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                  Edited by
             Anthony J. Hickey
             Heidi M. Mansour
CRC Press
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        Names: Hickey, Anthony J., 1955- editor. | Mansour, Heidi M., editor.
        Title: Inhalation aerosols : physical and biological basis for therapy /
        [edited by] Anthony J. Hickey, Heidi M. Mansour.
        Description: Third edition. | New York, NY : CRC Press, [2019] | Includes
        bibliographical references and index.
        Identifiers: LCCN 2018043533| ISBN 9781138064799 (hardback : alk. paper) |
        ISBN 9781315159768 (ebook)
        Subjects: | MESH: Aerosols--therapeutic use | Aerosols--pharmacology |
        Nebulizers and Vaporizers | Pulmonary Ventilation--physiology
        Classification: LCC RM161 | NLM WB 342 | DDC 615.8/36--dc23
        LC record available at https://lccn.loc.gov/2018043533
Preface                                                                                                     vii
Editors                                                                                                     ix
Contributors                                                                                                xi
Introduction                                                                                                xv
Part I FUNDAMENTALS 1
                                                                                                             v
vi Contents
Part III INTEGRATED STRATEGIES (REFLECTING COMBINED ELEMENTS FROM CHAPTERS 8 THROUGH 23) 377
Index                                                                                                                   409
Preface
Inhalation aerosols continue to be the basis for successful lung   application of a technology. It is evident from the num-
therapy for a variety of diseases. Since the turn of the mil-      ber of chapters in this section (13) that the opportunities
lennium, many new products have been approved. Arguably            for the application of aerosol drug delivery have increased
the most substantial have been the first approved inhaled          dramatically in recent years. Finally, an integrated strategies
drugs and drug combinations for the treatment of chronic            section (Part III) draws the major points from the applica-
obstructive pulmonary disease (COPD). More recently, the            tions regarding disease targets and drug products in the
development of drugs to treat pulmonary infection and dia-          form of generalizations that may be valuable to readers.
betes has continued the translation of drug therapy to aerosol         In modifying the approach to the structure of the book,
technology. With this background, it is evident that techno-       we are aligning with the translational imperative that has
 logical advancements and therapeutic strategies have evolved       emerged in the last decade. In addition, this third edition
 since the first two editions of this book were published. The      is aligned with the latest scientific initiatives on precision
 original focus on asthma as the most significant target of         medicine that has been gaining much attention recently.
 inhaled therapy has broadened to include numerous local and        This approach encompasses precision pulmonary medicine.
 systemic diseases. And the range of technology forming the         The ability to extract knowledge rapidly and effectively from
 basis for novel inhaler design has expanded significantly.         study data and apply it in a therapeutically relevant manner
    In this text, rather than simply expand and update              is considered an urgent demand of the scientific and clinical
 the original two editions, we decided to address the close         research community. In presenting the content as described
 integration of technology with its application. An intro-          in this preface, we hope that relevance to development and
 ductory section (Part I) on the fundamental science acts           clinical evaluation can be established.
 as a transition from past volumes to the present text by
 presenting briefly the general considerations that apply                                                   Anthony J. Hickey
 to physical chemistry, device technology, aerosol physics,                                         Chapel Hill, North Carolina
 lung deposition, clearance, physiology, and pharmacol-
 ogy. Part II represents a new approach in which a disease                                                    Heidi M. Mansour
 and therapeutic agent focus is employed to illustrate the                                                      Tucson, Arizona
                                                                                                                                vii
Editors
Anthony J. Hickey, PhD, DSc, is Distinguished RTI Fellow      Pharmacopeia (USP, 2010–2015, Chair of the Subcommittee
at the Research Triangle Institute (2010–present), Emeritus   on Aerosols), and formerly Chair of the Aerosols Expert
Professor of Molecular Pharmaceutics of the Eshelman          Committee of the USP (2005–2010). Dr. Hickey conducts a
School of Pharmacy (1993–2010), and Adjunct Professor         multidisciplinary research program in the field of pulmo-
Biomedical Engineering in the School of Medicine at           nary drug and vaccine delivery for treatment and preven-
the University of North Carolina at Chapel Hill. He           tion of a variety of diseases.
obtained PhD (1984) and DSc (2003) degrees in pharma-
ceutical sciences from Aston University, Birmingham,          Heidi M. Mansour, PhD, RPh, is a tenured Associate
United Kingdom, following postdoctoral positions at the       Professor of Pharmaceutical Sciences in the College of
University of Kentucky (1984–1988). Dr. Hickey then           Pharmacy with joint faculty appointments in the BIO5
joined the faculty at the University of Illinois at Chicago   Research Institute and the College of Medicine in the
(1988–1993). In 1990, he received the American Association    Division of Translational and Regenerative Medicine at The
of Pharmaceutical Scientists (AAPS) Young Investigator        University of Arizona (UA) in Tucson, Arizona. Dr. Mansour
Award in Pharmaceutics and Pharmaceutical Technology.         has faculty member affiliations in the UA Institute of the
He is a Fellow of the Royal Society of Biology (2000),        Environment, and the UA NCI Comprehensive Cancer
the American Association of Pharmaceutical Scientists         Center. She lectures in the BS Pharmaceutical Sciences
(2003), the American Association for the Advancement of       undergraduate program, the Pharm. D. professional pro-
Science (2005), and the Royal Society of Biology (2017). He   gram and in the Pharmaceutics and Pharmacokinetics
received the Research Achievement Award of the Particulate    track of the graduate program at The University of Arizona.
