The Strength and Compaction of Millispheres: The design of a controlled-release drug delivery system for ibuprofen in the form of a tablet comprising compacted polymer-coated millispheres

This paper reviews a case study of the design of a controlled-release drug delivery system for ibuprofen in the form of a tablet comprising compacted polymer-coated millispheres (multiparticulate pellets). The particular challenge was to prepare coated millispheres of ibuprofen (a high-dose drug) with the addition of minimal excipients so that the drug-release retarding polymeric membrane surrounding the millispheres remains intact during and after tablet compression, disintegration and release of the millispheres. The study included (a) the design of the uncoated core and its manufacture by wet massing, extrusion, spheronization and drying; (b) the coating of these millispheres with a range of possibly suitable polymers; (c) an assessment of the drug release profiles from these pellets; (d) the quantification by indentation rheology of the mechanical properties of the polymer films used to coat the spheres; (e) the measurement of the mechanical properties of individual uncoated and coated millispheres and f. the design, manufacture and evaluation of compressed tablets containing coated millispheres

The matching of millisphere and polymer mechanical properties was found to be essential in order to ensure minimal damage to the millispheres and the release of virtually intact coated spheres without destruction of their retarded drug-release characteristics. Aqueous polymeric dispersions which formed a film with similar elastic and tensile properties to the uncoated millisphere formulation resulted in the most satisfactory film coating for application to spherical particles which must withstand compaction. Those polymeric films exhibiting significantly greater resilience than the uncoated cores were inappropriate for the film coating of millispheres for compaction into tablets     

Effect of Polymer Loading on Drug Release from Film-Coated Ibuprofen Pellets Prepared by Extrusion-Spheronization

Abstract

Many factors are capable of influencing the mechanism of drug release from pellets prepared by extrusion-spheronization. This study was designed to elucidate the effect of polymer type and loading and the effect of processing variables on the rate and mechanism of drug release from ibuprofen pellets coated using aqueous polymeric dispersions. Qualitative and quantitative assessment of the success of the film coating process and the quality of the resultant films is made using scanning electron microscopy and in-vitro dissolution testing. The importance of plasticizer in polymeric film formation is also discussed. Uncoated pellets containing 60, 70 and 80% ibuprofen were coated with aqueous polymeric dispersions of polymethacrylates, ethylcellulose and silicone elastomer films. The high drug loading of these pellets adds special interest to this study. Drug release from uncoated pellets appears to follow first-order kinetics. The application of a polymeric membrane to uncoated cores has the effect of retarding drug release. There appears to be a critical coating level below which core coverage by the polymer is incomplete, drug release is diffusion controlled and first-order release kinetics are observed. Above a defined polymer level, drug release appears to be membrane controlled and zero-order kinetics are observed. The presence of plasticizer in the polymeric film imparts a hydrophilic component to an otherwise hydrophobic membrane. This enhances the penetration of aqueous solvent into the pellet core during in-vitro dissolution testing, increasing the rate of drug release. Scanning electron micrographs reveal the nature of these hydrophilic pores, beneath which a fine tortuous skeletal network of drug-depleted core is exposed.     

Effect of Polymer Loading on Drug Release from Film-Coated Ibuprofen Pellets Prepared by Extrusion-Spheronization

Many factors are capable of influencing the mechanism of drug release from pellets prepared by extrusion-spheronization. This study was designed to elucidate the effect of polymer type and loading and the effect of processing variables on the rate and mechanism of drug release from ibuprofen pellets coated using aqueous polymeric dispersions. Qualitative and quantitative assessment of the success of the film coating process and the quality of the resultant films is made using scanning electron microscopy and in-vitro dissolution testing. The importance of plasticizer in polymeric film formation is also discussed. Uncoated pellets containing 60, 70 and 80% ibuprofen were coated with aqueous polymeric dispersions of polymethacrylates, ethylcellulose and silicone elastomer films. The high drug loading of these pellets adds special interest to this study. Drug release from uncoated pellets appears to follow first-order kinetics. The application of a polymeric membrane to uncoated cores has the effect of retarding drug release. There appears to be a critical coating level below which core coverage by the polymer is incomplete, drug release is diffusion controlled and first-order release kinetics are observed. Above a defined polymer level, drug release appears to be membrane controlled and zero-order kinetics are observed. The presence of plasticizer in the polymeric film imparts a hydrophilic component to an otherwise hydrophobic membrane. This enhances the penetration of aqueous solvent into the pellet core during in-vitro dissolution testing, increasing the rate of drug release. Scanning electron micrographs reveal the nature of these hydrophilic pores, beneath which a fine tortuous skeletal network of drug-depleted core is exposed.     

