U.S. patent application number 10/217953 was filed with the patent office on 2003-07-24 for microencapsulation and sustained release of biologically active acid-stable or free sulfhydryl-containing proteins.
This patent application is currently assigned to Alkermes Controlled Therapeutics, Inc.. Invention is credited to Johnson, J. Keith, Scher, David S., Tracy, Mark A., Ward, Kevin L..
Application Number | 20030138491 10/217953 |
Document ID | / |
Family ID | 23995624 |
Filed Date | 2003-07-24 |
United States Patent
Application |
20030138491 |
Kind Code |
A1 |
Tracy, Mark A. ; et
al. |
July 24, 2003 |
Microencapsulation and sustained release of biologically active
acid-stable or free sulfhydryl-containing proteins
Abstract
This invention relates to sustained release compositions, and
methods of forming and using said compositions, for the sustained
release of biologically active acid-stable or free
sulfhydryl-containing proteins, in particular .beta.-IFN. The
sustained release composition of this invention comprises a
biocompatible polymer having dispersed therein a stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation and a nonionic polymer surfactant. The method
of the invention, for forming a composition for the sustained
release of biologically active acid-stable or free
sulfhydryl-containing protein, in particular .beta.-IFN, includes
dissolving a polymer in a polymer solvent to form a polymer
solution, adding a stabilized biologically active acid-stable or
free sulfhydryl-containing protein formulation and a nonionic
surfactant to the polymer solution, and then solidifying the
polymer to form a polymer matrix containing the stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation, and a nonionic surfactant. The method of using
the sustained release composition of the present invention
comprises providing a therapeutically effective blood level of
biologically active acid-stable or free sulfhydryl-containing
protein in a subject for a sustained period by administering to the
subject a dose of the sustained release composition described
herein.
Inventors: |
Tracy, Mark A.; (Arlington,
MA) ; Ward, Kevin L.; (Arlington, MA) ; Scher,
David S.; (Hudson, MA) ; Johnson, J. Keith;
(Hudson, MA) |
Correspondence
Address: |
HAMILTON, BROOK, SMITH & REYNOLDS, P.C.
530 VIRGINIA ROAD
P.O. BOX 9133
CONCORD
MA
01742-9133
US
|
Assignee: |
Alkermes Controlled Therapeutics,
Inc.
Cambridge
MA
02139
|
Family ID: |
23995624 |
Appl. No.: |
10/217953 |
Filed: |
August 13, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10217953 |
Aug 13, 2002 |
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09501934 |
Feb 10, 2000 |
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6465425 |
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Current U.S.
Class: |
424/486 ;
424/85.6 |
Current CPC
Class: |
A61K 9/1647 20130101;
A61K 47/34 20130101; A61K 38/215 20130101 |
Class at
Publication: |
424/486 ;
424/85.6 |
International
Class: |
A61K 038/21; A61K
009/14 |
Claims
What is claimed is:
1. A composition for the sustained release of biologically active
acid-stable or free sulfhydryl-containing protein comprising: a) a
biocompatible polymer; b) a stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation
comprising at least one biologically active acid-stable or free
sulfhydryl-containing protein, at least one disaccharide and at
least one acidic excipient; and c) surfactant wherein said
biologically active protein formulation and said surfactant are
dispersed within the biocompatible polymer.
2. The sustained release composition of claim 1 wherein the
biologically active acid-stable or free sulfhydryl-containing
protein is .beta.-IFN.
3. The sustained release composition of claim 2 wherein the
.beta.-IFN is present in the stabilized formulation from about 0.5%
(w/w) to about 50% (w/w) of the dry weight of the formulation.
4. The sustained release composition of claim 3 wherein the
.beta.-IFN is present in a range from about 0.5% (w/w) to about 30%
(w/w) of the dry weight of the formulation.
5. The sustained release composition of claim 1 wherein the acidic
excipient is an organic acid.
6. The sustained release composition of claim 5 wherein the organic
acid is selected form the group consisting of: citric acid,
ascorbic acid, acetic acid, ethylenediaminetetraacetic acid,
saturated fatty acids, dicarboxylic acids, bile acids, amino acids
and combinations thereof.
7. The sustained release composition of claim 6 wherein the organic
acid is an acidic amino acid.
8. The sustained release composition of claim 7 wherein the acidic
amino acid is glutamic acid, aspartic acid or a combination
thereof.
9. The sustained release composition of claim 1 wherein the
disaccharide is selected from the group consisting of: sucrose,
trehalose and combinations thereof.
10. The sustained release composition of claim 1 wherein the
surfactant is selected from the group consisting of: poloxamers,
polysorbates, polyethyleneglycols, polyoxyethlene fatty acid
esters, bile salts, benzalkonium chloride, polyoxyethylene (40)
monostearate and combinations thereof.
11. The sustained release composition of claim 1 further comprising
an acidic excipient which is separately dispersed within the
biocompatible polymer.
12. The sustained release composition of claim 10 wherein the
poloxamer is selected from the group consisting of: poloxamer 407,
poloxamer 188, and combinations thereof.
13. The sustained release composition of claim 10 wherein the
polysorbate is selected from the group consisting of: polysorbate
80, polysorbate 20 and combinations thereof.
14. The sustained release composition of claim 1 wherein the
biologically active protein is present from about 0.01%(w/w) to
about 30% (w/w) of the total weight of the sustained release
composition.
15. The sustained release composition of claim 14 wherein the
protein is present from about 0.5% (w/w) to about 5% (w/w) of the
total weight of the sustained release composition.
16. The sustained release composition of claim 1 wherein the
stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation further comprises a water
soluble polymer.
17. The sustained release composition of claim 16 wherein the water
soluble polymer is a polysaccharide.
18. The sustained release composition of claim 17 wherein the
polysaccharide is selected from the group consisting of: methyl
cellulose, ethylcellulose, ficoll, and combinations thereof.
19. The sustained release composition of claim 16 wherein the water
soluble polymer is a polymer surfactant.
20. The sustained release composition of claim 19 wherein the
polymer surfactant is nonionic.
21. The sustained release composition of claim 20 wherein the
nonionic surfactant is selected from the group consisting of:
poloxamers, polysorbates, polyethyleneglycol, polyoxyethlene fatty
acid esters and combinations thereof.
22. The sustained release composition of claim 21 wherein the
poloxamer is selected from the group consisting of: poloxamer 188,
poloxamer 407 and combinations thereof.
23. The sustained release composition of claim 21 wherein the
polysorbate is selected from the group consisting of: polysorbate
80, polysorbate 20 and combinations thereof.
24. The sustained release composition of claim 1 wherein the
biocompatible polymer is selected from the group consisting of
poly(lactides), poly(glycolides), poly(lactide-co-glycolides),
poly(lactic acid)s, poly(glycolic acid)s, poly(lactic
acid-co-glycolic acid)s, polycaprolactone, polycarbonates,
polyesteramides, polyanhydrides, poly(amino acids),
polyorthoesters, polycyanoacrylates, poly(p-dioxanone),
poly(alkylene oxalate)s, biodegradable polyurethanes, blends
thereof and copolymers thereof.
25. The sustained release composition of claim 24 wherein said
polymer comprises poly(lactide-co-glycolide).
26. The sustained release composition of claim 1 further comprising
a multivalent metal cation component dispersed within the
biocompatible polymer.
27. A method for providing a therapeutically effective amount of a
biologically active acid-stable or free sulfhydryl-containing
protein in a subject for a sustained period comprising
administering to the subject a dose of the sustained release
composition of claim 1.
28. A method for forming a composition for the sustained release of
a biologically active acid-stable or free sulfhydryl-containing
protein, comprising the steps of: a) dissolving a biocompatible
polymer in a polymer solvent to form a polymer solution; b) adding
at least one surfactant and a stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation
comprising: at least one biologically active acid-stable or free
sulfhydryl-containing protein; at least one disaccharide; and at
least one acidic excipient, to the polymer solution; and c)
solidifying the biocompatible polymer to form a polymer matrix
containing the stabilized biologically active protein formulation
and the surfactant dispersed therein.
29. The method of claim 28 wherein the biologically active
acid-stable or free sulfhydryl-containing protein is
.beta.-IFN.
30. The method of claim 29 wherein the .beta.-IFN is present in the
stabilized formulation from about 0.5% (w/w) to about 50% (w/w) of
the dry weight of the formulation.
