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Upon approval of a drug, the stability of the API and the FPP has to be studied intensively because it determines the shelf-life. If a drug is found to be stable, the expiry date is arbitrary set to five years at the maximum, if a drug tends to undergo degradation, the expiry date is set shorter. The drug product must comply with predefined specifications in accordance with the ICH guidelines Q6A and Q6B during its entire market life. The content of the active substance is required to be within a specification of 95–105% of its labeled claim until expiry corresponding to the ICH guideline Q1A(R2). However, there is little or scattered literature information addressing the stability of drug products beyond their expiry dates. The objective of this thesis was to study and assess the long-term stability of a collection involving numerous pure drug substances and ampoules manufactured in the 20th century. The content and the impurity profile were examined by means of appropriate analytical methods, mainly using liquid chromatography. The results were compared to data being available in the literature. Assessing the stability regarding the dosage form and the affiliation of the drug class was conducted.
The experimental studies comprise the examination of 50 drug substances manufactured 20–30 years ago and 14 long expired ampoules which were older than 40 years in the time of analysis, exceeding many times the maximum shelf life of five years.
For investigation of the solid drug substances, pharmacopoeial methods were applied as far as possible. Indeed, results of the study showed that 44 tested substances still complied with the specification of the Ph. Eur. with regard to the content and impurity profile, even after more than two decades of storage.
For analysis of the injection solutions, HPLC-UV and HPLC-ESI/MS techniques were applied, commonly based on liquid chromatography methods of the Ph. Eur. for determination of related substances. Each method was further validated for its application to ensure accurate API quantification corresponding to ICH Q2(R1). Quite a few ampoules were identified to show surprisingly high stability. In spite of their age of 53–72 years, APIs such as caffeine, etilefrine, synephrine, metamizole sodium, furosemide, and sodium salicylate complied with the specified content that is valid nowadays, respectively. Nevertheless, typical degradation reaction, e.g. hydrolysis, oxidation, or isomerization, was observed in all remaining ampoules. Various degrees of hydrolysis were revealed for scopolamine, procaine, and adenosine triphosphate, the contents were decreased to 71%, 70%, and 15% of the declared concentrations, respectively. In the epinephrine and dipyridamole ampoules, oxidative degradation has been occurred, finding respective API contents of more or less 70%. For dihydroergotamine, excessive decomposition by epimerization was observed, resulting in an API content of 21% and degradation by isomerization was found in lobeline, still containing 64% of the labeled claim.
In conclusion, supported by the data of the present studies and the literature, defining and authorizing a longer shelf-life may be applicable to numerous pharmaceuticals which should be considered by pharmaceutical manufacturers and regulatory authorities, if justified based on stability studies. A general extension of the shelf-lives of drug products and the abolishment or extension of the maximum shelf-life limit of five years would prevent disposing of still potent medications and save a lot of money to the entire health care system.
Background: Topical glucocorticosteroids are the first line therapy for airway inflammation. Modern compounds with higher efficacy have been developed, but head-to-head comparison studies are sparse.
Objective: To compare the activity of two intranasal glucocorticoids, fluticasone furoate (FF) and mometasone furoate (MF) with respect to the inhibition of T helper (Th)1, Th2 and Th17 cytokine release in airway mucosa.
Methods: We used an ex-vivo human nasal mucosal tissue model and employed pre-and post-Staphylococcus aureus enterotoxin B (SEB)-challenge incubations with various time intervals and drug concentrations to mimic typical clinical situations of preventive or therapeutic use.
Results: At a fixed concentration of 10(-10) M, FF had significantly higher suppressive effects on interferon (IFN)-gamma,interleukin (IL)-2 and IL-17 release, but not IL-5 or tumor necrosis factor (TNF)-alpha, vs. MF. While the maximal suppressive activity was maintained when FF was added before or after tissue stimulation, the cytokine suppression capacity of MF appeared to be compromised when SEB-induced cell activation preceded the addition of the drug. In a pre-challenge incubation setting with removal of excess drug concentrations, MF approached inhibition of IL-5 and TNF-alpha after 6 and 24 hours while FF maximally blocked the release of these cytokines right after pre-incubation. Furthermore, FF suppressed a wider range of T helper cytokines compared to MF.
