05 - Chapter 1
05 - Chapter 1
1
and targeting properties (9-15). These systems are mainly classified into immediate release (e.g.,
lactose-drug mixtures for DPI application) and controlled release systems (liposomes, micelles,
nanoparticles and microparticles). The modulation of the various physicochemical properties of
these systems has been explored to overcome the clearance mechanisms of the lungs and provide
prolonged residence times of the therapeutic agent within the respiratory tract (8, 10, 12) .
1.2 Anatomy and Physiology of Human Respiratory Tract
For the development of new PDD systems, one should have detailed knowledge of lung anatomy
and physiology. The respiratory tract is mainly divided into two regions i.e., the upper airway
and the lower airway with the line of division being the junction of the larynx and trachea (16).
The upper airway acts as an air transport system and consists of the nose, mouth, pharynx and
larynx. The lower respiratory tract consists of the tracheobronchial, gas-conducting airways and
the gas exchanging acini. The lower airway is divided into three zones: conducting, transitional,
and respiratory zones. The conducting zone is responsible for the bulk movement of air and
blood. In the central airways, air flow is rapid and turbulent and no gas exchange occurs. The
transitional zone has a limited role in gas exchange (16, 17) . The respiratory zone mainly
comprises of respiratory bronchioles and alveoli, where the actual gas exchange takes place (17).
Figure 1.1 shows a schematic representation of the lung. The bronchial tree trunk begins with the
trachea, which bifurcates to form the main bronchi: the left and right primary bronchi. Each
primary bronchus divides into still smaller secondary bronchi. The secondary bronchi branch
into many tertiary bronchi that further branch several times, ultimately giving rise to tiny
bronchioles that sub-divide many times, finally forming terminal bronchioles and respiratory
bronchioles. Each respiratory bronchiole sub-divides into several alveolar ducts that end in
clusters of small thin-walled air sacs called alveoli, which open into a chamber called the
alveolar sac (18) .
Two physical changes occur while moving from the trachea to the alveolar sacs in the airways
that are important in influencing airway function. Firstly, the airway diameter decreases with the
respiratory branches, e.g., a tracheal diameter (d) is 1.8 cm compared to an alveolar diameter of
0.04 cm. This permits adequate penetration of air to the lower airways for a given expansion of
the lungs. Secondly, the surface area of the airways increases with each generation, to the extent
that the total lung area at the level of the human alveolus is in the order of 140 m² (18). Alveoli
are the terminal air spaces of the respiratory system and are the actual site of gas exchange
2
between the air and the blood. About 100 million alveoli are found in each lung (19). Each
alveolus is a thin-walled polyhedral chamber of approximately 0.2 mm in diameter. Gases taken
up by inhalation need to cross alveolar epithelium, the capillary endothelium and their basement
membranes to reach blood; the distance makes up around 500 nm length (18). So, the alveolus,
providing increased surface area, becomes principal site of gas exchange in the airways (20). The
human lung consists of five lobules and ten broncho-pulmonary segments. The luminal surface
of the airways is lined by ciliated cells, which are the most common and numerous cell types.
Mucus cells are intermingled among the ciliated cells. The walls of the conducting airways are
coated by an adhesive, viscoelastic mucus layer (thickness: 5–55 μm) which is secreted by the
mucus cells. The major components of mucus are glycoproteins and water (22). This mucus
fulfils important functions, i.e., the protection of the respiratory epithelium from dehydration, the
water in the mucus promotes saturation of inhaled air, mucus contains antibacterial proteins and
3
peptides, such as defensins and lysozyme that inhibit microbial colonization of the airways, and
mucus is also involved in airway protection from inhaled xenobiotics or chemicals. Clearance of
mucus from the lung is driven by the motion of the ciliated cells ‘mucociliary escalator’, which
generates a mucus flow rate of ~5 mm/min. Thus, the mucus blanket is replaced every 20
minutes in healthy subjects (22). The mucociliary escalator serves as an important protective
mechanism for removing small inhaled particles from the lungs. The composition, thickness,
viscosity and clearance of the mucus is often altered in patients suffering from airway diseases
such as asthma, COPD and CF (7) .
The alveolar epithelium is composed of Type I and Type II alveolar cells and occasional brush
cells. The Type I pneumocytes are thin cells, cover most of the surface of the alveoli (95% of the
surface area) and the Type II pneumocytes are cuboidal secretory cells are interspersed among
the Type I cells (23) . The alveolar space is coated by a complex surfactant lining that reduces
surface tension to minimize the work of breathing and prevents collapse of the alveoli during
expiration (21). The majority of insoluble particles deposited in the upper airways are eliminated
by mucociliary clearance (24) . The most prominent defense mechanism of the respiratory region
is macrophage clearance. The particles deposited in the deeper lung will be taken up by alveolar
macrophages, which slowly migrate out of the lung, either following the broncho-tracheal
escalator or the lymphatic system (8). The blood supply to the lung is provided by a pulmonary
circulation and a systemic circulation. A drug delivered to the lower airways can enter the
systemic circulation by absorption into the alveolar capillaries of the pulmonary vascular bed
(21, 23).
