U.S. patent application number 10/435586 was filed with the patent office on 2003-10-30 for preparation of microparticles having a selected release profile.
This patent application is currently assigned to Alkermes Controlled Therapeutics Inc. II. Invention is credited to Lyons, Shawn L., Ramstack, J. Michael, Wright, Steven G..
Application Number | 20030203039 10/435586 |
Document ID | / |
Family ID | 22835812 |
Filed Date | 2003-10-30 |
United States Patent
Application |
20030203039 |
Kind Code |
A1 |
Lyons, Shawn L. ; et
al. |
October 30, 2003 |
Preparation of microparticles having a selected release profile
Abstract
An improved method for preparing microparticles that exhibit
controlled release of an effective amount of an active agent over
an extended period of time. More particularly, a method is provided
for preparing microparticles having a selected release profile for
release of active agent contained in the microparticles. By
adjusting the degree of drying that is performed during the
preparation of the microparticles, the release profile can be
controlled. By performing no intermediate drying, an initial burst
and a substantially linear release profile is achieved. By
performing substantially complete intermediate drying, an initial
lag phase and a substantially sigmoidal release profile is
achieved.
Inventors: |
Lyons, Shawn L.;
(Cincinnati, OH) ; Ramstack, J. Michael;
(Lunenburg, MA) ; Wright, Steven G.; (Madeira,
OH) |
Correspondence
Address: |
COVINGTON & BURLING
ATTN: PATENT DOCKETING
1201 PENNSYLVANIA AVENUE, N.W.
WASHINGTON
DC
20004-2401
US
|
Assignee: |
Alkermes Controlled Therapeutics
Inc. II
Cambridge
MA
|
Family ID: |
22835812 |
Appl. No.: |
10/435586 |
Filed: |
May 12, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10435586 |
May 12, 2003 |
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10059115 |
Jan 31, 2002 |
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6596316 |
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10059115 |
Jan 31, 2002 |
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09722335 |
Nov 28, 2000 |
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6379703 |
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09722335 |
Nov 28, 2000 |
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09223276 |
Dec 30, 1998 |
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6194006 |
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Current U.S.
Class: |
424/490 ;
264/4.1 |
Current CPC
Class: |
A61K 9/1694 20130101;
A61K 9/1647 20130101; Y10T 428/2982 20150115; B01J 13/02
20130101 |
Class at
Publication: |
424/490 ;
264/4.1 |
International
Class: |
A61K 009/14; A61K
009/16; A61K 009/50; B01J 013/02; B01J 013/04 |
Claims
1. A method for preparing microparticles having a selected release
profile for release of active agent contained in the
microparticles, comprising: (a) dissolving a polymer in a first
solvent to form a polymer solution; (b) dissolving an active agent
in a second solvent to form an active agent solution; (c) combining
the polymer solution and the active agent solution in a static
mixer to form an emulsion; (d) extracting at least a portion of the
first and second solvents from the emulsion using an extraction
liquid to form microparticles containing the active agent; (e)
selecting a degree of intermediate drying of the microparticles to
be performed so that the selected release profile is achieved; and
(f) final drying the microparticles.
2. The method of claim 1, wherein the selecting step (e) is carried
out to select no intermediate drying, thereby resulting in
microparticles having an initial burst and a substantially linear
release profile.
3. The method of claim 1, wherein the selecting step (e) is carried
out to select substantially complete intermediate drying, thereby
resulting in microparticles having an initial lag phase and a
substantially sigmoidal release profile.
4. The method of claim 3, further comprising after step (e) and
prior to step (f): (g) performing the selected degree of
intermediate drying.
5. The method of claim 4, wherein the substantially complete
intermediate drying results in the microparticles having a moisture
content of less than about 0.2% after step (g).
6. The method of claim 1, wherein the first solvent is ethyl
acetate.
7. The method of claim 1, wherein the second solvent is benzyl
alcohol.
8. The method of claim 6, wherein the second solvent is benzyl
alcohol.
9. The method of claim 1, wherein the active agent is selected from
the group consisting of risperidone, 9-hydroxyrisperidone, and
pharmaceutically acceptable salts of the foregoing.
10. The method of claim 8, wherein the active agent is selected
from the group consisting of risperidone, 9-hydroxyrisperidone, and
pharmaceutically acceptable salts of the foregoing.
11. A microencapsulated active agent having a selected release
profile prepared by a method for preparing microparticles, the
method comprising: (a) dissolving a polymer in a first solvent to
form a polymer solution; (b) dissolving an active agent in a second
solvent to form an active agent solution; (c) combining the polymer
solution and the active agent solution in a static mixer to form an
emulsion; (d) extracting at least a portion of the first and second
solvents from the emulsion to form microparticles containing the
active agent; (e) selecting a degree of intermediate drying of the
microparticles to be performed so that the selected release profile
is achieved; and (f) final drying the microparticles.
12. The microencapsulated active agent of claim 11, wherein the
selecting step (e) is carried out to select no intermediate drying,
thereby resulting in microparticles having an initial burst and a
substantially linear release profile.
13. The microencapsulated active agent of claim 11, wherein the
selecting step (e) is carried out to select substantially complete
intermediate drying, thereby resulting in microparticles having an
initial lag phase and a substantially sigmoidal release
profile.
14. The microencapsulated active agent of claim 11, wherein the
method further comprises after step (e) and prior to step (f): (g)
performing the selected degree of intermediate drying.
15. The microencapsulated active agent of claim 14, wherein the
substantially complete intermediate drying results in the
microparticles having a moisture content of less than about 0.2%
after step (g).
16. The microencapsulated active agent of claim 11, wherein the
first solvent is ethyl acetate and the second solvent is benzyl
alcohol.
17. The microencapsulated active agent of claim 16, wherein the
active agent is selected from the group consisting of risperidone,
9-hydroxyrisperidone, and pharmaceutically acceptable salts of the
foregoing.
18. Microparticles prepared by the method of claim 1.
19. The microparticles of claim 18, wherein the active agent is
selected from the group consisting of risperidone,
9-hydroxyrisperidone, and pharmaceutically acceptable salts of the
foregoing.
20. The microparticles of claim 18, wherein the first solvent is
ethyl acetate and the second solvent is benzyl alcohol.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to preparation of
microparticles containing an active agent More particularly, the
present invention relates to microparticles having a selected
release profile for release of the active agent from the
microparticles, and to a method for the preparation of such
microparticles.
[0003] 2. Related Art
[0004] A variety of methods is known by which compounds can be
encapsulated in the form of microparticles. It is particularly
advantageous to encapsulate a biologically active or
pharmaceutically active agent within a biocompatible, biodegradable
wall-forming material (e.g., a polymer) to provide sustained or
delayed release of drugs or other active agents. In these methods,
the material to be encapsulated (drugs or other active agents) is
generally dissolved, dispersed, or emulsified in a solvent
containing the wall forming material. Solvent is then removed from
the microparticles to form the finished microparticle product.
