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Developing Better

Treatments for
Poorly Soluble
Compounds with
OptiMeltTM HME
Kieran Crowley PhD
Catalent Pharma Solutions
Somerset NJ
USA

Catalyst + Talent. Our name combines these ideas.


From drug and biologic development to delivery technologies to
supply solutions, we are the catalyst for your success. Whether you
are looking for a single, tailored solution or multiple answers
throughout your products lifecycle, we can improve the total value
of your treatmentsfrom discovery to market and beyond.
Catalent. More products. Better treatments. Reliably supplied.

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WHY CATALENT? Unrivaled experience, deepest expertise, and


a track record of market success on a global scale.
We serve 49 of the top 50 pharmaceutical and
36 of the top 50 biotech companies
We operate 20+ global sites across 100+ markets
We create expert solutions from over 1,000 scientists
We support 40% of recent new U.S. drug approvals
We manufacture or package 100 billion units annually
We are the industry leader in drug delivery technology
We use a multi-faceted approach to solve bioavailability
and patient adherence challenges
We provide end-to-end biologics technologies, from
gene expression to fill/finish
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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

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Catalent Somerset, New Jersey USA

Somerset Pharmaceutical
Development Center

Softgel

MRT Oral
Solids

MRT
Zydis

We provide Drug Delivery Solutions from a wide


range of Drug Delivery Technology Platforms
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Bioavailability enhancement represents the biggest


challenge in oral drug delivery
What is your biggest challenge in oral drug
delivery/formulation development?
N=12

Other
2

It can be quite resource intensive to develop


formulations for poorly-soluble drugs. The
problem is most severe when the molecule
has both low solubility and high-dose
Exe. Director, Pharmaceutical R&D

10
Bioavailability
enhancement

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We are seeing more poorly soluble drugs in


early phase development. Most of the
compounds I have right now are poorly
soluble
VP, Pharmaceutical Development

Historically, our infrastructure is based on


conventional technologies. We dont have
enough capacity and capability in new
technologies that address bioavailability
issues
Director, Formulation Development

SOURCE: Mckinsey & Company Customer interviews

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,

Operational solution acceptable


unit dose cost
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Technology Platform Attributes Hot Melt Extrusion


Critical Attributes

OptiMeltTM

An effective solution

HME dispersions achieve a specific


solubility increase in vivo & utilize
GRAS excipients

Fully integrated solution

HME is a continuous process suited for


scale-up, and finished dosage forms
may be made using conventional
equipment

Compliant solution

Numerous oral products and devices


have been filed with regulatory
agencies

Exclusive solution

HME technology requires significant


know-how to commercialize. The drug
delivery profile may be patentable

Operational solution

Proven in pharma & other industries as


a robust process readily integrated into
a manufacturing operation

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HME Technology Platform OptiMeltTM


GMP Bench to Pilot to Commercial scale, with global capabilities

Schorndorf, Germany and Somerset, New Jersey

Broadest selection of downstream processing technologies, colocated with OptiMeltTM hot melt extrusion
Integrated solutions provider, with over 75 years of industry
experience

Development, formulation, scale-up, manufacturing, packaging

Formulation acceleration and optimization with open CatalentBASF bioavailability alliance

Broad range of excipients designed specifically to enhance solubility,


particularly with hot melt extrusion

Non-exclusive arrangement to increase development efficiency and deliver


better treatments for your molecules

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88

Solubility Enhancement Strategies / Technologies

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

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Crystalline
API
absent

Solid Dispersion Products Melt approach


common
Product

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

Isoptin SRE-240 (verapamil)

Soliqs

Melt (HME)

Various

Norvir (ritonavir)

Abbott

Melt (liquid fill cap)

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

* Withdrawn from market


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The Amorphous State


&
Solid Dispersions

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Amorphous State Structure

Hexagonal Close Packing


fraction of voids = 0.26
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Random Close Packing


fraction of voids > 0.36

DATA SOURCES: Jalali, J. Chem. Phys. 120 (2004) 1138; Bates, et al. Pharm.Res. 23 (2006) 2333

12

Amorphous State Thermodynamics


Enthalpy

Liquid

Supercooled
Liquid
Amorphous
(glass)

Crystal

Temp.
Tg

Tm

Higher Energy State of Amorphous phase is shown relative


to Crystalline phase
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Amorphous State Thermal Analysis


