Spherical Agglomerates of Lactose Reduce Segregation in Powder Blends and Improve Uniformity of Tablet Content at High Drug Loads.

We report here on improved uniformity of blends of micronised active pharmaceutical ingredients (APIs) using addition of spherical agglomerates of lactose and enhanced blend flow to improve tablet content uniformity with higher API loads. Micromeritic properties and intra-particle porosity (using nano-computed X-ray tomography) of recently introduced spherical agglomerates of lactose and two standard lactose grades for the direct compression processes were compared. Powder blends of the individual lactose types and different micronised API drug loads were prepared and subjected to specific conditions that can induce API segregation. Tablet content uniformity during direct compression was related to the lactose material attributes. The distinctive micromeritic properties of the lactose types showed that spherical agglomerates of lactose had high intra-particle porosity and increased specific surface area. The stability of binary blends after intense sieving was governed by the intra-particle porosity and surface roughness of the lactose particles, which determined the retention of the model substance. Greater intra-particle porosity, powder specific surface area, and particle size of the spherical agglomerates provided greater adhesion of micronised particles, compared to granulated and spray-dried lactose. Thus the spherical agglomerates provided enhanced final blend flow and uniformity of tablet content at higher drug loads.

Spherical agglomerates of lactose as potential carriers for inhalation.

We report here on spherical lactose agglomerates as potential carriers for inhalation applications. Micromeritic properties of three spherical lactose agglomerates (SA-A, SA-B, SA-C) and a standard lactose inhalation grade carrier (Lactohale 100; LH100) were evaluated and compared. Ordered mixtures with micronized salbutamol sulfate as the model active pharmaceutical ingredient (API) and lactose carriers at two drug loadings (2 wt%, 5 wt%) were prepared, and in-vitro aerosolization performance was assessed. The spherical crystallization process led to particles with tailored micromeritic properties. These had larger specific surface area and greater fine fraction < 10 µm, compared to LH100, due to their coarse morphology. Their properties were reflected in the flowability parameters, where two types of spherical agglomerates of lactose showed more cohesive behavior compared to the other lactose grades. Blend uniformity showed improved homogeneous distribution of the API at higher drug load. In-vitro aerosolization tests showed that the spherical agglomerates of lactose enhanced the dose of API, compared to LH100. SA-B and SA-C showed significantly higher fine particle fractions at low drug load compared to the others, whereas overall, the largest fine particle fraction was for SA-B at high drug load. The carrier material attributes related to particle size, specific surface area, compressibility, flowability (cohesion, flow function), and air permeability were critical for aerosolization performance.

Design of Experiments for Optimization of the Lactose Spherical Crystallization Process.

This study provides a comprehensive assessment of the parameters of the spherical crystallization process and their impact on the micromeritic properties of lactose spherical agglomerates. A recently introduced definitive screening design was used to study various process parameters, with particular focus on building predictive models. The parameters included were: lactose solution concentration; volume ratio between the antisolvent and the whole crystallization system; crystallization system temperature; velocity of the addition of the lactose water solution; agitation velocity; and agitation time after whole addition of the lactose solution. Their effects on process yield, particle size parameters D10, D50 and D90, particle size distribution, morphological properties (roundness, solidity) and Hausner ratio were studied. Active effects were identified for all of these responses, with quadratic and interaction effects included. Lactose concentration, volume ratio, crystallization system temperature, and agitation velocity were identified as critical process parameters. For every response, a statistical model was built, where those for Hausner ratio, yield and roundness provided the best predictive performances. Based on these models, D10 and yield were successfully optimized. Definitive screening design proved as useful especially in the screening phase; however, additional experiments are needed to build models with high predictive power for all of these responses.

Modified equation for particle bonding area and strength with inclusion of powder fragmentation propensity.

The paper considers a novel, modified equation for evaluation of relationship between tablet tensile strength, bonding area and bonding strength with inclusion of fragmentation as particle deformation mechanism. Four types of lactose particles for direct compression were assessed for their micromeritic and mechanical properties (compressibility and compactibility), with particular focus on fragmentation behaviour, bonding area and bonding strength. Compressibility properties were assessed using three established models. Walker and Kuentz-Leuenberger models distinguished lactose plastic properties more effectively in contrast to the Heckel model. Spherical agglomerates of lactose were most prone to fragmentation as determined with the fragmentation propensity coefficient and the number of interparticulate bonds. Fragmentation, together with plastic deformation were found to be the governing factors for tablet tensile strength in α-lactose samples, while high bonding force primarily controlled the tablet tensile strength of anhydrous lactose. Tensile strength of all lactose tablets showed best correlation to the ratio of fragmentation propensity and Walker compressibility coefficient, which is proposed as better deformation index, intended to describe the overall deformation properties of lactose more precisely. A novel expression for determining bonding area is proposed, established on the enhanced deformation index, which includes both plastic deformation and fragmentation as bond formation mechanisms.

Spherical agglomerates of lactose with enhanced mechanical properties.

The aim of this study was to prepare spherical agglomerates of lactose and to evaluate their physicochemical properties, flow properties, particle friability and compaction properties, and to compare them to commercially available types of lactose for direct compression (spray-dried, granulated and anhydrous ß-lactose). Porous spherical agglomerates of α-lactose monohydrate with radially arranged prism-like primary particles were prepared exhibiting a high specific surface area. All types of lactose analysed had passable or better flow properties, except for anhydrous ß-lactose, which had poor flowability. Particle friability was more pronounced in larger granulated lactose particles; however, particle structure was retained in all samples analysed. The mechanical properties of spherical agglomerates of lactose, in terms of compressibility, established with Walker analysis, and compactibility, established with a compactibility profile, were found to be superior to any commercially available types of lactose. Higher compactibility of spherical agglomerates of lactose is ascribed to significantly higher particle surface area due to a unique internal structure with higher susceptibility to fragmentation.