31. The method of claim 30 wherein the .beta.-IFN is present in a
range from about 0.5% (w/w) to 30% (w/w) of the dry weight of the
formulation.
32. The method of claim 28 wherein the acidic excipient is an
organic acid.
33. The method of claim 32 wherein the organic acid is selected
form the group consisting of: citric acid, ascorbic acid, acetic
acid, ethylenediaminetetraacetic acid, saturated fatty acids,
dicarboxylic acids, bile acids, and combinations thereof.
34. The method of claim 33 wherein the organic acid is an acidic
amino acid.
35. The method of claim 34 wherein the acidic amino acid is
glutamic acid, aspartic acid or a combination thereof.
36. The method of claim 28 wherein the disaccharide is selected
from the group consisting of: sucrose, trehalose and combinations
thereof.
37. The method of claim 28 wherein the surfactant is selected from
the group consisting of: poloxamers, polysorbates, polyethylene
glycol, polyoxyethlene fatty acid esters, bile salts, benzalkonium
chloride and combinations thereof.
38. The method of claim 37 wherein the poloxamer is selected from
the group consisting of: poloxamer 407, poloxamer 188 and
combinations thereof.
39. The method of claim 37 wherein the polysorbate is selected from
the group consisting of: polysorbate 80, polysorbate 20 and
combinations thereof.
40. The method of claim 28 wherein the biologically active
acid-stable or free sulfhydryl-containing protein is present from
about 0.01%(w/w) to about 30% (w/w) of the total weight of the
sustained release composition.
41. The method of claim 40 wherein the protein is present from
about 0.5% (w/w) to about 5% (w/w) of the total weight of the
composition.
42. The method of claim 30 wherein the stabilized biologically
active .beta.-IFN formulation further comprises a water soluble
polymer.
43. The method of claim 42 wherein the water soluble polymer is a
polysaccharide.
44. The method of claim 43 wherein the polysaccharide is selected
from the group consisting of: methyl cellulose, ethyl cellulose,
ficoll and combinations thereof.
45. The method of claim 42 wherein the water soluble polymer is a
polymer surfactant.
46. The method of claim 45 wherein the polymer surfactant is
nonionic.
47. The method of claim 46 wherein the nonionic surfactant is
selected from the group consisting of: poloxamers, polysorbates,
polyethyleneglycol, polyoxyethylene fatty acid esters, and
combinations thereof.
48. The method of claim 47 wherein the poloxamer is selected from
the group consisting of: poloxamer 407, poloxamer 188, and
combinations thereof.
49. The method of claim 47 wherein the polysorbate is selected from
the group consisting of: polysorbate 80, polysorbate 20, and
combinations thereof.
50. The method of claim 28 wherein the biocompatible polymer is
selected from the group consisting of poly(lactides),
poly(glycolides), poly(lactide-co-glycolides), poly(lactic acid)s,
poly(glycolic acid)s, poly(lactic acid-co-glycolic acid)s,
polycaprolactone, polycarbonates, polyesteramides, polyanhydrides,
poly(amino acids), polyorthoesters, polycyanoacrylates,
poly(p-dioxanone), poly(alkylene oxalate)s, biodegradable
polyurethanes, blends thereof and copolymers thereof.
51. The method of claim 50 wherein said polymer comprises
poly(lactide-co-glycolide).
52. The method of claim 28 further comprising the step of adding a
multivalent metal cation component to the polymer solution.
Description
RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 09/501,934, filed Feb. 10, 2000. The entire teachings of the
above application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Numerous acid-stable or free sulflhydryl-containing
proteins, such as .beta.-IFN, exhibit biological activity in vivo,
which renders them useful as medicaments in therapy. Many illnesses
or conditions which can be treated with this type of protein, for
example, Multiple Sclerosis (MS) which is currently treated with
.beta.-IFN, require administration of a constant or sustained level
of medicament to provide the most effective prophylactic and/or
therapeutic effects. For example, BETASERON.RTM. (Interferon
beta-1b) is currently administered for the treatment of MS at a
dose of 9 million IU, injected subcutaneously three time a week. As
such, administration of biologically active acid-stable or free
sulfhydryl-containing proteins requires frequent subcutaneous
injections, which result in fluctuating levels of medicament and
poor patient compliance.
[0003] As an alternative, the use of biodegradable materials, such
as polymers, encapsulating the medicament can be employed as a
sustained delivery system. The use of biodegradable polymers, for
example, in the form of microparticles or microcarriers, can
provide a sustained release of medicament, by utilizing the
inherent biodegradability of the polymer to control the release of
the medicament thereby providing a more consistent, sustained level
of medicament and improved patient compliance.
[0004] However, these sustained release devices can exhibit high
initial bursts of medicament and minimal release thereafter. In
addition, due to the high solution concentration of medicament
within and localized around these sustained release devices, the
medicament can aggregate thereby increasing immunogenicity in vivo
and interfering with the desired release profile for the
medicament. Further, methods used to form sustained release
compositions can result in loss of activity of the medicament due
to the instability of the medicament and the degradative effects of
the processing steps. In addition, adsorption of the biologically
active acid-stable or free sulfhydryl-containing proteins onto the
polymer surface can inhibit the release from the sustained release
composition.
[0005] Therefore, a need exists for a means of administering
biologically active acid-stable or free sulfhydryl-containing
proteins, for example, .beta.-IFN in a sustained fashion wherein
activity and potency of the protein is maintained.
SUMMARY OF THE INVENTION
[0006] This invention relates to compositions for the sustained
release of biologically active acid-stable or free
sulfhydryl-containing proteins, and methods of forming and using
said compositions, for the sustained release of biologically active
acid-stable or free sulfhydryl-containing proteins, in particular,
.beta.-IFN. The sustained release compositions of this invention
comprise a biocompatible polymer having dispersed therein a
stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation, and at least one
surfactant. The stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation of the sustained release
composition comprises at least one biologically active acid-stable
or free sulfhydryl-containing protein, at least one disaccharide
and at least one acidic excipient Optionally, the stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation further comprises a water soluble polymer.
[0007] The method of the invention, for forming a composition for
the sustained release of biologically active acid-stable or free
sulfhydryl-containing proteins, includes dissolving a biocompatible
polymer in a polymer solvent to form a polymer solution, adding at
least one surfactant and the stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation to
the polymer solution, and then solidifying the polymer to form a
polymer matrix containing the stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation and
the surfactant dispersed therein.
[0008] The method of using the sustained release composition of the
present invention comprises providing a therapeutically effective
blood level of biologically active acid-stable or free
sulfhydryl-containing protein, in particular, .beta.-IFN in a
subject for a sustained period by administering to the subject a
dose of the sustained release composition described herein.
[0009] The sustained release composition of the invention overcomes
the problem of aggregation of the biologically active acid-stable
or free sulfhydryl-containing protein, for example, .beta.-IFN
which can occur during processing and/or following administration
in vivo, when the biologically active protein is not stabilized.
Further, loss of activity of the biologically active protein due to
instability of the medicament, and chemical interactions between
the biologically active protein and other components, which are
contained in or used in formulating the sustained release
composition, are minimized.
[0010] The advantages of the sustained release formulation for
biologically active acid-stable or free sulfhydryl-containing
proteins, in particular, .beta.-IFN as described herein, include
increased patient compliance and acceptance by eliminating the need
for repetitive administration, increased therapeutic benefit by
eliminating fluctuations in active agent concentration in blood
levels by providing a desirable release profile, and a potential
lowering of the total amount of biologically active acid-stable or
free sulfhydryl-containing protein necessary to provide a
therapeutic benefit, by reducing these fluctuations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a graph of the % of .beta.-IFN dissolved following
incubation at 37.degree. C. for one hour in pH 7 phosphate buffer
for particular .beta.-IFN formulations described in Table 4.
[0012] FIG. 2 is a graph of the % of .beta.-IFN adsorbed on various
biocompatible polymer microparticles following incubation of the
microparticles with stabilized .beta.-IFN Formulation 24 of Table
4.
[0013] FIG. 3 is a graph of the % of .beta.-IFN adsorbed on polymer
microparticles following incubation with a stabilized .beta.-IFN
and various surfactants.
[0014] FIG. 4 is a graph of .beta.-IFN serum concentration in rats
receiving formulations containing excipients in the polymer phase
to minimize adsorption of .beta.-IFN to the biocompatible polymer
matrix.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The sustained release compositions of this invention
comprise a biocompatible polymer having dispersed therein a
stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation, and at least one
surfactant. The stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation of the sustained release
composition comprises at least one biologically active acid-stable
or free sulfhydryl-containing protein, at least one disaccharide
and at least one acidic excipient. Optionally, the stabilized
biologically active protein formulation further comprises a water
soluble polymer.
