WO2024010538A1 - A process for the preparation of dry powder compositions for inhalation using different mixers - Google Patents

A process for the preparation of dry powder compositions for inhalation using different mixers Download PDF

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Publication number
WO2024010538A1
WO2024010538A1 PCT/TR2022/050727 TR2022050727W WO2024010538A1 WO 2024010538 A1 WO2024010538 A1 WO 2024010538A1 TR 2022050727 W TR2022050727 W TR 2022050727W WO 2024010538 A1 WO2024010538 A1 WO 2024010538A1
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WO
WIPO (PCT)
Prior art keywords
process according
shear mixer
mixture
carrier
rpm
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PCT/TR2022/050727
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French (fr)
Inventor
Devrim Celik
Fatih CAN
Emine Yilmaz
Tansel KAYA
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Arven Ilac Sanayi Ve Ticaret Anonim Sirketi
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Priority to PCT/TR2022/050727 priority Critical patent/WO2024010538A1/en
Publication of WO2024010538A1 publication Critical patent/WO2024010538A1/en

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    • 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
    • A61K31/00—Medicinal preparations containing organic active ingredients
    • A61K31/13—Amines
    • A61K31/135—Amines having aromatic rings, e.g. ketamine, nortriptyline
    • A61K31/137—Arylalkylamines, e.g. amphetamine, epinephrine, salbutamol, ephedrine or methadone
    • 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
    • A61K31/56—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids
    • 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
    • A61K31/56—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids
    • A61K31/57—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids substituted in position 17 beta by a chain of two carbon atoms, e.g. pregnane or progesterone
    • A61K31/573—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids substituted in position 17 beta by a chain of two carbon atoms, e.g. pregnane or progesterone substituted in position 21, e.g. cortisone, dexamethasone, prednisone or aldosterone
    • 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
    • A61K9/141—Intimate drug-carrier mixtures characterised by the carrier, e.g. ordered mixtures, adsorbates, solid solutions, eutectica, co-dried, co-solubilised, co-kneaded, co-milled, co-ground products, co-precipitates, co-evaporates, co-extrudates, co-melts; Drug nanoparticles with adsorbed surface modifiers
    • A61K9/145—Intimate drug-carrier mixtures characterised by the carrier, e.g. ordered mixtures, adsorbates, solid solutions, eutectica, co-dried, co-solubilised, co-kneaded, co-milled, co-ground products, co-precipitates, co-evaporates, co-extrudates, co-melts; Drug nanoparticles with adsorbed surface modifiers with organic compounds