10000
5000

Power (uW)

Tg

Tc

Tm

0
-5000
-10000
-15000

Endothermic

-20000
20

40

60

80

100

120

140

160

180

Temperature ( C)

Differential Scanning Calorimetry of Amorphous


Indomethacin API
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Amorphous State Properties


The Amorphous State of a Poorly Soluble API can generate
enhanced dissolution and bioavailability due to increased
apparent solubility
The Amorphous State is a thermodynamically unstable relative
to the crystalline state, which must be considered when
developing a viable drug product
The Amorphous State is formed by quenching from a melt
(e.g. extrusion, granulation, capsule filling) or by controlled
precipitation (rotary evaporation, spray drying, freeze drying)

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Amorphous State Materials Characterization


Critical Properties

Analytical Tools

Absence of crystal lattice


(no 3D structure)

X-ray Diffraction (XRD)


Differential Scanning Calorimetry (DSC)
Polarized Light Microscopy

Molecular conformation /
mobility

Relaxation times (SSNMR, rheology)

Moisture absorption

Dynamic Vapor Sorption (DVS)

Increased apparent
solubility

Kinetic solubility studies

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Spectroscopy (Raman, SSNMR)

(e.g. dissolution, supersaturation)

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Amorphous State Stability


1

Model glass-former:
Tg ~ 45oC

Weight Fraction Crystallized

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)

Critical relationship between Glass Transition Temp (Tg)


and storage temperature
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SOURCE: Andronis and Zografi, J. Non-Cryst. Solids 271 (2000) p236

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Amorphous State Stability


Crystallization kinetics for different particle sizes of
amorphous IMC at 30 oC

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)

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SOURCE: Crowley and Zografi, Pharm. Res. 20 (2003) p1417

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Amorphous State Stabilization


Amorphous State Stabilization is directed at preventing the
initiation and/or reducing the rate of crystal nucleation and
growth
Regulatory Agencies will demand to see good control and
understanding of this property
Available strategies:

Avoid Tg reduction (e.g. moisture protection)

Elevate Tg significantly above room temperature

Chemical interactions (H-bonding, complexation)

Anti-nucleation methods (additives, surface modification)

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Principles of Solid Dispersions


Solid Dispersions are intimate mixtures of two (or more)
components that typically have a high degree of miscibility.
Poorly Soluble Drug Dispersions can achieve enhanced solubility
by creating a physically stable and processable non-crystalline
form.
Crystalline active
+ polymer

Solid Dispersion

Tablets

HME
Precipitate
methods

20
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GRAPHIC SOURCE: Modified from BASF Pharma Ingredients & Services

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Solid Dispersions Control of Tg


Stabilization of Amorphous IMC using poly(vinylpyrrolidone)
by increasing Tg in a molecular dispersion

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

PVP content (%w/w)

C
H

CH2

PVP
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SOURCE: Yoshioka et al. J. Pharm. Sci. 84 (1995) p983

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Solid Dispersions Drug-Polymer Interactions


Amorphous IMC containing 5% PVP has greatly increased
physical stability stored at 30 oC storage for 100 days

Percent crystallized

100
pure IMC
5% PVP

80
60
40
20
0
0

50

100

Time (days)

IMC-PVP H-bonding reduces crystal nucleation and growth


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SOURCE: Matsumoto and Zografi, Pharm. Res. 16 (1999) p1722

22

Hot Melt Extrusion


&
OptiMeltTM

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Hot Melt Extrusion The Basics


Twin-screw extruders with varying screw
design / rotation achieve intimate mixing
of drug and excipient
Shear forces drive co-melting of drug and
excipient
Cooled mixture is a Solid Dispersion
preferably containing amorphous (noncrystalline) drug
Process opportunities
Liquid drugs
Potent drugs
Labile drugs (solvent or moisture
sensitive)

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Hot-Melt Extrusion

HME Twin Screw Extruder Equipment Variables


polymer

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

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HME - Process Variables and Outputs


Feed rate input

polymer

API

Screw speed input


Barrel temperature
inputs

Main feed

Feed
motor

Drive motor
and
gearbox

Die

Material temp,
Pressure, PAT
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Barrel temperature
outputs

Screw
speed

Torque

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HME Downstream Extrudate Processing