[0005] An example of a conventional microencapsulation process is
disclosed in U.S. Pat. No. 3,737,337 wherein a solution of a wall
or shell forming polymeric material in a solvent is prepared. The
solvent is only partially miscible in water. A solid or core
material is dissolved or dispersed in the polymer-containing
solution and, thereafter, the core-material-polymer-containing
solution is dispersed in an aqueous liquid that is immiscible in
the organic solvent in order to remove solvent from the
microparticles.
[0006] Tice et al. in U.S. Pat. No. 4,389,330 describe the
preparation of microparticles containing an active agent by using a
two-step solvent removal process. In the Tice et al. process, the
active agent and the polymer are dissolved in a solvent. The
mixture of ingredients in the solvent is then emulsified in a
continuous-phase processing medium that is immiscible with the
solvent. A dispersion of microparticles containing the indicated
ingredients is formed in the continuous-phase medium by mechanical
agitation of the mixed materials. From this dispersion, the organic
solvent can be partially removed in the first step of the solvent
removal process. After the first stage, the dispersed
microparticles are isolated from the continuous-phase processing
medium by any convenient means of separation. Following the
isolation, the remainder of the solvent in the microparticles is
removed by extraction. After the remainder of the solvent has been
removed from the microparticles, they are dried by exposure to air
or by other conventional drying techniques.
[0007] Another conventional method of microencapsulating an agent
to form a microencapsulated product is disclosed in U.S. Pat. No.
5,407,609. This method includes: (1) dissolving or otherwise
dispersing one or more agents (liquids or solids) in a solvent
containing one or more dissolved wall-forming materials or
excipients (usually the wall-forming material or excipient is a
polymer dissolved in a polymer solvent); (2) dispersing the
agent/polymer-solvent mixture (the discontinuous phase) into a
processing medium (the continuous phase which is preferably
saturated with polymer solvent) to form an emulsion; and (3)
transferring all of the emulsion immediately to a large volume of
processing medium or other suitable extraction medium, to
immediately extract the solvent from the microdroplets in the
emulsion to form a microencapsulated product, such as microcapsules
or microspheres.
[0008] U.S. Pat. No. 5,650,173, the entirety of which is
incorporated herein by reference, discloses a process for preparing
biodegradable, biocompatible microparticles comprising a
biodegradable, biocompatible polymeric binder and a biologically
active agent, wherein a blend of at least two substantially
non-toxic solvents, free of halogenated hydrocarbons, are used to
dissolve both the agent and the polymer. The solvent blend
containing the dissolved agent and polymer is dispersed in an
aqueous solution to form droplets. The resulting emulsion is added
to an aqueous extraction medium preferably containing at least one
of the solvents of the blend, whereby the rate of extraction of
each solvent is controlled, whereupon the biodegradable,
biocompatible microparticles containing the biologically active
agent are formed. Active agents suitable for encapsulation by this
process include, but are not limited to, norethindrone,
risperidone, and testosterone, and a preferred solvent blend is one
comprising benzyl alcohol and ethyl acetate.
[0009] U.S. Pat. No. 5,654,008, the entirety of which is
incorporated herein by reference, describes a microencapsulation
process that uses a static mixer. A first phase, comprising an
active agent and a polymer, and a second phase are pumped through a
static mixer into a quench liquid to form microparticles containing
the active agent.
[0010] The documents described above all disclose methods that can
be used to prepare microparticles that contain an active agent. As
explained, for example, in U.S. Pat. No. 5,650,173, by
appropriately selecting the polymeric materials, a microparticle
formulation can be made in which the resulting microparticles
exhibit both diffusional release and biodegradation release
properties. For a diffusional mechanism of release, the active
agent is released from the microparticles prior to substantial
degradation of the polymer. The active agent can also be released
from the microparticles as the polymeric excipient erodes. However,
none of the foregoing documents disclose a specific method for
preparing microparticles that have a selected release profile for
release of the active agent from the microparticles.
[0011] Thus, there is a need in the art for a method for preparing
microparticles having a selected release profile for release of
active agent in the microparticles in accordance with the selected
release profile. There is a further need in the art for a method
for controlling the release profile of the active agent contained
in microparticles. The present invention, the description of which
is fully set forth below, solves the need in the art for such
methods.
SUMMARY OF THE INVENTION
[0012] The present invention relates to an improved method for
preparing microparticles that exhibit controlled release of an
effective amount of an active agent over an extended period of
time. More particularly, the present invention relates to a method
for preparing microparticles having a selected release profile for
release of active agent contained in the microparticles. In one
aspect, the method of the present invention comprises: preparing an
emulsion that comprises a first phase and a second phase, the first
phase comprising the active agent, a polymer, and a solvent for the
polymer, quenching the emulsion in a quench liquid to form
microparticles containing the active agent; and performing a degree
of intermediate drying of the microparticles so that the selected
release profile is achieved. If the degree of intermediate drying
performed is no intermediate drying, then the resulting
microparticles have an initial burst and a substantially linear
release profile. If the degree of intermediate drying performed is
substantially complete intermediate drying, then the resulting
microparticles have an initial lag phase and a substantially
sigmoidal release profile.
[0013] In a further aspect of the present invention, the method
further comprises, after the intermediate drying step, the steps of
washing the microparticles and final drying the microparticles. In
a preferred aspect of the invention, the washing step is carried
out by: introducing the microparticles into a vessel containing an
extraction medium having a temperature lower than the glass
transition temperature of the microparticles; agitating the vessel
contents to disperse the microparticles in the extraction medium;
and transferring the microparticles from the vessel to an
extraction tank having another extraction medium having a
temperature higher than the glass transition temperature of the
microparticles at the time of transfer of the microparticles.
[0014] In yet another aspect of the invention, a method for
controlling a release profile of an active agent contained in
microparticles is provided. The method comprises: forming
microparticles containing the active agent by quenching an emulsion
in a quench liquid, the emulsion comprising a first phase and a
second phase, the first phase comprising the active agent, a
polymer, and a solvent for the polymer, and adjusting a degree of
drying of the microparticles, the degree of drying affecting the
release profile of the active agent from the microparticles. In a
further aspect, the degree of drying is adjusted to comprise no
intermediate drying, thereby resulting in an initial burst of the
active agent and a substantially linear release of the active
agent. In another aspect, the degree of drying is adjusted to
comprise substantially complete intermediate drying, thereby
resulting in an initial lag in release of the active agent and a
substantially sigmoidal release of the active agent. In still a
further aspect of the invention, the adjusting step comprises:
performing a degree of intermediate drying of the microparticles;
washing the microparticles; and performing final drying of the
microparticles. In yet another aspect of the invention, the washing
step comprises: introducing the microparticles into a vessel
containing an extraction medium having a temperature lower than the
glass transition temperature of the microparticles; agitating the
vessel contents to disperse the microparticles in the extraction
medium; and transferring the microparticles from the vessel to an
extraction tank having another extraction medium having a
temperature higher than the glass transition temperature of the
microparticles at the time of transfer of the microparticles.
[0015] In still a further aspect of the present invention, a
microencapsulated active agent having a selected release profile is
provided. The microencapsulated active agent is prepared by a
method for preparing microparticles, which method comprises:
preparing an emulsion that comprises a first phase and a second
phase, the first phase comprising the active agent, a polymer, and
a solvent for the polymer, quenching the emulsion in a quench
liquid to form microparticles containing the active agent; and
performing a degree of intermediate drying of the microparticles so
that the selected release profile of the active agent from the
microparticles is achieved.