[0016] The method of the invention, for forming a composition for
the sustained release of biologically active acid-stable or free
sulfhydryl-containing proteins, includes dissolving a biocompatible
polymer in a polymer solvent to form a polymer solution, adding a
surfactant and the stabilized biologically active acid-stable or
free sulfhydryl-containing protein formulation, to the polymer
solution, and then solidifying the polymer to form a polymer matrix
containing the stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation and surfactant dispersed
therein.
[0017] The method of using the sustained release composition of the
present invention comprises providing a therapeutically effective
blood level of biologically active acid-stable or free
sulfhydryl-containing protein, in particular, .beta.-IFN in a
subject for a sustained period by administering to the subject a
dose of the sustained release composition described herein.
[0018] "Biologically active acid-stable or free
sulfhydryl-containing protein" as that term is used herein are
proteins which are stable under acidic conditions or contain a free
sulfhydryl group. Acid-stable or free sulfhydryl-containing
proteins suitable for use in the invention include, but are not
limited to, IL-2, basic fibroblast growth factor, granulocyte
colony stimulating factor, .beta.-IFN and muteins of .beta.-IFN,
for example, IFN-.beta..sub.ser17, MGDF (megakaryocyte growth and
differentation factor), TPA (tissue plasminogen activator), IGF-1
(insulin-like growth factor-1) and IL-1.beta. (interleukin
-1.beta.).
[0019] Proteins containing a free sulfhydryl can be determined
using, reagents which detect the presence of the free sulfhydryl.
Such a reagent is Ellman's reagent (5,5'-dithiobis (2-nitrobenzoic
acid)) also referred to as DTNB. DTNB reacts with free sulfhydryls
to give mixed disulfides plus 2-nitro-5-thiobenzoic acid (TNB)
which can be quantified by its absorbance at 412 nm.
[0020] Acid stable proteins can be determined by incubating the
protein under acidic conditions for a predetermined period of time
and then evaluating the integrity of the protein by, for example,
electrophoresis and/or circular dichroism. Proteins which do not
exhibit significant degradation can be defined as acid stable.
Degradation includes, for example, dimerization, particularly
oxidative dimerization, and/or aggregation of the protein which can
lead to an undesirable decrease in solubility. Preferably dimer
formation is less than about 10%.
[0021] ".beta.-IFN" or ".beta.-interferon" as that term is used
herein is an acid-stable or free sulfhydryl-containing protein
which is synthesized by mammalian cells in response to viral
infection, immune stimulation and other factors. .beta.-IFN has a
molecular weight of between 18,000 and 23,000 daltons depending on
the particular form, and is characterized by three cysteine amino
acids, two of which are linked in a disulfide bond leaving one
remaining as a free sulfhydryl (cysteine 17). .beta.-IFN includes
.beta.-IFN derived both from natural sources, including human,
bovine, canine, feline, porcine and equine, and by recombinant DNA
techniques. The term also includes modified forms of
.beta.-interferon, for example, wherein glycosylation, methylation,
substitution and/or deletion of a specified number of amino acids
has occurred. IFN-.beta..sub.ser17 refers to .rho.-IFN in which the
seventeenth amino acid present in the sequence (cysteine) has been
replaced by serine.
[0022] As defined herein, a sustained release of biologically
active acid-stable or free sulfhydryl-containing protein is a
release of the protein from the sustained release composition of
the invention which occurs over a period which is longer than that
period during which a biologically significant amount of the
protein, for example, .beta.-IFN would be available following
direct administration of a solution of the protein. It is preferred
that a sustained release be a release of acid-stable or free
sulfhydryl-containing protein which occurs over a period of greater
than two days. A sustained release of acid-stable or free
sulfhydryl-containing protein from a polymeric matrix can be a
continuous or a discontinuous release, with relatively constant or
varying rates of release. The continuity of release and level of
release can be affected by the type of polymer composition used
(e.g., monomer ratios, molecular weight, block composition, and
varying combinations of polymers), protein loading, and/or
selection of excipients to produce the desired effect.
[0023] A "therapeutically or prophylactically effective amount", as
used herein, is the amount of the composition for the sustained
release of a biologically active acid-stable or free
sulfhydryl-containing protein, for example, .beta.-IFN, necessary
to elicit the desired biological response following
administration.
[0024] "Stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation", as that term is used
herein, refers to a biologically active acid-stable or free
sulfhydryl-containing protein, for example, .beta.-IFN which can be
stabilized against degradation, aggregation, loss of potency and/or
loss of biological activity, all of which can occur during
formation of the sustained release composition, and prior to and/or
during in vivo release. For example, .beta.-IFN and other
acid-stable or free sulfhydryl-containing proteins can aggregate to
form a dimer which is not biologically active. The dimer can be
formed during processing of the sustained release composition or
following administration in vivo. When the protein contains a free
sulfhydryl, formation of covalent aggregates can result from
intermolecular disulfide formation.
[0025] In addition, interactions between the biologically active
acid-stable or free sulfhydryl-containing protein and the
biocompatible polymer of the sustained release composition can
shorten the period of sustained release. For example, it has been
determined that .beta.-IFN adsorbs onto the polymer of the
sustained release composition resulting in an undesirable release
profile. Furthermore, proteins which are acid-stable can be
significantly degraded when exposed in vivo to physiological pH
(7.4) for sustained periods of time.
[0026] Stabilization of the biologically active acid-stable or free
sulfhydryl-containing protein, for example, .beta.-IFN can be
accomplished, for example, by the use of a particular combination
of stabilizing agents. "A stabilizing agent" as that term is used
herein, is any agent which binds or interacts in a covalent or
non-covalent manner, or is included with the protein, for example,
.beta.-IFN to stabilize against degradation, loss of post hydration
solubility, loss of potency and/or loss of biological activity.
Stabilizing agents can also be added to the sustained release
composition which minimize the undesired interaction of the protein
with the biocompatible polymer, for example, adsorption of the
acid-stable or free sulfhydryl-containing protein to the surface of
the biocompatible polymer of the sustained release composition.
[0027] A "stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation," as defined herein,
comprises at least one acid-stable or free sulfhydryl-containing
protein in combination with at least one disaccharide, and at least
one acidic excipient. Optionally, at least one water soluble
polymer can also be present in the stabilized protein formulation.
The sustained release composition comprises the stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation, a biocompatible polymer and at least one
surfactant which is dispersed in the polymer phase. The water
soluble polymer, optionally present in the stabilized biologically
active protein formulation, can in some instances be the same as
the surfactant present in the polymer phase. The amount of
biologically active acid-stable or free sulfhydryl-containing
protein in the stabilized biologically active protein formulation
can range from about 0.5% (w/w) to about 50% (w/w) of the dry
stabilized biologically active protein formulation. For example,
from about 0.5% (w/w) to about 30% (w/w), or more specifically from
about 2% (w/w) to about 20% (w/w).
[0028] "Acidic excipient" as that term is used herein refers to any
organic acid. These excipients can be added as the acid, or as the
salt form of the conjugate base of the acid. For example, the
acidic excipient citric acid can be added either in the acid form,
citric acid, or as the salt form of the conjugate base, for
example, the mono-,di-, or trisodium salt of the citric acid.
Suitable acidic excipients include citric acid, ascorbic acid,
acetic acid, ethylenediaminetetraacetic acid, saturated fatty
acids, bile acids, dicarboxylic acids, and combinations thereof.
Suitable saturated fatty acids include, but are not limited to
butyric, caproic, caprylic, capric, lauric, myristic, palmitic,
stearic and arachadic. Suitable bile acids include cholic acid,
taurocholic acid, deoxycholic acid, taurodeoxycholic acid,
chenodeoxycholic acid, glycocholic acid, glycodeoxycholic, and
lithocholic acid. Suitable dicarboxylic acids include, but are not
limited to oxalic, malonic, succinic, glutaric, adipic, pimelic,
suberic, azelaic, and sebacic. Particular acidic excipients
suitable for use in the invention include amino acids. Preferred
amino acids are the acidic amino acids. "Acidic amino acids" as
that term is used herein, refers to amino acids having acidic side
chains, thereby resulting in the presence of more acidic groups
than basic groups. For example, aspartic acid and glutamic acid are
acidic amino acids. These particular amino acids are typically
referred to as aspartate and glutamate to emphasize that their side
chains are nearly always negatively charged at physiological pH.