Conclusion: The study demonstrates the potential of our human mucosal model and shows marked differences in the ability to suppress the release of various cytokines in pre-and post-challenge settings between FF and MF mimicking typical clinical situations of preventive or therapeutic use.
Breast cancer etiology is associated with both proliferation and DNA damage induced by estrogens. Breast cancer risk factors (BCRF) such as body mass index (BMI), smoking, and intake of estrogen-active drugs were recently shown to influence intratissue estrogen levels. Thus, the aim of the present study was to investigate the influence of BCRF on estrogen-induced proliferation and DNA damage in 41 well-characterized breast glandular tissues derived from women without breast cancer. Influence of intramammary estrogen levels and BCRF on estrogen receptor (ESR) activation, ESR-related proliferation (indicated by levels of marker transcripts), oxidative stress (indicated by levels of GCLC transcript and oxidative derivatives of cholesterol), and levels of transcripts encoding enzymes involved in estrogen biotransformation was identified by multiple linear regression models. Metabolic fluxes to adducts of estrogens with DNA (E-DNA) were assessed by a metabolic network model (MNM) which was validated by comparison of calculated fluxes with data on methoxylated and glucuronidated estrogens determined by GC- and UHPLC-MS/MS. Intratissue estrogen levels significantly influenced ESR activation and fluxes to E-DNA within the MNM. Likewise, all BCRF directly and/or indirectly influenced ESR activation, proliferation, and key flux constraints influencing E-DNA (i.e., levels of estrogens, CYP1B1, SULT1A1, SULT1A2, and GSTP1). However, no unambiguous total effect of BCRF on proliferation became apparent. Furthermore, BMI was the only BCRF to indeed influence fluxes to E-DNA (via congruent adverse influence on levels of estrogens, CYP1B1 and SULT1A2).
Insulin-like growth factor-I (IGF-I) is a 70-amino acid polypeptide with a molecular weight of approximately 7.6 kDa acting as an anabolic effector. It is essential for tissue growth and remodeling. Clinically, it is used for the treatment of growth disorders and has been proposed for various other applications including musculoskeletal diseases. Unlike insulin, IGF-I is complexed to at least six high-affinity binding proteins (IGFBPs) exerting homeostatic effects by modulating IGF-I availability to its receptor (IGF-IR) on most cells in the body as well as changing the distribution of the growth factor within the organism.1-3 Short half-lived IGF-I have been the driving forces for the design of localized IGF-I depot systems or protein modification with enhanced pharmacokinetic properties. In this thesis, we endeavor to present a versatile biologic into which galenical properties were engineered through chemical synthesis, e.g., by site-specific coupling of biomaterials or complex composites to IGF-I. For that, we redesigned the therapeutic via genetic codon expansion resulting in an alkyne introduced IGF-I, thereby becoming a substrate for biorthogonal click chemistries yielding a site-specific decoration.
In this approach, an orthogonal pyrrolysine tRNA synthetase (PylRS)/tRNAPyl CUA pair was employed to direct the co-translational incorporation of an unnatural amino acid—¬propargyl-L-lysine (plk)—bearing a clickable alkyne functional handle into IGF-I in response to the amber stop codon (UAG) introduced into the defined position in the gene of interest. We summarized the systematic optimization of upstream and downstream process alike with the ultimate goal to increase the yield of plk modified IGF-I therapeutic, from the construction of gene fusions resulting in (i) Trx-plk-IGF-I fusion variants, (ii) naturally occurring pro-IGF-I protein (IGF-I + Ea peptide) (plk-IGF-I Ea), over the subsequent bacterial cultivation and protein extraction to the final chromatographic purification. The opportunities and hurdles of all of the above strategies were discussed. Evidence was provided that the wild-type IGF-I yields were pure by exploiting the advantages of the pHisTrx expression vector system in concert with a thrombin enzyme with its highly specific proteolytic digestion site and multiple-chromatography steps. The alkyne functionality was successfully introduced into IGF-I by amber codon suppression. The proper folding of plk-IGF-I Ea was assessed by WST-1 proliferation assay and the detection of phosphorylated AKT in MG-63 cell lysate. The purity of plk-IGF-I Ea was monitored with RP-HPLC and SDS-PAGE analysis. This work also showed site-specific coupling an alkyne in plk-IGF-I Ea by copper (I)-catalyzed azide-alkyne cycloaddition (CuAAC) with potent activities in vitro. The site-specific immobilization of plk-IGF-I Ea to the model carrier (i.e., agarose beads) resulted in enhanced cell proliferation and adhesion surrounding the IGF-I-presenting particles. Cell proliferation and differentiation were enhanced in the accessibility of IGF-I decorated beads, reflecting the multivalence on cellular performance.
