Sustained release of pharmaceutical proteins from biocompatible polymers offers new opportunities in the treatment and prevention of disease. The manufacturing of such sustained-release dosage forms, and also the release from them, can impose substantial stresses on the chemical integrity and native, three-dimensional structure of proteins. Recently, novel strategies have been developed towards elucidation and amelioration of these stresses. Non-invasive technologies have been implemented to investigate the complex destabilization pathways that can occur. Such insights allow for rational approaches to protect proteins upon encapsulation and release from bioerodible systems. Stabilization of proteins when utilizing the most commonly employed procedure, the water-in-oil-in-water (w/o/w) double emulsion technique, requires approaches that are based mainly on either increasing the thermodynamic stability of the protein or preventing contact of the protein with the destabilizing agent (e.g. the water/oil interface) by use of various additives. However, protein stability is still often problematic when using the w/o/w technique, and thus alternative methods have become increasingly popular. These methods, such as the solid-in-oil-in-oil (s/o/o) and solid-in-oil-in-water (s/o/w) techniques, are based on the suspension of dry protein powders in an anhydrous organic solvent. It has become apparent that protein structure in the organic phase is stabilized because the protein is "rigidified" and therefore unfolding and large protein structural perturbations are kinetically prohibited. This review focuses on strategies leading to the stabilization of protein structure when employing these different encapsulation procedures.

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Protein inactivation and aggregation at the water/CH2Cl2 interface is one of the most detrimental events hindering the encapsulation of structurally unperturbed proteins into poly(lactide-co-glycolide) (PLG) microspheres for their clinical application as sustained release dosage forms. We have investigated the inactivation and aggregation of the model protein hen egg-white lysozyme at this interface and devised methods to prevent both events. When lysozyme was exposed to a large water/CH2Cl2 interface achieved by homogenization, lysozyme aggregation occurred. Fourier-transform infrared (FTIR) spectroscopic data demonstrated that the aggregates formed contained intermolecular beta-sheets. The aggregates were of a noncovalent nature because they slowly dissolved in D2O and the IR spectral bands typical for the intermolecular beta-sheets disappeared at approximately 1617 and 1690 cm(-1). The observed loss in specific enzyme activity of soluble lysozyme was caused by the irreversible formation of an unfolded lysozyme species, which was found to be monomeric, and was able to leave the water/CH2Cl2 interface and accumulate in the aqueous phase. Polyols were, in a concentration dependent fashion, efficient in ameliorating lysozyme unfolding and aggregation. However, prevention of lysozyme aggregation and activity loss in the various samples were unrelated. Thus, polyols must work by more than one mechanism preventing the two events. For the first time, an excipient effect on the conformational stability of lysozyme has been excluded from contributing to the prevention of lysozyme unfolding and aggregation.

Encapsulation of proteins in poly(lactic-co-glycolic) acid (PLGA) microspheres by the water-in-oil-in-water (w/o/w) technique is very challenging because of the inherent physical instability of proteins. In particular, exposure of proteins to the first water-in-oil emulsion causes unwanted interface-induced protein inactivation and aggregation. We tested whether salts could afford stabilization of a model protein, hen egg-white lysozyme, against the detrimental events occurring at the w/o interface and subsequently upon w/o/w encapsulation. First, we investigated the effect of salts on the specific enzyme activity and generation of soluble precipitates and insoluble aggregates upon emulsification of an aqueous lysozyme solution with methylene chloride. It was found that lysozyme precipitation occurred upon emulsification. The amount of precipitate formed at salt concentrations between 10-100 mM was related to the position of the anion in the electroselectivity series (SO(4) (2-) > SCN(-) > Cl(-) > H(2)PO(4) (-)) while high salt concentrations (1M) led to > 80% of lysozyme precipitation regardless of the salt. The precipitates consisted of buffer-soluble protein precipitates and water-insoluble noncovalent aggregates. Lysozyme precipitation, aggregation, and inactivation upon emulsification were largely prevented in the presence of 50 mM KH(2)PO(4) while KSCN caused an increase in these detrimental events. Second, it was tested whether the improved structural integrity of lysozyme at the w/o interface would improve its stability upon w/o/w encapsulation in PLGA microspheres. Some conditions indeed led to improved stability, particularly codissolving lysozyme with 50 mM KH(2)PO(4) reduced loss in the specific activity and aggregation. In conclusion, the type and concentration of salts is a critical parameter when encapsulating protein in PLGA microspheres.