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Optimizing amorphous multidrug formulations: A particle engineering approach through spray drying
Uppsala University, Disciplinary Domain of Medicine and Pharmacy, Faculty of Pharmacy, Department of Pharmacy. Recipharm OT Chemistry AB, SE-754 50 Uppsala, Sweden. (Molecular Pharmaceutics Group)ORCID iD: 0000-0003-0314-9065
College of Pharmacy, University of Sharjah, Sharjah, United Arab Emirates.
Uppsala University, Disciplinary Domain of Medicine and Pharmacy, Faculty of Pharmacy, Department of Pharmacy.
Recipharm OT Chemistry AB, SE-754 50 Uppsala, Sweden.
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2025 (English)In: European Journal of Pharmaceutical Sciences, ISSN 0928-0987, E-ISSN 1879-0720, Vol. 214, article id 107285Article in journal (Refereed) Published
Abstract [en]

Despite advances in the field of multidrug formulations, developing and manufacturing them still poses substantial challenges, particularly for drugs with low aqueous solubility. Here, this critical issue was addressed by engineering amorphous multidrug formulations with optimized performance at the site of absorption using the spray drying technique. Formulations containing atazanavir and ritonavir, alone or in combination, were produced by spray drying. Excipient content in aqueous solution was optimized to generate a stable feed suspension of amorphous particles with controlled particle size. The powder formulations were characterized by powder X-ray diffraction (PXRD), thermal analysis, laser diffraction, and scanning electron microscopy (SEM). The drug content was assayed, and a dissolution study was performed. Dynamic light scattering was used to measure particle size of the colloidal phase in the feed suspension and after dissolution of powder. A stability study was conducted at 25 °C/60 % RH and 40 °C/75 % RH condition for 4 weeks. DSC and PXRD confirmed the formulations to be amorphous. Drug content in the spray-dried formulations ranged from 98 to 108 %. Laser diffraction measured the particles to be from 5–10 µm and SEM showed they had wrinkled and irregularly shaped surfaces. The particle size of the colloidal phase formed upon dissolution of combination formulation was stable at 900 nm over 120 min. The formulations remained amorphous under both studied conditions throughout the stability study period. These findings highlight the potential of particle engineering, where a mechanistically informed selection of excipients is combined with an appropriate spray-drying process, to achieve highly stable and robust amorphous multidrug formulations —critical for ensuring effective drug performance and patient treatment.

Place, publisher, year, edition, pages
Elsevier, 2025. Vol. 214, article id 107285
Keywords [en]
Multidrug formulations, Amorphous, Particle size, Supersaturation, Spray drying, Particle engineering
National Category
Pharmaceutical Sciences
Research subject
Pharmaceutical Science
Identifiers
URN: urn:nbn:se:uu:diva-539688DOI: 10.1016/j.ejps.2025.107285ISI: 001592362600001PubMedID: 40983141Scopus ID: 2-s2.0-105016868320OAI: oai:DiVA.org:uu-539688DiVA, id: diva2:1903014
Funder
Swedish Foundation for Strategic Research, 17-0100Available from: 2024-10-02 Created: 2024-10-02 Last updated: 2025-10-28Bibliographically approved
In thesis
1. Oral Multidrug Amorphous Formulations: Impact of Solution Components on Drug Supersaturation, Solution Chemistry, and Thermodynamic Activity
Open this publication in new window or tab >>Oral Multidrug Amorphous Formulations: Impact of Solution Components on Drug Supersaturation, Solution Chemistry, and Thermodynamic Activity
2024 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Combination drug therapy offers substantial clinical benefits by enhancing treatment efficacy and improving patient compliance. However, it presents complex challenges from a dosage form development perspective, particularly for drugs with low water solubility. To enhance solubility and bioavailability, amorphous formulations are an attractive formulation strategy. This thesis aimed to optimize and implement a rational design approach for amorphous multidrug formulations with a robust and predictable performance after oral administration. This was achieved by investigating the influence of drugs, formulation excipients, and biorelevant intestinal media on solution chemistry, colloidal precipitate stability, and membrane transport of drug combinations.

Dissolution, solubility, and supersaturation of drug combinations were investigated in buffer and fasted state simulated intestinal fluids (FaSSIF). The solution behavior of the drugs was the same for structurally related compounds, highlighting the impact of their molecular properties and chemical diversity on the solubility profiles. A reduction in the maximum achievable concentration of drugs in combination was observed in buffer and FaSSIF, but the extent of reduction in FaSSIF was affected by the degree of solubilization by media components. Membrane transport studies demonstrated that drug transport across membranes is dominated by the degree of supersaturation, rather than solubilization. The colloidal particles formed as a result of liquid-liquid phase separation underwent uncontrolled coarsening. Polymers, in comparison to surfactants and small molecules, were more effective in controlling the particle size of this colloidal phase. 

The mechanistic studies on multidrug combinations led to the development of a novel approach for preparing amorphous formulations using spray drying. The developed formulation successfully maintained drug supersaturation and ensured controlled colloidal particle size upon dissolution.

The undertaken scientific efforts contribute to the knowledge in the evolving field of amorphous multidrug formulations. These findings highlight the potential of particle engineering, where a mechanistically informed selection of excipients is combined with an appropriate spray drying process, to achieve stable amorphous multidrug formulations—critical for ensuring robust drug performance and enabling intestinal absorption. 

Place, publisher, year, edition, pages
Uppsala: Acta Universitatis Upsaliensis, 2024. p. 81
Series
Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Pharmacy, ISSN 1651-6192 ; 360
Keywords
Amorphous multidrug formulations, Combination drug therapy, Excipients, LLPS, Membrane transport, Particle engineering, Solubility, Spray drying, Supersaturation
National Category
Pharmaceutical Sciences
Research subject
Pharmaceutical Science
Identifiers
urn:nbn:se:uu:diva-539689 (URN)978-91-513-2250-6 (ISBN)
Public defence
2024-11-21, A1:107a, Biomedical Centre (BMC), Husargatan 3, Uppsala, 09:15 (English)
Opponent
Supervisors
Funder
Swedish Foundation for Strategic Research, 17-0100
Available from: 2024-10-30 Created: 2024-10-03 Last updated: 2024-10-30

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El Sayed, MiraAsdagh, ArashBergström, Christel

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