The amount of acidic excipient present in the stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation can range from about 1% (w/w) to about 50%
(w/w) of the dry stabilized biologically active protein
formulation, for example from about 2% (w/w) to about 20%
(w/w).
[0029] A "disaccharide", as defined herein, is a compound which
upon hydrolysis yields two molecules of a monosaccharide. Suitable
disaccharides include, but are not limited to, sucrose and
trehalose. It is preferred that the disaccharide is non-reducing.
The amount of disaccharide present in the stabilized biologically
active acid-stable or free sulfhydryl-containing protein
formulation can range from about 5% to about 95%.
[0030] "Surfactants" as that term is used herein refers to any
substance which can reduce the surface tension between immiscible
liquids. Suitable surfactants include, polymer surfactants, such as
nonionic polymer surfactants, for example, poloxamers,
polysorbates, polyethylene glycols (PEGs), polyoxyethylene fatty
acid esters, polyvinylpyrrolidone and combinations thereof.
Examples of poloxamers suitable for use in the invention include
poloxamer 407 sold under the trademark PLURONIC.RTM. F127 and
poloxamer 188 sold under the trademark PLURONIC.RTM. F68, both
available from BASF Wyandotte. Examples of polysorbates suitable
for use in the invention include polysorbate 20 sold under the
trademark TWEEN.RTM. 20 and polysorbate 80 sold under the trademark
TWEEN.RTM. 80. Cationic surfactants, for example, benzalkonium
chloride, are also suitable for use in the invention. In addition,
bile salts, such as deoxycholate and glycocholate are suitable as
surfactants based on their highly effective nature as
detergents.
[0031] As described in the Experimental Section, the surfactant
assists in minimizing adsorption of the acid-stable or free
sulfhydryl-containing protein to the biocompatible polymer of the
polymer matrix. It has been found that in addition to the
surfactant, the presence of an acidic excipient in the polymer
phase of the sustained release composition described herein can
increase the anti-adsorption effect seen with the surfactant. The
amount of surfactant present in the polymer of the sustained
release composition can range from about 1% w/w to about 40% w/w of
the total weight of the composition.
[0032] A "water soluble polymer" as defined herein is any polymer
which is soluble in water. In a preferred embodiment, the water
soluble polymer is also soluble in the polymer solvent used in the
process for preparing the sustained release composition described
herein. Water soluble polymers suitable for use in the invention
include water soluble polysaccharides, for example, methyl
cellulose, ethyl cellulose, ficoll and combinations thereof, and
nonionic polymer surfactants such as poloxamers, for example
poloxamer 407, poloxamer 188 and combinations thereof, and
polysorbates, for example, polysorbate 80, polysorbate 20,
polyethylene glycol polymers, polyvinylpyrrolidone, polyoxyethylene
fatty acid esters and any combination thereof.
[0033] When present in the stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation the
water soluble polymer can range from about 0.5% (w/w) to about 40%
(w/w) of the dry weight of the stabilized formulation.
[0034] In a specific embodiment, the stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation is
stabilized .beta.-IFN comprising .beta.-IFN, glutamate and
trehalose. The .beta.-IFN can be present in the stabilized
biologically active .beta.-IFN in a range of from about 1% w/w to
about 30% w/w of the dry weight of the stabilized .beta.-IFN
formulation. The glutamate can be present in the stabilized
biologically active .beta.-IFN in a range of from about 1% w/w to
about 30% w/w of the dry weight of the stabilized .beta.-IFN
formulation. The trehalose can be present in the stabilized
biologically active .beta.-IFN in a range of from about 20% w/w to
about 90% w/w of the dry weight of the stabilized .beta.-IFN
formulation. When the optional water soluble polymer is present it
can be present in an amount from about 0.5% w/w to about 40% w/w of
the dry weight of the stabilized .beta.-IFN formulation.
[0035] Polymers suitable to form the sustained release composition
of this invention are biocompatible polymers which can be either
biodegradable or non-biodegradable polymers or blends or copolymers
thereof. A polymer is biocompatible if the polymer and any
degradation products of the polymer are non-toxic to the recipient
and also possess no significant deleterious or untoward effects on
the recipient's body, such as an immunological reaction at the
injection site.
[0036] "Biodegradable", as defined herein, means the composition
will degrade or erode in vivo to form smaller chemical species.
Degradation can result, for example, by enzymatic, chemical and
physical processes. Suitable biocompatible, biodegradable polymers
include, for example, poly(lactides), poly(glycolides),
poly(lactide-co-glycolides), poly(lactic acid)s, poly(glycolic
acid)s, polycarbonates, polyesteramides, polyanydrides, poly(amino
acids), polyorthoesters, poly(dioxanone)s, poly(alkylene
alkylate)s, copolymers or polyethylene glycol and polyorthoester,
biodegradable polyurethane, blends thereof, and copolymers
thereof.
[0037] Suitable biocompatible, non-biodegradable polymers include
non-biodegradable polymers selected from the group consisting of
polyacrylates, polymers of ethylene-vinyl acetates and other acyl
substituted cellulose acetates, non-degradable polyurethanes,
polystyrenes, polyvinylchloride, polyvinyl flouride, poly(vinyl
imidazole), chlorosulphonate polyolefins, polyethylene oxide,
blends thereof, and copolymers thereof.
[0038] Acceptable molecular weights for polymers used in this
invention can be determined by a person of ordinary skill in the
art taking into consideration factors such as the desired polymer
degradation rate, physical properties such as mechanical strength,
and rate of dissolution of polymer in solvent. Typically, an
acceptable range of molecular weight is of about 2,000 Daltons to
about 2,000,000 Daltons. In a preferred embodiment, the polymer is
biodegradable polymer or copolymer. In a more preferred embodiment,
the polymer is a poly(lactide-co-glycolide)(hereina- fter "PLGA")
with a lactide:glycolide ratio of about 1:1 and a molecular weight
of about 5,000 Daltons to about 70,000 Daltons. In an even more
preferred embodiment, the molecular weight of the PLGA used in the
present invention has a molecular weight of about 5,000 Daltons to
about 42,000 Daltons.
[0039] To prepare stabilized biologically active acid-stable or
free sulfhydryl-containing protein formulations, such as a
stabilized biologically active .beta.-IFN formulation, at least one
protein is mixed in an aqueous solution comprising at least one
disaccharide and at least one acidic excipient. Optionally, at
least one water soluble polymer can be included. The resulting
solution is then spray freeze dried to form the stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation, for example, .beta.-IFN. Spray freeze drying
of the solution can be accomplished by atomizing the solution to
form liquid droplets, contacting the liquid droplets with a
freezing medium to produce frozen droplets, removing the solvent
from the frozen droplets to form a stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation. The
solvent can be removed from the droplets by, for example,
lyophilization.
[0040] Preferably, the formulation comprises particles of
stabilized biologically active acid-stable or free
sulfhydryl-containing protein, for example, .beta.-IFN, having a
volume median particle size of 10 micrometers or less. The
stabilized .beta.-IFN and other stabilized protein particles can be
fragmented separately, as described in co-pending U.S. patent
application Ser. No. 08/006,682, filed Jan. 21, 1993, which
describes a process for producing small particles of biologically
active agents, the entire content of which is incorporated herein
by reference. Alternatively, the stabilized .beta.-IFN or other
stabilized protein particles can be fragmented after being added to
a polymer solution as part of the process for producing the
sustained release composition described herein. Fragmentation can
be accomplished, for example, by means of an ultrasonic probe,
homogenization, mechanical shear, or ultrasonic nozzle.
[0041] It has been found that addition of a water soluble polymer
to the solution which is spray freeze dried to form the
biologically active acid stable or free sulfhydryl-containing
protein formulation can result in a reduction in the volume median
particle size of the stabilized biologically active acid-stable or
free sulfhydryl-containing protein formulation. More specifically,
subsequent fragmentation of the stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation, in a
solvent which is a nonsolvent for the protein but a solvent for the
water soluble surfactant and biocompatible polymer of the resulting
sustained release composition, can achieve this reduction in
particle size. In a preferred embodiment, the water soluble polymer
is a nonionic water soluble polymer surfactant which is likewise
soluble in the solvent for the biocompatible polymer of the
sustained release composition. Use of a water soluble polymer as a
means of reducing the particle size of biologically active agent is
described in detail in U.S. application Ser. No. 09/501,636
entitled "A Method of Preparing a Sustained Release Composition and
Use Thereof" filed on Feb. 10, 2000 and incorporated herein by
reference.