Next, we aimed at effectively showing the disease environment by co-delivery of fibroblast growth factor 2 (FGF2) and IGF-I, deploying localized matrix metalloproteinases (MMPs) upregulation as a surrogate marker driving the response of the drug delivery system. For this purpose, we genetically engineered FGF2 variant containing an (S)-2-amino-6-(((2-azidoethoxy)carbonyl)amino)hexanoic acid incorporated at its N-terminus, followed by an MMPs-cleavable linker (PCL) and FGF2 sequence, thereby allowing site-directed, specific decoration of the resultant azide-PCL-FGF2 with the previously mentioned plk-IGF-I Ea to generate defined protein-protein conjugates with a PCL in between. The click reaction between plk-IGF-I Ea and azide-PCL-FGF2 was systematically optimized to increase the yield of IGF-FGF conjugates, including reaction temperature, incubation duration, the addition of anionic detergent, and different ratios of the participating biopharmaceutics. The challenge here was that CuAAC reaction components or conditions might oxidize free cysteines of azide-PCL-FGF2 and future work needs to present the extent of activity retention after conjugation. Furthermore, our study provides potential options for dual-labeling of IGF-I either by the introduction of unnatural amino acids within two distinct positions of the protein of interest for parallel “double-click” labeling of the resultant plk-IGF-I Ea-plk or by using a combination of enzymatic-catalyzed and CuAAC bioorthogonal coupling strategies for sequentially dual-labeling of plk-IGF-I Ea.
In conclusion, genetic code expansion in combination with click-chemistry provides the fundament for novel IGF-I analogs allowing unprecedented site specificity for decoration. Considerable progress towards IGF-I based therapies with enhanced pharmacological properties was made by demonstrating the feasibility of the expression of plk incorporated IGF-I using E. coli and retained activity of unconjugated and conjugated IGF-I variant. Dual-labeling of IGF-I provides further insights into the functional requirements of IGF-I. Still, further investigation warrants to develop precise IGF-I therapy through unmatched temporal and spatial regulation of the pleiotropic IGF-I.
In 1998, the aminoglycoside antibiotic gentamicin sulfate caused several cases of deaths in the United States, after the switch from twice- to once-daily application. Endotoxins were discussed as the cause for the adverse effects and sisomicin was identified as the lead impurity; batches containing sisomicin were contaminated with more impurities and were responsible for the fatalities. In 2016, anaphylactic reactions in horses, and later in humans with one fatality, were observed after application of gentamicin sulfate contaminated with histamine. To determine whether histamine was responsible for the 1990s death cases as well, histamine was quantified by means of liquid chromatography–tandem mass spectrometry (LC-MS/MS) in 30 samples of gentamicin sulfate analyzed in previous studies. Furthermore, a relative quantification of sisomicin was performed to check for a correlation between histamine and the lead impurity. A maximum amount of 11.52 ppm histamine was detected, which is below the limit for anaphylactic reactions of 16 ppm, and no correlation of the two impurities was observed. However, the European Medicines Agency recommends a stricter limit with regard to the maximum single dose of gentamicin sulfate to reach a greater gap between the maximum histamine exposition of 4.3 µg and the quantity known to cause hypotension of 7 µg. The low amounts of histamine and the fact that there is no connection with the contamination with sisomicin showed that histamine was not the cause for the death cases in the United States in 1998, and endotoxins remain the most probable explanation.
Analysis of Drug Impurities by Means of Chromatographic Methods: Targeted and Untargeted Approaches
(2022)
The presented works aimed on the analysis of new impurities in APIs and medicinal products. Different subtypes of LC were coupled to suitable detection methods, i.e. UV and various MS techniques, depending on the chemical natures of the analytes and the analytical task.