Preparation and evaluation of metoprolol tartrate sustained-release pellets using hot melt extrusion combined with hot melt coating

The objective of this study was to prepare and evaluate metoprolol tartrate sustained-release pellets. Cores were prepared by hot melt extrusion and coated pellets were prepared by hot melt coating. Cores were found to exist in a single-phase state and drug in amorphous form. Plasticizers had a significant effect on torque and drug content, while release modifiers and coating level significantly affected the drug-release behavior. The mechanisms of drug release from cores and coated pellets were Fickian diffusion and diffusion–erosion. The coated pellets exhibited sustained-release properties in vitro and in vivo.     

Compaction of and drug release from coated pellets of different mechanical properties

The aim of this work was to relate the mechanical properties of film-coated pellets to their damage received during compaction, and to establish the significance of this damage for the release of a model drug from the resulting tablets. The formulations contained paracetamol and various excipient combinations chosen to provide different mechanical properties of the pellets, which were film-coated with Surelease® at various film thicknesses, and then compacted into tablets using three different compaction pressures. The drug release from the tablets was determined and compared to that of the uncompacted pellets. The compressibility and compactability of the various types of pellets was significantly influenced by the nature of the excipient combinations and binder liquids used to prepare the pellet cores, which also affected the drug release from the tablets. This could be attributed to the different responses of the pellets to compressive and shear stress. The film thickness and the mechanical properties of the film coating were found to be less important for tablet formation, but the film thickness played an important role in controlling the drug release rate from the tablets.     

Development of Terbutaline Sulfate Sustained-Release Coated Pellets

Sustained-release coated pellets containing terbutaline sulfate (TS) 1.8% w/w were prepared. The suitable core formulation that gave round-shape TS pellets was preformulated and was composed of microcrystalline cellulose:lactose 38.61%:57.92%, hydroxypropyl cellulose (HPC-M®) 1.67%, and water 40%, respectively. The core pellets containing active drug were coated with various amounts of ethylcellulose (EC) and a combination of EC/HPC-M polymers. The effects of fluidized bed polymeric film coats on drug release were studied in vitro. The dissolution characteristics were also investigated. The release of the active drug decreased as the amount of EC increased. This may be due to water-insoluble EC film, leading to decreased permeability in water. In the case of the combination of EC/HPC-M, the release of the active drug increased as the amount of HPC-M in the coating solution increased. Since HPC-M is a water-soluble polymer, it may be suggested that formation of pores were increased in the coating layer. Among five coating formulas in this study, formulation 1 (F1) (at 1.1% EC concentration) shows a similar dissolution profile to Bricanyl Durules®; however, lag time for the release occurred. In conclusion, the formulation that gave an insignificant release profile (p <. 01) when compared with commercial product was the capsule containing F1 (at 1.1% EC concentration) mixed with uncoated pellets at a ratio of 7:1, and the release was found to be reproducible.     

Influence of the inlet air temperature in a fluid bed coating process on drug release from shellac-coated pellets

Context: Since the introduction of aqueous ammoniacal solutions, shellac regained importance for pharmaceutical applications. However, as shellac is a material obtained from natural resources, its quality and thus its physicochemical properties may vary depending on its origin and the type of refining. Objective: In this study theophylline pellets were coated with aqueous solutions of three different commercially available shellac types. The inlet air temperature of the coating process was varied, and its influence on drug release from the coated pellet formulations was investigated. Film formation was correlated to the physicochemical and mechanical properties of the investigated shellac types. Results: Pellets coated at lower temperatures showed distinct cracks in the coating film resulting in a loss of the barrier function during dissolution testing. These cracks were nonreversible by additional curing. The physicochemical and mechanical properties of the investigated shellac types varied significantly and could hardly be related to the drug release performance of the investigated formulations. Conclusion: Obviously, with shellac a minimum inlet air temperature must be exceeded to achieve a coherent coating film. This temperature was dependent on the investigated shellac type.     