1.3 Deposition mechanisms of inhaled particles
There are five mechanisms by which particles deposit in the respiratory tract namely, impaction,
sedimentation, brownion motion, interception and electrostatic precipitation. Impaction is the
inertial deposition of a particle onto an airway surface and occurs at bifurcation of airway where
flow velocities are at higher and sudden change in direction of flow take place, generating
considerable inertial forces. Higher velocity, high rate of breathing, and particles > 5 μ size and
high density increases impaction based deposition (25). Gravitational sedimentation is an
important mechanism for deposition of particles over 0.5 µm and below 5 µm in size in the small
conducting airways where the air velocity is low. Deposition due to gravity is increased by large
particle size and by longer residence times, and decreases with increasing breathing rate (25).
4
Impact of surrounding air on particles < 0.5 µm size cause a random motion in particles. Such
Brownian motion can cause particle deposition by diffusion in small airways and alveoli where
air flow is low in contrast to upper respiratory airways. Interception is usually significant only
for fibers and aggregates. Even though, center of mass of such particles remain to be in flow
stream, contact of such particles with airway wall cause deposition of such particles (25). Some
freshly generated particles can be electrically charged during the mechanical generation of
aerosols and may exhibit enhanced deposition due to charge induced deposition, though at a low
contribution to other mechanisms (26). In fact, the deposition patterns of inhaled particles may
be expressed as functions of three classes of variables: ventilatory parameters, respiratory tract
morphologies and aerosol characteristics (e.g., particle size, shape, and density). The efficiencies
of the different deposition mechanisms of inertial impaction, sedimentation and diffusion can, in
turn, be formulated in terms of these variables.
1.4 Barriers in Pulmonary Delivery
The past 30 years have been marked by intensive research efforts on PDD for local and systemic
therapy including diagnostic agents (5). The success of a PDD using aerosolized medications
depends on its ability to deliver sufficient concentration of drug to the appropriate site of action
in the lungs while exerting minimal side effects (27). Drugs for lung diseases and drugs that
undergo extensive first-pass metabolism or gastrointestinal degradation are ideal candidates for
pulmonary delivery. The lower incidence of side effects is often observed due to localized drug
deposition and reduced systemic and generalized exposure to other tissues. Despite such great
advantages of PDD, delivering therapeutic agents to lungs is a challenging task for the
formulation scientist because of the barriers of the pulmonary region and finding a suitable
delivery device.
The lungs are in direct contact with the atmosphere and thus, different lines of defense systems
exist to protect the deep parts of the lungs from exposure to particles present in the inhaled air (7)
(24). Several mechanisms are involved in the removal of particles from the upper respiratory
tract and thus, they reduce further deposition in the lower airways. The deposition of aerosol
particles in the lungs involves three mechanisms: impaction, sedimentation and diffusion (5).
Deposition in the respiratory tract is affected by the particle size, the patient’s inhalation
parameters e.g. flow rate, ventilation volume, end-inspiratory breath holding, and the aerosol
delivery system. The most crucial formulation variable for PDD is the mass median aerodynamic
5
diameter (MMAD) of the particles. Figure 1.2 shows the effects of particle size on the deposition
efficiency of particles in respiratory system. Large particles with a MMAD of more than 5 μm
experience impaction in the oropharynx and upper conducting airways because of their high
momentum, while particles with an MMAD between 1 and 5 μm sediment in the deeper airways
and bronchioles. Small particles with an MMAD below 0.5 μm obey the principle of Brownian
diffusion, remain suspended in air and are exhaled during normal breathing (Table 1.1) (27).
Apart from the size, the deposition of aerosol particles also depends on density, hygroscopicity,
and the shape of the aerosolized particles. The anatomy of the airways and the breathing pattern
also determines impaction, sedimentation and diffusion of particles in the airflow. It is
commonly accepted that the optimal particle size (1-5 μm) is essential for the effective delivery
of particles to lungs, as particles smaller than 1 μm can possibly be exhaled without being
deposited (28). However, some recent investigations showed that nanoscale particles are also
effectively deposited in the alveolar region because of increased diffusional mobility, especially
in individuals suffering from asthma and increasingly during physical exercise (29).
Table 1.1: Deposition fate of inhaled particles in lungs
6
Figure 1.2 Deposition efficiency of particle in the respiratory system as function of the particle
size (28) .