Definitions

  • the invention relates to a process for the preparation of dry powder pharmaceutical compositions using different mixers in the treatment of chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases.
  • COPD chronic obstructive pulmonary disease
  • Obstructive lung disease is a significant public health problem. Asthma, chronic obstructive pulmonary disease (COPD) and other obstructive airway diseases are highly prevalent chronic diseases in the general population. These obstructive airway illnesses are manifested with chronic inflammation affecting the whole respiratory tract. Obstruction is usually intermittent and reversible in asthma but is progressive and irreversible in COPD.
  • COPD chronic obstructive pulmonary disease
  • DPIs dry powder inhalers
  • these goals can be met with a suitable powder formulation, an efficient metering system, and a carefully selected device. Dry powder inhalers are well known devices for administering pharmaceutically active agents to the respiratory tract to treat respiratory diseases such as asthma and chronic obstructive pulmonary disease (COPD).
  • COPD chronic obstructive pulmonary disease
  • compositions for inhalation used in the treatment of obstructive airway diseases can comprise various active agents such as long acting muscarinic antagonists (LAMA), long acting beta agonists (LABA), short acting beta-2 agonists (SABA) and corticosteroids.
  • LAMA long acting muscarinic antagonists
  • LABA long acting beta agonists
  • SABA short acting beta-2 agonists
  • corticosteroids corticosteroids
  • Inhaled corticosteroids are medications used to treat chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases.
  • COPD chronic obstructive pulmonary disease
  • Inhaled corticosteroids reduce inflammation in the airways that carry air to the lungs (bronchial tubes) and reduce the mucus made by the bronchial tubes which makes easier to breathe. They are taken by using an inhaler. This medication should be taken consistently so that it decreases inflammation in the airways of your lungs and prevents chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases flare-ups.
  • Inhaled corticosteroids are considered the most effective long-term usage medication for control and management of asthma.
  • the clinical benefits of inhaled corticosteroids in other obstructive airway diseases include a decrease in airway hyperresponsiveness, an improvement in lung function and a reduction in severity of symptoms, frequency of exacerbations, the need for rescue medication, and an increase in symptom-free days.
  • Fluticasone is the most commonly used corticosteroid in the dry powder formulations for inhalation.
  • Fluticasone furoate which is a salt of fluticasone, is a synthetic trifluorinated corticosteroid with potent anti-inflammatory activity.
  • Fluticasone furoate is available as a combination product with vilanterol, under the tradename Breo Ellipta®. Its use is indicated for the long-term, once-daily maintenance treatment of airflow obstruction in patients with COPD, including chronic bronchitis and emphysema.
  • LSAs Long-acting adrenoceptor agonists
  • COPD chronic obstructive pulmonary disease
  • long-acting p2-adrenergic agonists are bronchodilators taken routinely in order to control and prevent bronchoconstriction. They are not intended for fast relief. These medications may take longer to begin working but relieve airway constriction for up to 12 hours. They are used in combination with a corticosteroid to treat asthma in a metered-dose or dry powder inhaler. They relax the smooth muscles lining the airways that carry air to the lungs (bronchial tubes). This allows the tubes to stay open longer and makes breathing easier.
  • Salmeterol is a selective long-acting beta2-adrenergic agonist (LABA) used in the maintenance and prevention of asthma symptoms and maintenance of chronic obstructive pulmonary disease (COPD) symptoms. Symptoms of bronchospasm include shortness of breath, wheezing, coughing and chest tightness. It is also used to prevent breathing difficulties during exercise.
  • LUA beta2-adrenergic agonist
  • COPD chronic obstructive pulmonary disease
  • Inhalers are well known devices for administering pharmaceutically active materials to the respiratory tract by inhalation.
  • active materials commonly delivered by inhalation include bronchodilators such as P2 agonists and anticholinergics, corticosteroids, antiallergies and other materials that may be efficiently administered by inhalation, thus increasing the therapeutic index and reducing side effects of the active material.
  • DPI formulations consist of micronized drug blended with larger carrier particles, which enhance flow, reduce aggregation, and aid in dispersion.
  • a combination of intrinsic physicochemical properties, particle size, shape, surface area, and morphology effects the forces of interaction and aerodynamic properties, which in turn determine fluidization, dispersion, delivery to the lungs, and deposition in the peripheral airways.
  • Small drug particles are likely to agglomerate. Said agglomeration can be prevented by employing suitable carrier or carrier mixtures. It also assists in controlling the fluidity of the drug coming out of the carrier device and ensuring that the active ingredient reaching to lungs is accurate and consistent.
  • difference of the particle sizes between the carrier and the drug is important in order to optimize the cohesive forces and also to ensure the content uniformity.
  • inhalation device delivers sufficient amount of the medicament to the patient for inhalation.
  • the homogeneity of the discharge is basically dependent on the agglomeration tendency of the dry powder in the capsule or in the blister and the agglomeration tendency is related to both the content of the formulation (such as selected carriers and their hygroscopicity etc.) and the particle size distribution (the ratio of fine particles and coarse particles) of this content.
  • Fine-particle dose (FPD) is defined as the dose of the aerosolized drug particles with an aerodynamic diameter ⁇ 5 micron and fine particle fraction (FPF) is the ratio of FPD to the total recovered dose.
  • FPF is an essential factor which directly effects the amount of the drug which reaches to the lungs of the patient.
  • Drug particles less than 5 pm have the greatest probability of deposition in the lung, whereas those less than 2 pm tend to be concentrated in the alveoli.
  • the dose emitted from an inhaled product contains a large proportion of particles within the 2-5 pm range ensuring a fairly even distribution throughout the lungs.
  • Selection of the carrier and optionally other excipients is one the main approaches to adjust FPF.
  • the preparation process of the dry powder composition is as important as the carrier selection to maintain FPF at a desirable range. The process can comprise several steps such as mixing/blending, sieving and filling the powder mixture into capsules or blisters.
  • Blending is the step in which distinct bulk material particles are brought into close contact to produce a homogenous powder mixture.
  • a mixture can be defined as homogeneous if every sample of the mixture has the same composition and properties as any other.
  • the phenomena of particle segregation and agglomeration present a challenge in developing a reproducible blending process.
  • blending parameters such as blending speed and blending volume are just as important as carrier selection to achieve both homogeneity and uniformity of the composition.
  • Low shear and high shear mixers are used for dry powder blending.
  • the quality profile displayed changes when only a low shear mixer is used or only a high shear mixer is used during dry powder blending processes.
  • Low shear mixers basically have the principle of mixing the mixture in a three-dimensional axis with low rpm. Since low rpm is used during mixing in the low shear mixer, the forces applied to the active ingredients (active ingredients) are low. In this way, the active substances can advantageously bind to the excipients better. However, long mixing times are needed to ensure the homogeneity of the mixture in low shear mixers. Increasing mixing times pose a microbiological problem for the product. At the same time, due to the electrostatic forces formed in the powder blend during mixing due to the increased mixing time, the adhesion of the active substances on the auxiliary substances cannot be standardized.
  • High shear mixers are basically mixers designed to be the main mixer at the bottom of the bowl, impeller with 2/4 blades and a chopper with 2/4 blades on the inner wall of the bowl, and they have the principle of mixing with high rpm.
  • the advantage of high shear mixers is that the production processes are short because their duration is short. Active substances and auxiliary substances can be added to the mixture more easily during the process.
  • the low production time provides advantages in terms of microbiology.
  • temperature increases can be seen during the process.
  • the impurity profile of the desired product may deteriorate with temperature increases.
  • Active substances and auxiliary substances can form agglomerates due to high rpm.
  • the use of High shear mixer using high rpm is not suitable for mixture preparations containing fine lactose by weight in the unit formula. In mixture preparations containing fine lactose by weight, accumulations and agglomerations may occur on the inner walls of the high shear mixer due to high rpm.
  • the main purpose of the invention is to use a low shear and high shear mixer for dry powder blending in the same process, to obtain a process that includes the advantages of both mixers and is free from the disadvantages. In this way, the obtained product exhibits a better quality profile than a process using a single mixer during the stability period. It can be seen that the prior art has not put enough emphasis on alternative solutions for this problem. Thus, there is still a need for innovative processes that will solve the homogeneity problem, and which will provide a standardized method for the fast production of stable inhalation compositions with enhanced FPF.
  • the main object of the present invention is to provide a novel process for preparing dry powder inhalation compositions using different mixers which eliminate all aforesaid problems and bring additional advantages to the relevant prior art.
  • Another object of the present invention is to provide a novel process for manufacturing dry powder compositions for inhalation using different mixers with enhanced uniformity and homogeneity.
  • Another object of the present invention is to provide a novel process for preparing dry powder inhalation compositions using different mixers with increased uniformity and homogeneity, enhanced fine particle dose (FPD) and fine particle fraction (FPF).