[0016] Features and Advantages
[0017] Advantages of the method of the present invention are that
it provides, inter alia, a biodegradable, biocompatible system that
can be injected into a patient, the ability to mix microparticles
containing different active agents, and the ability to program
release by preparing microparticles with selected release profiles
and with multiphasic release patterns to give faster or slower
rates of active agent release as needed.
[0018] A particular advantage of the method of the present
invention is that it provides an additional parameter, the degree
of intermediate drying, to control the release pattern or profile
of microparticles. The method of the present invention is
advantageous in that after such parameters as monomer size,
coreload, and molecular weight have been determined, the release
profile can be adjusted through the degree of intermediate
drying.
[0019] An advantage of the products prepared by the method of the
present invention is that durations of action ranging from several
days to more than 200 days can be obtained, depending upon the type
of microparticle and release profile selected. In preferred
embodiments, the microparticles are designed to afford treatment to
patients during duration of action periods of 30 to 100 days. A 60
day duration of action period is considered to be particularly
advantageous. As readily apparent to one of skill in the relevant
at the duration of action can be controlled by manipulation of the
polymer composition, polymer drug ratio, microparticle size,
excipients, and concentration of residual solvent remaining in the
microparticle.
BRIEF DESCRIPTION OF THE FIGURES
[0020] The present invention is described with reference to the
accompanying drawings. In the drawings, like reference numbers
indicate identical or functionally similar elements. Additionally,
the left-most digit(s) of a reference number identifies the drawing
in which the reference number first appears.
[0021] FIG. 1 shows a flow diagram illustrating one embodiment of a
method for preparing microparticles in accordance with the present
invention;
[0022] FIG. 2 shows one embodiment of an equipment configuration
for preparing microparticles in accordance with the present
invention, the embodiment shown in FIG. 2 suitable for performing a
degree of intermediate drying ranging from no intermediate drying
to substantially complete intermediate drying;
[0023] FIG. 3 shows another embodiment of an equipment
configuration for preparing microparticles in accordance with the
present invention, the embodiment shown in FIG. 3 suitable for
performing no intermediate drying;
[0024] FIG. 4 shows yet another embodiment of an equipment
configuration for preparing microparticles in accordance with the
present invention, the embodiment shown in FIG. 4 suitable for
performing no intermediate drying with washing in the dryer;
[0025] FIG. 5 shows a graph of in vitro release profiles
(Cumulative Release %) as a function of time to illustrate the
effect of the degree of intermediate drying on in vitro release;
and
[0026] FIG. 6 shows a graph of cumulative release profiles
(Cumulative Release %) as a function of time of microparticles made
with substantially complete intermediate drying to achieve a
sigmoidal release profile.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Overview
[0028] The present invention relates to microparticles having a
selected release profile for release of the active agent from the
microparticles, and to a method for the preparation of such
microparticles. The release profile refers to the quantity or
amount of active agent that is released from the microparticles as
a function of time. Release profiles are typically illustrated as
the cumulative release, expressed as a percentage of the total
amount of active agent present in the microparticles, as a function
of time. Different clinical applications, and/or different active
agents, may require different types of release profiles. For
example, one type of release profile includes an "initial burst,"
or release of a significant amount of active agent from the
microparticles within the first 24 hour period. The initial burst
may then be followed by a substantially linear release profile
after the initial burst. Another type of release profile is a
sigmoidal release profile. As used herein, the term "sigmoidal"
refers to a release profile that is substantially "S"-shaped. As
shown, for example, in FIG. 6, a sigmoidal release profile is
characterized by an initial lag phase, a steep intermediate release
phase, and a flat final release phase.
[0029] The inventors have unexpectedly discovered that the release
profile of the microparticles can be controlled by adjusting the
degree of drying that is performed on the microparticles during
their preparation. Particularly, if an intermediate drying step
(between the quench/primary extraction step and the washing step as
explained below) is eliminated or is incomplete, then the release
profile of the microparticles includes an initial burst followed by
a substantially linear release profile. However, if a substantially
complete intermediate drying step is performed on the
microparticles, then the release profile will be substantially
sigmoidal with an initial lag phase.
[0030] After the microparticles undergo the degree of intermediate
drying needed for the selected release profile, the microparticles
are preferably washed and subjected to a final drying step. To
solve the problem of agglomeration of the microparticles during the
washing step, in the process of the present invention the
microparticles are first introduced into a vessel containing an
extraction medium having a temperature lower than the glass
transition temperature (T.sub.g) of the microparticles, and the
vessel is agitated to wet and to disperse the microparticles in the
extraction medium. The cold extraction medium allows the
microparticles to be dispersed without agglomeration caused by
elevated temperatures. The microparticles are then preferably
transferred to a larger extraction tank having extraction medium at
a temperature higher than the glass transition temperature of the
microparticles for extraction and washing.
[0031] As used herein, "glass transition temperature" or "T.sub.g"
refers to the temperature at which the polymer or polymer matrix
material of the microparticles changes from a rigid or glassy
condition to a soft rubbery condition upon heating. As would be
readily apparent to one of skill in the relevant art, the T.sub.g
of the microparticles will depend in part on processing conditions,
such as the solvent used. For example, benzyl alcohol acts as a
plasticizer that decreases the T.sub.g of the microparticles.
Hydrolyzing will also decrease the T.sub.g of the microparticles.
The molecular weight of the polymer also affects the T.sub.g of the
microparticles--the higher the molecular weight of the polymer, the
higher the T.sub.g.
[0032] To ensure clarity of the description that follows, the
following definitions are provided. By "initial burst" is meant
release of a significant amount of active agent from the
microparticles within the first 24 hour period, typically greater
than about 5% cumulative release. By "microparticles" or
"microspheres" is meant solid particles that contain an active
agent dispersed or dissolved within a polymer that serves as the
matrix of the particle. The polymer is preferably biodegradable and
biocompatible. By "biodegradable" is meant a material that should
degrade by bodily processes to products readily disposable by the
body and should not accumulate in the body. The products of the
biodegradation should also be biocompatible with the body. By
"biocompatible" is meant not toxic to the body, is pharmaceutically
acceptable, is not carcinogenic, and does not significantly induce
inflammation in body tissues. As used herein, "body" preferably
refers to the human body, but it should be understood that body can
also refer to a non-human animal body. By "weight %" or "% by
weight" is meant parts by weight per total weight of microparticle.
For example, 10 wt. % active agent would mean 10 parts active agent
by weight and 90 parts polymer by weight.
[0033] Method and Equipment Description
[0034] With reference now to the drawings, FIG. 1 illustrates one
embodiment of a method for preparing microparticles in accordance
with the present invention. In a step 110, a first phase 101 and a
second phase 102 are combined to form an emulsion. One of the two
phases is discontinuous, and the other of the two phases is
continuous. The first phase preferably comprises an active agent, a
polymer, and a solvent for the polymer.