Compression Behavior of Acetylsalicylic Acid Pellets

An instrumented tablet press was used to study the compression behavior of different acetylsalicylic acid (AAS) formulations. Formulations of AAS crystals and uncoated AAS pellets have compression behavior similar to formulations of AAS pellets coated with acrylic resins (Eudragit RS) and mixed with a 20% of microcrystalline cellulose. Formulations of AAS coated pellets without any excipient exhibited a more plastic compression behavior then the other formulations. Matrix tablets of AAS were produced by compression of formulations of AAS coated pellets without any excipients.

The drug release profile of the pellets before and after compression was also studied. Microcrystalline cellulose concentrations higher than 15% w/w were required to obtain tablets of coated pellets with drug release profiles similar to the coated pellets before compression. It can be concluded from the present work that compression data of coated particles can be useful to study the possible damage of the film coat of the particles during tableting. Futhermore, instrumented tablet press data can be a good complement of in vitro drug release studies.     

Development of an osmotically-driven pellet coated with acrylic copolymers (Eudragit® RS 30 D) for the sustained release of oxymatrine,a freely water soluble drug used to treat stress ulcers (I): in vitro and in vivo evaluation in rabbits

Purpose: To develop an osmotically-driven pellet coated with polymeric film for sustained release of oxymatrine (OMT), a freely water soluble drug.

Methods: Pellet containing OMT and sodium chloride (NaCl), an osmotically active agent, were prepared by extrusion/spheronization and then coated with acrylic copolymers (Eudragit^® RS 30 D) by the fluidized bed coating process. In vitro release and swelling behavior studies were employed to optimize and to evaluate the sustained-release behavior from the osmotically-driven pellets with film coated. Finally, in vivo evaluation in rabbits was employed to investigate the sustained plasma level of OMT and its active metabolite matrine.

Results: It was found that the F3 formulation, prepared with 20% NaCl and an 8% coating level, showed a continuous NaCl-induced water influx into the pellets providing a gradual sustained release of OMT for over 12?h. Finally, we confirmed that oral OMT with sustained release led to a gradual sustained plasma profile of both OMT, with a reduction in its bioavailability, and MT with an increase in the bioavailability compared with that of oral OMT with immediate release. Conclusions: The pharmaceutical parameters obtained suggested the potential usefulness of oral OMT with sustained release for the treatment of stress ulcers, as well as reducing the risk of MT-induced side effects.     

Development of terbutaline sulfate sustained-release coated pellets

Sustained-release coated pellets containing terbutaline sulfate (TS) 1.8% w/w were prepared. The suitable core formulation that gave round-shape TS pellets was preformulated and was composed of microcrystalline cellulose:lactose 38.61%:57.92%, hydroxypropyl cellulose (HPC-M) 1.67%, and water 40%, respectively. The core pellets containing active drug were coated with various amounts of ethylcellulose (EC) and a combination of EC/HPC-M polymers. The effects of fluidized bed polymeric film coats on drug release were studied in vitro. The dissolution characteristics were also investigated. The release of the active drug decreased as the amount of EC increased. This may be due to water-insoluble EC film, leading to decreased permeability in water. In the case of the combination of EC/HPC-M, the release of the active drug increased as the amount of HPC-M in the coating solution increased. Since HPC-M is a water-soluble polymer, it may be suggested that formation of pores were increased in the coating layer. Among five coating formulas in this study, formulation 1 (F1) (at 1.1% EC concentration) shows a similar dissolution profile to Bricanyl Durules; however, lag time for the release occurred. In conclusion, the formulation that gave an insignificant release profile (p < .01) when compared with commercial product was the capsule containing F1 (at 1.1% EC concentration) mixed with uncoated pellets at a ratio of 7:1, and the release was found to be reproducible.     

