Efficient optimization of high-dose formulation of novel lyophilizates for dry powder inhalation by the combination of response surface methodology and time-of-flight measurement.

Inhalation of proteins/peptides has recently received attention as various biopharmaceuticals have emerged on the market. Novel lyophilisates for dry powder inhalation (LDPIs), which are aerosolized by air impact, have been reported and LDPIs are considered an attractive option for the pulmonary administration of biopharmaceuticals. However, desirable disintegration and aerosolization properties have been unavailable in high-dose formulations, which has been a critical issue. This study aimed to investigate high-dose LDPIs and their optimization. In the present study, lysozyme (Lysoz) was used as a stable model protein and formulated with various amino acids. Furthermore, response surface methodology (RSM) and time-of-flight measurement were applied for efficient optimization. Superior disintegration and aerosolization properties were confirmed in the LDPIs with phenylalanine (Phe) and leucine (Leu). RSM results revealed that 0.5 mg/vial of Phe and 1.0 mg/vial of Leu are the optimal quantities for high-dose formulation. Based on these optimum quantities, high-dose LDPI formulations were prepared and the maximum formulable quantity of Lysoz with acceptable inhalation performance was confirmed to be 3.0 mg/vial. The results suggest that LDPI can cover the milligram-order pulmonary administration of proteins/peptides. LDPIs are expected to have biopharmaceutical applications.

Mechanism of collapse of amorphous-based lyophilized cake induced by slow ramp during the shelf ramp process.

We previously found that a slow ramp rate during the shelf ramp process induced product collapse. However, the cause of the collapse could not be explained by the hypothesized mechanism of collapse. To identify the cause, drying parameters such as sublimation rate and dry layer resistance (Rp) were calculated from cycle data by mathematical model. As a result, the behavior of these parameters in the slow ramp cycles showed a different profile from that of the fast ramp cycles. From the cross-sectional appearance of the lyophilized cakes, the point at which the onset of collapse occurred in vial lyophilization during the slowest ramp cycle was estimated, and collapse occurred as expected, at a dry layer thickness (Ldry) = 1.5 mm in the Rp - Ldry profile. The time-point of Ldry = 1.5 mm corresponded to the shelf ramp process; the subliming ice front temperature (Ti) at this point was lower than the collapse temperature (Tc) measured by LT-FDM. Although Ti in the fastest ramp cycle exceeded the above temperature, no macroscopic collapse was observed. Thus, the real Tc during the shelf ramp process in vial lyophilization was decreased by the slow ramp rate, and this was considered the reason for collapse in the slow ramp cycle.

Effect of temperature ramp rate during the primary drying process on the properties of amorphous-based lyophilized cake, Part 2: Successful lyophilization by adopting a fast ramp rate during primary drying in protein formulations.

In the lyophilization process for injections, the shelf temperature (Ts) and chamber pressure (Pc) have mainly been investigated to optimize the primary drying process. The objective of this study was to show that lyophilization of protein formulations can be achieved by adopting a fast ramp rate of Ts in the beginning of the primary drying process. Bovine serum albumin was used as the model protein, and seven different lyophilized formulations obtained were stored at elevated temperature. We found that although acceptable cake appearance was confirmed by the fast ramp cycle, all formulations of lyophilized cakes obtained by the slow ramp cycle severely collapsed (macrocollapse). It is thought that the collapse in the slow ramp cycle occurred during the shelf ramp in the beginning of primary drying and that insufficient removal of water from the dried matrix caused viscous flow (product collapse). Regarding storage stability, moisture-induced degradation was confirmed in some of the formulations prepared by the slow ramp cycle, whereas all lyophilized BSA formulations prepared by the fast ramp cycle were stable. Thus, the results indicate that the ramp rate appears to be one of the critical operational parameters required to establish a successful lyophilization cycle.

Solution properties of amphiphilic telomers with multiple sugar chains and terminal alkyl chain.

Amphiphilic telomers with multiple sugar chains and a terminal undecyl or heptadecyl chain (i.e., C(n)Am-mGEMA, where n and m represent alkyl chain lengths of 11 or 17 with a degree of polymerization of 2.0 or 3.0 for glucosyloxyethyl methacrylate (GEMA) units, respectively) were synthesized via monomeric radical telomerization in the presence of 2-aminoethanethiol hydrochloride. Surface tension, pyrene fluorescence, and dynamic light scattering were measured to characterize the solution properties of the synthesized telomers. In addition, the effects of alkyl chain length and degree of polymerization of hydrophilic GEMA units on the measured properties were evaluated by comparison with those of conventional polyoxyethylene dodecyl ether nonionic surfactants. C(n)Am-mGEMA telomers exhibited higher critical micelle concentration (CMC) values than polyoxyethylene dodecyl ether surfactants with similar number of hydrophilic groups did. The synthesized telomers are highly efficient in reducing the surface tension of water, despite the relatively large hydrophilic structures within the sugar units (GEMA). A unique behavior was observed in that adsorption at the air-water interface and solution aggregation occurred simultaneously at a concentration below CMC (as determined by the surface tension method). This suggests that aggregate formation occurs readily in solution along with the adsorption at the interface because of strong attractive interactions between multiple sugar GEMA chains. Further, aggregates formed by C(n)Am-mGEMA telomers differ depending on the number of sugar chains, i.e., an increase in the degree of polymerization of the telomers increases the size of the aggregates. This indicates that it is easier for telomers with more sugar GEMA chains to form large aggregates due to the interactions between their hydroxyl groups.