The respiratory mucus covers the conducting airways and captures foreign matter inhaled with
each breath. The non-absorptive process involves transport of particles to the ciliated region
following clearance by the mucociliary escalator. In normal airways, the respiratory cilia
transport mucus at a rate of 2.5-5 mm/min towards the oropharynx where it is either swallowed
or expectorated (30). The mucus acts as a physical barrier, as increased viscosity of mucus
reduces drug penetration and its diffusion. Upon deposition in the lung, the particles are wetted
by mucus and subsequently transported toward the oesophagus by ciliated cells. The mucociliary
clearance of mucus-trapped foreign substances is an important pulmonary defense mechanism
against inhaled pathogens and particles and as well it acts as a barrier to gene transfer vectors
(31). The alveolar epithelium is not covered by mucus but a thin layer of alveolar fluid is
secreted on the surface of the alveoli epithelium. Alveolar fluid is composed of phospholipids
and lung surfactant excreted from Type II pneumocytes. The surface activity of the surfactant is
mainly provided by the phospholipids, surfactant proteins B and C, which also lower the surface
tension, whereas surfactant proteins A and D can opsonize foreign matter in the lungs (32). The
alveolar macrophages located in the alveoli can rapidly engulf the foreign particles by
phagocytosis as a defense mechanism. Every single alveolus is covered by 12-14 macrophages,
which gives approximately 19,000 alveolar macrophages per microlitre of bronchoalveolar
7
lavage fluid (BALF) (33). Crystalline powders of pharmaceutical application which exhibit
specific gravity approaching 1 and which are in the range of respirable aerodynamic diameter
show rapid macrophage uptake and clearance. Such uptake has been shown to be dependent on
the geometric diameter of inhaled particles, while lung deposition depends the aerodynamic
diameter of particles (34).
These anatomical and physiological barriers of the lungs play an important role in pulmonary
delivery of therapeutics and various approaches have been utilized to overcome these limitations.
Particulate nanocarriers can be used to improve the therapeutic index, reduce metabolism,
prolong half-life or reduce toxicity, increase bioavailability and site specific targeting resulting in
a reduction in the biological dosage frequency and improved patient compliance.
1.5 Delivery devices
Delivery device for pulmonary delivery should produce aerosolized particles ideally in the range
of 0.5-5 μ size with reproducible dosing and should maintain physical and chemical stability of
drug formulation. Additionally, the system should be simple, easy to use, cheap and portable
(35). Inhaled drug delivery devices can be divided into three principal categories: nebulizers,
pressurized metered-dose inhalers (pMDIs) and dry powder inhalers (DPIs), each class with its
unique strengths and weaknesses.
1.5.1 Nebulizers
Nebulizers have been used in inhalation therapy since the early 19th century. Marketed
respiratory solutions are generally composed of drug dissolved in aqueous, isotonic solvent
systems that may contain preservatives to reduce microbial growth. There are two traditional
devices: air-jet and ultrasonic nebulizers. For a typical jet nebulizer (Figure 1.3), compressed air
passes through a narrow hole and entrains the drug solution from one or more capillaries mainly
by momentum transfer. Large droplets impact on baffles and gets refined to the size required,
while droplets with smaller size run in a streamline flow of air bypassing the impact on baffles
(36). Approximately 50-60% of the particles produced are in the respirable range.
8
Figure 1.3: Schematic presentation of a jet nebulizer (36)
Alternatively, ultrasonic nebulizers use a high frequency vibrating plate to provide the energy
required to aerosolize the liquid. The frequency of the vibrating piezoelectric crystal determines
the droplet size for a given solution. Approximately 70% of the particles produced present sizes
of between 1 and 5 µm. However, heat generated from frictional forces induced by movement of
the transducing crystal may be harmful to thermolabile formulations. Some of the most
commonly available nebulizers on the market are: Ventolin® (Salbutamol, ß2-mimetic
bronchodilator), Bricanyl® (Terbutaline, ß2-mimetic bronchodilator), Atrovent® (Ipratropium,
anticholinergic bronchodilator), Pulmozyme® (Dornase alpha, mucolytic) and Tobi®
(Tobramycin, antibiotic).
9
inspired is equivalent, more or less, to half of the delivered amount. Of this inhaled amount, it is
still necessary to remove a fraction of particles that are not in the “respirable range”. In
conclusion, the pulmonary fractions obtained using a nebulizer may vary from 2-10% of the
nominal dose. For example, 2.5 ml of Pulmozyme at 1 mg/ml is delivered by a jet nebulizer with
a delivery efficiency of 10% (39).