[0042] The amount of biologically active acid-stable or free
sulfhydryl-containing protein, for example .beta.-IFN, which is
contained within the polymeric matrix of a controlled release
composition, is a therapeutically or prophylactically effective
amount which can be determined by a person of ordinary skill in the
art, taking into consideration factors such as body weight,
condition to be treated, type of polymer used, and release rate
from the polymer.
[0043] Typically, the sustained release composition can contain
from about 0.01% (w/w) to about 30% (w/w) of the biologically
active acid-stable or free sulfhydryl-containing protein (dry
weight of composition). The amount of the acid-stable or free
sulfhydryl-containing protein will vary depending upon the desired
effect of the acid-stable or free sulfhydryl-containing protein,
the planned release levels, and the time span over which the
protein, for example .beta.-IFN will be released. A specific range
of loading is between about 0.1% (w/w) to about 10% (w/w) such as
0.5% (w/w) to about 5% (w/w).
[0044] It is understood that the amount of stabilized biologically
active acid-stable or free sulfhydryl-containing protein
formulation needed to achieve a theoretical load of protein in the
sustained release composition can be determined based on the
percentage of protein present in the formulation. For example, if a
theoretical protein load of 1% is desired in the sustained release
composition and the stabilized biologically active acid-stable or
free sulfhydryl-containing protein formulation contains 10%
protein, then the final sustained release composition should
contain 10% (w/w) of the formulation.
[0045] Bulking agents can also be present in the sustained release
composition of the invention. Typically these bulking agents
comprise inert materials. Suitable bulking agents are known to
those skilled in the art.
[0046] A metal cation component which is dispersed within the
polymer matrix can also be used as an optional excipient. This
metal cation component acts to further modulate the release of the
acid-stable or free sulfhydryl-containing protein and is not
complexed with the protein. A metal cation component used in
modulating release typically comprises at least one type of
multivalent metal cation. Examples of metal cation components
suitable to modulate protein release include or contain, for
example, Mg(OH).sub.2, MgCO.sub.3 (such as 4MgCO.sub.3.Mg(OH).sub.2
5H.sub.2O), MgSO.sub.4, Zn(OAc).sub.2, ZnSO.sub.4, ZnCl.sub.2,
MgCl.sub.2 and magnesium citrate. A suitable ratio of metal cation
component to polymer is between about 1:99 to about 1:2 by weight.
The optimum ratio depends upon the polymer and the metal cation
component utilized. A polymeric matrix containing a dispersed metal
cation component to modulate the release of a biologically active
agent from the polymeric matrix is further described in U.S. Pat.
No. 5,656,297 and co-pending U.S. patent application Ser. No.
08/727,531, the teachings of both of which are incorporated herein
by reference in their entirety.
[0047] The sustained release composition of this invention can be
formed into many shapes such as a film, a pellet, a cylinder, a
disc or a microparticle. A microparticle, as defined herein,
comprises a polymer component having a diameter of less than about
one millimeter and having stabilized biologically active
acid-stable or free sulfhydryl-containing protein, for example,
.beta.-IFN dispersed or dissolved therein. A microparticle can have
a spherical, non-spherical or irregular shape. Typically, the
microparticle will be of a size suitable for injection. A typical
size range for microparticles is 1000 microns or less. In a
particular embodiment, the microparticle ranges from about one to
about 180 microns in diameter.
[0048] In the method of this invention for forming a composition
for the sustained release of a biologically active acid-stable or
free sulfhydryl-containing protein, for example, .beta.-IFN, a
predetermined amount of particles of stabilized biologically active
acid-stable or free sulfhydryl-containing protein formulation is
dispersed in a polymer solution. The amount of formulation is
determined based on the load of protein desired.
[0049] A suitable polymer solution contains between about 1% (w/v)
and about 30% (w/v) of a suitable biocompatible polymer, wherein
the biocompatible polymer is typically dissolved in a suitable
polymer solvent. Preferably, a polymer solution contains about 2%
(w/v) to about 20% (w/v) polymer.
[0050] A suitable polymer solvent, as defined herein, is a solvent
in which the polymer is soluble, in which some, none, or all of the
stabilized biologically active acid-stable or free
sulfhydryl-containing protein formulation is soluble and in which
the formulation is non-reactive. Examples of suitable polymer
solvents include polar organic liquids, such as methylene chloride,
chloroform, ethyl acetate, methyl acetate, hexafluoroisopropanol,
acetone, dimethylsulfoxide and combinations thereof.
[0051] One suitable method for forming sustained release
microparticles from a polymer solution is described in U.S. Pat.
No. 5,019,400, issued to Gombotz et al., and U.S. Pat. No.
5,912,253 issued to Herbert et al., the teachings of which are
incorporated herein by reference in their entirety. This method of
microparticle formation, as compared with other methods such as
phase separation, can also reduce the amount of biologically active
acid-stable or free sulfhydryl-containing protein, such as
.beta.-IFN, required to produce a sustained release composition
with a specific biologically active protein content.
[0052] In this method, a polymer solution, containing the
stabilized biologically active .beta.-IFN or other stabilized
biologically active acid-stable or free sulfhydryl-containing
protein formulation which can be present in solution or as a
particle dispersion, is processed to create droplets, wherein at
least a significant portion of the droplets contains polymer,
polymer solvent and the stabilized .beta.-IFN or other biologically
active acid-stable or free sulfhydryl-containing protein particles.
These droplets are then frozen by means suitable to form
microparticles. Examples of means for processing the mixture
comprising a polymer solution and the stabilized biologically
active .beta.-IFN formulation or other biologically active
acid-stable or free sulfhydryl-containing protein formulation to
form droplets include directing the dispersion through an
ultrasonic nozzle, pressure nozzle, Rayleigh jet, or by other known
means for creating droplets from a solution.
[0053] Means suitable for freezing droplets to form microparticles
include directing the droplets into or near a liquified gas, such
as liquid argon or liquid nitrogen to form frozen microdroplets
which are then separated from the liquid gas. It is to be
understood that the stabilized biologically active .beta.-IFN
formulation can be spray freeze dried following the above described
procedure.
[0054] The frozen microdroplets are then exposed to a liquid or
solid non-solvent, such as ethanol, hexane, ethanol mixed with
hexane, heptane, ethanol mixed with heptane, pentane or oil. The
solvent in the frozen microdroplets is extracted as a solid and/or
liquid into the non-solvent to form stabilized .beta.-IFN or other
stabilized biologically active acid-stable or free
sulfhydryl-containing protein containing microparticles. Mixing
ethanol with other non-solvents, such as hexane, heptane or
pentane, can increase the rate of solvent extraction, above that
achieved by ethanol alone, from certain polymers, such as
poly(lactide-co-glycolide) polymers.
[0055] A wide range of sizes of sustained release microparticles
can be made by varying the droplet size, for example, by changing
the ultrasonic nozzle frequency. If very large microparticles are
desired, the microparticles can be extruded, for example, through a
syringe directly into the cold liquid. Increasing the viscosity of
the polymer solution can also increase microparticle size. The size
of the microparticles which can be produced by this process ranges,
for example, from greater than about 1000 to about 1 micrometers in
diameter. The particles can be isolated from the extraction solvent
by filtration and can be dried by evaporation to further remove
remaining solvent. The particles can be sized by passing them
through an appropriately sized mesh.
[0056] Yet another method of forming sustained release composition,
from a polymer solution, includes film casting, such as in a mold,
to form a film or a shape. For instance, after putting the polymer
solution containing a stabilized biologically active acid-stable or
free sulfhydryl-containing protein formulation into a mold, the
polymer solvent is then removed by means known in the art, or the
temperature of the polymer solution is reduced, until a film or
shape, with a consistent dry weight, is obtained. Film casting of a
polymer solution, containing a biologically active agent, is
further described in U.S. Pat. No. 5,656,297, the teachings of
which are incorporated herein by reference in their entirety.