Unexpected impurities in medicinal products and APIs caused several scandals in the past, concomitant with fatalities or severe side effects in human and veterinary patients. The detection of nitrosamines in sartans led to the discovery of nitrosamines in various other drugs, of which the antibiotic rifampicin was analyzed in this work. An examination of the synthesis of rifampicin revealed a high potential for the formation of 4-methyl-1-nitrosopiperazine (MeNP). An LC-MS/HRMS method suitable for the quantification of MeNP was applied in the analysis of drugs collected from Brazil, Comoros, India, Nepal, and Tanzania, where a single dose of rifampicin is used in the post-exposure prophylaxis of leprosy. All batches were contaminated with MeNP, ranging from 0.7-5.1 ppm. However, application of rifampicin containing up to 5 ppm MeNP was recommended by the regulatory authorities for the post-exposure prophylaxis of leprosy.
In the 1990s the aminoglycoside antibiotic gentamicin attracted attention after causing fatalities in the USA, but the causative agent was never identified unequivocally. The related substance sisomicin was recognized as a lead impurity by the Holzgrabe lab at the University of Würzburg: sisomicin was accompanied by a variety of other impurities and batches containing sisomicin had caused the fatalities. In 2016, anaphylactic reactions were reported after application of gentamicin. A contamination of the medicinal products with histamine, an impurity of the raw material fish peptone used upon the production, could be identified as the cause of the adverse effects. Batches of gentamicin sulfate, which had been stored at the University of Würzburg since the earlier investigations, were analyzed regarding their contamination with histamine to determine whether the biogenic amine was responsible for the 1990s fatalities as well. Furthermore, a correlation with the lead impurity sisomicin was checked. Histamine could be detected in all analyzed batches, but at a lower level than in the batches responsible for the anaphylactic reactions. Moreover, there is no correlation of histamine with the lead impurity sisomicin. Hence, the causative agent for the 1990s fatalities was not histamine and remains unknown.
Another source of impurities is the reaction of APIs with excipients, e.g. the esterification of naproxen with PEG 600 in soft gel capsules. The influence of the formulation’s composition on this reaction was investigated by means of LC-UV. Therefore, the impurity naproxen-PEG-ester (NPEG) was synthesized and used for the development of a method suitable for the analysis of soft gel capsule formulations. Different formulations were stressed for 7 d at 60 °C and the relative amount of NPEG was determined. The formation of NPEG was influenced by the concentrations of water and lactic acid, the pH, and the drug load of the formulation, which can easily be explained by the chemistry behind esterification reactions.
Keeping in mind the huge variety of sources of impurities, it might be impossible to predict all potential impurities of a drug substance/product. Targeted and untargeted approaches were combined in the impurity profiling of bisoprolol fumarate. Eight versions of an LC-HRMS method were developed to enable the detection of a maximum number of impurities: an acidic and a basic buffered LC was coupled to MS detection applying ESI and APCI, both in positive in negative mode. MS and MS/MS data were acquired simultaneously by information dependent acquisition. In the targeted approach, potential impurities were derived from a reaction matrix based on the synthesis route of the API, while the untargeted part was based on general unknown comparative screening to identify additional signals. 18 and 17 impurities were detected in the targeted and the untargeted approach, respectively. The molecular formulae were assessed based on the exact mass and the isotope pattern. Theoretical fragment spectra generated by in silico fragmentation were matched with experimental data to estimate the plausibility of proposed/elucidated structures. Moreover, the detected impurities were quantified with respect to an internal standard.
The aim of this thesis was the application of the functional prepolymer NCO-sP(EO-stat-PO) for the development of new biomaterials. First, the influence of the star-shaped polymers on the mechanical properties of biocements and bone adhesives was investigated. 3-armed star-shaped macromers were used as an additive for a mineral bone cement, and the influence on the mechanical properties was studied. Additionally, a previously developed bone adhesive was examined regarding cytocompatibility. The second topic was the examination of novel functionalization steps which were performed on the surface of electrospun fibers modified with NCO-sP(EO-stat-PO). This established method of functionalizing electrospun meshes was advanced regarding the modification with proteins which was then demonstrated in a biological application. Two different kinds of antibodies were immobilized on the fiber surface in a consecutive manner and the influence of these proteins on the cell behavior was investigated. The final topic involved the quantification of surface-bound peptide sequences. By functionalization of the peptides with the UV-reactive molecule 2-mercaptopyridine it was possible to quantify this compound via UV measurements by cleavage of disulfide bridges and indirectly draw conclusions about the number of immobilized peptides.