[0035] Preferred active agents that can be encapsulated by the
process of the present invention include 1,2-benzazoles, more
particularly, 3-piperidinyl-substituted 1,2-benzisoxazoles and
1,2-benzisothiazoles. The most preferred active agents of this kind
for treatment by the process of the present invention are
3-[2-[4-(6-fluoro-1,2-benzisoxazol-3-
-yl)-1-piperidinyl]ethyl]-6,7,8,9-tetrahydro-2-methyl-4H-pyrido[1,2-a]pyri-
midin-4-one ("risperidone") and
3-[2-[4-(6-fluoro-1,2-benzisoxazol-3-yl)-1-
-piperidinyl]ethyl]-6,7,8,9-tetrahydro-9-hydroxy-2-methyl-4H-pyrido[1,2-a]-
pyrimidin-4-one ("9-hydroxyrisperidone") and the pharmaceutically
acceptable salts thereof. Risperidone (which term, as used herein,
is intended to include its pharmaceutically acceptable salts) is
most preferred. Risperidone can be prepared in accordance with the
teachings of U.S. Pat. No. 4,804,663, the entirety of which is
incorporated herein by reference. 9-hydroxyrisperidone can be
prepared in accordance with the teachings of U.S. Pat. No.
5,158,952, the entirety of which is incorporated herein by
reference.
[0036] Other biologically active agents that can be incorporated
using the process of the present invention include gastrointestinal
therapeutic agents such as aluminum hydroxide, calcium carbonate,
magnesium carbonate, sodium carbonate and the like; non-steroidal
antifertility agents; parasympathomimetic agents; psychotherapeutic
agents; major tranquilizers such as chlorpromazine HCl, clozapine,
mesoridazine, metiapine, reserpine, thioridazine and the like;
minor tranquilizers such as chlordiazepoxide, diazepam meprobamate,
temazepam and the like; rhinological decongestants;
sedative-hypnotics such as codeine, phenobarbital, sodium
phenobarbital, sodium secobarbital and the like; steroids such as
testosterone and testosterone propionate; sulfonamides;
sympathomimetic agents; vaccines; vitamins and nutrients such as
the essential amino acids; essential fats and the like;
antimalarials such 4-aminoquinolines, 8-aminoquinolines,
pyrimethamine and the like, anti-migraine agents such as mazindol,
phentermine and the like; anti-Parkinson agents such as L-dopa;
anti-spasmodics such as atropine, methscopolamine bromide and the
like; antispasmodics and anticholinergic agents such as bile
therapy, digestants, enzymes and the like; antitussives such as
dextromethorphan, noscapine and the like; bronchodilators;
cardiovascular agents such as anti-hypertensive compounds,
Rauwolfia alkaloids, coronary vasodilators, nitroglycerin, organic
nitrates, pentaerythritotetranitrate and the like; electrolyte
replacements such as potassium chloride; ergotalkaloids such as
ergotamine with and without caffeine, hydrogenated ergot alkaloids,
dihydroergocristine methanesulfate, dihydroergocormine
methanesulfonate, dihydroergokroyptine methanesulfate and
combinations thereof; alkaloids such as atropine sulfate,
Belladonna, hyoscine hydrobromide and the like; analgesics,
narcotics such as codeine, dihydrocodienone, meperidine, morphine
and the like; non-narcotics such as salicylates, aspirin,
acetaminophen, d-propoxyphene and the like; antibiotics such as
salicylates, aspirin, acetaminophen, d-propoxyphene and the like;
antibiotics such as the cephalosporins, chloranphenical,
gentamicin, Kanamycin A, Kanamycin B, the penicillins, ampicillin,
streptomycin A, antimycin A, chloropamtheniol, metromidazole,
oxytetracycline penicillin G, the tetracylines, and the like,
anti-cancer agents; anti-convulsants such as mephenytoin,
phenobarbital, trimethadione; anti-emetics such as
thiethylperazine; antihistamines such as chlorophinazine,
dimenhydrinate, diphenhydramine, perphenazine, tripelennamine and
the like; anti-inflammatory agents such as hormonal agents,
hydrocortisone, prednisolone, prednisone, non-hormonal agents,
allopurinol, aspirin, indomethacin, phenylbutazone and the like;
prostaglandins; cytotoxic drugs such as thiotepa; chlorambucil,
cyclophosphamide, melphalan, nitrogen mustard, methotrexate and the
like; antigens of such microorganisms as Neisseria gonorrhea,
Mycobacterium tuberculosis, Herpes virus (humonis, types 1 and 2),
Candida albicans, Candida tropicalis, Trichomonas vaginalis,
Haemophilus vaginalis, Group B Streptococcus ecoli, Microplasma
hominis, Hemophilus ducreyi, Granuloma inguinale, Lymphopathia
venereum, Treponema pallidum, Brucella abortus, Brucella
melitensis, Brucella suis, Brucella canis, Campylobacter fetus,
Campylobacter fetus intestinalis, Leptospira pomona, Listeria
monocytogenes, Brucella ovis, Equine herpes virus 1, Equine
arteritis virus, IBR-IBP virus, BVD-MB virus, Chlamydia psittaci,
Trichomonas foetus, Toxoplasma gondfi, Escherichia coli,
Actinobacillus equuli, Salmonella abortus ovis, Salmonella aborus
equi, Pseudomonas aeruginosa, Corynebacterium equi, Corynebacterium
pyogenes, Actinobacillus seminis, Mycoplas bovigenitalium,
Aspergillus funigastus, Absidia ramosa, Trypanosoma equiperdum,
Babesia caballi, Clostridium tetani, and the like; antibodies that
counteract the above microorganisms; and enzymes such as
ribonuclease, neuramidinase, trypsin, glycogen phosphorylase, sperm
lactic dehydrogenase, sperm hyaluronidase, adenosinetriphosphatase,
alkaline phosphatase, alkaline phosphatase esterase, amino
peptidase, trypsin, chymotrypsin, amylase, muramidase, acrosomal
proteinase, diesterase, glutamic acid dehydrogenase, succinic acid
dehydrogenase, beta-glycophosphatase, lipase, ATP-ase alpha-peptate
gamma-glutarylotranspeptidase, sterol-3-beta-ol-dehydrogenase, and
DPN-di-apropos.
[0037] Other suitable active agents include estrogens such as
diethyl stilbestrol, 17-beta-estradiol, estrone, ethinyl estradiol,
mestranol, and the like; progestins such as norethindrone,
norgestryl, ethynodiol diacetate, lynestrenol, medroxyprogesterone
acetate, dimesthisterone, megestrol acetate, chlormadinone acetate,
norgestimate, norethisterone, ethisterone, melengestrol,
norethynodrel and the like; and the spennicidal compounds such as
nonylphenoxypolyoxyethylene glycol, benzethonium chloride,
chlorindanol and the like.