[0057] Without being bound by a particular theory it is believed
that the release of the biologically active acid-stable or free
sulfhydryl-containing protein, for example, .beta.-IFN, can occur
by two different mechanisms. First, the biologically active
acid-stable or free sulfhydryl-containing protein can be released
by diffusion through aqueous filled channels generated in the
polymeric matrix, such as by the dissolution of the protein, or by
voids created by the removal of the polymer solvent during the
preparation of the sustained release composition. A second
mechanism is the release of the protein, for example .beta.-IFN,
due to degradation of the polymer. The rate of degradation can be
controlled by changing polymer properties that influence the rate
of hydration of the polymer. These properties include, for
instance, the ratio of different monomers, such as lactide and
glycolide, comprising a polymer; the use of the L-isomer of a
monomer instead of a racemic mixture; and the molecular weight of
the polymer. These properties can affect hydrophilicity and
crystallinity, which control the rate of hydration of the polymer.
By altering the properties of the polymer, the contributions of
diffusion and/or polymer degradation to release can be controlled.
For example, increasing the glycolide content of a
poly(lactide-co-glycolide) polymer and/or decreasing the molecular
weight of the polymer can enhance the hydrolysis of the polymer and
thus, provides an increased rate of release of protein due to
polymer erosion.
[0058] In addition, the rate of polymer hydrolysis is increased in
non-neutral pH. Therefore, an acidic or a basic excipient can be
added to the polymer solution, used to form the microparticle, to
alter the polymer erosion rate.
[0059] The composition of this invention can be administered to a
human, or other animal, by injection, implantation (e.g.,
subcutaneously, intramuscularly, intraperitoneally, intracranially,
and intradermally), administration to mucosal membranes (e.g.,
intranasally, intravaginally, intrapulmonary or by means of a
suppository), or in situ delivery (e.g., by enema or aerosol spray)
to provide the desired dosage of biologically active acid-stable or
free sulfhydryl-containing protein, for example .beta.-IFN, based
on the known parameters for treatment with such protein of the
various medical conditions.
[0060] Even though the invention has been described with a certain
degree of particularity, it is evident that many alternatives,
modifications, and variations will be apparent to those skilled in
the art in light of the foregoing disclosure. Accordingly, it is
intended that all such alternatives, modifications, and variations
which fall within the spirit and scope of the invention be embraced
by the defined claims.
[0061] The invention will now be further and specifically described
by the following examples.
[0062] Exemplifications
[0063] The following methods were employed to analyze samples
produced during the production and characterization of the
.beta.-IFN containing microparticles. For example, the bulk drug
can be analyzed, .beta.-IFN lyophilizates can be analyzed,
.beta.-IFN extracted from the microparticles can be analyzed, as
well as protein released from the microparticles.
[0064] Methods of Analysis Size Exclusion Chromatography
[0065] Size Exclusion Chromatography (SEC) was employed to
determine the % of native monomeric .beta.-IFN in an aqueous
solution. SEC was conducted on a 7.8 mm.times.30 cm TSK G2000SWXL 5
.mu.m column available from Supelco (Cat. #: 08540) using a
precolumn filter. The flow rate was 0.5 mL/min with a column load
of between 0.1 and 30 .mu.g and a detector setting of 214 nm. The
elution system was isocratic using 30% MeCN/0.2% TFA.
[0066] Reversed Phase HPLC (RPHPLC)
[0067] Reversed Phase HPLC was used to determine the purity of
.beta.-IFN samples isolated at various stages as detailed above.
Specifically, the quantity of oxidized beta-IFN was determined
employing this method. RPHPLC was conducted on a 4.6 mm.times.250
mm Supelco C4 5 .mu.m Supelcosil LC-304 column available from
Supelco (Part #: 5-8824). The flow rate was 1 mL/min with a run
time of 70 minutes. A column load of between 0.5 .mu.g and 30 .mu.g
and a detector setting at 214 nm. The elution system consisted of
Mobile Phase A (40% MeCN/0. 14% HFBA(n-heptafluorobutyric acid),
Mobile Phase B (80% MeCN/0.14% HFBA) and Mobile Phase C (80%
MeCN/0.1% TFA) employing the following gradient:
1 0' 70% A 30% B 5' 70% A 30% B 58' 62% A 38% B 63' 0% A 100% B 68'
0% A 0% B 100% C 69' 70% A 30% B
[0068] SDS-PAGE
[0069] As a complement to the SEC method described above, an
SDS-PAGE method performed under non-reducing conditions was
employed to measure covalent aggregation of .beta.-IFN in
lyophilizate samples compared to the bulk drug. Samples were
reconstituted in 50 mM sodium acetate buffer (pH 3.8) at a
concentration of about 0.4 mg/mL. The solution or suspension was
sampled and then diluted to 0.3 mg/mL with a 4.times.Novex SDS
solubilization solution, available from Novex, Inc. After boiling
for 5 minutes, solutions were allowed to cool to room temperature
and 4 uL was applied to an 8-15% Gradient Phast Gel with SDS-buffer
blocks. The separation and Coomassie staining were performed by the
Standard Phast System protocol available from Amersham Pharmacia.
Gels were scanned using a laser densitometer and relative amounts
monomer, dimer, and aggregate were quantitated. The results were
compared to the bulk drug carried through the same SDS-PAGE sample
preparation procedure.
[0070] ELISA
[0071] The amount of .beta.-IFN in rat serum was determined using
an ELISA kit available from Toray-Fuji Bionics, Inc. (TFB, Inc.).
The kit utilizes the one step sandwich method for the quantitation
of .beta.-IFN in serum.
[0072] Extraction of .beta.-IFN from Microparticles
[0073] The following procedure was employed to extract .beta.-IFN
from poly(lactide-co-glycolide) microparticles in order to
determine the integrity of the drug post-encapsulation. The
procedure was performed at room temperature and used an extraction
buffer composed of 80% acetic acid and 0.5% TWEEN 80. One and a
half milliliters of this extraction buffer was added to a 10 mg
sample of the microspheres and it was vortexed for about 5 minutes.
The acetic acid dissolved both the polymer and the protein. The
sample was centrifuged to remove any remaining particles. 300 .mu.L
of the resulting supernatant was transferred to a tube containing
1200 .mu.L of water to precipitate the polymer. The tube was
vortexed for about 10 seconds and centrifuged for about 10 minutes
to remove the precipitated polymer. The supernatant was analyzed by
SEC to determine protein integrity.
[0074] Preparative Methods
[0075] Polymer
[0076] The polymers employed in the following examples were
purchased from Alkermes, Inc. of Cincinnati, Ohio and can be
described as follows:
[0077] Polymer A: Cat. No. 5050 2M; Poly(lactide-co-glycolide;
50:50 lactide:glycolide ratio; 10 kD Mol. Wt.; Esterified end
group.
[0078] Polymer B: Cat. No. 5050 2A; Poly(lactide-co-glycolide;
50:50 lactide:glycolide ratio; 10 kD Mol. Wt.; Carboxylic acid end
group.
[0079] Polymer C: Cat. No. 5050 4A; Poly(lactide-co-glycolide;
50:50 lactide:glycolide ratio; 40 kD Mol. Wt.; Carboxylic acid end
group.
[0080] Polymer D: Cat. No. 8515 2A; Poly(lactide-co-glycolide;
85:15 lactide:glycolide ratio; 10 kD Mol. Wt.; Carboxylic acid end
group.
[0081] Process for Preparing Microparticles
[0082] Formation of a polymer solution by dissolving polymer in a
suitable polymer solvent.
[0083] Addition of a nonionic surfactant to the polymer phase.
[0084] Addition of the stabilized biologically active acid-stable
or free sulfhydryl-containing protein formulation to the polymer
solution to form a polymer/protein mixture. The biologically active
acid-stable or free sulfhydryl-containing protein formulation can
be soluble or insoluble in the polymer solution.
[0085] Optional homogenization of the polymer/protein mixture.
[0086] Atomization of the polymer/protein mixture by sonication,
and freezing of the droplets by contact with liquid nitrogen.
[0087] Extraction of the polymer solvent from the polymer/protein
droplets into an extraction solvent (e.g., -80.degree. C. ethanol),
thereby forming particles comprising a polymer/stabilized protein
matrix.
[0088] Isolation of the particles from the extraction solvent by
filtration.
[0089] Removal of remaining solvent by evaporation.
[0090] Sizing of particles by passage through an appropriately
sized mesh so as to produce an injectable product.
