Spray freezing into liquid (SFL) particle engineering technology to enhance dissolution of poorly water soluble drugs: organic solvent versus organic/aqueous co-solvent systems

A spray freezing into liquid (SFL) particle engineering technology has been developed to produce micronized powders to enhance the dissolution of poorly water soluble active pharmaceutical ingredients (APIs). Previously, a tetrahydrofuran (THF)/water co-solvent was used as the solution source in the SFL process. In the present study, an organic system was developed to further enhance the properties of particles produced by SFL. The influence of solution type (e.g. organic versus organic/water) on the physicochemical properties of SFL powders was investigated and compared. The physicochemical properties of SFL carbamazepine (CBZ)/poloxamer 407/PVP K 15 (2: 1:1 ratio) powders were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), particle size distribution, surface area analysis, contact angle measurement, Karl-Fisher (KF) titration, gas chromatography (GC) analysis, HPLC analysis, and dissolution testing. The CBZ loading in the feed solution of the SFL acetonitrile system was 2.2% (w/w), which was greater than 0.22% (w/w) loading of the THF/water co-solvent system. XRD results indicated CBZ was amorphous in SFL powders produced by either system. SEM micrographs indicated that SFL powders from acetonitrile appeared less porous with a smaller primary particle size than particles from the co-solvent. The M50 (50% cumulative percent undersize) of micronized powder from the SFL acetonitride system and the THF/water co-solvent system with 0.22% CBZ loading were 680 nm and 7.06 mum, respectively. The surface area of SFL powders from the acetonitrile and co-solvent systems were 12.89 and 13.31 m(2)/g, respectively. The contact angle of the SFL powders against purified water was about 35degrees for both systems. The SFL powders from both systems exhibited similar and significantly enhanced dissolution rates compared to the bulk CBZ. Acetonitrile was an effective alternative solvent to THF/water co-solvent for use with the SFL micronization process to produce free flowing particles containing CBZ with significantly enhanced wetting and dissolution properties. (C) 2003 Elsevier B.V. All rights reserved.