Physicochemical properties of the formulation determine the particle size and size distribution of
an MDI aerosol. For example, aerosol size for suspension formulations may be reduced if the
formulation has a high vapour pressure, small particle size and low drug concentration. For
instance, studies have shown that the aerosol size for suspension formulations may be reduced if
the formulation has a high vapor pressure, a small drug particle size, or a low drug concentration
(42). A surfactant such as sorbitan trioleate, oleic acid, and lecithins, at levels between 0.1% and
10
2.0% w/w, are typically added to aid the suspension or solubility of drug and to lubricate the
metering mechanism (41). Flavors and suspended sweeteners may be present to combat the
unpleasant taste. To enhance chemical stability, antioxidants (ascorbic acid) or chelating agents
(EDTA) may be added to formulations (38) .
The essential components of an MDI are the container, the metering valve, and the actuator.
Usual valve volumes range from 25-100 µl, which deliver a drug dose of about 50 µg to 5 mg.
The most commonly available MDIs on the market are: Flixotide® (Fluticasone, corticosteroid),
Atrovent® (Ipratropium bromide, anticholinergic bronchodilator), Ventolin® (Salbutamol, ß2-
mimetic bronchodilator) and Combivent® (Ipratropium bromide + Salbutamol, anticholinergic +
ß2-mimetic bronchodilator). Chlorofluorocarbon (CFC)-based MDIs usually contain a mix of
liquefied low boiling-poing propellant (CFC 12- dichlorodifluoromethane) and a high boiling-
point propellant (CFC 11- trichlorofluoromethane or CFC 114 – dichlorotetrafluoromethane).
However, the success of CFC propellant-driven MDIs has been overshadowed by their
contribution to ozone depletion in the upper atmosphere and the concomitant health effects (43).
In fact, the international community agreed to phase out CFC propellants in 2000. So nowadays,
the main emphasis in MDI developments is on the introduction of non-CFC propellants. But the
non-CFC propellant hydrofluoroalkanes (HFA 134a - 1, 1, 1, 2-tetrafluoroethane and HFA 227 -
heptafluoropropane) exhibit very different physicochemical properties and extremely low solvent
properties. This however is advantageous in preventing the dissolution of small drug particles but
may also be disadvantageous This feature is beneficial in preventing the dissolution of small
drug particles, but it is also disadvantageous in that the commonly used surface-active agents are
almost totally insoluble and not able to provide any physical stabilization of drug particles in
suspension. A number of approaches have been undertaken to overcome the problems of drug
particles instability in HFAs, addition of cosolvents, requirement to develop new specific surface
active agents, modification of surface properties of particles to reduce interfacial tension, and
production of particles compatible to HFA (44). However, MDIs have several other
disadvantages. There may also be chances of “cold-Freon effect” which may cause inhalation
problems to patients due to cold propellant spray on the back of the throat (45). Moreover,
because an MDI is pressurized, it emits the dose at high velocity, which makes premature
deposition in the oropharynx more likely (46). Thus MDIs require careful coordination of
actuation and inhalation. Only a small fraction of the drug (10-20%) escaping the inhaler
11
penetrates the patient’s lungs due to a combination of high particle exit velocity and poor
coordination between actuation and inhalation. The deposition of aerosolized drugs in the mouth
and the oropharyngeal regions varies considerably according to the application technique, but
losses using the pressurized devices are routinely greater than 70% and can exceed 90%. Particle
losses that occur proximally to the lung are a long-documented problem that continues to
compromise the effectiveness of current aerosol therapy protocols.
Spacer devices and reservoirs were developed to allow the deceleration of the aerosol cloud
before reaching the throat and to make perfect coordination between actuation and inhalation
slightly less important (Figure 1.5). Nevertheless, adding a chamber to an MDI makes it less
portable, and many chambers can develop static electrical charges on the inner walls and thereby
reduce the lung delivery (47). Despite these enhancements, incorrect use of MDIs is still a
prevalent problem (48). About 75% of patients made at least one error when using an MDI (49).
Figure 1.5: Representation of the use of a spacer device with an MDI (50)
The introduction of “breath-actuated” MDI devices has provided a convenient and portable
means to achieve coordination between actuation and inhalation. Breath-actuated inhalers have
been developed that sense patient’s inhalation and automatically fire the inhaler. Examples are
the Autohaler® (3M Pharmaceuticals, U.S.A) or Easybreathe® (Norton Healthcare, U.K.) (51).
12
device design in order to disperse dry particles as an aerosol in the patient’s inspiratory airflow
(52).
