Spray-freeze-drying (SFD) is a unique powderization technique to produce highly porous dry powders with a low density. The characteristic morphology can markedly contribute to the superior inhalation performances of SFD powders. Due to the increased specific surface area of the powders, however, moisture adsorption may readily occur, subsequently leading to losses of their inhalation potentials. In this study, hydrophobic amino acids were newly applied as pharmaceutical excipients to obtain SFD powders with both a favorable inhalation performance and antihygroscopic property. SFD powders composed of several hydrophobic amino acids were prepared. The morphology, particle size distribution, and crystallinity of the prepared powders were evaluated by scanning electron micrography, laser diffraction, and X-ray powder diffraction, respectively. The inhalation characteristics of the SFD powders were examined using a twin-stage liquid impinger equipped with an inspiratory pattern simulator and devices. To investigate their antihygroscopicity, moreover, the SFD powders were stored under a humidified condition to assess the morphology, crystallinity, and inhalation performance as described above. It was demonstrated that a SFD powder composed of L-leucine, L-isoleucine, or L-phenylalanine showed a superior inhalation performance, which was sufficiently maintained after storage under the humidified condition, strongly indicating their antihygroscopicity. These results indicated that the hygroscopicity of SFD powders can be effectively improved by the application of hydrophobic amino acids as excipients.
Key words dry powder inhaler (DPI); spray-freeze-drying (SFD); hydrophobic amino acid; inhalation performance; antihygroscopic propertyInhalants that can deliver a drug deep into the lungs directly and noninvasively have attracted attention as dosage forms for the therapy of not only local diseases such as asthma, chronic obstructive pulmonary disease, and cystic fibrosis but also systemic diseases such as diabetes. [1][2][3] There are three kinds of inhalant on the market: pressurized metered-dose inhalers (pMDIs), inhalation solutions, and dry powder inhalers (DPIs). DPIs have many advantages compared to the other two forms: (1) no propellant or battery is required, (2) the device is small, and (3) powders are dispersed on inhalation by a patient, minimizing the mismatch between the timing of inhalation and drug dispersal. 4,5) The powders for DPIs should have an appropriate mass median aerodynamic diameter (MMAD) suitable for inhalation and small adhesion cohesiveness. The commonly recognized optimum MMAD is in the range of 1-6 µm.4) However, the adhesion cohesiveness of such small particles is usually high, and they easily aggregate to form large particles that are not suitable for inhalation. 6) To solve this problem, the small particles of an active ingredient are generally mixed with large inert carrier particles (50-100 µm) such as lactose monohydrate to prevent the small particles of an active ingredient from unde...