  • FPD fine particle dose
  • FPF fine particle fraction
  • Another object of the present invention is to obtain inhalation combinations with high homogeneity and uniformity by using low shear mixer and high shear mixer at the same process.
  • Another object of the present invention is to obtain inhalation combinations with high homogeneity and uniformity by portioning the second active agent used in the process.
  • the first portion of the second active agent also encourages the preventation of the plastering of the powder to the walls of the container.
  • Another object of the present invention is to obtain dry powder inhalation compositions provided by the above-mentioned process comprising at least one active agent selected from the group comprising corticosteroids, long-acting beta2-adrenergic agonists (LABAs), shortacting beta-2 agonists (SABA), ultra-long-acting beta2-adrenergic agonist and long-acting muscarinic antagonists (LAMAs).
  • a further object of the present invention is to obtain dry powder inhalation compositions comprising a corticosteroid and a selective long-acting beta2-adrenergic agonist (LABA) in combination.
  • Another object of the present invention is to obtain inhalation compositions comprising fluticasone or a pharmaceutically acceptable salt thereof and salmeterol or a pharmaceutically acceptable salt thereof.
  • Another object of the present invention is to obtain inhalation compositions having appropriate particle size and ratios of both carriers and active agents ensuring content uniformity and dosage accuracy in each blister or capsule.
  • Another object of the present invention is to obtain inhalation compositions having appropriate particle size and ratios of both carriers and active agents ensuring that effective doses of active agents reach the alveoli.
  • a further object of the present invention is to obtain inhalation compositions which can be administered in blister pack or in capsule using an inhaler.
  • a further object of the present invention is to obtain a blister pack filled with the above- mentioned dry powder inhalation combinations.
  • a further object of the present invention is to obtain a capsule filled with the above-mentioned dry powder inhalation combinations.
  • a further object of the present invention is to obtain an inhaler that is applicable to the above- mentioned blister pack or the above-mentioned capsule.
  • the present invention relates to a process for preparing dry powder inhalation compositions, comprising the following steps: a- obtaining Mixture-1 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with first portion of first carrier ii. adding second carrier, first active agent and first portion of second active agent and mixing the composition with the low shear mixer iii. sieving the composition b- obtaining Mixture-2 by: i. plastering the inner wall of the mixing vessel of the high shear mixer with second portion of first carrier ii. adding Mixture-1 and mixing the composition with the high shear mixer c- obtaining Mixture-3 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with third portion of first carrier ii.
  • said mixer further comprises a chopper with a rotation speed of 0-2200 rpm, preferably 0-1000 rpm, more preferably 0-500 rpm.
  • chopper speed is open from the beginning to the end of the process if necessary.
  • the filling volume of mixer is between %30- 80, preferably %32-78 and more preferably %44-76 of the total volume.
  • the volume ratio of the different types of mixers to each other is also important to provide proper sub batches by adding the proper portions of the active agents and the carriers to the process in order to inhibit the variations and provide the homogeneity of the powder.
  • the volume of the low shear mixer to the high shear mixer is between 0.01-1 , preferably 0.1-1 and more preferably 0.1.
  • plastering the inner wall of the mixing vessel of the low shear mixer with first portion of first carrier in the step numbered a-(i) is continued for at least 3 minutes.
  • adding second carrier, first active agent and first portion of second active agent and mixing the composition with the low shear mixer which has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm in the step numbered a-(ii) is continued for at least 10 minutes.
  • sieving the composition mentioned in the step numbered a- (iii) is performed by a vibrating sieve with ultrasonic having 100-250 pm, more preferably 150-200 mesh size.
  • the sieving process is done to inhibit agglomerated particles, thus contributing to powder homogeneity.
  • the sieving process is not performed to reduce the particles, it is only used to blend the coarse and the fine particles properly.
  • Sieving process is performed in different steps of the process in order to be sure of the proceed the homogeneity at each step by interfacing the carrier and active agent particles.
  • Reason of the sieving process at this step is to improve the interaction between the active agent and carrier particles in order to provide a homogenious powder product. According to the proper powder homogeneity, it is allowed to deliver the powder deep into the lungs.
  • plastering the inner wall of the mixing vessel of the high shear mixer with second portion of first carrier in the step numbered b-(i) is continued for at least 3 minutes.
  • adding Mixture-1 and mixing the composition with the high shear mixer which has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm for obtaining Mixture-2 in the step numbered b-(ii) is continued for at least 3 minutes.
  • This step is one of the major steps of the process as both mixers starts to be used in the process.
  • mixtures starts to be formed in low shear mixer, and then continues to mix in high shear mixer.
  • plastering the inner wall of the mixing vessel of the low shear mixer with third portion of first carrier in the step numbered c-(i) is continued for at least 3 minutes.
  • adding second portion of second active agent and mixing the composition with the low shear mixer which has a rotation speed of 9-100 rpm, preferably 11- 80 rpm more preferably 13-60 rpm in the step numbered c-(ii) is continued for at least 15 minutes.
  • the production process it is especially aimed to mix the active agent and carrier portions one by one in order to provide a proper and homogenous mixture.
  • second active agent is also added to the process with a proper ratio in order not to cause an agglomeration. Process ingredients are added to the process by scaling up.
  • sieving the composition mentioned in the step numbered c- (iii) for obtaining Mixture-3 is performed by a vibrating sieve with ultrasonic having 100-250 pm, more preferably 150-200 mesh size.
  • Sieving process is performed in different steps of the process in order to be sure of the proceed the homogeneity at each step by interfacing the carrier and active agent particles.
  • Reason of the sieving process at this step is to improve the interaction between the active agent and carrier particles in order to provide a homogenious powder product.
  • Mixture-3 adds to Mixture-2 mentioned in the step numbered d-(i) for obtaining Mixture-4.
  • the majority of this step is to add the ingredients into the process by scaling up the ingredient amounts in order not to cause an agglomeration.
  • sieving the fourth portion of the first carrier mentioned in the step numbered e-(i) for obtaining Mixture-5 is performed by a vibrating sieve with ultrasonic having 100-250 pm, more preferably 150-200 mesh size and after that mixture-4 adds to the mixture for the obtaining Mixture-5.
  • Reason of the sieving process at this step is to improve the interaction between the active agent and carrier particles in order to provide a homogenious powder product.
  • another task of this step is to prevent the loss of ingredients as the prosess approaches to the end.
  • mixing the composition with high shear mixer which has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm in the step numbered e-(ii) is continued for at least 3 minutes.
  • the first carrier mentioned in the step numbered a- (i), b-(i), c-(i) and e-(i) is coarse carrier particles.
  • Said coarse carrier particles is selected from the group comprising lactose, mannitol, sorbitol, inositol, xylitol, erythritol, lactitol and maltitol. Most preferably, said the first carrier is lactose having coarse particle.
  • the coarse lactose is divided into 4 equal portions for adding in the different steps into the process.
  • Coarse lactose is divided into portions to plaster the walls of the container in order to prevent the loss of ingredients, to provide a homogenious powder product by scaling up the amount of the ingredients and to prevent agglomeration of the powder product.
  • a coarse carrier particle such as lactose monohydrate
  • the particle size distribution of the carrier plays a crucial role for the qualification of the composition subjected to the invention.
  • the step numbered a-(i),b-(i), c-(i) and e-(i) of the process is lactose having coarse particle size which means the mean particle size (D50 value) is in the range of 25-250 pm, preferably 35-100 pm.
  • the first active agent and the second active agent have a d90 particle size less than 15 pm, preferably less than 12 pm, more preferably less than 10 pm.
  • the first active agent mentioned in the step numbered a-(ii) is which is small in mass in the composition is selected from a group comprising short-acting p2 agonists (SABAs), long-acting p2 agonists (LABAs), ultra-long acting p2 agonists or long-acting muscarinic antagonists (LAMAs) or a pharmaceutically acceptable salt thereof in combination.
  • SABAs short-acting p2 agonists
  • LAMAs long-acting p2 agonists
  • LAMAs long-acting muscarinic antagonists
  • said short-acting p2 agonists is selected from the group comprising bitolterol, fenoterol, isoprenaline, levosalbutamol, orciprenaline, pirbuterol, procaterol, ritodrine, salbutamol, terbutaline, albuterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
  • SABAs short-acting p2 agonists
  • said long-acting p2 agonists is selected from the group comprising arformoterol, bambuterol, clenbuterol, formoterol, salmeterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
  • said ultra long-acting p2 agonists is selected from the group comprising abediterol, carmoterol, indacaterol, olodaterol, vilanterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
  • said long-acting muscarinic antagonists is selected from the group comprising aclidinium, glycopyrronium, tiotropium, umeclidinium or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
  • said long-acting p2 agonists is salmeterol salt.
  • said salmeterol salt is salmeterol xinafoate.