All DPIs have four basic features: a dose-metering mechanism, an aerosolization mechanism, a
deaggregation mechanism, and an adaptor to direct the aerosol into the mouth. DPIs are subject
to strict pharmaceutical and manufacturing standards by regulatory bodies, the most challenging
of which is the demonstration of device reliability in terms of delivered dose uniformity and
delivered dose deposition (53). Indeed, comparative in-vitro data for a generic product versus the
innovator product must be provided on the complete individual stage particle size distribution
profile using a multistage impactor/impinger with various impaction stages, such as the NGI
(53).
For DPIs, the dose received by the patient is dependent on four interrelated factors (54)
1. The properties of the drug formulation, particularly powder flow, particle size and drug carrier
interaction
2. The performance of the inhaler device, including aerosol generation and delivery
Therefore, a balance between the design of an inhaler device, drug formulation, and the
inspiratory flow rate of patient is required (55). DPIs are a widely-accepted inhaled delivery
dosage form, particularly in Europe where they are currently used by an estimated 40% of
patients to treat asthma and chronic obstructive pulmonary disease. Their use will continue to
grow (54). Presently, over 20 DPI devices are available on the market (Table 1.2) and more than
25 are in development (Table 1.3). Today there are essentially two types of DPIs: those in which
the drug is packaged in individual doses (capsules) (Single dose or Unit-dose devices) and those
that contain multiple doses in a foil-foil blister or a reservoir of drug from which the doses are
metered out (Multi-unit and Multi-dose devices).
13
Table 1.2: DPI devices currently available on the market (56)
14
Easyhaler Multi- Orion Pharma Reservoir Salbutamol sulphate
dose Beclomethasone dipropionate
Ultrahaler Multi- Aventis Reservoir Ciclesonide
dose
Pulvinal Multi- Chiesi Reservoir Salbutamol sulphate
dose Beclomethasone dipropionate
Novolizer Multi- ASTA Reservoir Budesonide
dose
MAGhaler Multi- Boeringher-Ingelheim Reservoir Salbutamol sulphate
dose
Taifun Multi- LAB Pharma Reservoir Salbutamol sulphate
dose
Eclipse Multi- Aventis Capsule Sodium cromoglycate
dose
Clickhaler Multi- Innoveta Biomed Reservoir Salbutamol sulphate
dose Beclomethasone dipropionate
Twisthaler Multi- Schering-Plough Reservoir Mometasone furoate
dose
Active device
Airmax Multi- Norton Healthcare Reservoir Formoterol
dose Budesonide
Inhance Single Pfizer Blister Insulin
dose
15
Airmax Multi-unit Norton Healthcare Reservoir Formoterol,
Budesonide
AIR Single dose Alkermes Capsule Placebo powders
MicroDose Multi-unit MicroDose/ 3M Powder/Electronic Insulin
Cyclovent Multi-unit Pharmachemie Reservoir Morphine
Conix One Single dose Cambridge Consultant Foil seal Vaccines
Microhaler Single dose Harris Pharmaceutical Capsule Sodium cromoglycate
Spiros Multi-unit Dura Blister/Active Albuterol sulphate
Miat-Haler Multi-unit MiatSpA Reservoir Formoterol,
Fluticasone
propionate,
Budesonid
Acu-Breath Multi-unit Respirics Powder Fluticasone
propionate
Swinhaler Multi-unit Otsuka Powder Budesonide
Pharmaceutical
Certihaler Multi-unit Novartis Powder Formoterol
1.5.4 Unit-dose devices
The Spinhaler® (Aventis) was the first dry powder device, described in 1971 (57) which works
on the mechanism to pierce the capsule. The caps fits into an impeller. The impeller rotates as
the patient breaths through the device (Figure 1.6) during which powder deaggregates and
relative motion imparted due to impeller rotation. This low-resistance device has presented low
in vitro fine particle fractions (FPF) (% < 5 µm) of 4-12% (58).
A similar DPI, the Rotahaler® (GlaxoSmithKline) breaks the capsules into two, the body part
falling inside the device and the cap being retained in the entry port. As the patient inhales, the
portion of the capsule containing the dug experiences erratic motion in the airstream, causing
dislodged particles to be entrained and subsequently inhaled. Turbulence due to grid upstream of
the mouthpiece deaggregates particles. A FPF of 26% has been reported for this low resistance
device (58).
16
Figure 1.6: Schematic presentation of the Spinhaler (59)
The Handihaler® (Boehringer Ingelheim) delivers drug contained in a capsule through rumbling
motion after piercing pins opens the capsule. The particles are dispersed through turbulence due
to plastic grid during inhalation. This device is more complicated as it requires at least 7 distinct
steps to deliver the dose. For some patients, two inhalations are required to completely empty the
capsule and achieve the therapeutic dose (54)
Unit-dose devices are considered as not patient-friendly and not easy to use because there are
several manoeuvres to accomplish before inhalation, such as taking the capsule from the
package, loading it and piercing it within the device. Furthermore, there have been recent reports
of patients ingesting the capsule instead of placing it in the device and inhaling the contents (60).
