Professional Documents
Culture Documents
Treatments for
Poorly Soluble
Compounds with
OptiMeltTM HME
Kieran Crowley PhD
Catalent Pharma Solutions
Somerset NJ
USA
Presentation Overview
1. Introduction to Drug Delivery Technologies
2. The Amorphous State and Solid Dispersions
3. Hot Melt Extrusion (HME) & OptiMeltTM
4. HME Formulation Case Studies
5. Summary Comments Capturing Value with HME
Somerset Pharmaceutical
Development Center
Softgel
MRT Oral
Solids
MRT
Zydis
Other
2
10
Bioavailability
enhancement
Drug Delivery Technology Platform What attributes are needed to capture full value?
An effective solution delivers drug
precisely, reproducibly & safely
Fully integrated solution
equipment, materials, human
resource from End-to-End
Compliant solution equipment,
controls, scientific knowledge are
current & approvable
Exclusive solution / Freedom to Operate
IP or technical barriers to competition,
OptiMeltTM
An effective solution
Compliant solution
Exclusive solution
Operational solution
Broadest selection of downstream processing technologies, colocated with OptiMeltTM hot melt extrusion
Integrated solutions provider, with over 75 years of industry
experience
88
Neat API
Size-Reduced
High-Energy
Solid
Liquid API
Disintegrants,
Surfactants
Micron Nano
scale
scale
Amorphous,
Softgels, SEDDS,
liq.fill caps, etc.
Solid Dispersion
Dissolution
Crystalline
API
present
Crystalline
API
absent
Company
Technology
Matrix Excipient
Afeditab (nifedipine)
Elan
Melt (granulation)
Poloxamer/PVP
Certican (everolimus)
Novartis
Solvent (SDD)
HPMC
Cesamet (nabilone)
Valeant
Solvent (granulation)
PVP
Fenoglide (fenofibrate)
LifeCycle Ph.
Melt (spray)
PEG
Gris-Peg (griseofulvin)
Pedinol
Melt (tablet)
PEG
Ibuprofen
Soliqs
Melt (HME)
Various
Intelence (etravirine)
Tibotec
Solvent (SDD)
HPMC
Soliqs
Melt (HME)
Various
Norvir (ritonavir)
Abbott
PEG-glyceride
Kaletra (lopinavir/ritonavir)
Abbott-Soliqs
Melt (HME)
PVP/PVA
LCP-Tacro (tacrolimus)
LifeCycle Ph.
Melt (granulation)
HPMC
Rezulin (troglitazone)*
Pfizer
Melt (HME)
PVP
Sporanox (itraconazole)
Janssen
Solvent (layering)
HPMC
10
11
DATA SOURCES: Jalali, J. Chem. Phys. 120 (2004) 1138; Bates, et al. Pharm.Res. 23 (2006) 2333
12
Liquid
Supercooled
Liquid
Amorphous
(glass)
Crystal
Temp.
Tg
Tm
13
Power (uW)
Tg
Tc
Tm
0
-5000
-10000
-15000
Endothermic
-20000
20
40
60
80
100
120
140
160
180
Temperature ( C)
14
15
Analytical Tools
Molecular conformation /
mobility
Moisture absorption
Increased apparent
solubility
16
Model glass-former:
Tg ~ 45oC
Indomethacin (IMC)
0.9
40 C
30 C
20 C
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
100
200
300
Time (days)
17
Percent crystallinity
100
80
0-40 m
60
75-150 m
40
250-425 m
600-710 m
20
0
0
20
40
60
80
100
Time (days)
18
19
Solid Dispersion
Tablets
HME
Precipitate
methods
20
CONFIDENTIAL for CATALENT
20
Cl
200
180
CH3
160
140
CH3O
Tg ( C)
120
100
CH2COOH
Indomethacin
80
60
40
20
N
0
0
20
40
60
80
100
C
H
CH2
PVP
CONFIDENTIAL for CATALENT
21
Percent crystallized
100
pure IMC
5% PVP
80
60
40
20
0
0
50
100
Time (days)
22
23
24
Hot-Melt Extrusion
Feeder configuration
Processing zone configuration
Die size / number
Main feed
Feed
motor
Liquid injection
Vent
API
Liquid injection
Die
Drive motor
and
gearbox
Side stuffer
Forward Elements
Distributive
Mixing
Dispersive
Mixing
Conveying
Zoning
Feeding/ Compressing
30 degree
90 degree
25
polymer
API
Main feed
Feed
motor
Drive motor
and
gearbox
Die
Material temp,
Pressure, PAT
CONFIDENTIAL for CATALENT
Barrel temperature
outputs
Screw
speed
Torque
26
Feeder I
Feeder II
2. Compounding Extrusion
Granulator
Extruder
27
28
Technical
analysis / IP
Miscibility study
Accelerated
stability study
Formulation
concept
Stability
prediction
GLP / GMP
batches
Downstream
dosage form trials
Scale-up
CONFIDENTIAL for CATALENT
29
29
30
Tg / Tm (oC)
Solubility at pH7 (g/mL)
Fenofibrate
Indomethacin
Itraconazole
-20 / 80
45 / 155
59 / 166
~1
~1
31
32
fill rate
input
temperature
drug load
high
screw speed
low
output
operating states
high
low
drug load
30%
10%
torque
temperature
140C
130C
pressure
fill rate
400 g/h
200 g/h
screw speed
200 rpm
100 rpm
residence time
trial
drug load
temperature
screw speed
fill rate
high
high
high
high
low
high
high
high
high
low
high
low
high
low
low
high
high
high
low
low
low
high
high
low
low
high
low
high
low
low
low
low
center point
center point
center point
center point
33
10
T or que( Nm)
8
6
400
4
300
170
70
FEED_SP ( g/h)
180
T emper atur e( C )
19
90
200
34
Drug-Polymer Extrusion
20% Fenofibrate Kollidon VA64 dispersion extrusion prepared
Equipment: Leistritz ZSE-18
Temperature Zones
(oC)
Scale: 12 Kg
Z8
Z7
Z6
Z5
Z4
Z3
Z2
Z1
120
140
140
140
140
140
120
80
800
DSC
File: C:...\Preformulation\2012\ZDSC0917.001
Operator: Vitez
Run Date: 21-May-2012 16:58
Instrument: DSC Q1000 V9.9 Build 303
0.0
700
600
-0.2
500
Lin (Counts)
VA64 99405616KO
400
300
-0.4
61.14C(I)
-0.6
200
-0.8
0
2
10
20
30
2-Theta - Scale
Fenofibrate 22110, #0910791 - File: XRD4604.raw - Type: 2Th/Th locked - Start: 2.000 - End: 40.000 - Step: 0.050 - Step time: 1. s - Temp.: 24 C - Time Started: 9 s - 2-Theta: 2.000 - Theta: 1.00
Operations: Import
VA64 99405616KO - File: XRD4563.raw - Type: 2Th/Th locked - Start: 2.000 - End: 40.000 - Step: 0.050 - Step time: 1. s - Temp.: 23 C - Time Started: 9 s - 2-Theta: 2.000 - Theta: 1.000 - Chi: 0.
