In this study, we investigated the effect of manufacturing factors such as particle size, water content and manufacturing method on the physical stability and solubility of solid dispersion formulations of a lowglass-transition-temperature (T g ) drug. Solid dispersions were prepared from polyvinylpyrrolidone (PVP) and hydroxypropylmethylcellulose (HPMC) by hot melt extrusion or spray drying. Water content of solid dispersions prepared by hot melt extrusion determined by dynamic moisture sorption measurement was increased drastically with relative humidity below a certain level of particle size. The blends with a lower water content (0.8%) prepared by hot melt extrusion during storage were more stable than those with a higher water content (3.5%) prepared by spray drying, which caused rapid recrystallization. Physical stability in the hot melt blends may be attributed to reduced molecular mobility due to a higher T g . Dissolution study revealed that solid dispersions prepared by hot melt extrusion with the smallest particle size showed decreased solubility, attributed to reduced wetting properties (surface energy), which is not predictable by the Noyes-Whitney equation. Taken together, these results indicate that the control of particle size concerned in water content or wetting properties is critical to ensuring the physical stability or enhancing solubility of low-T g drugs. Further, hot melt extrusion, which can reduce water content, is a suitable manufacturing method for solid dispersions of low-T g drugs.Key words water content; particle size; low-glass-transition-temperature drug; hot-melt extrusion; stability; solubility Amorphous solid dispersions have been frequently used to enhance the dissolution properties and bioavailability of poorly water-soluble drugs.1-3) However, these solid dispersion formulations are physically unstable and are apt to crystallize during storage, which may alter drug absorption properties. Previous studies have reported that one important factor affecting the physical stability of the amorphous state is molecular mobility, with high molecular mobility leading to rapid nucleation and crystal growth. 4,5) Glass transition temperature (T g ), which delineates a temperature range between high and low molecular mobility, is a critical parameter affecting the molecular mobility of amorphous state compounds; solid dispersions with low T g have relatively high molecular mobility, which can subsequently lead to rapid nucleation and crystal growth above the T g .
6)Numerous studies have investigated the physical stability of amorphous solid dispersions in terms of molecular mobility and thermodynamic quantities at temperatures below T g . 7,8) Further, amorphous solid dispersions are more hygroscopic than their crystalline counterparts, due to their ability to absorb water content into their bulk structure, in addition to surface adsorption.9) This absorbed water content can induce plasticization and enhance molecular mobility, thereby leading to crystallization. Because an increase in...