However some studies show that adherence to correct inhaler use depends on the importance
given to appropriate training prior to product use and device education by health-care providers
(61).
The Diskhaler® (GlaxoSmithKline) makes use of individual doses packed on disc type blister
packs (Figure 1.7). Piercing and subsequent flow of air through packaging depression containing
the dose leads to dispersion of powder. The aerosol stream is mixed with a bypass flow entering
17
through two holes in the mouthpiece that, together with a grid, gives rise to turbulence that
promotes deagglomeration.
The Diskus® (GlaxoSmithKline) is quite similar except that it contains a foil strip with 60 single
dose blisters (Figure 1.8). FPF have been reported to be approximately 23-30% for these two low
resistance devices (58).
18
Figure 1.9: Schematic presentation of Turbuhaler (62)
The advantages of the reservoir systems are their relative ease and low cost of manufacture and
the ease of including a large number of doses within the device (63). Nevertheless, reproducible
dose metering remains the most difficult challenge in device design. Indeed, the variability of
dose emissions from DPIs, and in particular from the reservoir system, at the recommended flow
rate has been found to be relatively high, with a total relative standard deviation of more than
15% about the average emitted dose for the Pulmicort Turbuhaler (64). Furthermore, powders
contained in reservoirs may be more susceptible to deterioration through entrance of moisture,
and the use of a desiccant is recommended. For these reasons, pre-metered doses from multi-unit
dose systems are more consistent than doses delivered from the reservoir devices, as they are
individually sealed and protected from the environment until the point of use by the patient. It is
also vital to ensure that no accidental or additional dose is inhaled. This has led to the
incorporation of dose counters on new reservoir devices.
20
metering system within the inhaler itself to produce a convenient device that is comfortable and
easy to use for the patient.
Other sugars, such as glucose, mannitol and trehalose (55, 71-73) have been shown to be
feasible alternatives to lactose, and it is expected that these sugars will eventually find their way
into approved products. An additional benefit that may be gained from the use of a sugar carrier
21
is the taste/sensation on inhaling, which can assure the patient that a dose has been taken (63).
Phospholipids and cholesterol have also been used in experimental liposomal formulations (74)
or as solid lipidic carriers or fillers (75). The availability of the active drug depends afterwards
on the redispersion of the particles in the inspired air, as a function of the cohesive forces
between drug particles and the adhesive forces between drug and carrier particles. The larger
carrier particles deposit on the oropharynx, while the fine drug particles partly reach the deep
lung. These adhesive forces must be carefully considered, as inadequate separation of drug and
carrier is the main reason for deposition problems. So, as excipients can make up over 99% of
the product by weight, their choice is a crucial determinant of overall DPI performance. Despite
the apparent lack of choices, the excipient must be carefully selected, as its physicochemical
properties, such as size and morphology, profoundly affect the performance of the formulation
(76). In general, the morphology and roughness of carrier particles are not uniform, containing
regions that exhibit different roughness parameters. Clearly, these variations in physicochemical
properties in the surface of a carrier material may lead to differences in apparent adhesion
properties of drug particles. Furthermore, during the dynamic process of mixing, the adherence
of drug particles to the more adhesive areas of the carrier surface is likely to occur (77). Indeed,
it has been proposed that the surfaces of larger particles consisted of distinct regions containing
so-called “active sites”. It was further suggested that when the amount of fine carrier particles in
the mixture is below the saturation limit of the large carrier particles’ adhesive potential, the fine
particles will preferentially bind to these active sites. When these active sites have been
completely occupied by fine particles, a binary carrier system will then exist, i.e., carrier with
strongly bound fine particles, and carrier with weakly bound fine particles or free fine particles
(78).
This presence of active sites has obvious implications for DPI drug delivery since retention of
drug particles on these relatively high-energy sites during processing and aerosolization would
result in a decrease in apparent respirable drug fraction, as suggested by Staniforth (78).
Furthermore, it is suggested that the active sites present on the surface of the carrier will have a
specific energy distribution with a critical, average adhesion point below which particles - drug
or lactose could be removed. Current methods for overcoming such issues include ”filling” the
potential active sites by increasing the fine particle content present on the carrier surface or
pacifying the effects of active sites by the addition of so-called “force control agents” such as
22
magnesium stearate (79, 80). This additional or ternary component can be added to occupy and
presaturate higher-energy binding sites on the carrier before the drug is added, consequently
increasing the release and the respirable fraction of the active drug.
1.7.1.2 Blending
After drug and excipient(s) have individually been brought to their desired forms, they are
combined in the blending process. The flow properties of the components of the powder blend
will play an important role in the efficiency of blending and, ultimately, in aerosol dispersion.
