Understanding the dissolution mechanisms
of amorphous solid dispersions
(ASDs) and being able to link enhanced drug exposure with process
parameters are key when formulating poorly soluble compounds. Thus,
in this study, ASDs composed by itraconazole (ITZ) and hydroxypropylmethylcellulose
acetate succinate (HPMCAS) were formulated with different polymer
grades and drug loads (DLs) and processed by spray drying with different
atomization ratios and outlet temperatures. Their in vitro performance and the ability to form drug-rich colloids were then
evaluated by a physiologically relevant dissolution method. In gastric
media, drug release followed a diffusion-controlled mechanism and
drug-rich colloids were not formed since the solubility of the amorphous
API at pH 1.6 was not exceeded. After changing to intestinal media,
the API followed a polymer dissolution-controlled release, where the
polymer rapidly dissolved, promoting the immediate release of API
and thus leading to liquid–liquid phase separation (LLPS)
and consequent formation of drug-rich colloids. However, the release
of API and polymer was not congruent, so API surface enrichment occurred,
which limited the further dissolution of the polymer, leading to a
drug-controlled release. ASDs formulated with M-grade showed the highest
ability to maintain supersaturation and the lowest tendency for AAPS
due to its good balance between acetyl and succinoyl groups, and thus
strong interactions with both the hydrophobic drug and the aqueous
dissolution medium. The ability to form colloids increased for low
DL (15%) and high specific surface area due to the high amount of
polymer released until the occurrence of API surface enrichment. Even
though congruent release was not observed, all ASDs formed drug-rich
colloids that were stable in the solution until the end of the dissolution
study (4 h), maintaining the same size distribution (ca. 300 nm).
Drug-rich colloids can, in vivo, act as a drug reservoir
replenishing the drug while it permeates. Designing ASDs that are
prone to form colloids can overcome the solubility constraints of
Biopharmaceutics Classification System (BCS) II and IV drugs, posing
as a reliable formulation strategy.