Presentations and Design Division of the Powder Technology    In addition to teaching, Dr. Mansour serves as Faculty
Society of Japan (2012), the Distinguished Scientist Award    Advisor in the Pharm. D./PhD Dual Degree Joint Program
of the American Association of Indian Pharmaceutical          and Director of the Pharmaceutics and Pharmacokinetics
Scientists (2013), the David W. Grant Award in Physical       track in the Pharmaceutical Sciences graduate program in
Pharmacy of the American Association of Pharmaceutical        The UA College of Pharmacy. Dr. Mansour has published
Scientists (2015), the Thomas T. Mercer Joint Prize for       over 80 peer-reviewed scientific journal papers, 9 book
Excellence in Inhaled Medicines and Pharmaceutical            chapters, 2 edited books, and over 100 scientific conference
Aerosols of the American Association for Aerosol Research     abstracts. She serves on the editorial advisory boards of the
and the International Society for Aerosols in Medicine        Royal Society of Chemistry Molecular Systems Design &
(2017). He has published numerous papers and chapters         Engineering, APhA/FIP Journal of Pharmaceutical Sciences,
(over 250) in the pharmaceutical and biomedical literature,   and Pharmaceutical Technology.
one of which received the AAPS Meritorious Manuscript            Dr. Mansour is an annual Faculty Instructor at
Award in 2001. He has edited five texts on pharmaceutical     International Society of Aerosols in Medicine (ISAM)
inhalation aerosols and co-authored three others on phar-     Aerosol School, instructor in two online webinars on
maceutical process engineering, pharmaceutical particulate    inhalation aerosol drug delivery, and instructor in Buchi
science, and pharmaco complexity. He holds 25 U.S. patents    Advanced Spray Drying short courses. She was recently
on a variety of inhaler device technologies, and pulmonary    Co-Chair of the Drug Delivery: New Devices & Emerging
and oral drug delivery formulation technologies. He is        Therapies Group in ISAM, and has been an expert mem-
founder (1997, and formerly president and CEO, 1997–2013)     ber of the National Institutes of Health (NIH) NICHD
of Cirrus Pharmaceuticals, Inc., which was acquired by        U.S. Pediatric Formulations Initiative New Drug Delivery
Kemwell Pharma in 2013; founder (2001, and formerly CSO,      Systems Aerosols Working Group for several years.
2002–2007) of Oriel Therapeutics, Inc., which was acquired    Dr. Mansour currently serves on the Drug/Device Discovery
by Sandoz in 2010; and founder and CEO of Astartein,          and Development (DDDD) Committee of the American
Inc. (2013–present). He is a member of the Pharmaceutical     Thoracic Society (ATS). She regularly serves as an expert
Dosage Forms Expert Committee of the United States            reviewer for scientific journals and grant funding agencies,
                                                                                                                         ix
x Editors
including NIH study sections; Department of Defense           successfully graduated several PhDs. Her innovative research
(DOD) study panels; National Science Foundation (NSF)         program has produced assistant professors employed at
study panels; American Association for the Advancement        research universities in the United States and in the Republic
of Science (AAAS); Catalent Drug Delivery Institute; and      of South Korea, and senior research scientists employed at
international funding agencies such as the German–Israeli     major pharmaceutical companies in the United States.
Foundation, German International Exchange Service                Dr. Mansour is an active, long-time member of several
(DAAD), Cochrane Airways Group of the National                scientific organizations and elected member to honor soci-
Health Service (London, United Kingdom), Engineering          eties, including the Sigma Xi Scientific Research Honor
and Physical Sciences Research Council (London, United        Society, Rho Chi Pharmaceutical Honor Society, and Golden
Kingdom), PRESTIGE Postdoc Fellowship Programme               Key International Honor Society. A registered pharmacist for
of the European Commission (Paris, France), and the           over 20 years, she earned her BS in pharmacy with honors and
Biomedical Innovation Program of the French National          distinction, a PhD minor in advanced physical and interfa-
Research Agency (Paris, France).                              cial chemistry (Department of Chemistry), and a PhD major
   In addition to serving on NSF study panels, NIH study      in drug delivery/pharmaceutics (School of Pharmacy) from
sections, and international study panels in the European      the University of Wisconsin–Madison. Also at the University
Union and Great Britain, her innovative research program      of Wisconsin–Madison, she was a clinical instructor for a
continuously attracts competitive funding awards from fed-    few years. Having completed postdoctoral fellowships at the
eral sources (NIH, NSF, FDA, DOD) and the pharmaceutical      University of Wisconsin–Madison and at the University of
industry. In addition to lecturing in the BS Pharmaceutical   North Carolina–Chapel Hill, she was awarded the University
Sciences undergraduate, PhD graduate, and Pharm. D. pro-      of North Carolina–Chapel Hill Postdoctoral Award for
fessional programs, Dr. Mansour leads her research labs       Research Excellence from the Office of the Vice-Chancellor,
where she trains postdoctoral scholars, visiting scholars,    the AAPS Postdoctoral Fellow Award in Research Excellence,
visiting professors, graduate students, Pharm. D. student     and the PhRMA Foundation Postdoctoral Fellowship Award.
researchers, and physician-scientist (MD/PhD) fellows.        As an instructor, she served on the Graduate Faculty at the
As Major Professor and mentor, her research program has       University of North Carolina–Chapel Hill.