[0038] Still other suitable active agents include antifungals,
antivirals, anticoagulants. anticonvulsants, antidepressants,
antihistamines, hormones, vitamins and minerals, cardiovascular
agents, peptides and proteins, nucleic acids, immunological agents,
antigens of such bacterial organisms as Streptococcus pneumoniae,
Haemophilus influenzae, Staphylococcus aureus, Streptococcus
pyrogenes, Corynebacterium diptheriae, Bacillus anthracis,
Clostridium tetani, Clostridium botulinum, Clostridium pergens,
Streptococcus mutans, Salmonella typhi, Haemophilus parainfluenzae,
Bordetella perrussis, Francisella tularensis, Yersinia pestis,
Vibrio cholerae, Legionella pneumophila, Mycobacterium leprae,
Leptspirosis interrogans, Borrelia burgdorferi, Campylobacter
jejuni, antigens of such viruses as smallpox, influenza A and B,
respiratory syncytial, parainfluenzae, measles, HIV,
varicella-zoster, herpes simplex 1 and 2, cytomeglavirus,
Epstein-Barr, rotavirus, rhinovirus, adenovirus, papillomavirus,
poliovirus, mumps, rabies, rubella, coxsackieviruses, equine
encephalitis, Japanese encephalitis, yellow fever, Rift Valley
fever, lymphocytic choriomeningitis, hepatitis B, antigens of such
fungal protozoan, and parasitic organisms such as Cryptococcuc
neoformans, Histoplasma capsulatum, Candida albicans, Candida
tropicalis, Nocardia asteroides, Rickettsia ricketsii, Rickettsia
typhi, Mycoplasma pneumoniae, Chlamydial psittaci, Chlamydial
trachomatis, Plasmodium falciparum, Trypanosoma brucei, Entamoeba
histolytica, Taxoplasma gondii, Trichomonas vaginalis, Schistosoma
mansoni. These antigens may be in the form of whole killed
organisms, peptides, proteins, glycoproteins, carbohydrates, or
combinations thereof.
[0039] Still other macromolecular bioactive agents that may be
chosen for incorporation include, but are not limited to, blood
clotting factors, hemopoietic factors, cytokines, interleukins,
colony stimulating factors, growth factors, and analogs and
fragments thereof.
[0040] The microparticles can be mixed by size or by type so as to
provide for the delivery of active agent to the patient in a
multiphasic manner and/or in a manner that provides different
active agents to the patient at different times, or a mixture of
active agents at the same time. For example, secondary antibiotics,
vaccines, or any desired active agent, either in microparticle form
or in conventional, unencapsulated form can be blended with a
primary active agent and provided to the patient.
[0041] Preferred examples of polymer matrix materials include
poly(glycolic acid), poly(d,1-lactic acid), poly(1-lactic acid),
copolymers of the foregoing, and the like. Various commercially
available poly(lactide-co-glycolide) materials (PLGA) may be used
in the method of the present invention. For example, poly
(d,1-lactic-co-glycolic acid) is commercially available from
Alkermes, Inc. (Blue Ash, Ohio). A suitable product commercially
available from Alkermes, Inc. is a 50:50
poly(d,1-lactic-co-glycolic acid) known as MEDISORB.RTM. 5050 DL.
This product has a mole percent composition of 50% lactide and 50%
glycolide. Other suitable commercially available products are
MEDISORB.RTM. 6535 DL, 7525 DL, 8515 DL and poly(d,1-lactic acid)
(100 DL). Poly(lactide-c-glycolides) are also commercially
available from Boehringer Ingelheim (Germany) under its
Resomer.RTM. mark, e.g., PLGA 50:50 (Resomer.RTM. RG 502), PLGA
75:25 (Resomer.RTM. RG 752) and d,1-PLGA (Resomer.RTM. RG 206), and
from Birmingham Polymers (Birmingham, Ala.). These copolymers are
available in a wide range of molecular weights and ratios of lactic
acid to glycolic acid.
[0042] The most preferred polymer for use in the practice of the
invention is the copolymer, poly(d,1-lactide-co-glycolide). It is
preferred that the molar ratio of lactide to glycolide in such a
copolymer be in the range of from about 85:15 to about 50:50.
[0043] The molecular weight of the polymeric matrix material is of
some importance. The molecular weight should be high enough to
permit the formation of satisfactory polymer coatings, i.e., the
polymer should be a good film former. Usually, a satisfactory
molecular weight is in the range of 5,000 to 500,000 daltons,
preferably about 150,000 daltons. However, since the properties of
the film are also partially dependent on the particular polymeric
matrix material being used, it is very difficult to specify an
appropriate molecular weight range for all polymers. The molecular
weight of the polymer is also important from the point of view of
its influence upon the biodegradation rate of the polymer. For a
diffusional mechanism of drug release, the polymer should remain
intact until all of the drug is released from the microparticles
and then degrade. The drug can also be released from the
microparticles as the polymeric excipient bioerodes. By an
appropriate selection of polymeric materials a microparticle
formulation can be made in which the resulting microparticles
exhibit both diffusional release and biodegradation release
properties. This is useful in according multiphasic release
patterns.
[0044] The formulation prepared by the process of the present
invention contains an active agent dispersed in the microparticle
polymeric matrix material. The amount of such agent incorporated in
the microparticles usually ranges from about 1 wt. % to about 90
wt. %, preferably 30 to 50 wt. %, more preferably 35 to 40 wt.
%.
[0045] The emulsion is transferred into a quench liquid for the
quench or primary extraction step (120). The primary purpose of the
quench step is to extract or remove residual solvent from the
microparticles that are formed. In a preferred embodiment of the
present invention, quench step 120 is followed by a de-watering
step 122 and a rinse step 124. The objective of de-watering step
122 is to concentrate the microparticles from the dilute suspension
that is formed during extraction step 120 to a concentrated slurry
prior to subsequent drying of the microparticles. The objective of
rinse step 124 is to reduce stickiness of the microparticles.
Alternatively, rinse step 124 is omitted so that drying occurs
after de-watering step 122.
[0046] An intermediate drying step 130 is performed after rinse
step 124, or, alternatively, after de-watering step 122 if the
rinse step is omitted. The objective of intermediate drying step
130 is to perform a degree of intermediate drying of the
microparticles so that the selected release profile is achieved. As
will be explained in more detail below in the Examples, when the
degree of intermediate drying performed in step 130 is no
intermediate drying, the result is microparticles having an initial
burst and a substantially linear release profile. When the degree
of intermediate drying performed in step 130 is substantially
complete intermediate drying, the result is microparticles having
an initial lag phase and a substantially sigmoidal release
profile.
[0047] After intermediate drying step 130, the microparticles are
washed in a step 140 to remove or extract any further residual
solvent. The microparticles are de-watered in a step 145 prior to a
final drying step 150. Final drying step 150 is preferably carried
out so that the moisture content of the microparticles is less than
about 1%, more preferably approximately equal to about 0.2%. The
microparticles are recovered in a step 160.
[0048] With reference now to FIG. 2, one embodiment is shown of an
equipment configuration for preparing microparticles in accordance
with the present invention. The embodiment shown in FIG. 2 is
particularly well suited for performing a degree of intermediate
drying ranging from no intermediate drying to substantially
complete intermediate drying. In a preferred embodiment of the
present invention, the equipment contained within the dotted line
boundary shown generally at 270 is sterilized using a
"steam-in-place" (SIP) process.
