Amorphous drugs are used to improve bioavailability of
poorly water-soluble
drugs. Crystallization must be managed to take full advantage of this
formulation strategy. Crystallization of amorphous drugs proceeds
in a sequence of crystal nucleation and growth, with different kinetics.
At low temperatures, crystal nucleation is fast, but crystal growth
is slow. Therefore, amorphous drugs may generate dense but nanoscale
crystal nuclei. Such tiny nuclei cannot be detected using routine
powder X-ray diffraction (PXRD) and polarized light microscopy (PLM).
However, they may negate the dissolution advantage of amorphous drugs.
In this work, for the first time, the impact of crystal nuclei on
dissolution of amorphous drugs was studied by monitoring the real-time
dissolution from amorphous drug films, with and without crystal nuclei,
and the evolving crystallinity in the films. Three model drugs (ritonavir/RTV,
posaconazole/POS, and nifedipine/NIF) were chosen to represent different
crystallization tendencies in the supercooled liquid state, namely,
slow-nucleation-and-slow-growth (SN-SG), fast-nucleation-and-slow-growth
(FN-SG), and fast-nucleation-and-fast-growth (FN-FG), respectively.
We find that although the amorphous films containing nuclei do not
show obvious differences from the nuclei-free films under PLM and
PXRD before dissolution, they have inferior dissolution performance
relative to the nuclei-free amorphous films. For SN-SG drug RTV, crystal
nuclei have negligible impact on the crystallization of amorphous
films, dissolution rate, and supersaturation achieved. However, they
cause earlier de-supersaturation by inducing crystallization in solution
as heterogeneous seeds. For FN-SG drug POS and FN-FG drug NIF, crystal
nuclei accelerate crystallization in the amorphous films leading to
lower supersaturation achieved with POS, and elimination of any supersaturation
with NIF. Dissolution profiles of amorphous films can be further analyzed
using a derivative function of the apparent dissolution rate, which
yields amorphous solubility, initial intrinsic dissolution rate, and
onset of crystallization in the amorphous films. This study highlights
that although crystal nuclei are undetectable with routine analytical
methods, they can significantly negate, or even eliminate, the dissolution
advantage of amorphous drugs. Hence, understanding crystal nucleation
process and developing approaches to prevent it are necessary to fully
realize the benefits of amorphous solids.