Comparative Evaluations of Aqueous Film Coated Tablet Formulations by High Humidity Aging

Compressed tablets of ticlopidine hydrochloride were coated with three aqueous film coating formulations and aged under 95% relative humidity at 23° and 37°. The in vitro dissolution of the drug from tablets coated with the formulation containing polymethacrylic acid esters before aging was slower than the tablets coated with the formulations containing hydroxypropyl methylcellulose or ethylcellulose dispersion. On aging, the in vitro drug dissolution of the coated and uncoated tablets decreased and the decrease depended on the film forming excipient in the coating formulation and the temperature of aging. The tablets coated with the formulation containing polymethacrylic acid esters dissolved very slowly after aging. Higher moisture contents of the tablets after aging under 95% relative humidity at 23° compared to 37° resulted in a consistently lower tablet crushing strength. The tablets coated with the formulation containing 10% hydroxypropy1 methylcellulose showed a smaller decrease in the tablet crushing strength on aging compared to the other two formulations.     

Formulation and Compaction of Microspheres

Abstract

The factors affecting the tabletability of formulations containing uncoated and/or coated microspheres were discussed by presenting a case study. The size and shape, as well as surface properties of microspherical particles, the type and amount of coating agent, selection of the external additives, and the rate and magnitude of the pressure applied were found to be the most critical factors to be considered in order to obtain and maintain the desired drug release properties of the microspheres. It was found that microcrystalline cellulose was needed in order to produce satisfactory beads in terms of size, shape and surface characteristics. The microsphere formulations, which were found to be highly sensitive to lubrication, were more compressible than their powder forms, but produced much weaker tablets. When coated with Surelease, increasing the amount of coating on the pellets reduced the tensile strength of their compacts. Compaction of the microspheres at high velocities resulted in a decrease in the tensile strength values and an increase in the volumetric strain recovery values. Dissoultion studies revealed that, regardless of the amount of coating applied, the coated microspheres lost their sustained release properties during compaction.     

The Effect of Curing on Drug Release and Morphological Properties of Ethylcellulose Pseudolatex-Coated Beads

Abstract

Drug-containing nonpareil beads were coated in a fluidized bed with a commercial ethylcellulose pseudolatex, Aquacoat. The drug release was investigated as a function of curing conditions (curing time and temperature) for a hydrophilic and lipophilic drug (chlorpheniramine maleate and ibuprofen) at different levels of plasticizer (triethyl citrate). Curing of coated beads at elevated temperatures immediately after the coating process significantly changed the drug release pattern. Both a retardation and an enhancement in drug release were seen, with the extent being dependent on the type of drug and curing conditions. With chlorpheniramine maleate, a drug with low affinity for the ethylcellulose coating, a curing step was necessary at intermediate plasticizer levels to obtain good film formation and a limiting drug release pattern, while the use of higher plasticizer levels eliminated the need for a curing step. With ibuprofen, a lipophilic drug with high solubility in the ethylcellulose coating, drug crystals were apparent on the bead surface after curing. Curing of ibuprofen beads as a function of time initially decreased but then substantially increased the drug release as a result of drug diffusion across the ethylcellulose membrane with subsequent crystallization on the bead surface. An intermediate seal coat reduced the diffusion of the drug into the ethylcellulose coating.     

Study of Drug Release from Pellets Coated with Surelease Containing Hydroxypropylmethylcellulose

The release of metoclopramide hydrochloride (a very water soluble cationic drug) and diclofenac sodium (a sparingly soluble anionic drug) from pellets coated with Surelease containing hydroxypropylmethylcellulose (HPMC) at different coating loads was investigated. The release rates of either drug at each coating composition decreased as the coating load increased. Inclusion of HPMC E15 increased the release rates of both drugs compared to pellets coated only with Surelease. This was thought to be due to the leakage of the soluble part of the film (HPMC E15) during dissolution, which left pores for drug release. The Surelease:HPMC E15 ratio had a major role in the release rates of drugs. Addition of HPMC E15 into Surelease did not change the release mechanism for metoclopramide hydrochloride (the mean value of n ≈ 0.57) from that of Surelease alone, and diffusion remained the main mechanism controlling the release. However, the release exponent (≈1.28) increased for diclofenac sodium on addition of HPMC E15, indicating a dissolutioncontrolled mechanism. Despite its lower water solubility, diclofenac sodium was released slightly faster than metoclopramide hydrochloride from pellets coated with Surelease containing HPMC E15 at equivalent coating loads.     