  • second active agent mentioned in the step numbered a-(ii) and c-(ii) is corticosteroid.
  • said corticosteroid is selected from the group comprising ciclesonide, budesonide, fluticasone, aldosterone, beklometazone, betametazone, chloprednol, cortisone, cortivasole, deoxycortone, desonide, desoxymetasone, dexametasone, difluorocortolone, fluchlorolone, flumetasone, flunisolide, fluquinolone, fluquinonide, flurocortisone, fluorocortolone, flurometolone, flurandrenolone, halcynonide, hydrocortisone, icometasone, meprednisone, methylprednisolone, mometasone, paramethasone, prednisolone, prednisone, tixocortole, triamcynolondane or mixtures thereof.
  • said corticosteroid is divided into two portions.
  • the first portion of the second active agent consists of 10% by weight of the total corticosteroid mentioned in the step numbered a-(ii) and the second portion of the second active agent consists of 90% by weight of the total corticosteroid mentioned in the step numbered c-(ii).
  • 10% of corticosteroid is used in the process step numbered a-(ii) because it reduces sticking in the mixing vessel and increases homogeneity.
  • Research and development studies have shown that during in the process step numbered a-(ii), it has been determined that it prevents the adhesions formed on the walls of container and contributes to homogeneity.
  • said corticosteroid is fluticasone.
  • said fluticasone salt is fluticasone propionate.
  • second carrier mentioned in the step numbered a-(ii) is fine carrier particles.
  • Said fine carrier particles is selected from the group comprising lactose, mannitol, sorbitol, inositol, xylitol, erythritol, lactitol and maltitol.
  • said second carrier is fine lactose.
  • lactose monohydrate having fine particle size which means the mean particle size (D50 value) is in the range of 0.01-25 pm, preferably 0.01-20 pm.
  • the choice of carrier is essential in ensuring that the device works correctly and delivers the right amount of active to the patient. Therefore, to use lactose as a carrier in two different particle sizes (fine and coarse) is essential.
  • Particle size distribution of the carrier plays a crucial role for the qualification of the composition subjected to the invention.
  • particle size distribution means the cumulative volume size distribution as tested by any conventionally accepted method such as the laser diffraction method (Malvern analysis).
  • Laser diffraction measures particle size distributions by measuring the angular variation in intensity of light scattered as a laser beam passes through a dispersed particulate sample. Large particles scatter light at small angles relative to the laser beam and small particles scatter light at large angles. The angular scattering intensity data is then analyzed to calculate the size of the particles responsible for creating the scattering. The particle size is reported as a volume equivalent sphere diameter.
  • the D50 value is the size in microns that splits the distribution with half above and half below this diameter.
  • said lactose monohydrate is present in the composition in two parts.
  • One of these parts is lactose monohydrate having fine particle size which means the mean particle size (D50 value) is in the range of 0.01-25 pm, preferably 0.01-20 pm.
  • the other part is lactose monohydrate having coarse particle size which means the mean particle size (D50 value) is in the range of 25-250 pm, preferably 35-100 pm.
  • Coarse carrier particles are used to prevent agglomeration of the active agent particles having mean particle size lower than 10 pm.
  • shape and surface roughness of the carrier particles are especially important. Particles having smooth surface will be separated much easier from the active agents compared to the particles in the same size but having high porosity.
  • Active agent particles will tend to concentrate on the regions having higher energy as the surface energy does not dissipate on the coarse carrier particles evenly. This might prevent separation of the active agent particles from the coarse carrier after pulmonary administration, especially in low dose formulations. In this sense, fine carrier particles are used to help the active agents to reach to the lungs easier and in high doses. As the high- energy regions of coarse carrier particles will be covered by fine carrier particles, the active agent particles will be attaching to low energy regions; thus, the amount of active agent particles detached from the coarse carrier particles will potentially increase.
  • This preferred selection of carrier and its particle size distribution eliminates agglomeration of active agent particles and assures the enhanced stability, moisture resistance, fluidity, content uniformity and dosage accuracy.
  • the inventors have found more decreases in the FPD and FPF values in the stability of the trial productions produced using only high shear mixers, compared to the trial productions produced using the low shear mixer.
  • the reason for the decreases experienced during the stability period is the agglomeration of the cohesive active agents and carriers due to high-speed mixing and the increasing temperature increase during the high-speed process.
  • the inventors have determined the risk of microbiological contamination and the increase in electrostatic charges in the mixture due to long mixing times in trial productions produced using only Low shear mixers.
  • the inventors blended the mixture using the low rpm and 3D mixing features of the low shear mixer in the step numbered (a) and (c) of the process.
  • the process was finalized with a high shear mixer, and the production process was terminated in a very short time.
  • the low shear mixer has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm and the high shear mixer has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm
  • surprisingly high uniformity and homogeneity are provided by using the low shear mixer and high shear mixer at the different steps. Besides, fine particle fraction and particle size distribution of the final powder mixture are enhanced which means the accurate and consistent transport of the active agents to the lungs is guaranteed.
  • the using different mixers which are the low shear mixer and high shear mixer in different process steps and its particle size distribution eliminates agglomeration of active agent particles and assures the enhanced homogeneity, stability, moisture resistance, fluidity, content uniformity and dosage accuracy.
  • the pharmaceutical compositions subjected to the invention are prepared by these steps: a- obtaining Mixture-1 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with first portion of coarse lactose ii. adding second carrier, salmeterol xinafoate and first portion of fluticasone propionate and mixing the composition with the low shear mixer iii. sieving the composition b- obtaining Mixture-2 by: i. plastering the inner wall of the mixing vessel of the high shear mixer with second portion of coarse lactose ii. adding Mixture-1 and mixing the composition with the high shear mixer c- obtaining Mixture-3 by: i.
  • the low shear mixer has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm and the high shear mixer has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm.
  • the invention also defines dry powder inhalation compositions obtained by the process subjected to the invention.
  • the dry powder composition comprises a corticosteroid or pharmaceutically acceptable salt thereof and a selective long-acting beta2- adrenergic agonist (LABA) or pharmaceutically acceptable salt thereof in combination.
  • a corticosteroid or pharmaceutically acceptable salt thereof and a selective long-acting beta2- adrenergic agonist (LABA) or pharmaceutically acceptable salt thereof in combination.
  • LAA beta2- adrenergic agonist
  • the dry powder composition comprises fluticasone propionate and salmeterol xinafoate.
  • the amount of fluticasone propionate is between 0.4-14%, preferably 0.6-12%, more preferably 0.8-10% by weight of the total composition.
  • the amount of salmeterol xinafoate is between 0.02-4%, preferably 0.04-3%, more preferably 0.06-2% by weight of the total composition.
  • the total amount of total lactose is between 82- 99.58%, preferably 85-99.36%, more preferably 88-99.14% by weight of the total composition.
  • the total amount of lactose having fine particle size (fine lactose) which is added into the mixing vessel in step numbered a-(ii) is between 0.1- 15%, preferably 0.3-13%, more preferably 0.5-11% by weight of the total composition.
  • process for the dry powder composition subjected to the invention comprises;
  • the below given formulations can be used a process for preparing dry powder inhalation compositions using different mixers subjected to the invention. These examples are not limiting the scope of the present invention and should be considered under the light of the foregoing detailed disclosure.
  • Example 1 Dry powder composition for inhalation
  • Example 2 Dry powder composition for inhalation
  • Example 3 Dry powder composition for inhalation
  • the uniformity and FPD value are enhanced by the coordinated effect of the selected blending speed of high shear-low shear mixer. As FPD and FDP values are enhanced, the accurate and consistent transport of the active agents to the lungs is guaranteed.
  • the dry powder composition subjected to the invention is suitable for administration in dosage forms such as capsules, cartridges or blister packs.
  • the one-unit dose of the composition in the dosage form is ranging between 50 to 500 mcg for fluticasone propionate and 10 to 100 mcg for salmeterol xinafoate.
  • the dry powder composition is presented in one dose capsule.
  • the said capsule may be a gelatin or a natural or synthetic pharmaceutically acceptable polymer such as hydroxypropyl methylcellulose and it is arranged for use in a dry powder inhaler and the composition is configured to be delivered to the lungs by the respiratory flow of the patient via the said inhaler.
  • one dose capsule contains 3-30 mg dry powder composition.
  • the dry powder composition subjected is suitable for administration in a multi-dose system, more preferably in a multi-dose blister pack which has more than one blister with air and moisture barrier property.
  • Each blister contains the same amount of active agent and carrier which is provided via content uniformity and dosage accuracy of the composition. For this invention, it is ensured by the specific selection of carriers, their amounts and their mean particle sizes.
  • a blister contains 3-30 mg dry powder composition.
  • dry powder composition subjected to the invention is used in the treatment of the respiratory diseases selected from asthma and chronic obstructive pulmonary disease and other obstructive respiratory diseases.