A wide range of finished dosage forms can be generated
1. Upstream

Feeder I

Feeder II

2. Compounding Extrusion

Granulator

Extruder

3. Downstream Pellets, Granules, Calendering, Inj molding

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SOURCE: BASF Pharma Ingredients & Services

27

HME Process Advantages


Twin-screw design delivers excellent co-mixing of components
Solvent free
Process is well-controlled and scalable
Good materials handling/ containment
Extrudate downstream processing is flexible
Feasibility trials are easy to design and predictive

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HME Development OptiMeltTM Feasibility Plan


Request for
Proposal

Technical
analysis / IP

Miscibility study

Accelerated
stability study

Formulation
concept

HME process simulation

Stability
prediction

HME small scale


trials

GLP / GMP
batches

Downstream
dosage form trials

Scale-up
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29

HME Feasibility Assessments


Miscibility may be assessed by predictive or small-scale
experimental techniques
DSC of binary mixtures to identify single Tg
Hot stage microscopy to observe phase melting/dissolution at
different temperatures
Film casting of binary mixtures from common solvent visual
examination for crystal formation

A significant benefit of HME is that proof-of-concept evaluations


may be performed at small-scale, quickly and with minimal API

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HME Feasibility Assessments


The following API information directs formulation strategy:
API Tg if available or otherwise estimate
(Tg / Tm [Kelvin] Ratio ~0.7 based on fragility theory )
API chemical stability at increased temperature
API availability for H-bonding
Poorly Soluble Model Drugs:

Tg / Tm (oC)
Solubility at pH7 (g/mL)

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Fenofibrate

Indomethacin

Itraconazole

-20 / 80

45 / 155

59 / 166

~1

~1

31

Hot Melt Extrusion


Formulation
Case Studies

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HME Process Design of Experiments

fill rate

input
temperature

drug load

high

screw speed

Using 2 model drugs (fenofibrate, itraconazole) and 2 carriers


(Soluplus, Kollidon VA 64)
to identify a knowledge space for HME processing

low

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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

SOURCE: Catalent Pharma Solutions Schornforf site

33

HME Process Design of Experiments


Surface Plot of Torque(Nm) vs FEED_SP(g/h); Temperature(C)

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

Worksheet: HotMelt_Basics_Experimentations; 12/06/2012; Luc Burgard; Catalent

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SOURCE: Catalent Pharma Solutions Schorndorf site

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

XRD & DSC Results indicate Molecular Dispersion (Tg 61oC)

XRPD Comparison of Fenofibrate, VA-64 and 20% Feno HM Extrudate

Sample: 12JM-120E grnd extrudate18May12


Size: 4.3000 mg
Method: Feno HME Temp Cycling 3
Comment: Catalent Pharma Solutions, INS-J0946

20% Fenofibrate in VA64 extrudate CPS Ops 18May2012

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

Heat Flow (W/g)

Lin (Counts)

VA64 99405616KO

400

300

-0.4
61.14C(I)

-0.6

200

Fenofibrate 22110, #0910791


100

-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

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-1.0
-10

40

Exo Up

SOURCE: Catalent Pharma Solutions Somerset site

90

Temperature (C)

140

190
Universal V4.5A TA Instruments

35

Polymer Extrudate Processing Milling DOE


Fitz-mill Process DOE performed using Kollidon VA64
Goal: to identify processing knowledge space for extrudate
Surface Plot of Carr Index (%)

Surface Plot of Product Temperature (C)

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)

Worksheet: Worksheet 1; 5/21/2012

5000
12

M ill Speed ( r pm)

M ill Speed ( r pm)

2500
0.009

0.006

0.003

Scr een Size ( inches)

Worksheet: Worksheet 1; 5/21/2012

Outcome: Milling gave good yield with minimal Temp increase & acceptable
Carrs Index. Particle size remained granular (>200 micron)
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SOURCE: Catalent Pharma Solutions Somerset site

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HME Process DOE and Solubility Studies


HME Equipment
Extruder

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

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Sotax AT7 Type 2 apparatus (paddle)


700 ml; 0.08 N HCL; 50 rpm
on-line sampling,
sequence: 5 minutes
HPLC/UV detection at 286 nm

SOURCE: Catalent Pharma Solutions Schornforf site

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Fenofibrate-Soluplus Solubility Enhancement


Solubility
FENOFIBRATE + SOLUPLUS
extrudate Fenofibrate:Soluplus 10%

Solubility [mg/l]