Development of a Formulation of Sustained Release Potassium Chloride

Abstract

The purpose of this work has been the designing and “in vitro” evaluation of a potassium chloride tablet using a wax matrix.

Camauba wax, stearyl alcohol and stearic acid ware employed to prepare granulates at different drug/wax ratios. Fran dissolution kinetic studies and technological performances a 75/25 – KCl/camauba wax granulates was selected. The rheolqgical properties of granulates were characterized and tablets were manufactured employing ccrrmun tablets excipients. Also a coating procedure was developed. The coated tablet formulation selected release the potassium chloride according to the USP requirements.

The dissolution kinetics of the potassium chloride from both coated and uncoated tablets fit the Higuchi diffusion model, giving a straight line when the amount dissolved is plotted against the square root of time.     

Preparation and evaluation of enteric coated tablets of hot-melt extruded lansoprazole

Abstract

The objective of this work was to use hot-melt extrusion (HME) technology to improve the physiochemical properties of lansoprazole (LNS) to prepare stable enteric coated LNS tablets. For the extrusion process, we chose Kollidon^® 12?PF (K12) polymeric matrix. Lutrol^® F 68 was selected as the plasticizer and magnesium oxide (MgO) as the alkalizer. With or without the alkalizer, LNS at 10% drug load was extruded with K12 and F68. LNS changed to the amorphous phase and showed better release compared to that of the pure crystalline drug. Inclusion of MgO improved LNS extrudability and release and resulted in over 80% drug release in the buffer stage. Hot-melt extruded LNS was physically and chemically stable after 12 months of storage. Both formulations were studied for compatibility with Eudragit^® L100-55. The optimized formulation was compressed into a tablet followed by coating process utilizing a pan coater using L100-55 as an enteric coating polymer. In a two-step dissolution study, the release profile of the enteric coated LNS tablets in the acidic stage was less than 10% of the LNS, while that in the buffer stage was more than 80%. Drug content analysis revealed the LNS content to be 97%, indicating the chemical stability of the enteric coated tablet after storage for six months. HME, which has not been previously used for LNS, is a valuable technique to reduce processing time in the manufacture of enteric coated formulations of an acid-sensitive active pharmaceutical ingredient as compared to the existing methods.     

Drug Release and Surface Morphology Studies on Salbutamol Controlled Release Pellets

The air suspension technique was employed to prepare controlled release pellets of Salbutamol (as the sulphate). The aim of the present study was to determine the influence of various film coating additives on the release characteristics and surface morphology features of salbutamol sulphate pellets coated with Eudragit^R RS30D which is the aqueous dispersion of a polymer synthesised from acrylic and methacrylic acid esters. Surface morphology features, which were examined using Scanning Electron Microscopy, revealed that triethyl citrate (plasticiser) was essential for the coalescence of polymeric membranes around the drug-loaded spheres. Higher concentrations (12.5%) of triethyl citrate displayed a more uniform and continuous polymer film resulting in a slower in vitro drug release. Micrographs of the cross-sections of pellets with higher concentrations of Eudragit^R RS30D indicated the formation of thicker polymer membranes which accounted for the slower drug release rates. Hydroxypropyl methylcellulose (HPMC) inclusion in the polymer film coating increased salbutamol release rates due to its hydrophilic nature which promoted the formation of pores and cracks on the polymer films. A slower in vitro release of salbutamol was observed with higher concentrations of the hydrophobic anti-tackiness agent, magnesium stearate. The addition of salbutamol sulphate powder to the polymer dispersion enhanced drug release rates due to increased film permeability. Polyethylene glycol 200 (PEG 200) resulted in an increased in vitro drug release due to both its water soluble nature as well as impairment of film formation attributed to too high a plasticiser content in the coating formulation. As compared to polyethylene glycol 300 (PEG 300) as a plasticiser, triethyl citrate retarded drug release to a greater extent and formed more homogeneous and compact polymer films. The moisture content of PEG 300 plasticised pellets showed a 0.6% increase in moisture content while triethyl citrate plasticised pellets displayed a loss of 0.01% moisture 8 weeks after storage at room temperature.     