Blended formulations consist of small drug particles that are mixed with large excipient carrier
particles (50-200 µm). It is a critical step in the manufacture of a DPI product and is in fact
subject to substantial optimization work during development. When mixing powders with
different properties, particle sizes, and ratios, as is the case with DPI formulations, inadequate
mixing can cause poor dose uniformity. In many cases, inadequate mixing cannot be overcome
simply by increasing the mixing time. Mixer selection, rotation speed, capacity, and fill level are
all subject to optimization, as they can all affect the blend homogeneity (81). Different powders
may have different mixing requirements, depending on the interaction forces present between the
various particles (78). For low concentration (drug-carrier ratio) blends, geometric dilutions are
necessary, using multiple pre-blending steps. Various blending options are available: low-energy
tumbling blending, tumbling blending with sieving to break up agglomerates of micronized drug
and aid distribution with the powder mass, and high energy blending, with paddles, impeller
blades and redistributing powder within the blending vessel (82). An interactive mixture of the
two components is prepared by blending until the mixture can remain intact during the filling
process (to produce an accurate metered dose) and then freely separate into its primary
components during inhalation. There, the drug particles separate from the carrier particles and
are carried deep into the lungs, while the larger carrier particles impact in the oropharynx and are
cleared. Inadequate drug/carrier separation is one of the main explanations for the low deposition
efficiency encountered with DPIs (83).
Though there are tremendous advantages of the pulmonary drug delivery, pulmonary
administration of these therapeutics is limited by the defense mechanisms of the lung. The
mucociliary escalator, coughing, and alveolar clearance are the 3 major physical ways of
23
removing deposited particles. In the conducting airways deposited particles are rapidly cleared
by the mucociliary clearance into the pharynx. In the terminal airways (alveoli), absorptive or
non-absorptive processes remove deposited particles. The absorptive process may involve either
direct penetration into the epithelial cells or uptake and clearance by the alveolar macrophages.
The non-absorptive process involves transport of particles to the ciliated region (conducting
airways) followed by clearance by the mucociliary escalator (84). To overcome these challenges
encountered during pulmonary delivery, particulate drug delivery system is another option for
pulmonary administration.
24
In both mechanisms, the total surface area increases, which increases the free energy of the
particles. The system compensates for this increase in free energy by dissolving crystalline nuclei
and precipitating onto other particles in a process known as Ostwald Ripening (19), or by
agglomerating smaller particles. Generating stable nanoparticle colloids typically necessitates the
use of surfactants, which decrease the surface tension at the particle surface and thereby help to
reduce the increase in free energy (18). This decreases the degree of Ostwald Ripening and
agglomeration within the system. Many chemical processing technologies have been used to
produce nanostructured materials suitable for pulmonary delivery. Some processes that are
currently under investigation involve wet milling (18), supercritical fluid extraction (21), spray
drying (22), electrospray (86), high-pressure homogenization and recrystallization via solvent
displacement (87). Wet milling is a process that utilizes either ceramic or metallic milling media
to grind a suspension of insoluble drug and surfactant. Wet milling has also been used to
formulate budesonide for nebulized delivery to the lungs (18). Spray drying is a process that
forces fluid through a nozzle, producing a mist that is dried to produce a fine powder. The
technique employs a variety of different types of nozzles, some of which use ultrasound or air-jet
shear to nebulize drug suspensions. Supercritical fluid extraction is a technique that is currently
being developed for use in nanoparticle drug formulations. It uses supercritical fluid to extract a
solvent from a drug emulsion or solution, leaving behind a suspension of drug particles (21).
These processes are advantageous because they generally offer better scalability, and are
therefore industrially relevant. Unfortunately, some processes (such as spray drying) often utilize
co-solvents to improve drying and/or large amounts of excipient to stabilize the drug and to
maintain powder properties. In addition to chemical processing technologies, multiple recent
studies have examined different polymeric nanoparticle fabrication methods as applied to
pulmonary drug formulations (88, 89). These techniques generally involve polyelectrolyte
complex formation, double emulsion/solvent evaporation techniques, or emulsion polymerization
techniques. Polyelectrolyte complexes use oppositely charged polymers to entrap drugs into a
polymeric matrix nanoparticle, which then releases the drug either through polymer degradation
or drug diffusion. Double emulsion/solvent evaporation techniques involve dissolving the drug
and polymer in an organic solvent, which is then emulsified in an aqueous solution. The organic
solvent diffuses out of the polymer phase and into the aqueous phase, and is then evaporated,
leaving behind drug-loaded polymeric nanoparticles. Emulsion polymerization is similar to
25
emulsion/solvent evaporation except that monomer is emulsified into droplets and then
polymerization is initiated. Liposomal formulations are typically produced by extruding or
homogenizing a suspension of dissolved, hydrated lipids. (90). This suspension can then be
delivered via nebulization, freeze-dried, or incorporated into larger particles.
