Amorphous Solid Dispersions Containing Residual Crystallinity: Competition Between Dissolution and Matrix Crystallization.

Crystallinity in an amorphous solid dispersion (ASD) may negatively impact dissolution performance by causing lost solubility advantage and/or seeding crystal growth leading to desupersaturation. The goal of the study was to evaluate underlying dissolution and crystallization mechanisms resulting from residual crystallinity contained within bicalutamide (BCL)/polyvinylpyrrolidone vinyl acetate copolymer (PVPVA) ASDs produced by hot melt extrusion (HME). In-line Raman spectroscopy, polarized light microscopy, and scanning electron microscopy were used to characterize crystallization kinetics and mechanisms. The fully amorphous ASD (0% crystallinity) did not dissolve completely, and underwent crystallization to the metastable polymorph (form 2), initiating in the amorphous matrix at the interface of the amorphous solid with water. Under non-sink conditions, higher extents of supersaturation were achieved because dissolution initially proceeded unhindered prior to nucleation. ASDs containing residual crystallinity had markedly reduced supersaturation. Solid-mediated crystallization (matrix crystallization) consumed the amorphous solid, growing the stable polymorph (form 1). Under sink conditions, both the fully amorphous ASD and crystalline physical mixture achieve faster release than the ASDs containing residual crystallinity. In the latter systems, matrix crystallization leads to highly agglomerated crystals with high relative surface area. Solution-mediated crystallization was not a significant driver of concentration loss, due to slow crystal growth from solution in the presence of PVPVA. The high risk stemming from residual crystallinity in BCL/PVPVA ASDs stems from (1) fast matrix crystallization propagating from crystal seeds, and (2) growth of the stable crystal form. This study has implications for dissolution performance outcomes of ASDs containing residual crystallinity.

Application and limitations of thermogravimetric analysis to delineate the hot melt extrusion chemical stability processing window.

Thermogravimetric analysis (TGA) is frequently used to define the threshold of acceptable processing temperatures for hot melt extrusion. Herein, evaluation of chemical stability of amorphous drug and polymer systems was assessed by a critical evaluation of TGA nonisothermal and isothermal methods. Nonisothermal analysis of three crystalline APIs of high glass-forming ability (posaconazole, indomethacin, and bicalutamide), as well as six common polymers, identified a degradation onset temperature that ranged from 52 to 170 °C, depending on heating rate and degradation detection method employed. In particular, the tangent method significantly overestimated the onset of acceptable levels of degradation, while weight loss threshold criteria were more suitable. Isothermal analysis provided a more direct indication of chemical stability, however neat amorphous materials are likely to recrystallize. By forming an amorphous solid dispersion, the polymer can stabilize the amorphous drug against recrystallization, enabling isothermal analysis of chemical degradation. However, TGA mass loss of volatiles should be considered only as an approximate indicator of degradation, as actual potency loss is likely to be significantly higher; this was confirmed by high performance liquid chromatographic analysis of samples. TGA methods should be selected to generate highly sensitive outcomes, and caution should be applied when extrapolating suitability of processing conditions.