Novel double-layer delivery devices based on soy protein derived materials were designed and produced using an innovative two material co-injection moulding technique. It was demonstrated that the viscosity ratio between core and skin layer materials played an important role in the formation of the interfacial shape, namely the skin thickness and uniformity of the bi-materials. The adequate selection of the materials used and the optimisation of the respective processing conditions enabled an accurate control of the relative thickness of the layers of the device. The preliminary results confirmed the potential of these systems to achieve a controlled drug delivery.

The aim of this study was to develop new soy protein drug delivery matrix systems by melt-processing techniques, namely, extrusion and injection moulding. The soy matrix systems with an encapsulated drug (theophylline, TH) were previously compounded by extrusion performed at two different pH values, (i) pH 4 (SIpDtp) and (ii) pH 7 (SIDtp), and further injection-moulded into a desired shape. During the extrusion process the matrixes SIDtp were also cross-linked with glyoxal (0.6X-SIDtp) and reinforced with a bioactive filler, hydroxylapatite (SI-HADtp). The obtained mouldings were used to study the drug-release mechanisms from the plastic soy-TH matrixes. In an isotonic saline solution (ISS) buffered at pH 5.0 (200 mM acetate buffer), the resulting release kinetics could be described using the Fick's second law of diffusion. Because the diffusion coefficients were found to be constant and the boundary conditions to be stationary, these systems are drug-diffusion controlled. Conversely, the dominant phenomena in an isotonic saline solution buffered at pH 7.4 (200 mM Tris/HCl buffer) are more complex. In fact, because of the higher polymer solubility, the resulting matrix is time-variant. So, the drug release is affected by swelling, drug diffusion, and polymer dissolution, being faster when compared to ISS-200 mM acetate buffer, pH 5.0. The changes in the formulation composition affecting the correspondent release rates were also investigated. At pH 7.4, increasing the cross-linking degree of the polymer matrix (via reaction with glyoxal or heat treatment) or decreasing the net charge (extruding at pH near its isoelectric point) led to lower release rates. The incorporation of ceramic filler caused the opposite effect. Because of the low solubility of the matrix at pH 5.0, no significant variations were detected with variations in the selected formulations. These systems, based on a nonstandard protein-based material, seem to be very promising to be used as carriers for drug delivery.

Processing and modification routes to produce and to improve properties of biodegradable plastics from soy isolate were studied. Soy isolate, acid-treated and crosslinked soy were subsequently compounded, extruded, and injection molded. Acetic acid and glyoxal were examined concerning their suitability for acid treating and crosslinking of soy, and their effect on the final properties of the obtained materials. Heat treatment was also used as a possible methodology to crosslink the protein structure. The molded specimens were tested in terms of their tensile properties and solubility at different pHs, and were also evaluated for the degree of crosslinking and molecular weight distributions. The obtained plastics were rigid and brittle with stiffness ranging from 1436 MPa for soy, to 1229 MPa for glyoxal crosslinked soy, up to 2698 MPa for heat-treated soy. The differences in stiffness were discussed in terms of the crosslinking efficiency and spatial distribution. The solubility profiles were studied as a function of the pH of the immersion solutions and the crosslinking degree of each material. A reduction in protein solubility with decreasing pH was observed, with a minimum between pH 4 and 5 and a resolubilization of the protein at pHs lower than pH 4 and greater than 8. Higher levels of crosslinking resulted in a decrease of the solubility and an aggregation of the protein molecules. The soy plastics proved to be very versatile materials with potential to be used in applications where quite demanding performances are expected, such as in the biomedical field.

The aim of this study was to design new soy protein-based bi-layered co-injection moulded matrix systems aimed to achieve controlled drug delivery. The devices consisted of a drug-free outer layer (skin) and a drug-containing core. The systems overcame the inherent disadvantage of non-linear release associated with diffusion-controlled single-layer matrix devices by providing additional releasing area with time to compensate for the decreasing release rate. As expected, the bi-layer devices presented a significant decrease in drug release rate when compared with a correspondent single layer matrix system. The skin thickness and the degree of crosslinking of the core appeared to be very important tools to tailor the release patterns. Furthermore, due to the amphoteric nature of the soy protein, the developed devices evidenced a pH-dependent behaviour. The mechanisms of drug release were also elucidated at two different pH values: i) pH 5.0, near the isoelectric point of soy (low matrix solubility); and ii) pH 7.4, physiological pH (high matrix solubility). Consequently, changing the release medium from pH 5.0 to pH 7.4 after two hours, led to an abrupt increase in drug release and the devices presented a typical controlled drug delivery profile: slow release/fast release. These evidences may provide for the development of individual systems with different release onsets that in combination may exhibit drug releases at predetermined times in a pre-programmed way. Another possibility is the production of three-layer devices presenting bimodal release profiles (fast release/slow release/fast release) by similar technologies. Scanning electron micrograph of a developed bi-layer device.