[0049] A first phase 201 is provided. First phase 201 is preferably
the discontinuous phase, comprising a polymer dissolved in one or
more solvents, and an active agent. The active agent can be
dissolved or dispersed in the same or a different solvent than the
solvent(s) in which the polymer is dissolved. A second phase 202 is
preferably the continuous phase, preferably comprising water as the
continuous processing medium. Preferably, an emulsifying agent such
as a surfactant or a hydrophilic colloid is added to the continuous
phase to prevent the microdroplets from agglomerating and to
control the size of the microdroplets in the emulsion. Examples of
compounds that can be used as surfactants or hydrophilic colloids
include, but are not limited to, poly(vinyl alcohol) (PVA),
carboxymethyl cellulose, gelatin, poly(vinyl pyrrolidone), Tween
80, Tween 20, and the like. The concentration of surfactant or
hydrophilic colloid in the continuous phase will be from about 0.1%
to about 10% by weight based on the continuous processing medium,
depending upon the surfactant, hydrophilic colloid, the
discontinuous phase, and the continuous processing medium used. A
preferred continuous phase is 0.1 to 10 wt. %, more preferably 0.5
to 2 wt. %, solution of PVA in water. Although not absolutely
necessary, it is preferred to saturate the continuous phase with at
least one of the solvents forming the discontinuous phase. This
provides a stable emulsion, preventing transport of solvent out of
the microparticles prior to quench step 120.
[0050] First phase 201 and second phase 202 are combined under the
influence of mixing means to form an emulsion. A preferred type of
mixing means is a static mixer 210. Other mixing means suitable for
use with the present invention include, but are not limited to,
devices for mechanically agitating the first and second phases,
such as homogenizers, propellers, impellers, stirrers, and the
like.
[0051] Preferably, the discontinuous and continuous phases 201 and
202 are pumped through static mixer 210 to form an emulsion, and
into a large volume of quench liquid, to obtain microparticles
containing the active agent encapsulated in the polymeric material.
A pump 203 pumps first phase 201 into static mixer 210, and a pump
204 pumps second phase 202 into static mixer 210. An especially
preferred method of mixing with a static mixer in the process of
the present invention is disclosed in U.S. Pat. No. 5,654,008, the
entirety of which is incorporated herein by reference.
[0052] First and second phases 201 and 202 are mixed in static
mixer 210 to form an emulsion. The emulsion formed comprises
microparticles containing active agent encapsulated in the
polymeric matrix material. The microparticles are then preferably
stirred in a quench or extraction tank 220 containing a quench
liquid in order to remove most of the solvent from the
microparticles, resulting in the formation of hardened
microparticles. Following the movement of the microparticles from
static mixer 210 and entrance into quench tank 220, the continuous
processing medium is diluted, and much of the solvent in the
microparticles is removed by extraction. In this extractive quench
step (step 120), the microparticles can be suspended in the same
continuous phase (second phase 202) used during emulsification,
with or without hydrophilic colloid or surfactant, or in another
quench liquid. The quench liquid removes a significant portion of
the solvent from the microparticles, but does not dissolve them.
During the extractive quench step, the quench liquid containing
dissolved solvent can, optionally, be removed and replaced with
fresh quench liquid.
[0053] Upon completion of quench step 120 in quench tank 220, the
microparticles are transferred by a pump 224 to a device 230 that
functions as a microparticle collecting device, de-watering device,
and drying device. Device 230 is used to carry out de-watering step
122, rinse step 124, intermediate drying step 130, de-watering step
145, and final drying step 150.
[0054] Device 230 comprises a vibrating sieve or screen. The
vibration causes smaller particles and liquid to drop through the
screen, while larger particles are retained. The smaller particles
and liquid that drop through the screen are removed as waste 235.
Device 230 also functions as a vacuum dryer, through the use of a
vacuum line 237. The microparticles are fluidized by the
vibrational energy, and by a small amount of a dry gas bleed,
preferably a dry nitrogen (N.sub.2) bleed 236. The dry nitrogen
bleed, passed on the underside of the screen helps the
microparticles dry more quickly and without agglomeration by
assisting in keeping the microparticles moving around. After
drying, an internal port on the screen may be opened, and the
vibrational energy causes the remaining microparticles to
self-discharge.
[0055] A suitable device 230 for a process of approximately 1 Kg
scale is a PHARMASEP Model PH12Y vibratory sieve available from
Sweco, Florence, Ky. This device consists of a 25 .mu. (nom)
stainless steel screen approximately eleven inches in diameter that
fits in a stainless steel frame. The flame is attached to a base
weldment. A smaller six-inch diameter 150 .mu. screen may also be
attached to the weldment but positioned upstream from the 25 .mu.
screen to filter out oversized material. The machine is driven by a
one-third horsepower motor (motion generator) designed to transmit
vibration to the screen(s).
[0056] After the completion of intermediate drying step 130, the
dried microparticles need to be transferred to another extraction
medium to carry out wash step 140. Wash step 140 is preferably
carried out in quench tank 220, using an extraction medium 222
having a temperature higher than the glass transition temperature
(T.sub.g) of the microparticles. Directly dispersing the dried
microparticles (now in the form of a dry powder) in quench tank 220
is problematic because the dry powder takes time to wet out before
dispersing. Because the temperature of the extraction medium in
quench tank 220 is higher than the microparticle T.sub.g, the
microparticles have a tendency to agglomerate before dispersing.
The process of the present invention solves this agglomeration
problem in the following manner. To carry out wash step 140, the
microparticles are first introduced into a re-slurry tank or other
type of vessel 240, as shown by path 231. The temperature of the
extraction medium 242 that is used in vessel 240 is lower than the
T.sub.g of the microparticles. The cold extraction medium in vessel
240 allows the dried microparticles to wet and to disperse without
agglomeration caused by elevated temperatures, i.e., temperatures
above the T.sub.g of the microparticles.
[0057] At the time of transfer of the microparticles into
extraction medium 222 in quench tank 220, the temperature of
extraction medium 222 is higher than the T.sub.g of the
microparticles. The T.sub.g of the microparticles changes during
wash step 140 as solvents are extracted. At the end of wash step
140, the T.sub.g of the microparticles is higher than the
temperature of extraction medium 222.
[0058] Vessel 240 is preferably smaller in size/volume than quench
tank 220; consequently the volume of extraction medium in vessel
240 will be less than the volume of extraction medium in quench
tank 220. The volume of the extraction medium in vessel 240 is
preferably small enough relative to the volume of extraction medium
in quench tank 220 so that when the extraction medium and
microparticles are transferred from vessel 240 into quench tank 220
(as shown by path 244), the temperature of the extraction medium in
quench tank 220 is affected only a few degrees.
[0059] Vessel 240 preferably has an impeller or other form of
agitating device used to agitate the vessel contents, but
preferably does not include any baffles. The smaller volume of
vessel 240 allows intense agitation so that the microparticles can
be dispersed in the extraction medium.
