate, 17-propionate] obtained from a commercial source was mixed with 62.5L acetone. The mixture was heated to 35 Q C, and then cooled to 20 Q C. The solution was added to a separate agitated vessel containing 47L water and 15.5L acetone at 20 Q C over a period of 2 hours. Crystallisation of the product was observed during the addition.
• Example 10 Particle size data as measured by laser diffraction
• the particle size distribution was measured on the Malvern Mastersizer 2000 laser diffraction system equipped with a Hydro 2000S liquid dispersion unit and flow cell.
• the sample was prepared by adding 15 drops of Tween 80 to crystallised fluticasone propionate within the glass 4 dram vial and mixing into a paste using a spatula, until all of the powder is wetted out and a smooth, uniform paste is achieved. Then the paste is added to the Hydro 2000S containing dispersant (0.1 % Tween 80 in deionised water) using a spatula.
• the obscuration target is achieved (20% ⁇ 5%) the sample is left to stir within the Hydro 2000S for 1 minute to allow the particles to wet out, disperse and ensure a stable obscuration is achieved. Measurement is initiated after 1 minute of stirring.
• the particle size distribution was measured on the Sympatec HELOS laser diffraction system (with R1 optical module giving a measuring range of 0.1 / 0.18 - 35 ⁇ ) together with SUCELL dispersing module.
• 100 mg of micronised sample is weighed into a 4-dram vial and 15 drops (approximately 0.5 ml_) of Tween 80 is added from a 3ml wide-tipped pipette to the powder. The mixture is then carefully stirred into a paste until all the particles are wetted out and a uniform smooth mixture is achieved. Then the paste is added to the SUCELL containing dispersant (0.025% Tween 80 in deionised water) using a spatula. Once the optical concentration target is achieved (10-15%) then a measurement is taken.
• D[v, 0.1 ], D[v, 0.5] and D[v, 0.9] represent the 10 th percentile volume diameter; 50 th percentile volume diameter; and 90 th percentile volume diameter respectively.
• n th percentile volume diameter is defined so that n% of the particles have a volume equivalent particle diameter smaller than or equal to the n th percentile diameter. In the case of D[v, 0.5], it coincides with the median value.
• Example 11 particle size data before and after micronisation
• An additional and significant advantage of the particles resulting from the process according to the present invention is the increased yield in micronized fluticasone propionate due to lower loss of product in the jet milling chamber, compared to micronisation input obtained from a conventional anti-solvent process such as the one described in Example 1 .
• Several batches crystallised by either conventional anti-solvent techniques (as described in Example 1 ) or reverse anti-solvent techniques according to the present invention (as described Examples 2-9) were micronized, and the results summarised on Table 4 below show that the percentage of product collected after micronisation was on average much higher for reverse anti-solvent product batches than for conventional anti-solvent ones. Additionally, a much lower portion of product was left in the mill chamber if the product had originated from reverse anti-solvent.

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