EXAMPLE 1
Preparation of Stabilized .beta.-IFN Lyophilizate
[0091] Excipients were identified that stabilized .beta.-IFN
through the spray freeze drying process steps necessary to prepare
the stabilized .beta.-IFN formulation for encapsulation. Table 1
lists formulations of .beta.-IFN initially investigated in
assessing agents as potential stabilizers of .beta.-IFN. Briefly,
an aqueous solution containing the protein and the desired
excipients, is sprayed into liquid nitrogen by pumping it through
an ultrasonic nozzel. The resulting slurry of ice crystals and
liquid nitrogen is kept at about -20 to -40.degree. C. until the
liquid nitrogen evaporates. The frozen solution is freeze-dried in
a programmable lyophilizer (FTS Systems) over the course of three
days.
[0092] The formulations from Table 1 which are listed in Table 2
are those which resulted in a .beta.-IFN formulation which was as
stable as bulk drug substance (BDS) after the initial spray freeze
drying step of the process. Stability was assessed using SDS-PAGE
and SEC methods as described above. The .beta.-IFN formulations
which gave values of % monomer greater than lyophilized bulk drug
(Control) were determined as being stabilized .beta.-IFN
formulations.
2TABLE 1 Composition of .beta.-IFN Formulations .beta.-IFN
Formulation No. Composition (% (w/w) of the solid formulation) 1
90% sodium acetate, 10% .beta.-IFN 2 83% trehalose, 10% .beta.-IFN,
7% acetate buffer salts pH4 3 80% HSA, 10% .beta.-IFN, 2% NaCl
(from HSA solution) 8% acetate buffer salts pH4 4 82% sucrose, 10%
.beta.-IFN, 8% acetate buffer salts pH4 5 77% trehalose, 10%
.beta.-IFN, 4% zinc acetate 9% acetate buffer salts pH5 6 77%
trehalose, 10% .beta.-IFN, 4% zinc acetate 9% acetate buffer salts
pH4 7 73% mannitol, 10% .beta.-IFN, 10% glycine, 7% acetate buffer
salts pH4 8 73% mannitol, 10% .beta.-IFN, 10% PEG 8000, 7% acetate
buffer salts pH4 9 80% mannitol, 10% .beta.-IFN, 10% buffer salts
(acetate + bicarbonate) pH7.7 10 63% mannitol, 10% .beta.-IFN, 10%
cysteine, 17% acetate buffer salts pH4 11 80% ammonium sulfate, 10%
.beta.-IFN, 10% acetate buffer salts pH4 12 80% ammonium sulfate,
10% .beta.-IFN, 1% Tween 80, 9% acetate buffer salts pH4 13 80%
ammonium sulfate, 10% .beta.-IFN, 10% phosphate buffer salts pH5 14
70% mannitol, 10% .beta.-IFN, 9% beta-cyclodextrin 11% buffer salts
(acetate + bicarbonate) pH7 Formulation pH is of solution prior to
lyophilization. If no pH listed, the pH was about 4.
[0093]
3TABLE 2 Integrity .beta.-IFN Formulation % Monomer % Monomer Area
No. (SEC) (SDS-PAGE) BDS 98 85-92 (0.35 mg/mL solution) 1 92 74 2
96-98 85-90 3 nb 83-87 4 98 81 5 97 86 6 97 83 nb: SEC could not be
used due to interference with HSA. BDS = Bulk Drug Substance
EXAMPLE 2
Encapsulation of Lyophilizate Formulations
[0094] Stabilized .beta.-IFN formulations 2, 3 and 6 were
encapsulated into biocompatible polymers A, B, and C described
above, employing the process outlined above with a target load of
.beta.-IFN of about 1%. Table 3 lists the various characteristics
of the prepared microparticle formulations. The data suggests that
the stabilized .beta.-IFN lyophilizates are not deleteriously
effected by the encapsulation process, and that the encapsulation
efficiency of the stabilized .beta.-IFN is high.
4TABLE 3 Microparticle Characterization Microsphere Particle Size
(Volume % Native Microparticle .beta.-IFN Polymer Median %
.beta.-IFN .beta.-IFN Formulation Formulation Type % Diameter
Monomer by No. No. Used Protein .mu.m) by SEC rHPLC I 3 B 1.0* 56
NQ 99 II 3 A 1.0* 63 NQ 99 III 3 C 1.0* 62 NQ 100 IV 2 B 1.0 63 98
98 V 2 A 0.9 57 97 98 VI 2 C 1.0 57 96 97 VII 2 A 0.9 61 97 97
(w/zinc citrate) VIII 6 A 0.9 54 97 98 *= Estimated from % nitrogen
minus nitrogen due to HSA NQ = Not Quantifiable due to HSA
interference
EXAMPLE 3
Preparation of .beta.-IFN Formulations Having Post Hydration
Stability
[0095] A water-jacketed incubator (purchased from Forma Scientific)
having a 100% humidity level and a temperature of 37.degree. C. was
used to simulate conditions experienced by microparticle
formulations following administration in vivo. Use of the humidity
chamber allowed assessment of formulations without the need for
encapsulating the stabilized .beta.-IFN in the polymer.
[0096] The .beta.-IFN lyophilizate compositions tested are set
forth in Table 4. Following incubation for 1 day monomer content
was evaluated using SEC as described above. The humidity exposed
stabilized .beta.-IFN formulations were dissolved in a solution of
80% acetic acid/0.5% TWEEN.RTM. 80. The change in % monomer was
determined by SEC and is listed in Table 4.
5TABLE 4 .beta.-IFN % Monomer (After 1 Day) Formulation Incubation
in No. Composition (% W/W) 100% Humidity 15 10% .beta.-IFN 56 80%
Trehalose 10% Acetate 16-1 10% .beta.-IFN 42 16-2 12% Citrate 55
16-3 78% Trehalose 80 17 10% .beta.-IFN 64 12% Citrate 5% PLURONIC
.RTM. F68 73% Trehalose 18 2.5% Tween .RTM. 80 45 12% Citrate 10%
.beta.-IFN 75.5% Trehalose 19 10% .beta.-IFN 42 1% Tween .RTM. 80
12% Citrate 77% Trehalose 20 10% .beta.-IFN 36 50% Citrate 40%
Trehalose 21 10% .beta.-IFN 63 .+-. 4 (COV: 6.3%) 12% Citrate 5%
PEG 8000 73% Trehalose 22 10% .beta.-IFN 48 .+-. 2.3 (COV: 4.8%)
12% Citrate 0.5% PEG 8000 77.5% Trehalose 23 10% .beta.-IFN 54 .+-.
4 (COV: 7.4%) 12% Citrate 5% PVP 73% Trehalose 24 10% .beta.-IFN 59
.+-. 1.4 (COV: 2.3%) 12% Citrate 0.5% PVP 77.5% Trehalose 25-1 10%
.beta.-IFN 88.0 .+-. 0.3 (COV: 0.3%) 25-2 12% Glutamate 84 78%
Trehalose 26 10% .beta.-IFN 79.0 .+-. 0.9 (COV: 1.1%) 12% Ascorbic
Acid 78% Trehalose 12% Citrate COV = Coefficient of Variation
[0097] The results presented in Table 4 show that the stabilized
.beta.-IFN Formulation 15 (Same components as Formulation 2 of
Table 1), which was earlier determined to be stable to processing
steps, did not sufficiently stabilize the .beta.-IFN under
conditions of hydration and likely release in vivo. Formulations
17, 21, 25 and 26 of Table 4, which all contain an acidic excipient
were determined to be more stable than Formulation 15, and were
therefore chosen for further investigation. Formulation 25
exhibited the greatest % increase in monomer over Formulation 15
(57% greater monomer content at Day 1). Formulation 16 exhibited
low % monomer at Day 1 for two of the three batches tested. The
data indicate that an acidic excipient is needed in the stabilized
.beta.-IFN formulation in order to minimize aggregation of
.beta.-IFN upon hydration.
EXAMPLE 4
Further Formulation Development
[0098] Additional formulations as well as ones described previously
which contain various combinations of an acidic excipient and a
disaccharide were prepared and tested in vitro for post hydration
stability beyond one day of exposure to humidity. The stabilized
.beta.-IFN formulations were exposed to 100% humidity as detailed
above. The results are presented in Table 5.
6TABLE 5 % Monomer of .beta.-IFN .beta.-IFN Formulation Formulation
(Humidification) No. Composition Day 0 Day 1 Day 7 25 10%
.beta.-IFN/12% 98 84 79 Glutamate/78% Trehalose 27 10%
.beta.-IFN/30% 98 80 70 Glutamate/60% Trehalose 28 10%
.beta.-IFN/12% 98 81 70 Aspartate/78% Trehalose 29 10%
.beta.-IFN/25% 98 93 65 Ascorbate/65% Trehalose 30 10%
.beta.-IFN/12% 97 76 35 Glutamate/13% Ascorbate/65% Trehalose
[0099] Stabilized .beta.-IFN formulations were prepared using water
soluble polymers. The stability of the formulations was evaluated
over 7 days at 37.degree. C. and 100% humidity as earlier
described. The results are presented in Table 6.