[0060] After wash step 140 is completed in quench tank 220, the
microparticles are again transferred via pump 224 into device 230
for de-watering step 145 and final drying step 150. At the
completion of final drying step 150, the microparticles are
discharged from device 230 in the manner described above into a
sifter 250, as shown by path 232. Sifter 250 is used to fractionate
the microparticles by size for filling into vials and for bulk
in-process testing (e.g., aspect, active agent content, residual
solvents, in vitro release, and particle size distribution).
[0061] FIG. 3 shows another embodiment of an equipment
configuration for preparing microparticles in accordance with the
present invention. The embodiment shown in FIG. 3 is particularly
suitable for performing no intermediate drying. As with the
embodiment shown in FIG. 2, the embodiment of FIG. 3 combines first
and second phases 201 and 202 in static mixer 210 to form an
emulsion. Quench step 120 is carried out in quench tank 220.
[0062] Upon completion of quench step 120, the microparticles are
transferred via pump 224 through a filter 310 that removes small
particles and excess liquid through a waste line 315. The
microparticles are then transferred back into quench tank 220 along
path 340 to perform wash step 140 using extraction medium 222. In
this embodiment, intermediate drying step 130 is effectively
eliminated, i.e., a degree of intermediate drying that is no
intermediate drying.
[0063] Upon completion of wash step 140, the microparticles are
transferred via pump 224 through filter 310 along path 350 into a
strainer 320 for de-watering step 145. Excess water and waste is
removed from strainer 320 via a waste line 325. Final drying step
150 is performed in a dryer 330, from which finished microparticles
360 arm recovered.
[0064] FIG. 4 shows an alternate embodiment of an equipment
configuration suitable for performing no intermediate drying. In
the embodiment shown in FIG. 4, intermediate drying step 130 is
effectively eliminated, i.e., a degree of intermediate drying that
is no intermediate drying, and wash step 140 is performed in dryer
330.
[0065] As with the embodiments shown in FIGS. 2 and 3, the
embodiment of FIG. 4 combines first and second phases 201 and 202
in static mixer 210 to form an emulsion. Quench step 120 is carried
out in quench tank 220.
[0066] Upon completion of quench step 120, the microparticles are
transferred via pump 224 through filter 310 that removes small
particles and excess liquid through waste line 315. The
microparticles are then transferred along path 440 through strainer
320 and into dryer 330. Extraction medium 242 is transferred into
dryer 330 via pump 430 so that wash step 140 can be performed in
dryer 330.
[0067] De-watering step 145 and final drying step 150 become
essentially the same step using the embodiment of FIG. 4. The final
drying is performed in dryer 330, from which finished
microparticles 360 are recovered.
EXAMPLES
[0068] The following examples further describe the materials and
methods used in carrying out the invention. The examples are not
intended to limit the invention in any manner.
Example 1
[0069] Effect of Drying Parameters on In Vitro Release
[0070] Nine samples were prepared in accordance with the 1 Kg
process described below in Example 6. Intermediate drying step 130
was varied to determine the effect on the 24 hour in vitro release.
An example of measurement of in vitro release is provided below in
Example 7. As shown below in Table 1, the intermediate drying step
varied from no intermediate drying (sample K), to drying under
vacuum in a dryer (samples L M, and N), to drying under vacuum in a
dryer with an additional dry gas sweep (samples O, P, Q, R, and
0121-7). The highest 24 hour in vitro release occurred for the
samples having the least amount of intermediate drying. Conversely,
the lowest 24 hour in vitro release occurred for the samples having
the greater amount of intermediate drying. It was found that
substantially complete intermediate drying was achieved by drying
under vacuum for a period in the range of approximately 18-24
hours, and drying with a gas sweep (such as a N.sub.2 or an air
sweep) for a period in the range of approximately 6-24 hours.
1TABLE 1 Effect of drying parameters on in vitro burst Initial
Sample time in dryer AddL dry gas sweep 24 hr In vitro release
0121-7- hrs hrs % K 0 0 12.6 L 6 0 16.1 M 12 0 16.8 N 18 0 5.3 0 18
6 4.3 P 18 12 8.3 Q 18 18 2.7 R 18 24 3.3 0121.7 18 24 3.4
Example 2
[0071] Effect of Drying Parameters on 15-Day Release
[0072] Nine samples were prepared in accordance with the 1 Kg
process described below in Example 6. As shown in Table 2, for six
of the samples, intermediate drying step 130 was performed to
achieve substantially complete intermediate drying using vacuum
drying with an air sweep. For two of the samples, intermediate
drying step 130 was performed as no intermediate drying. For one
sample, intermediate drying step 130 was performed to be a degree
of intermediate drying that is partial intermediate drying, between
no intermediate drying and substantially incomplete intermediate
drying.
[0073] As shown in Table 2, the in vitro release at 15 days was
highest for the samples for which no intermediate drying was
performed. The samples for which substantially complete
intermediate drying was performed showed a cumulative release of
active agent from the microparticles that is less than about 15%
after 15 days. The sample for which partial intermediate drying was
performed had a 15 day release between the substantially complete
intermediate drying samples and the no intermediate drying
samples.
2TABLE 2 Effect of drying parameters on 15-day release Amount of
drying Sample (with air system) % Released @ 15 days 715 Complete
13.6 903 Complete 9.4 909 Complete 12.6 1015 Complete 7,8 1216
Complete 10.2 0107 Complete 6.7 813 None 30.5 826 None 32.1 916
Partial 19.3
Example 3
[0074] Moisture Data and Drying Time
[0075] Four batches (0812-7, 0819-7, 0825-7, and 0902-7) were eared
in accordance with the 1 Kg process described below. Table 3 below
shows the time in hours of intermediate drying step 130, performed
using a small dry N.sub.2 bleed under a full vacuum. The percent
moisture was measured using a batch sample after the indicated
drying time using a Karl Fischer process (U.S. Pharmacopeia 921)
known to one of skill in the relevant art For samples 0819-7a and
0902-7g, the percent release was measured after 24 hours and after
15 days. These samples exhibit minimal release within 24 hours,
indicative of an initial lag phase in release of the active agent.
The cumulative release of active agent from these samples are 10.3%
and 8.3%, respectively, after 15 days. Samples 0812-7a, 7b, 7c,
0819-7a, 0825-7a, and 0902-7g represent substantially complete
intermediate drying, resulting in a moisture content of less than
about 0.2% after intermediate drying. Samples 0902-7e and 7f
represent a degree of intermediate drying between substantially
complete intermediate drying and no intermediate drying, resulting
in a moisture content of approximately 7% after intermediate
drying.
3TABLE 3 24 Hours 15 days Cumulative Cumulative Sample # Time Hrs.
Moisture % Release % Release % -0812-7a 16.26 0.14 -0812-7b 23 0.10
-0812-7c 40 0.08 -0819-7a 16.5 0.11 1.3 10.3 -0825-7a 40.6 0.10
-0902-7e 7.25 6.78 -0902-7f 7.25 6.99 -0902-7g 23 0.09 1.0 8.3
Example 4
[0076] In Vitro Release Profiles
[0077] The in vitro release profiles shown in FIG. 5 illustrate the
effect on release profiles as a function of the degree of
intermediate drying. The solid line without any data points labeled
"Mean Data" represents a baseline sigmoidal release profile. The
line labeled "Without Intermediate Drying" (.tangle-solidup. shaped
data points), and the two lines labeled "Intermediate Drying
Incomplete" (two lines with .box-solid. shaped data points), have a
higher release within 24 hours than does the Mean Data line, and
these three lines are more linear and less "S"-shaped than the Mean
Data Line.