In the field of mineral biocements and bone adhesives, NCO-sP(EO-stat-PO) was able to influence the setting behavior and mechanical performance of mineral bone cements based on calcium phosphate chemistry. The addition of NCO-sP(EO-stat-PO) resulted in a pseudo-ductile fracture behavior due to the formation of a hydrogel network in the cement, which was then mineralized by nanosized hydroxyapatite crystals following cement setting. Accordingly, a commercially available aluminum silicate cement from civil engineering could be modified.
In addition, it could be shown that the use of NCO-sP(EO-stat-PO) is beneficial for adjusting specific material properties of bone adhesives. Here, the crosslinking behavior of the prepolymer in an aqueous medium was exploited to form an interpenetrating network (IPN) together with a photochemically curing poly(ethylene glycol) dimethacrylate (PEGDMA) matrix. This could be used for the development of a bone adhesive with an improved adhesion to bone in a wet environment. The developed bone adhesive was further investigated in terms of possible influences of the initiator systems. In addition, the material system was tested for cytocompatibility by using different cell lines.
Moreover, the preparation of electrospun fiber meshes via solution electrospinning consisting of poly(lactide-co-glycolide) (PLGA) as a backbone polymer and NCO-sP(EO-stat-PO) as functional additive is an established method for the application of the meshes as a replacement of the native extracellular matrix (ECM). In general, these fibers reveal diameters in the nanometer range, are protein and cell repellent due to the hydrophilic properties of the prepolymer and show a specific biofunctionalization by immobilization of peptide sequences. Here, the isocyanate groups presented on the fiber surface after electrospinning were used to carry out various functionalization steps, while retaining the properties of protein and cell repellency. The modification of the electrospun fibers involved the immobilization of analogs or antagonists of tumor necrosis factor (TNF) and the indirect detection of these by interaction with a light-producing enzyme. Here, a multimodal modification of the fiber surface with RGD to mediate cell adhesion and two different antibodies could be achieved. After culturing the cell line HT1080, the pro- or anti-inflammatory response of cells could be detected by IL-8 specific ELISA measurements.
Furthermore, the quantification of molecules on the surface of electrospun fibers was investigated. It was tested whether the detection by means of super-resolution microscopy would be possible. Therefore, experiments were performed with short amino acid sequences such as RGD for quantification by fluorescence microscopy. Based on earlier results, in which a UV-spectrometrically active molecule was used to detect the quantification of RGD, it was shown that short peptides can also be quantified in a small scale on flat functional substrates (2D) such as NCO-sP(EO-stat-PO) hydrogel coatings, and modified electrospun fibers produced from PLGA and NCO-sP(EO-stat-PO) (3D). In addition, a collagen sequence was used to prove that a successful quantification can be carried out as well for longer peptide chains.
These studies have revealed that NCO-sP(EO-stat-PO) can serve as a functional additive for many applications and should be considered for further studies on the development of novel biomaterials. The rapid crosslinking reaction, the resulting hydrogel formation and the biocompatibility are to be mentioned as positive properties, which makes the prepolymer interesting for future applications.
In DNA-encoded library synthesis, amine-substituted building blocks are prevalent. We explored isocyanide multicomponent reactions to diversify DNA-tagged amines and reported the Ugi-azide reaction with high yields and a good substrate scope. In addition, the Ugi-aza-Wittig reaction and the Ugi-4-center-3-component reaction, which used bifunctional carboxylic acids to provide lactams, were explored. Five-, six-, and seven-membered lactams were synthesized from solid support-coupled DNA-tagged amines and bifunctional building blocks, providing access to structurally diverse scaffolds.
Lattice forces are based on the attraction between the single moieties of molecules. The strength of lattice forces has an impact on the solid state and related physical properties such as melting point, boiling point, vapor pressure solvation and solubility. For solvation to occur, energy is required to break the lattice forces attracting ions and molecules among themselves. The energy for breaking up the attraction between the molecules is gained from the energy released when ions or molecules of the lattice associate with molecules of the solvent. Solubility is therefore, directly linked to the energy which is required to break the lattice forces and the energy which is liberated by solvation of the molecules or ions. Based on this relation, the lattice forces in two acidic compounds and a neutral compound were subsequently lowered by different approaches with the intention to increase the solubility, supersaturation, and dissolution rate.