Abstract

The invention relates to a process for the preparation of dry powder pharmaceutical compositions using different mixers and compositions obtained by said process which are used in the treatment of chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases.

Description

A PROCESS FOR THE PREPARATION OF DRY POWDER COMPOSITIONS FOR INHALATION USING DIFFERENT MIXERS
Technical Field
The invention relates to a process for the preparation of dry powder pharmaceutical compositions using different mixers in the treatment of chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases.
Background of the Invention
Obstructive lung disease is a significant public health problem. Asthma, chronic obstructive pulmonary disease (COPD) and other obstructive airway diseases are highly prevalent chronic diseases in the general population. These obstructive airway illnesses are manifested with chronic inflammation affecting the whole respiratory tract. Obstruction is usually intermittent and reversible in asthma but is progressive and irreversible in COPD.
Drugs combines pharmacologic activity with pharmaceutical properties. Desirable performance characteristics expected form them are physical and chemical stability, ease of processing, accurate and reproducible delivery to the target organ, and availability at the site of action. For the dry powder inhalers (DPIs), these goals can be met with a suitable powder formulation, an efficient metering system, and a carefully selected device. Dry powder inhalers are well known devices for administering pharmaceutically active agents to the respiratory tract to treat respiratory diseases such as asthma and chronic obstructive pulmonary disease (COPD).
Pharmaceutical compositions for inhalation used in the treatment of obstructive airway diseases can comprise various active agents such as long acting muscarinic antagonists (LAMA), long acting beta agonists (LABA), short acting beta-2 agonists (SABA) and corticosteroids.
Inhaled corticosteroids are medications used to treat chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases. Inhaled corticosteroids reduce inflammation in the airways that carry air to the lungs (bronchial tubes) and reduce the mucus made by the bronchial tubes which makes easier to breathe. They are taken by using an inhaler. This medication should be taken consistently so that it decreases inflammation in the airways of your lungs and prevents chronic obstructive pulmonary disease (COPD), asthma and other obstructive airway diseases flare-ups. Inhaled corticosteroids are considered the most effective long-term usage medication for control and management of asthma.
The clinical benefits of inhaled corticosteroids in other obstructive airway diseases include a decrease in airway hyperresponsiveness, an improvement in lung function and a reduction in severity of symptoms, frequency of exacerbations, the need for rescue medication, and an increase in symptom-free days.
Fluticasone is the most commonly used corticosteroid in the dry powder formulations for inhalation. Fluticasone furoate, which is a salt of fluticasone, is a synthetic trifluorinated corticosteroid with potent anti-inflammatory activity. Fluticasone furoate is available as a combination product with vilanterol, under the tradename Breo Ellipta®. Its use is indicated for the long-term, once-daily maintenance treatment of airflow obstruction in patients with COPD, including chronic bronchitis and emphysema.
Long-acting adrenoceptor agonists (LABAs, more specifically, long-acting 2 adrenergic receptor agonists) are usually prescribed for moderate-to-severe persistent asthma patients or patients with chronic obstructive pulmonary disease (COPD).
On the other hand, long-acting p2-adrenergic agonists are bronchodilators taken routinely in order to control and prevent bronchoconstriction. They are not intended for fast relief. These medications may take longer to begin working but relieve airway constriction for up to 12 hours. They are used in combination with a corticosteroid to treat asthma in a metered-dose or dry powder inhaler. They relax the smooth muscles lining the airways that carry air to the lungs (bronchial tubes). This allows the tubes to stay open longer and makes breathing easier.
Salmeterol is a selective long-acting beta2-adrenergic agonist (LABA) used in the maintenance and prevention of asthma symptoms and maintenance of chronic obstructive pulmonary disease (COPD) symptoms. Symptoms of bronchospasm include shortness of breath, wheezing, coughing and chest tightness. It is also used to prevent breathing difficulties during exercise. The combination of a long-acting p2-agonist (LABA) and an inhaled corticosteroid is more efficacious in asthma and chronic obstructive pulmonary disease (COPD) than other combination therapies or than either alone.
Inhalers are well known devices for administering pharmaceutically active materials to the respiratory tract by inhalation. Such active materials commonly delivered by inhalation include bronchodilators such as P2 agonists and anticholinergics, corticosteroids, antiallergies and other materials that may be efficiently administered by inhalation, thus increasing the therapeutic index and reducing side effects of the active material.
Most DPI formulations consist of micronized drug blended with larger carrier particles, which enhance flow, reduce aggregation, and aid in dispersion. A combination of intrinsic physicochemical properties, particle size, shape, surface area, and morphology effects the forces of interaction and aerodynamic properties, which in turn determine fluidization, dispersion, delivery to the lungs, and deposition in the peripheral airways.
Small drug particles are likely to agglomerate. Said agglomeration can be prevented by employing suitable carrier or carrier mixtures. It also assists in controlling the fluidity of the drug coming out of the carrier device and ensuring that the active ingredient reaching to lungs is accurate and consistent.
Changes in the particle size of the powder, is known to significantly affect its deposition to the lungs and therefore, affect the efficacy. The drug particles and carrier particles are entrained in this air stream together, but only the fine drug particles enter the deep recesses of the lung (which is the site of action of the drug). The inert excipient is deposited either in the mouth or in the upper region of the lungs. Likewise, the cohesive forces between drug and carrier particles play a significant role in this delivery process. If the cohesion is too strong, the shear of the airflow may not be sufficient to separate the drug from the carrier particles, which results in low deposition efficiency. On the other hand, if the cohesion is undesirably weak, a considerable amount of drug particles inherently may stick within the mouth or within the upper lungs, which also causes low deposition efficiency.
Thus, difference of the particle sizes between the carrier and the drug is important in order to optimize the cohesive forces and also to ensure the content uniformity.
The modern era of drug delivery to the lungs using DPIs essentially began in the 1940's with the appearance of the first approved commercial DPI product, namely the Abbott Aerohaler®. This product was used to deliver penicillin and norethisderone and contains many features which would be recognizable today, in that it uses a small capsule reservoir (also described as a ‘sifter’) containing a lactose-based formulation, designed to be used in a device which utilizes the patient generated inspiratory airflow to disperse the therapeutic particles in an airstream.
It is potentially desirable that inhalation device delivers sufficient amount of the medicament to the patient for inhalation. The homogeneity of the discharge is basically dependent on the agglomeration tendency of the dry powder in the capsule or in the blister and the agglomeration tendency is related to both the content of the formulation (such as selected carriers and their hygroscopicity etc.) and the particle size distribution (the ratio of fine particles and coarse particles) of this content. Fine-particle dose (FPD) is defined as the dose of the aerosolized drug particles with an aerodynamic diameter < 5 micron and fine particle fraction (FPF) is the ratio of FPD to the total recovered dose. FPF is an essential factor which directly effects the amount of the drug which reaches to the lungs of the patient.
Drug particles less than 5 pm have the greatest probability of deposition in the lung, whereas those less than 2 pm tend to be concentrated in the alveoli. The dose emitted from an inhaled product contains a large proportion of particles within the 2-5 pm range ensuring a fairly even distribution throughout the lungs. Selection of the carrier and optionally other excipients is one the main approaches to adjust FPF. On the other hand, the preparation process of the dry powder composition is as important as the carrier selection to maintain FPF at a desirable range. The process can comprise several steps such as mixing/blending, sieving and filling the powder mixture into capsules or blisters.
Blending is the step in which distinct bulk material particles are brought into close contact to produce a homogenous powder mixture. A mixture can be defined as homogeneous if every sample of the mixture has the same composition and properties as any other. The phenomena of particle segregation and agglomeration present a challenge in developing a reproducible blending process. For dry particle blending, the cohesive and adhesive forces acting between particles depend on molecular forces. Therefore, blending parameters such as blending speed and blending volume are just as important as carrier selection to achieve both homogeneity and uniformity of the composition.
Low shear and high shear mixers are used for dry powder blending. However, there are several disadvantages for both types of mixers. The quality profile displayed changes when only a low shear mixer is used or only a high shear mixer is used during dry powder blending processes.
Low shear mixers basically have the principle of mixing the mixture in a three-dimensional axis with low rpm. Since low rpm is used during mixing in the low shear mixer, the forces applied to the active ingredients (active ingredients) are low. In this way, the active substances can advantageously bind to the excipients better. However, long mixing times are needed to ensure the homogeneity of the mixture in low shear mixers. Increasing mixing times pose a microbiological problem for the product. At the same time, due to the electrostatic forces formed in the powder blend during mixing due to the increased mixing time, the adhesion of the active substances on the auxiliary substances cannot be standardized.
High shear mixers, on the other hand, are basically mixers designed to be the main mixer at the bottom of the bowl, impeller with 2/4 blades and a chopper with 2/4 blades on the inner wall of the bowl, and they have the principle of mixing with high rpm. The advantage of high shear mixers is that the production processes are short because their duration is short. Active substances and auxiliary substances can be added to the mixture more easily during the process. The low production time provides advantages in terms of microbiology. However, since high shear mixers work with high rpm, temperature increases can be seen during the process. The impurity profile of the desired product may deteriorate with temperature increases. Active substances and auxiliary substances (Fine lactose monohydrate) with cohesive properties can form agglomerates due to high rpm. The use of High shear mixer using high rpm is not suitable for mixture preparations containing fine lactose by weight in the unit formula. In mixture preparations containing fine lactose by weight, accumulations and agglomerations may occur on the inner walls of the high shear mixer due to high rpm.
On the other hand, in the state of the art, there is no include any mention of motivation that obtains a dry powder inhalation product obtained with a process that includes the advantages of both mixers and is free from the disadvantages, by using the low shear and high shear mixer used for dry powder blending in the same process.
The main purpose of the invention is to use a low shear and high shear mixer for dry powder blending in the same process, to obtain a process that includes the advantages of both mixers and is free from the disadvantages. In this way, the obtained product exhibits a better quality profile than a process using a single mixer during the stability period. It can be seen that the prior art has not put enough emphasis on alternative solutions for this problem. Thus, there is still a need for innovative processes that will solve the homogeneity problem, and which will provide a standardized method for the fast production of stable inhalation compositions with enhanced FPF.