Operations: Y Scale Add 100 | Y Scale Add 100 | Y Scale Add 100 | Y Scale Add 100 | Import
20% Fenofibrate in VA64 extrudate CPS Ops 18May2012 - File: XRD4646.raw - Type: 2Th/Th locked - Start: 2.000 - End: 40.000 - Step: 0.050 - Step time: 1. s - Temp.: 24 C - Time Started: 15 s - 2
Operations: Y Scale Add 100 | Y Scale Add 100 | Y Scale Add 100 | Y Scale Add 100 | Y Scale Add 100 | Y Scale Add 100 | Import
-1.0
-10
40
Exo Up
90
Temperature (C)
140
190
Universal V4.5A TA Instruments
35
24
26.5
P r oduct T emp ( C ) 26.0
20
C ar r Index ( % )
25.5
7500
16
25.0
7500
5000
0.009
2500
0.006
0.003
Scr een Size ( inches)
5000
12
2500
0.009
0.006
0.003
Outcome: Milling gave good yield with minimal Temp increase & acceptable
Carrs Index. Particle size remained granular (>200 micron)
CONFIDENTIAL for CATALENT
36
Materials
RONDOL 10 mm TS Extruder
- barrel length 40 L/D
- 8 barrel heating zones
- output 25 400 g per hour
APIs
- Itraconazole
- Fenofibrate
polymers
- Soluplus
- Kollidon VA 64
Analytical Methods
Dissolution
37
Solubility [mg/l]
125,0
100,0
suspensions - tested at pH ~ 1
75,0
50,0
solubility
[mg/L]
enhancement
<1
1.8
111
101
./.
>2
>100
>100
fenofibrate
physical mixture
10+90 extrudate
30+70 extrudate
25,0
0,0
0
20
40
60
80
100
120
Time [minutes]
38
Solubility [mg/l]
125,00
100,00
suspensions - tested at pH ~ 1
75,00
solubility enhancement
[mg/L]
50,00
fenofibrate
physical mixture
10+90 extrudate
30+70 extrudate
25,00
0,00
0
25
50
75
Time [minutes]
<1
0.1
104
109
./.
~
>100
>100
100
39
Solubility [mg/l]
125,00
100,00
suspension - tested at pH ~ 1
solubility
[mg/L]
75,00
50,00
Itraconazole
physical mixture
10+90 extrudate
30+70 extrudate
25,00
0,00
0
25
50
75
<1
8.1
114
124
enhancement
./.
>8
>114
>124
100
Time [minutes]
40
100
90
80
70
15% itraconazole in Soluplus
60
50
40
30
20
10
0
0
30
60
90
120
t [min]
Very high drug loads (~50%) are possible without affecting the
release profiles in a negative way
CONFIDENTIAL for CATALENT
41
- after production
- after storage
40
20
0
0
20
40
60
80
100
120
Time [min]
42
450
400
350
solid solution
300
physical mixture
crystalline itraconazole
250
200
150
100
50
0
0
10
15
20
t [h]
43
Summary
Comments
44
45
Source: Newman et al. Journal of Pharmaceutical Sciences, Vol. 101, No. 4, April 2012
46
OptiMeltTM
An effective solution
Compliant solution
Exclusive solution
Operational solution
47
In Summary
OptiMeltTM: A Viable Platform Technology
An effective solution delivers drug
precisely, reproducibly & safely
Fully integrated solution
equipment, materials, human
resource from End-to-End
Compliant solution equipment,
controls, scientific knowledge are
current & approvable
Exclusive solution / Freedom to Operate
IP or technical barriers to competition,
48
acknowledgements.
Somerset team, CATALENT PHARMA SOLUTIONS
Schorndorf team, CATALENT PHARMA SOLUTIONS
Dr. Andreas Gryczke, BASF Pharma Ingredients & Services
Prof. George Zografi, University of Wisconsin-Madison
49
discover more.
CATALENT PHARMA SOLUTIONS
14 SCHOOLHOUSE ROAD
SOMERSET, NJ 08873
+ 1 866 720 3148
www.catalent.com