The conversion to an ionic liquid and the embedding of the compound in a pH-sensitive matrix in an amorphous state were investigated with an acidic compound and its pro-drug. The tetrabutylphosphonium (TBPH) salt showed the most promising properties among the tested counter ions. It alters the properties of the compound from a highly crystalline physicochemical state to an amorphous readily soluble material showing supersaturation in a wider pH range and higher solubility than the sodium and potassium salts. A solid dispersion approach was developed in parallel. Solid dispersions with two different pH-sensitive polymers and different drug load were prepared by lyophilization to determine the miscibility of the compound and the polymer by differential scanning calorimetry (DSC). A miscibility of 50% of the amorphous acid with the pH-sensitive Eudragit L100-55 matrix and a miscibility of 40% with hydroxypropyl methylcellulose acetate succinate (HPMC-AS) was found. Both approaches, the TBPH salt and the solid dispersion based on the pH-sensitive Eudragit L100-55 were tested in vivo. The TBPH salt was dosed in a buffered solution to prevent precipitation in the acidic stomach pH. This resulted in BAV higher than the crystalline suspension but lower than the solid dispersion. There were no acute toxicology effects seen. Thus, TBPH was considered safe for further studies. The TBPH salts were very hygroscopic, sticky and prone to precipitation as free compound when exposed to low pH when simulating the passage through the stomach. Thus, the principle of the ionic liquid was combined with the principle of an amorphous solid dispersion. This mitigated the risk of precipitation of the TBPH salt during the passage of the stomach. Also delinquency upon open storage was improved by embedding the TBPH salt in a pH-sensitive polymer. Dissolution tests mimicking the pH gradient in the gastro intestinal tract confirmed the protective properties of the pH-sensitive polymer matrices against recrystallization at low stomach pH in vitro. Furthermore, supersaturation at pH ranges relevant in the intestines of preclinical species or humans was observed. The TBPH solid dispersion showed superior supersaturation behavior in vitro compared to the free acid in pH-sensitive matrix. However, equally increased bioavailability (BAV) was observed when the amorphous solid dispersion contained the free acid form or the TBPH salt. Absorption seemed to be so fast that the short in vitro supersaturation observed for the free from in pH-sensitive matrix was already sufficient for complete absorption within 15 - 30 minutes. This is in accordance with the short tmax of around 15 - 30 minutes after oral application of the low lattice force principles. The pharmacokinetic (PK) profile became the main focus of further optimization as the BAV was maximized already. Early maximal plasma concentration (tmax) went along with high maximal plasma concentration (Cmax) for the low lattice force principles. Central nervous system related side effects as consequence of the PK profile with such a high Cmax were likely to happen and therefore, the formulation principles were modified to maintain the doubled BAV and reduce the observed Cmax. Additionally, the compound showed a short half-life requiring a two times daily dose, which is suboptimal for a chronic treatment. The amorphous acid in pH-matrix showed a modified PK profile when dosed in a hydrogel but not in an oleo gel. Surprisingly, administration of the TBPH salt in pH-matrix suspended in oil showed a massive delay of the tmax to 8 hours and a reduction of Cmax by factor 2 - 3 with unchanged good BAV when administered as a suspension in oil without increased viscosity. TBPH salt solution with a high viscosity resulted in the same PK profile as when administered without increased viscosity.