Objects and Brief Description of the Invention
The main object of the present invention is to provide a novel process for preparing dry powder inhalation compositions using different mixers which eliminate all aforesaid problems and bring additional advantages to the relevant prior art.
Another object of the present invention is to provide a novel process for manufacturing dry powder compositions for inhalation using different mixers with enhanced uniformity and homogeneity.
Another object of the present invention is to provide a novel process for preparing dry powder inhalation compositions using different mixers with increased uniformity and homogeneity, enhanced fine particle dose (FPD) and fine particle fraction (FPF).
Another object of the present invention is to obtain inhalation combinations with high homogeneity and uniformity by using low shear mixer and high shear mixer at the same process.
Another object of the present invention is to obtain inhalation combinations with high homogeneity and uniformity by portioning the second active agent used in the process. The first portion of the second active agent also encourages the preventation of the plastering of the powder to the walls of the container.
Another object of the present invention is to obtain dry powder inhalation compositions provided by the above-mentioned process comprising at least one active agent selected from the group comprising corticosteroids, long-acting beta2-adrenergic agonists (LABAs), shortacting beta-2 agonists (SABA), ultra-long-acting beta2-adrenergic agonist and long-acting muscarinic antagonists (LAMAs). A further object of the present invention is to obtain dry powder inhalation compositions comprising a corticosteroid and a selective long-acting beta2-adrenergic agonist (LABA) in combination.
Another object of the present invention is to obtain inhalation compositions comprising fluticasone or a pharmaceutically acceptable salt thereof and salmeterol or a pharmaceutically acceptable salt thereof.
Another object of the present invention is to obtain inhalation compositions having appropriate particle size and ratios of both carriers and active agents ensuring content uniformity and dosage accuracy in each blister or capsule.
Another object of the present invention is to obtain inhalation compositions having appropriate particle size and ratios of both carriers and active agents ensuring that effective doses of active agents reach the alveoli.
A further object of the present invention is to obtain inhalation compositions which can be administered in blister pack or in capsule using an inhaler.
A further object of the present invention is to obtain a blister pack filled with the above- mentioned dry powder inhalation combinations.
A further object of the present invention is to obtain a capsule filled with the above-mentioned dry powder inhalation combinations.
A further object of the present invention is to obtain an inhaler that is applicable to the above- mentioned blister pack or the above-mentioned capsule.
Detailed Description of Invention
In accordance with the objects outlined above, detailed features of the present invention are given herein.
The present invention relates to a process for preparing dry powder inhalation compositions, comprising the following steps: a- obtaining Mixture-1 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with first portion of first carrier ii. adding second carrier, first active agent and first portion of second active agent and mixing the composition with the low shear mixer iii. sieving the composition b- obtaining Mixture-2 by: i. plastering the inner wall of the mixing vessel of the high shear mixer with second portion of first carrier ii. adding Mixture-1 and mixing the composition with the high shear mixer c- obtaining Mixture-3 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with third portion of first carrier ii. adding second portion of second active agent and mixing the composition with the low shear mixer iii. sieving the composition d- obtaining Mixture-4 by: i. adding Mixture-3 to Mixture-2 e- obtaining Mixture-5 by: i. sieving the fourth portion of the first carrier and adding to Mixture-4 ii. mixing the composition with the high shear mixer wherein the low shear mixer has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm and the high shear mixer has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm.
According to one embodiment, said mixer further comprises a chopper with a rotation speed of 0-2200 rpm, preferably 0-1000 rpm, more preferably 0-500 rpm.
According to one embodiment, chopper speed is open from the beginning to the end of the process if necessary.
Active agent particles in the dry powder mixture with small particles adhere to the walls of the container when the filling volume of mixer is low. In cases where the filling volume of mixer is high, active agent particles do not distribute homogeneously between the carrier particles and agglomerate. According to one embodiment, the filling volume of mixer is between %30- 80, preferably %32-78 and more preferably %44-76 of the total volume. The volume ratio of the different types of mixers to each other is also important to provide proper sub batches by adding the proper portions of the active agents and the carriers to the process in order to inhibit the variations and provide the homogeneity of the powder. The volume of the low shear mixer to the high shear mixer is between 0.01-1 , preferably 0.1-1 and more preferably 0.1.
According to one embodiment, plastering the inner wall of the mixing vessel of the low shear mixer with first portion of first carrier in the step numbered a-(i) is continued for at least 3 minutes.
According to one embodiment, adding second carrier, first active agent and first portion of second active agent and mixing the composition with the low shear mixer which has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm in the step numbered a-(ii) is continued for at least 10 minutes.
According to one embodiment, sieving the composition mentioned in the step numbered a- (iii) is performed by a vibrating sieve with ultrasonic having 100-250 pm, more preferably 150-200 mesh size. The sieving process is done to inhibit agglomerated particles, thus contributing to powder homogeneity. The sieving process is not performed to reduce the particles, it is only used to blend the coarse and the fine particles properly. Sieving process is performed in different steps of the process in order to be sure of the proceed the homogeneity at each step by interfacing the carrier and active agent particles. Reason of the sieving process at this step is to improve the interaction between the active agent and carrier particles in order to provide a homogenious powder product. According to the proper powder homogeneity, it is allowed to deliver the powder deep into the lungs.
According to one embodiment, plastering the inner wall of the mixing vessel of the high shear mixer with second portion of first carrier in the step numbered b-(i) is continued for at least 3 minutes.
According to one embodiment, adding Mixture-1 and mixing the composition with the high shear mixer which has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm for obtaining Mixture-2 in the step numbered b-(ii) is continued for at least 3 minutes. This step is one of the major steps of the process as both mixers starts to be used in the process. In the continuation of this step, mixtures starts to be formed in low shear mixer, and then continues to mix in high shear mixer. According to one embodiment, plastering the inner wall of the mixing vessel of the low shear mixer with third portion of first carrier in the step numbered c-(i) is continued for at least 3 minutes.
According to one embodiment, adding second portion of second active agent and mixing the composition with the low shear mixer which has a rotation speed of 9-100 rpm, preferably 11- 80 rpm more preferably 13-60 rpm in the step numbered c-(ii) is continued for at least 15 minutes. In the production process, it is especially aimed to mix the active agent and carrier portions one by one in order to provide a proper and homogenous mixture. As the amount of the second active agent is more than the first one, second active agent is also added to the process with a proper ratio in order not to cause an agglomeration. Process ingredients are added to the process by scaling up.
According to one embodiment, sieving the composition mentioned in the step numbered c- (iii) for obtaining Mixture-3 is performed by a vibrating sieve with ultrasonic having 100-250 pm, more preferably 150-200 mesh size. Sieving process is performed in different steps of the process in order to be sure of the proceed the homogeneity at each step by interfacing the carrier and active agent particles. Reason of the sieving process at this step is to improve the interaction between the active agent and carrier particles in order to provide a homogenious powder product.
According to one embodiment, Mixture-3 adds to Mixture-2 mentioned in the step numbered d-(i) for obtaining Mixture-4. The majority of this step is to add the ingredients into the process by scaling up the ingredient amounts in order not to cause an agglomeration.
According to one embodiment, sieving the fourth portion of the first carrier mentioned in the step numbered e-(i) for obtaining Mixture-5 is performed by a vibrating sieve with ultrasonic having 100-250 pm, more preferably 150-200 mesh size and after that mixture-4 adds to the mixture for the obtaining Mixture-5. Reason of the sieving process at this step is to improve the interaction between the active agent and carrier particles in order to provide a homogenious powder product. And another task of this step is to prevent the loss of ingredients as the prosess approaches to the end.
According to one embodiment, mixing the composition with high shear mixer which has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm in the step numbered e-(ii) is continued for at least 3 minutes. As this step provides the final mixing, it has an essential impact on the final powder product. According to the preferred embodiment, the first carrier mentioned in the step numbered a- (i), b-(i), c-(i) and e-(i) is coarse carrier particles. Said coarse carrier particles is selected from the group comprising lactose, mannitol, sorbitol, inositol, xylitol, erythritol, lactitol and maltitol. Most preferably, said the first carrier is lactose having coarse particle.
According to the preferred embodiment, the coarse lactose is divided into 4 equal portions for adding in the different steps into the process. Coarse lactose is divided into portions to plaster the walls of the container in order to prevent the loss of ingredients, to provide a homogenious powder product by scaling up the amount of the ingredients and to prevent agglomeration of the powder product.
According to the preferred embodiment, in the step numbered a-(i),b-(i), c-(i) and e-(i) of the process, a coarse carrier particle, such as lactose monohydrate, is applied to deagglomerate the drug particles and optimize the deposition of the drug in the lung. The particle size distribution of the carrier plays a crucial role for the qualification of the composition subjected to the invention. The step numbered a-(i),b-(i), c-(i) and e-(i) of the process is lactose having coarse particle size which means the mean particle size (D50 value) is in the range of 25-250 pm, preferably 35-100 pm.
According to one embodiment, the first active agent and the second active agent have a d90 particle size less than 15 pm, preferably less than 12 pm, more preferably less than 10 pm.
According to the preferred embodiment, the first active agent mentioned in the step numbered a-(ii) is which is small in mass in the composition is selected from a group comprising short-acting p2 agonists (SABAs), long-acting p2 agonists (LABAs), ultra-long acting p2 agonists or long-acting muscarinic antagonists (LAMAs) or a pharmaceutically acceptable salt thereof in combination.
According to the preferred embodiment, said short-acting p2 agonists (SABAs) is selected from the group comprising bitolterol, fenoterol, isoprenaline, levosalbutamol, orciprenaline, pirbuterol, procaterol, ritodrine, salbutamol, terbutaline, albuterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
According to the preferred embodiment, said long-acting p2 agonists (LABAs) is selected from the group comprising arformoterol, bambuterol, clenbuterol, formoterol, salmeterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
According to the preferred embodiment, said ultra long-acting p2 agonists is selected from the group comprising abediterol, carmoterol, indacaterol, olodaterol, vilanterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