[0078] In contrast, the two lines labeled "Intermediate Drying"
(.diamond-solid. and - shaped data points), have a low release
within 24 hours like the Mean Data line, and an "S"-shaped
sigmoidal release profile that closely follows the Mean Data
line.
Example 5
[0079] Sigmoidal Release Profiles
[0080] FIG. 6 shows the release profiles for three batches
(0812-7,0819-7, and 0902-7) that were prepared in accordance with
the 1 Kg process described below in Example 6. Each release profile
shown in FIG. 6 is a sigmoidal release profile characterized by an
initial lag phase (approximately days 1-15), a steep intermediate
release phase (approximately days 16-40), and a flat final release
phase (approximately days 41-60). Each batch was divided into three
sub-samples for in vitro release measurements. The average
cumulative release (%) of the three sub-samples after day 1 (24
hours) was 0.97% for batch 0812-7, 1.03% for batch 0902-7, and
1.33% for batch 0819-7. The average cumulative release (%) of the
three sub-samples after day 15 was 7.36% for batch 0812-7, 8.33%
for batch 0902-7, and 10.34% for batch 0819-7. Thus, these samples
prepared with substantially complete intermediate drying exhibit
minimal release within 24 hours, with an initial lag phase in
release of the active agent. Further, the cumulative release of
active agent from the microparticles was less than about 15% after
15 days.
Example 6
[0081] 1 Kg Process
[0082] A process for preparing microparticles containing
risperidone as the active agent in accordance with the present
invention will now be described. The following 1 Kg process (400
grams of active agent and 600 grams of polymer) is preferably
carried out using the equipment configuration shown in FIG. 2. The
theoretical drug loading of the microparticles is 40%. The actual
drug loading that is achieved by the process described below ranges
from about 35% to about 39%.
[0083] A drug solution is prepared by dissolving 400 grams of
risperidone (Janssen Pharmaceutica, Beerse, Belgium) in 1267 grams
of benzyl alcohol to form a 24 wt. % drug solution. A polymer
solution is formed by dissolving 600 grams of 75:25 DL PLGA polymer
(Alkermes, Inc., Blue Ash, Ohio) in 3000 grams of ethyl acetate to
form a 16.7 wt. % polymer solution. The drug solution and the
polymer solution are combined to form a first, discontinuous
phase.
[0084] The second, continuous phase is prepared by preparing a 30
liter solution of 1% PVA, the PVA acting as an emulsifier. To this
is added 2086 grams of ethyl acetate to form a 6.5 wt. % solution
of ethyl acetate.
[0085] The two phases are combined using a static mixer, such as a
1/2" Kenics static mixer available from Chemineer, Inc., North
Andover, Mass. A total flow rate of 3 L/min generally provides
microparticle size distributions with a mass median diameter (MMD)
in the range of about 80-90.mu.. The ratio of continuous phase to
discontinuous phase is 5:1 (v/v). The length of the static mixer
can vary from about 9 inches to about 88 inches. Lengths greater
than about 48 inches results in the greatest percent yield in a
microparticle size range of 25-150 .mu..
[0086] The quench liquid is 2.5% solution of ethyl acetate and
water-for-injection (WFI) at 5-10.degree. C. The volume of the
quench liquid is 0.25L per gram of batch size. The quench step is
carried out for a time period greater than about 4 hours, with
stirring of the microparticles in the quench tank.
[0087] After completion of the quench step, the microparticles are
transferred to the collecting, de-watering, and drying device 230
shown in FIG. 2 and described above. The microparticles are rinsed
using a chilled (approximately 5.degree. C.) 17 liter 25% ethanol
solution.
[0088] To form microparticles with a sigmoidal release profile, the
microparticles are then subjected to substantially complete
intermediate drying. The microparticles are dried in device 230
using vacuum and a 2-26 SCFH (Standard Cubic Feet per Hour) of
nitrogen bleed. To avoid agglomeration, the temperature is
maintained at less than 10.degree. C. by chilling the feed
nitrogen. Dryness is monitored by an absolute humidity probe,
available from Vaisala, Inc., Woburn, Mass., in the vacuum line of
the drying device. Absolute humidity refers to the ratio of the
mass of water vapor to the volume of moist air within which the
water vapor is contained. To ensure a sigmoidal release profile
with an initial lag phase, the drying is carried for a time period
greater than about four hours after substantially zero absolute
humidity is reached in the drying device. The moisture content of
the microparticles at this point is typically less than about 0.2%,
generally less than about 0.15%. If the microparticles are not
substantially completely dried at this point, then the release
profile will be altered to eliminate the lag phase, resulting in an
initial burst followed by a substantially linear release profile.
The substantially complete intermediate drying can be performed by
drying under vacuum with a gas bleed or sweep (air, nitrogen or
other dry gas) for a period in the range of approximately 16-48
hours.
[0089] The microparticles are then re-slurried in a re-slurry tank
(such as vessel 240 shown in FIG. 2) using a 25% ethanol solution
(extraction medium) maintained at a temperature lower than the
T.sub.g of the microparticles. The temperature in the re-slurry
tank is preferably in the range of about 0.degree. C. to about
15.degree. C., preferably less than about 10.degree. C., still more
preferably 6.degree..+-.2.degree. C. The microparticles are then
transferred back to the quench tank for washing for a time period
of at least 6 hours with another extraction medium (25% ethanol
solution) that is maintained at a temperature higher than the
T.sub.g of the microparticles. The T.sub.g of the microparticles is
about 18.degree. C. (about room temperature), and the temperature
of the extraction medium in the quench tank is greater than about
18.degree. C., preferably 25.degree..+-.1.degree. C.
[0090] The microparticles are transferred back to the collecting,
de-watering, and drying device for de-watering and final drying.
The final drying step is carried out in a manner similar to that
described above for the intermediate drying step, but the
temperature is warmed to greater than about 20.degree. C. but below
40.degree. C. Drying continues for a time period greater than about
16 hours.
Example 7
[0091] Measurement of In Vitro Release
[0092] To measure in vitro release as a function of time for a
sample of microparticles, the sample is incubated in physiological
(pH7) buffer at 37.degree. C. At periodic time points, a test
sample of the incubating sample is drawn. Release of the active
agent into the buffer in the test sample is measured
spectrophotometrically in a manner well known to one of skill in
the relevant art. The results are typically presented as cumulative
release % as a function of time.
[0093] Conclusion
[0094] While various embodiments of the present invention have been
described above, it should be understood that they have been
presented by way of example only, and not limitation. The present
invention is not limited to a particular active agent, polymer or
solvent, nor is the present invention limited to a particular scale
or batch size. Thus, the breadth and scope of the present invention
should not be limited by any of the above-described exemplary
embodiments, but should be defined only in accordance with the
following claims and their equivalents.
* * * * *