The animal model was changed from rat to dog. The dose was limited to 15 mg/dog since they reacted much more sensitively to the drug. BAV at this dose level was 100% for the crystalline suspension already, thus the focus of this study was not increasing BAV but to achieve prolonged and/or delayed exposure using different formulation principles elaborated in rats before. An immediate release formulation of 3 mg was combined with a delayed/modified release principle containing 12 mg of the compound. An additional study arm was conducted with a remote controlled device programmed to deliver a first dose of 3 mg instantaneously after passing the stomach and a second dose of 12 mg when entering the caecum. The tmax remained short for all formulation principles and it seemed that delayed and modified release lead to BAV reduction. The modified PK profiles could not be translated to an oral dog model which endorsed the hypothesis of an absorption window; however, the in vitro results could be translated to a dog model for colonic absorption. A nanosuspension of the crystalline compound, the TBPH salt in pH-matrix and the TBPH salt of the pro-drug of the compound were administered rectally to determine colonic absorption. The nanosuspension showed exposure around the limit of quantification whereas the TBPH in pH-matrix showed 4% BAV and the pro-drug as TBPH salt in pH-matrix resulted in 12% BAV although the pro-drug is factor 3 less soluble. This was in line with the increased permeation of the pro-drug which was observed in the Caco2 experiments. The bioavailability was increased by using the low lattice force principles and validated the hypothesis for the acidic drug and its pro-drug in the colonic dog model. Chemical and physicochemical stability of the investigated solid dispersions was confirmed for at least 18 months at room temperature.
Amorphous solid dispersions were investigated to lower lattice forces of a neutral molecule. Solid dispersions are well known from literature; however, they are not frequently used as principles for dosage forms due to limitations in physical stability and complex manufacturing processes. A viable formulation principle was developed for a neutral compound assuming that the stability of a solid dispersion with a drug load below the maximal miscibility will be better than one which exceeds the maximal miscibility. The dispersed and amorphous state of the neutral compound resulted in a higher energy level and chemical potential compared to a crystalline form implying that they are thermodynamically instable and sensitive to recrystallization. This was confirmed by the fast recrystallization of an amorphous solid dispersion made from HPMC with 50% drug load which recrystallized within a few days. Solid dispersions with different drug loads in different polymers and in polymer mixtures were prepared by lyophilization. The miscibility of the compound and the polymer was determined by DSC as the miscibility is a surrogate for maximal stable drugload of the solid dispersion. HPMC was found to be miscible with 20% compound confirming the instability of the 50% HPMC solid dispersion observed earlier. Based on dosing needs, a miscibility/drug load of at least 30% was mandatory because of the dosing requirements to dose less than 1500 mg of final formulation. This was considered as maximal swallowable volume for later clinical development. Thus, all systems with a miscibility higher or equal to 30% drug in polymer were evaluated in an in vitro dissolution test and ranked in comparison with amorphous pure compound, crystalline compound and a 20% drug load solid dispersion made from HPMC. The HPMC based solid dispersion which gave good exposure in previous in vivo experiments did not support the high drugload that was needed. Therefore, similar in vitro behavior of this solid dispersion should result in similar in vivo performance. The polyvinylpyrrolidone (PVP) based solid dispersions scored with high drug load and medium initial kinetic solubility. The Soluplus based solid dispersion offer lower drug load and slightly lower initial kinetic solubility, but showed an extended supersaturation. The 4 best performing systems were evaluated in rats. They resulted in a short Tmax of 15 minutes and BAV higher than 85% indicating fast and complete absorption. The reference HPMC based solid dispersion with a drug load of 20% showed 65% BAV. This showed that higher drug loads were feasible and did not limit absorption in this animal model.