Bhavane et al. developed a novel type of drug delivery vehicle composed of liposomal
nanocarriers covalently linked by enzymatically labile spacers (90). The liposomes were between
80 and 195 nm in size and loaded with ciprofloxacin with 90% efficiency. Agglomeration was
induced using dimethyl 3,3-dithiobispropionimidate 2HCl (DTBP), which is a homobifunctional
imidoester capable of reacting with primary amines and also contains thiol-cleavable disulfide
26
bonds, making it enzymatically labile (90). Agglomerated liposomes differ from
unagglomerated liposomes in their release characteristics, the former being more slow releasing
than latter, as well as agglomerated particles may give burst release. Upon nebulization, the
agglomerated particles were reported to retain the encapsulated drug and nebulized droplets had
aerodynamic diameters between 1 and 5 µm, putting them within the respirable range (90).
Liposomal formulations have also been investigated in potential dry powder formulations.
Chougule et al. loaded nano-sized liposomes with tacrolimus, an immunosuppressant often used
to prevent rejection of allotropic lung transplants. The liposomal suspension with lactose,
sucrose, or trehalose and L-leucine was spray dried to produce particles with an aerodynamic
diameter of approximately 2.2 µm that demonstrated good aerosolization properties when
administered from a DPI (94)
27
healthy volunteers of dry powder tobramycin, using lipid-based Pulmosphere technology, has
already been made, giving a mean whole lung deposition of 34 ± 6 % (37, 96) .
28
small size of nanoparticles may not be the most important factor affecting their toxicity (103).
This notwithstanding, the toxicity of nanoparticles is a legitimate concern and should be
thoroughly investigated. In addition to the possible inherent toxic effects of nanoparticles, some
materials used to formulate nanoparticles may have toxic effects and therefore may not be viable
for developing therapeutic products. For example, the toxicity of polycyanoacrylates has been
demonstrated by Brzoska et al (104). They prepared poly (butyl) cyanoacrylate and poly
(hexyl)cyanoacrylate nanoparticles. They determined that both types of nanoparticles caused an
increase in lactate dehydrogenase (LDH) activity in human pulmonary epithelial cells. The
degree of toxicity was greater for the poly (butyl) cyanoacrylate and independent of the stabilizer
used, which stands to reason because shorter chain polycyanoacrylates have been associated with
higher cytotoxicity. The degree of toxicity also increased with increasing nanoparticle
concentration, most likely due to the subsequent increase in polycyanoacrylate concentration.
Polyethyleneimine (PEI) has also demonstrated cytotoxicity in lung cells (105). Bivas-Benita et
al. also reported increasing cytotoxicity of PEI-DNA complexes with increasing ratio of PEI to
DNA (106). Despite this, Dailey et al. have shown that PLGA nanoparticles induce less
inflammation than polystyrene particles of similar size when delivered to the lungs (88). Based
on this observation, nanoparticle toxicity in the lungs may be more dependent on material choice
than particle size. Therefore, it is essential to investigate the toxicity of these particles and
alternatives or methods can be investigated to mitigate pulmonary toxicity of these system.
Nanocarrier drug formulations offer many advantages over traditional aerosol powders and
liquid pulmonary dose formulations. The bioavailability of poorly water-soluble drugs can be
greatly enhanced by the large surface area of drug nanocarrier formulations. Additionally,
nanoparticles can be formulated in such a way to offer enhanced control over the morphology of
dry powder drug formulations and the ability to produce structures with both a low-density
microstructure for delivery to the deep lung and nanostructure for enhanced dissolution and
bioavailability. The literature suggests many different formulation approaches for drugs that use
a variety of excipients to fabricate nanocarrier or nanocarrier complexes suitable for pulmonary
delivery. Many chemical processing techniques such as lyophilization, supercritical fluid
extraction and spray drying have been successfully used for therapeutic nanoparticle processing.
Additionally, a range of formulation techniques are available, for example, emulsion
polymerization, double emulsion/solvent evaporation, polyelectrolyte complexation,
29
nanoprecipitation and liposomal loading that suits different requirements. These techniques offer
the ability to produce nanocarriers with a high degree of control over particle size, however,
residual solvents, presence of cytotoxic components, drug loading problems as well as scale up
issues need to be addressed to have commercial applicability of such formulations. With the
perfection of pulmonary nanocarrier drug formulations, the lungs may become a preferred route
of drug delivery for many more local and systemic therapeutic interventions.
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