7TABLE 6 Humidification .beta.-IFN Results Formulation % Monomer
No. Composition Day 1 Day 7 31 10% .beta.-IFN/13% Glutamate/20%
F68/ 71 56 57% Trehalose 32 10% .beta.-IFN/13% Glutamate/10% 86 79
F127/67% Trehalose 33 10% .beta.-IFN/13% Glutamate/20% 88 82
F127/57% Trehalose 85 78 89 80 34 10% .beta.-IFN/13% Glutamate/10%
PEG 85 80 8000/67% Trehalose 88 84 35 10% .beta.-IFN/13%
Glutamate/20% PEG 85 81 8000/57% Trehalose 36 10% .beta.-IFN/13%
Glutamate/20% 91 84 Methyl Cellulose/57% Trehalose 98 83 98 93 37
10% .beta.-IFN/12% Glutamate/5% 82 65 F68/73% Trehalose 38 10%
.beta.-IFN/12% Glutamate/10% 86 73 F68/68% Trehalose 39 10%
.beta.-IFN/12% Aspartate/10% 82 72 F68/68% Trehalose 82 68
[0100] The results presented in Table 6 indicate that stability of
the .beta.-IFN formulation can be further increased by the presence
of a water soluble polymer.
EXAMPLE 5
Evaluation of Lyophilizate Dissolution Before and After
Hydration
[0101] Formulations 15, 16, 17, 18, 21, 25 and 26 of Table 4 were
evaluated for dissolution in phosphate buffer at pH 7. Each of the
stabilized .beta.-IFN formulations evaluated were added to
phosphate buffer at pH 7 at a concentration of approximately 2
mg/mL of .beta.-IFN, and then incubated at 37.degree. C. for one
hour. The samples were then centrifuged to remove precipitates and
the supernatant was diluted in 250 mM acetate buffer for analysis
by the Bio-Rad Protein Assay available from Bio-Rad Laboratories.
The dissolution results are presented graphically in FIG. 1. FIG. 1
shows that a significant increase in dissolution is achieved with
the presence of an acidic excipient alone or in combination with a
water soluble polymer.
[0102] Additional formulations were prepared and evaluated for
dissolution after one day of exposure to humidity. The dissolution
of the humidified formulations was determined at both pH 3.8
(acetate buffer) and pH 7 (phosphate buffer) at a target
concentration of at least 200 .mu.g/mL of .beta.-IFN. As controls,
dissolution of non-humidified formulations in acetate buffer (pH
3.8) was also determined. The actual concentration of .beta.-IFN in
the solutions was measured using SEC.
8TABLE 7 Incubation at 37.degree. C., 100% Humidity pH .beta.-IFN
of Incubation Formulation Dissolution Time % .beta.-IFN No.
Composition Buffer (Days) Dissolved 33 10% .beta.-IFN/13% 3.8 0 101
Glutamate/ 1 91 20% F127/57% Trehalose 7 1 48 33 10% .beta.-IFN/
3.8 0 92 13% Glutamate/ 1 82 20% F127/57% Trehalose 7 1 49 40 10%
.beta.-IFN/13% 3.8 0 95 Aspartate/ 1 38 20% F127/57% Trehalose 7 1
28 34 10% .beta.-IFN/ 3.8 0 101 13% Glutamate/ 1 83 10% PEG 8000/
57% Trehalose 7 1 52 35 10% .beta.-IFN/ 3.8 0 93 13% Glutamate/ 1
83 20% PEG 8000/ 57% Trehalose 7 1 42 36 10% .beta.-IFN/ 3.8 0 100
13% Glutamate/ 1 94 20% Methyl Cellulose/57% 7 1 66 Trehalose
EXAMPLE 6
Determination of Adsorption of .beta.-IFN to a Biodegradable
Polymer
[0103] Experiments were performed to determine whether stabilized
.beta.-IFN formulations would be adsorbed onto the biocompatible
polymer of the sustained release composition. The stabilized
.beta.-IFN Formulation 15 was added to three buffers (pH=3.8
acetate, pH=7 phosphate, and pH=7 HEPES) in an amount sufficient to
achieve a concentration of 2 mg stabilized formulation/mL
(.about.0.2 mg .beta.-IFN/mL). Four batches of polymer
microparticles were prepared as described above using polymers A-D
also described above. 10 mg of each microparticle batch was added
to 0.5 mL of each buffer. The .beta.-IFN concentration in the
supernatant was determined using SEC after two hours at 37.degree.
C. followed by centrifugation. The % adsorption was determined by
comparing the concentrations of the samples exposed to polymer to
control samples without polymer using the following equation:
% Adsorption=[1-Sample concentration/Control concentration (no
polymer)].times.100
[0104] The results are presented graphically in FIG. 2. The results
show that .beta.-IFN adsorbs to the polymers evaluated. In
addition, the extent of adsorption depends on other factors such as
buffer type, pH and polymer type.
EXAMPLE 7
Effect of Additives on Adsorption of .beta.-IFN to Polymer
[0105] Stabilized .beta.-IFN Formulation 36 was added to pH=7
phosphate buffer containing the following additives at a
concentration of 4 mg/mL: methyl cellulose, F127, MYRJ 52,
deoxycholate, and benzalkonium chloride. MYRJ 52 is commonly
referred to as Polyoxy 40 Stearate of Polyoxyethylene (40)
Monostearate and is a member of the general class of
polyoxyethylene fatty acid esters. The final concentration of
.beta.-IFN was 0.2 mg/mL. 0.5 mL of each mixture was added to about
10 mg of microparticles prepared using Polymer D. The slurries were
incubated at 37.degree. C. for two hours. Each supernatant was
isolated by centrifugation, diluted with an equal volume of 250 mM
acetate buffer, and the concentration of .beta.-IFN determined by
SEC. Percent adsorption was calculated according to the formula
provided in Example 6. The results are presented graphically in
FIG. 3.
EXAMPLE 8
Effect of Formulation Additives on Release in vivo
[0106] Microparticles were produced as described above using
Stabilized .beta.-IFN Formulation 39 (10% .beta.-IFN/12%
Aspartate/10% F68/68% Trehalose) and 33, and Polymer A. A
description of each microparticle formulation is shown in Table
8.
[0107] The in vivo release profile for each microparticle
formulation is shown in FIG. 4. Briefly, cyclosporin
immunosuppressed male Sprague-Dawley rats weighing approximately
450 g were injected subcutaneously in the mid scapular region with
45 mgs of microparticle formulations IX-XVII listed in Table 8.
Blood samples were taken at 1, 2, 4, 8, 24, 48 and 72 hours.
.beta.-IFN concentration in the samples was determined using an
ELISA available from Toray-Fuji Bionics, Inc. (TFB, Inc.). The
results are shown graphically in FIG. 4.
[0108] The release profiles in FIG. 4 show that the presence of a
poloxamer significantly increased the total amount of .beta.-IFN
released as compared to the same formulation without poloxamer. The
presence of an acidic excipient also demonstrated an increase in
the total amount of .beta.-IFN released during the time evaluated,
but the increase was much less than that seen with the poloxamer.
In addition, the combination of poloxamer and acidic excipient
(Formulation XVII) showed an increase over surfactant alone. All
profiles in FIG. 4 were normalized to a dose of 0.45 mg .beta.-IFN
per rat.
9 TABLE 8 Microparticle .beta.-IFN Polymer Formulation Formulation
Phase No. Encapsulated Additive IX 39 None X 39 20% F127 XI 39 20%
F68 XII 39 20% PEG 8000 XIII 39 15% Aspartic Acid XIV 39 13.5%
Aspartic Acid/1.5% Zinc Citrate XV 33 None XVI 33 20% F127 XVII 33
20% F127 15% Sodium Citrate
[0109] Equivalents
[0110] While this invention has been particularly shown and
described with references to preferred embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
spirit and scope of the invention as defined by the appended
claims. Those skilled in the art will recognize or be able to
ascertain using no more than routine experimentation, many
equivalents to the specific embodiments of the invention described
specifically herein. Such equivalents are intended to be
encompassed in the scope of the claims.
* * * * *