According to the preferred embodiment, said long-acting muscarinic antagonists (LAMAs) is selected from the group comprising aclidinium, glycopyrronium, tiotropium, umeclidinium or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
According to this preferred embodiment, said long-acting p2 agonists (LABAs) is salmeterol salt. According to this preferred embodiment, said salmeterol salt is salmeterol xinafoate.
According to the preferred embodiment, second active agent mentioned in the step numbered a-(ii) and c-(ii) is corticosteroid.
In a preferred embodiment of the invention, said corticosteroid is selected from the group comprising ciclesonide, budesonide, fluticasone, aldosterone, beklometazone, betametazone, chloprednol, cortisone, cortivasole, deoxycortone, desonide, desoxymetasone, dexametasone, difluorocortolone, fluchlorolone, flumetasone, flunisolide, fluquinolone, fluquinonide, flurocortisone, fluorocortolone, flurometolone, flurandrenolone, halcynonide, hydrocortisone, icometasone, meprednisone, methylprednisolone, mometasone, paramethasone, prednisolone, prednisone, tixocortole, triamcynolondane or mixtures thereof.
According to the preferred embodiment, said corticosteroid is divided into two portions. The first portion of the second active agent consists of 10% by weight of the total corticosteroid mentioned in the step numbered a-(ii) and the second portion of the second active agent consists of 90% by weight of the total corticosteroid mentioned in the step numbered c-(ii). 10% of corticosteroid is used in the process step numbered a-(ii) because it reduces sticking in the mixing vessel and increases homogeneity. Research and development studies have shown that during in the process step numbered a-(ii), it has been determined that it prevents the adhesions formed on the walls of container and contributes to homogeneity. According to the preferred embodiment, said corticosteroid is fluticasone. According to this preferred embodiment, said fluticasone salt is fluticasone propionate.
According to the preferred embodiment, second carrier mentioned in the step numbered a-(ii) is fine carrier particles. Said fine carrier particles is selected from the group comprising lactose, mannitol, sorbitol, inositol, xylitol, erythritol, lactitol and maltitol. Most preferably, said second carrier is fine lactose. In the step numbered a-(ii) of the process is lactose monohydrate having fine particle size which means the mean particle size (D50 value) is in the range of 0.01-25 pm, preferably 0.01-20 pm.
According to one embodiment, the choice of carrier is essential in ensuring that the device works correctly and delivers the right amount of active to the patient. Therefore, to use lactose as a carrier in two different particle sizes (fine and coarse) is essential.
Particle size distribution of the carrier plays a crucial role for the qualification of the composition subjected to the invention. As used herein, ‘particle size distribution’ means the cumulative volume size distribution as tested by any conventionally accepted method such as the laser diffraction method (Malvern analysis).
Laser diffraction measures particle size distributions by measuring the angular variation in intensity of light scattered as a laser beam passes through a dispersed particulate sample. Large particles scatter light at small angles relative to the laser beam and small particles scatter light at large angles. The angular scattering intensity data is then analyzed to calculate the size of the particles responsible for creating the scattering. The particle size is reported as a volume equivalent sphere diameter.
According to this measuring method, the D50 value is the size in microns that splits the distribution with half above and half below this diameter.
In the preferred embodiment of the invention, said lactose monohydrate is present in the composition in two parts. One of these parts is lactose monohydrate having fine particle size which means the mean particle size (D50 value) is in the range of 0.01-25 pm, preferably 0.01-20 pm. The other part is lactose monohydrate having coarse particle size which means the mean particle size (D50 value) is in the range of 25-250 pm, preferably 35-100 pm.
Coarse carrier particles are used to prevent agglomeration of the active agent particles having mean particle size lower than 10 pm. During inhalation, as the active agent and the carrier particles need to be separated from each other, shape and surface roughness of the carrier particles are especially important. Particles having smooth surface will be separated much easier from the active agents compared to the particles in the same size but having high porosity.
Active agent particles will tend to concentrate on the regions having higher energy as the surface energy does not dissipate on the coarse carrier particles evenly. This might prevent separation of the active agent particles from the coarse carrier after pulmonary administration, especially in low dose formulations. In this sense, fine carrier particles are used to help the active agents to reach to the lungs easier and in high doses. As the high- energy regions of coarse carrier particles will be covered by fine carrier particles, the active agent particles will be attaching to low energy regions; thus, the amount of active agent particles detached from the coarse carrier particles will potentially increase.
This preferred selection of carrier and its particle size distribution eliminates agglomeration of active agent particles and assures the enhanced stability, moisture resistance, fluidity, content uniformity and dosage accuracy.
In their R&D studies, the inventors have found more decreases in the FPD and FPF values in the stability of the trial productions produced using only high shear mixers, compared to the trial productions produced using the low shear mixer. The reason for the decreases experienced during the stability period is the agglomeration of the cohesive active agents and carriers due to high-speed mixing and the increasing temperature increase during the high-speed process. Besides that, the inventors have determined the risk of microbiological contamination and the increase in electrostatic charges in the mixture due to long mixing times in trial productions produced using only Low shear mixers.
The inventors blended the mixture using the low rpm and 3D mixing features of the low shear mixer in the step numbered (a) and (c) of the process. In the step numbered (b) and (e), the process was finalized with a high shear mixer, and the production process was terminated in a very short time. The inventor surprisingly found that obtaining a fast, reliable and homogeneous product and providing the desired quality profile.
According to one embodiment, the low shear mixer has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm and the high shear mixer has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm In this invention, surprisingly high uniformity and homogeneity are provided by using the low shear mixer and high shear mixer at the different steps. Besides, fine particle fraction and particle size distribution of the final powder mixture are enhanced which means the accurate and consistent transport of the active agents to the lungs is guaranteed.
The using different mixers which are the low shear mixer and high shear mixer in different process steps and its particle size distribution eliminates agglomeration of active agent particles and assures the enhanced homogeneity, stability, moisture resistance, fluidity, content uniformity and dosage accuracy.
According to one embodiment, the pharmaceutical compositions subjected to the invention are prepared by these steps: a- obtaining Mixture-1 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with first portion of coarse lactose ii. adding second carrier, salmeterol xinafoate and first portion of fluticasone propionate and mixing the composition with the low shear mixer iii. sieving the composition b- obtaining Mixture-2 by: i. plastering the inner wall of the mixing vessel of the high shear mixer with second portion of coarse lactose ii. adding Mixture-1 and mixing the composition with the high shear mixer c- obtaining Mixture-3 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with third portion of coarse lactose ii. adding second portion of fluticasone propionate and mixing the composition with the low shear mixer iii. sieving the composition d- obtaining Mixture-4 by: i. adding Mixture-3 to Mixture-2 e- obtaining Mixture-5 by: i. sieving the fourth portion of the coarse lactose and adding to Mixture-4 ii. mixing the composition with the high shear mixer wherein the low shear mixer has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm and the high shear mixer has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm.
The invention also defines dry powder inhalation compositions obtained by the process subjected to the invention.
According to the preferred embodiment, the dry powder composition comprises a corticosteroid or pharmaceutically acceptable salt thereof and a selective long-acting beta2- adrenergic agonist (LABA) or pharmaceutically acceptable salt thereof in combination.
According to a preferred embodiment, the dry powder composition comprises fluticasone propionate and salmeterol xinafoate.
According to one embodiment, the amount of fluticasone propionate is between 0.4-14%, preferably 0.6-12%, more preferably 0.8-10% by weight of the total composition.
According to one embodiment, the amount of salmeterol xinafoate is between 0.02-4%, preferably 0.04-3%, more preferably 0.06-2% by weight of the total composition.
According to the preferred embodiment, the total amount of total lactose is between 82- 99.58%, preferably 85-99.36%, more preferably 88-99.14% by weight of the total composition.
According to the preferred embodiment, the total amount of lactose having fine particle size (fine lactose) which is added into the mixing vessel in step numbered a-(ii) is between 0.1- 15%, preferably 0.3-13%, more preferably 0.5-11% by weight of the total composition.
According to one preferred embodiment, process for the dry powder composition subjected to the invention comprises;
- 0.4-14 % by weight of fluticasone propionate
- 0.02-4 % by weight of salmeterol xinafoate
- 82-99.58% by weight of total lactose monohydrate
- 0.1-15% by weight of fine lactose monohydrate According to all these embodiments, the below given formulations can be used a process for preparing dry powder inhalation compositions using different mixers subjected to the invention. These examples are not limiting the scope of the present invention and should be considered under the light of the foregoing detailed disclosure.
Example 1 : Dry powder composition for inhalation
Figure imgf000018_0001
Example 2: Dry powder composition for inhalation
Figure imgf000018_0002
Example 3: Dry powder composition for inhalation
Figure imgf000018_0003
The uniformity and FPD value are enhanced by the coordinated effect of the selected blending speed of high shear-low shear mixer. As FPD and FDP values are enhanced, the accurate and consistent transport of the active agents to the lungs is guaranteed.
The dry powder composition subjected to the invention is suitable for administration in dosage forms such as capsules, cartridges or blister packs. The one-unit dose of the composition in the dosage form is ranging between 50 to 500 mcg for fluticasone propionate and 10 to 100 mcg for salmeterol xinafoate.
In an embodiment, the dry powder composition is presented in one dose capsule. The said capsule may be a gelatin or a natural or synthetic pharmaceutically acceptable polymer such as hydroxypropyl methylcellulose and it is arranged for use in a dry powder inhaler and the composition is configured to be delivered to the lungs by the respiratory flow of the patient via the said inhaler. In a preferred embodiment, one dose capsule contains 3-30 mg dry powder composition.
In the preferred embodiment, the dry powder composition subjected is suitable for administration in a multi-dose system, more preferably in a multi-dose blister pack which has more than one blister with air and moisture barrier property.
Each blister contains the same amount of active agent and carrier which is provided via content uniformity and dosage accuracy of the composition. For this invention, it is ensured by the specific selection of carriers, their amounts and their mean particle sizes. In a preferred embodiment, a blister contains 3-30 mg dry powder composition.
According to a preferred embodiment, dry powder composition subjected to the invention is used in the treatment of the respiratory diseases selected from asthma and chronic obstructive pulmonary disease and other obstructive respiratory diseases.