Coated pelletized dosage form: Effect of compaction on drug release

Abstract

The goal of this study was to investigate the effect of compaction of a coated pelletized dosage form on drug release. Three sizes of microcrystalline cellulose and hydrous lactose pellets containing 4% chlorpheniramine maleate (CPM) were manufactured using a rotogranulator (Glatt GPCG-1). Pellets having mesh cuts of: 590–840 μm (20/30 mesh); 420–590 μm (30/40 mesh); and 250–420 μm (40/60 mesh) were then coated with an aqueous ethylcellulose pseudolatex dispersion plasticized with 24% dibutyl sebacate (DBS). Percent weight gains were 25, 30 and 35% for the 20/30, 30/40 and 40/60 mesh pellets, respectively. Coated pellets were blended with 39.3% by weight excipients, then mixtures lubricated and compacted using a Korsch PH106 instrumented rotary press set at 5 kN and 20 rpm (0.30 s contact time). Magnesium stearate was used as the lubricant at a 0.7% level. Excipients used were microcrystalline cellulose, spray dried lactose, pregelatinized starch, dicalcium phosphate, spray dried sorbitol, polyethylene glycol 8000 powder and compressible sugar. Results indicated this coating to be suitable for the controlled release of CPM from small pellets (250–840 μm). However, films did not have the appropriate mechanical properties to withstand compaction stress without rupturing, regardless of the pellets particle size and excipients used. After compaction, depending on pellet size, between 65–100% CPM was released after one hour as opposed to 10–30% for the non-compacted material. The controlled release properties of the pellets were therefore lost during the process.     

Application of Powder-Layering Technology and Film Coating for Manufacture of Sustained-Release Pellets Using a Rotary Fluid Bed Processor

The main objective of this study was to prepare pellets in a Roto-processor using the powder-layering process onto inert nonpareils and to evaluate the applicability of the Roto-processor setup for film coating. Nonpareils were loaded with phenylpropanolamine hydrochloride and coated with ethyl cellulose polymeric dispersion (Surelease®). The drug loading was analyzed to test the eficiency of powder layering. The effect of polymer level on the drug release from the pellets and the pore size distribution in the membrane were studied. The yields for powder layering were greater than 90%. The dissolution studies on the Blm-coated pellets showed sustained release over a 10-hr period. The time required for 50% of drug release increased and the mean pore diameter decreased with an increase in polymer coating.     

The Influence of Polymeric Subcoats and Pellet Formulation on the Release of Chlorpheniramine Maleate from Enteric Coated Pellets

Abstract

The influences of aqueous polymeric subcoats and pellet composition on the release properties of a highly water-soluble drug, chlorpheniramine maleate (CPM), from enteric coated pellets were investigated. Three different aqueous polymeric subcoats, Eudragit® RD 100, Eudragit® RS 30D, and Opadry® AMB, were applied to 10% w/w CPM-loaded pellets that were then enteric coated with Eudragit® L 30D-55. Observed drug release from the coated pellets in acidic media correlated with water vapor transmission rates derived for the subcoat films. The influence of pellet composition on retarding the release of CPM from enteric coated pellets in 0.1 N HCl was investigated. The rate of drug release was greatest for pellets prepared with lactose, microcrystalline cellulose, or dibasic calcium phosphate compared with pellets formulated with citric acid and microcrystalline cellulose. Citric acid reduced the pellet micro-environmental pH, decreasing the amount of drug leakage in 0.1 N HCL during the first 2 hr of dissolution. Polymer flocculation was observed when CPM was added to the Eudragit L 30D-55 dispersion. An adsorption isotherm was generated for mixtures of CPM and the polymer and the data were found to fit the Freundlich model for adsorption. Adsorption of CPM to the polymer decreased with the addition of citric acid to the drug-polymer mixtures.