Grid-based systematic search methods are used to investigate
molecule–molecule,
molecule–surface, and surface–surface contributions
to interparticle interactions in order to identify the crystal faces
that most strongly affect particle behavior during powder blend formulation
and delivery processes. The model system comprises terbutaline sulfate
(TBS) as an active pharmaceutical ingredient (API) and α-form
lactose monohydrate (LMH). A combination of systematic molecular modeling
and X-ray computed tomography (XCT) is used to determine not only
the adhesive and cohesive interparticle energies but, also the agglomeration
behavior during manufacturing and de-agglomeration behavior during
delivery after inhalation. This is achieved through a detailed examination
of the balance between the adhesive and cohesive energies with the
XCT results confirming the blend segregation tendencies, through the
particle–particle de-agglomeration process. The results reveal
that the cohesive interaction energies of TBS–TBS are higher
than the adhesive energies between TBS and LMH, but that the cohesive
energies of LMH–LMH are the smallest between molecule and molecule,
molecule and surface, and surface and surface. This shows how systematic
grid-search molecular modeling along with XCT can guide the digital
formulation design of inhalation powders in order to achieve optimum
aerosolization and efficacy for inhaled medicines. This will lead
to faster pharmaceutical design with less variability, higher quality,
and enhanced performance.