Claims

1. A process for preparing dry powder inhalation compositions, comprising the following steps: a- obtaining Mixture-1 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with first portion of first carrier ii. adding second carrier, first active agent and first portion of second active agent and mixing the composition with the low shear mixer iii. sieving the composition b- obtaining Mixture-2 by: i. plastering the inner wall of the mixing vessel of the high shear mixer I with second portion of first carrier ii. adding Mixture-1 and mixing the composition with the high shear mixer c- obtaining Mixture-3 by: i. plastering the inner wall of the mixing vessel of the low shear mixer with third portion of first carrier ii. adding second portion of second active agent and mixing the composition with the low shear mixer iii. sieving the composition d- obtaining Mixture-4 by: i. adding Mixture-3 to Mixture-2 e- obtaining Mixture-5 by: i. sieving the fourth portion of the first carrier and adding to Mixture-4 ii. mixing the composition with the high shear mixer wherein the low shear mixer has a rotation speed of 9-100 rpm, preferably 11-80 rpm more preferably 13-60 rpm and the high shear mixer has a rotation speed of 100-500 rpm, preferably 125-475 rpm, more preferably 150-450 rpm.
2. The process according to claim 1, wherein the first active agent is selected from a group comprising short-acting p2 agonists (SABAs), long-acting p2 agonists (LABAs), ultra-long acting p2 agonists or long-acting muscarinic antagonists (LAMAs) or pharmaceutically acceptable salt thereof in combination.
3. The process according to claim 2, wherein said short-acting p2 agonists (SABAs) is selected from the group comprising bitolterol, fenoterol, isoprenaline, levosalbutamol, orciprenaline, pirbuterol, procaterol, ritodrine, salbutamol, terbutaline, albuterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
4. The process according to claim 2, wherein said long-acting p2 agonists (LABAs) is selected from the group comprising arformoterol, bambuterol, clenbuterol, formoterol, salmeterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
5. The process according to claim 2, wherein said ultra long-acting p2 agonists is selected from the group comprising abediterol, carmoterol, indacaterol, olodaterol, vilanterol or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
6. The process according to claim 2, wherein said long-acting muscarinic antagonists (LAMAs) is selected from the group comprising aclidinium, glycopyrronium, tiotropium, umeclidinium or a pharmaceutically acceptable salt or ester thereof, or an enantiomerically pure form thereof, or a racemic mixture thereof, or a combination of two or more thereof.
7. The process according to claim 2, wherein said long-acting beta-2-adrenergic agonist is salmeterol.
8. The process according to claim 1, wherein the second active agent is a corticosteroid or pharmaceutically acceptable salt thereof.
9. The process according to claim 8, wherein said corticosteroid is selected from the group comprising ciclesonide, budesonide, fluticasone, aldosterone, beklometazone, betametazone, chloprednol, cortisone, cortivasole, deoxycortone, desonide, desoxymetasone, dexametasone, difluorocortolone, fluchlorolone, flumetasone, flunisolide, fluquinolone, fluquinonide, flurocortisone, fluorocortolone, flurometolone, flurandrenolone, halcynonide, hydrocortisone, icometasone, meprednisone, methylprednisolone, mometasone, paramethasone, prednisolone, prednisone, tixocortole, triamcynolondane or mixtures thereof.
10. The process according to claim 9, wherein said corticosteroid is fluticasone.
11. The process according to claim 1, wherein said carrier is selected from the group comprising lactose, mannitol, sorbitol, inositol, xylitol, erythritol, lactitol and maltitol.
12. The process according to claim 1 , wherein the volume of the low shear mixer to the high shear mixer is between 0.01-1 , preferably 0.1-1 and more preferably 0.1.
13. The process according to any one of the preceding claims, wherein said carriers are preferably lactose and more preferably lactose monohydrate.
14. The process according to any one of the preceding claims, wherein said first carrier is lactose having coarse particle.
15. The process according to any one of the preceding claims, wherein said second carrier is lactose having fine particle.
16. The process according to any one of the preceding claims, wherein said lactose having coarse particle size which means the mean particle size (D50 value) is in the range of 25-250 pm, preferably 35-100 pm.
17. The process according to any one of the preceding claims, wherein lactose monohydrate having fine particle size which means the mean particle size (D50 value) is in the range of 0.01-25 pm, preferably 0.01-20 pm.
18. The process according to claim 1, wherein the filling volume of mixer is between %30- 80, preferably %32-78 and more preferably %44-76 of the total volume.
19. The process according to claim 1, wherein the first active agent and the second active agent have a d90 particle size less than 15 pm, preferably less than 12 pm, more preferably less than 10 pm.
PCT/TR2022/050727 2022-07-07 2022-07-07 A process for the preparation of dry powder compositions for inhalation using different mixers WO2024010538A1 (en)

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Citations (3)

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Publication number Priority date Publication date Assignee Title
US20030185764A1 (en) * 2000-04-17 2003-10-02 Staniforth John Nicholas Pharmaceutical formulations for dry powder inhalers
EP3175842A1 (en) * 2015-12-03 2017-06-07 Alfred E. Tiefenbacher (GmbH & Co. KG) Dry powder mixing process
WO2020031119A1 (en) * 2018-08-07 2020-02-13 Norton (Waterford) Limited Application of raman spectroscopy for the manufacture of inhalation powders

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030185764A1 (en) * 2000-04-17 2003-10-02 Staniforth John Nicholas Pharmaceutical formulations for dry powder inhalers
EP3175842A1 (en) * 2015-12-03 2017-06-07 Alfred E. Tiefenbacher (GmbH & Co. KG) Dry powder mixing process
WO2020031119A1 (en) * 2018-08-07 2020-02-13 Norton (Waterford) Limited Application of raman spectroscopy for the manufacture of inhalation powders

Non-Patent Citations (1)

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Title
HERTEL MATS; SCHWARZ EUGEN; KOBLER MIRJAM; HAUPTSTEIN SABINE; STECKEL HARTWIG; SCHERLIEß REGINA: "The influence of high shear mixing on ternary dry powder inhaler formulations", INTERNATIONAL JOURNAL OF PHARMACEUTICS, ELSEVIER, NL, vol. 534, no. 1, 1 January 1900 (1900-01-01), NL , pages 242 - 250, XP085280609, ISSN: 0378-5173, DOI: 10.1016/j.ijpharm.2017.10.033 *

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