125,0

extrudate Fenofibrat:Soluplus 30%


powder mix Fenofibrat+Soluplus 30+70

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]

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SOURCE: Catalent Pharma Solutions Schornforf site

38

Fenofibrate Kollidon Solubility Enhancement


Solubility
FENOFIBRATE + KOLLIDON VA 64
extrudate Fenofibrate:KollidonVA 64 10%

Solubility [mg/l]

125,00

extrudate Fenofibrate:Kollidon VA 64 30%


powder mix Fenofibrat+Kollidon VA 64

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

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25

50
75
Time [minutes]

<1
0.1
104
109

./.
~
>100
>100

100

SOURCE: Catalent Pharma Solutions Schornforf site

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Itraconazole Kollidon Solubility Enhancement


Solubility
ITRACONAZOLE + KOLLIDON VA 64
extrudate Itraconazole+Kollidon VA 64 10+90
extrudate Itraconazole+Kollidon VA 64 30+70
powder mix Itraconazole+Kollidon VA 64

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]

CONFIDENTIAL for CATALENT

SOURCE: Catalent Pharma Solutions Schornforf site

40

Drug Release from Soluplus Extrudates


USP II, 50 rpm, 700 mL 0.1 N HCl, cut extrudates, 100 mg API (n=3)

100

drug release [%]

90
80
70
15% itraconazole in Soluplus

60

30% itraconazole in Soluplus

50

45% itraconazole in Soluplus

40

60% itraconazole in Soluplus

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
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SOURCE: BASF Pharma Ingredients & Services

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Stability of Solid Dispersion


(3 month 40oC/75%RH)
USP II, 50 rpm, 700 mL 0.1 N HCl, granulated extrudates with 100 mg itraconazole, (n=3)

Drug release [%]


100
80
60

- after production
- after storage

40
20
0
0

20

40

60

80

100

120
Time [min]

After accelerated storage conditions dissolution rates are


still comparable
CONFIDENTIAL for CATALENT

SOURCE: BASF Pharma Ingredients & Services

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In vivo Performance of Solid Dispersion


Itraconazole 10 mg / kg bw, beagle dogs (n=5) fasted state

blood concentration [ng/mL]

450
400
350

solid solution

300

physical mixture
crystalline itraconazole

250
200
150
100
50
0
0

10

15

20

t [h]

Massively increased bioavailability of itraconazole from Soluplus


extrudates compared to physical mixture and crystalline API
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SOURCE: BASF Pharma Ingredients & Services

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Summary
Comments

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HME: Journey from Rotavap to Viable Technology


Platform
1971. Pharmaceutical Applications of Solid Dispersion Systems.
J. Pharm. Sci. Vol. 60 p1281. Chiou & Riegelman

1997. Characteristics and significance of amorphous solids in


pharmaceutical systems. J. Pharm. Sci. Vol. 86 p1. Hancock & Zografi
1999. Solid dispersions of poorly water-soluble drugs: Early
promises, subsequent problems, and recent breakthroughs.
J. Pharm. Sci. Vol. 88 p1058. Serajuddin

2012. Assessing the Performance of Amorphous Dispersions.


J. Pharm. Sci. Vol. 101 p1355 Newman et al.

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HME: Capturing Value in the future


Relative to crystalline references, Amorphous Solid
Dispersions improve bioavailability in 82%

HME provides the platform to realize this potential and


capture the full value of your API
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Source: Newman et al. Journal of Pharmaceutical Sciences, Vol. 101, No. 4, April 2012

46

Future of OptiMeltTM Platform Technology


Critical Attributes

OptiMeltTM

An effective solution

Expertise in selecting formulations that


maximize solubility enhancement
potential of Solid Dispersions

Fully integrated solution

Parallel R&D effort on downstream


processing (e.g. milling, compression,
calendering)

Compliant solution

Leverages Catalents strong audit


record. Working with reliable
equipment and raw materials suppliers

Exclusive solution

Optimized HME formulations may yield


IP for customers. Opportunities to
combine with Catalent proprietary
platforms

Operational solution

Fully integrated with other


manufacturing, analytical and
packaging services

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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,

Operational solution acceptable


unit dose cost
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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

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49

discover more.
CATALENT PHARMA SOLUTIONS
14 SCHOOLHOUSE ROAD
SOMERSET, NJ 08873
+ 1 866 720 3148
www.catalent.com

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