Since the estimated human dose required a higher formulation density than obtained from lyophilization or spray drying, melt extrusion of the solid dispersion was considered to be the most adequate technology. The process temperature needed to be below 200 °C as this value represents the degradation temperature of the polymers. It was investigated by differential scanning calorimetry whether the compound can be mixed with the molten polymer. None of the polymers could dissolve the crystalline compound below the degradation point of the polymer. The temperature had to be increased to 260 °C until the compound was molten together to a monophasic system with polymer. This resulted in degradation of the polymers. Therefore, different plasticizers and small organic molecules with similar functional groups as the compound were investigated on their ability to reduce the melting point of the mixture of polymer and compound. Positive results were obtained with several small molecules. Based on a literature review, nicotinamide had the least concerning pharmaceutical activities and was chosen for further development. Solid dispersions with the same composition as the ones tested in rat were prepared with 9% nicotinamide as softener. Extrusion without nicotinamide was not possible at 135 °C or at 170 °C whereas the addition of 9% nicotinamide led to a homogenous extrudate when processed at 135 °C. The solid state of the extrudates was not molecularly dispersed but the compound was in a crystalline state. They could not reach the in vitro performance observed for the lyophilized solid dispersions with Soluplus or PVP derivatives. Nevertheless, the performances in the supersaturation assay were comparable to the HPMC based lyophilized solid dispersion. The Soluplus and PVP based crystalline extrudates were evaluated in a dog PK showing that the crystalline solid dispersion does not enable BAV higher than 90% within 24 hours after application. In parallel, the hygroscopicity of the meltextrudates was investigated by DVS and the best performing system based on Kollidon VA64 was further optimized regarding the solid state after its extrusion. The minimal process temperature to obtain a fully amorphous solid dispersion was determined by hot stage X-ray powder diffraction analysis (XRPD) and confirmed by lab scale extrusion. Addition of 9% nicotinamide lowered the process temperature from 220 °C (without nicotinamide) to 200 °C with nicotinamide. The minimal temperature for obtaining crystal free material was independent of the nicotinamide amount as soon as it exceeded 9%. Lowering the process temperature with nicotinamide reduced the impurity levels from 3.5% at 220 °C to 1.1% at 200 °C. The fully amorphous extrudates performed now better in the in vitro supersaturation assay than the lyophilized amorphous HPMC solid dispersion and the crystalline extrudates which were extruded at 135 °C. The process was up-scaled to a pilot scale extruder with alternative screw designs increasing mechanical shear forces and mixing which enabled lower process temperatures. This resulted in a maximal process temperature of 195 °C when nicotinamide was present and 205 °C without nicotinamide. However, shorter process time and reduced process temperatures (compared to the lab scale equipment) resulted in impurity levels smaller than 0.5% for both compositions and temperatures and made the nicotinamide obsolete. The amorphous extrudates from the pilot scale extruder performed better in vitro than the crystalline extrudates from the lab scale extruder and the lyophilized HPMC solid dispersion. A comparable PK profile of the HPMC solid dispersion and the amorphous melt extruded formulation principle was anticipated from these in vitro results. This was confirmed by the pharmacokinetic profile in dogs after oral administration of the final extruded solid dispersion formulation which was equivalent with the pharmacokinetic profile of the HPMC based solid dispersion formulation. The assumption that using a drug load below the miscibility prevents the solid dispersion from recrystallization was verified at least for a limited time by a stability test at elevated temperatures for 3 months showing no change in solid state. This indicates the opportunities of the low lattice forces approach, but also showed the importance of developing principles first assuring stable solid state, performance in vitro and in vivo, tailor them in a second step based on performance and combine them with technology such as melt extrusion as third step. If these steps are done in the context of clinical needs and quality it can rationalize the development of a solid dispersion and minimalize the formulation related risks regarding biopharmacy and stability.
Poor or variable oral bioavailability is of major concern regarding safety and efficacy for the treatment of patients with poorly water-soluble drugs (PWSDs). The problem statement of this work involves a pharmaceutical development perspective, the physicochemical basis of the absorption process and physiological / biopharmaceutical aspects. A methodology was developed aiming at closing the gap between drug liberation and dissolution on the one hand and the appearance of drug in the blood on the other. Considering what is out of control from a formulation development perspective, a clear differentiation between bioavailability and bioaccessibility was necessary. Focusing on the absorption process, bioaccessibility of a model compound, a poorly soluble but well permeable weak base, was characterized by means of flux across artificial biomimetic membranes. Such setups can be considered to reasonably mimic relevant oral absorption resistances in vitro in terms of diffusion through an unstirred water layer (UWL) and a lipidic barrier. Mechanistic understanding of the driving force for permeation was gained by differentiating drug species and subsequently linking them to the observed transfer rates using a bioaccessibility concept. The three key species that need to be differentiated are molecularly dissolved drug, drug associated in solution with other components (liquid reservoir) and undissolved drug (solid reservoir). An innovative approach to differentiate molecularly dissolved drug from the liquid reservoir using ultracentrifugation in combination with dynamic light scattering as control is presented. A guidance for rational formulation development of PWSDs is elaborated based on the employed model compound. It is structured into five guiding questions to help drug formulation scientists in selecting drug form, excipients and eventually the formulation principle. Overall, the relevance but also limitations of characterizing bioaccessibility were outlined with respect to practical application e.g. in early drug formulation development.