Contributors
                                                                                                                  xi
xii Contributors
The evolution of inhalation aerosol technology over the            of drugs in pharmacokinetic studies. Each of the common
last half-century has created unique opportunities to treat        therapeutic aerosol systems can be evaluated for its poten-
disease. The fundamentals of pharmaceutical aerosol gen-           tial to serve the needs of particular diseases.
eration and delivery are well established and require the             A major debilitating lung disease, asthma has been the
consideration of physical pharmacy, aerosol physics, device        primary focus of aerosol treatment since the 1950s. As the
technology, process and product engineering, and pulmo-            understanding of key elements of effectiveness was identi-
nary biology. The latter includes knowledge of lung depo-          fied, aerosol treatment has been expanded to include a wide
sition, clearance, and local and systemic pharmacology of          range of diseases. Chronic obstructive pulmonary disease
delivered drugs.                                                   (COPD) was a logical target for treatment as manifestations
    As the use of aerosols in the treatment of disease has been    of this disease are similar to asthma. As the vision of aero-
explored, a greater understanding of the best therapeutic          sol therapy broadened and new drug and biochemical tar-
approaches has been developed. The nature of questions             gets were identified, other areas such as genetic disorders,
regarding selection of technologies has progressed from a          airway remodeling, vascular disease, and infectious disease
desire to be informed about performance specifications to          have received considerable attention, from which new prod-
greater curiosity about the suitability of the technology for      ucts have been developed.
a specific disease therapy. The facility with which particular        As in other areas of human endeavor, the discoveries
technologies can be adapted for use allows the optimiza-           that have occurred in the parallel field of research serve to
tion of all elements of the inhaled drug product to meet the       inform each other in a manner that synergistically moves
needs of the biological and therapeutic endpoints.                 the field in a sometime discontinuous or disruptive manner.
    A number of outstanding texts on the subject of aerosols       Several recent events have promoted discoveries and inven-
and aerosol technology have been published (1–7). In the           tions. The most substantial was the implication of chlo-
field of inhalation aerosols, the focus varies from fundamen-      rofluorocarbon (CFC) propellants in ozone depletion and
tal science (8,9) and technology (10–15), and expands to clin-     their subsequent phase-out, which resulted in the develop-
ical application (16–18) and the entire topic of drug delivery     ment of hydrofluoroalkane (HFA) alternatives. A similar
and translation to the clinic (19). The present text is arranged   phenomenon is now occurring as the role of HFAs in global
to cover some basic principles and then to focus extensively       warming is evident and the desire for potential alternatives
on translation of pharmaceutical inhalation aerosol technol-       is driving new developments. A second event of arguably
ogy into the clinic to treat specific diseases. Figure I.1 indi-   similar magnitude to the propellant replacement was the
cates the sequence of topics this volume covers.                   desire for methods to deliver the products of biotechnology
    The fundamental aspects of medicinal aerosol delivery          that were difficult to prepare as stable formulations, that
may be considered as a sequence of events that first involve       were difficult to deliver by other routes of administration,
the formation of the aerosol from a variety of formulations        or that would simply benefit from the characteristic dis-
and devices, each of which is optimized for a specific appli-      position from the lungs. The need for a stable formulation
cation. Once the aerosol is formed, the physicochemical            and dose considerations resulted in a focus on dry powder
properties and airborne behavior of the aerosol interacts          inhalers (DPIs), which were until the late 1980s were poorly
with the pulmonary physiology to dictate deposition and            designed and inefficient systems with respect to the needs
disposition of drugs from the lungs. These properties and          for macromolecule delivery. The innovations arising from
parameters can be modeled to predict deposition of par-            the research of the following twenty years, particularly that
ticles and droplets in the lungs, and these predictions can        focused on insulin delivery, elevated the field significantly
be supplemented with experimental measures of deposi-              and positioned the technology for the many successes that
tion achieved by radiological imaging. After deposition,           have occurred since 2000. Finally, the same drivers in the
disposition can be followed by considering local transport         context of aqueous solution aerosol delivery resulted in an
and metabolism in the context of the systemic appearance           evolution from the dominant theme of air jet and ultrasonic
                                                                                                                             xv
xvi Introduction
                                                                            •   Genec
                                                                            •   Immune
                                                         DISEASE            •   Remodeling
                                                                            •   Vascular
                                                                            •   Infecous
                                                                            •   Systemic
Figure I.1 The sequence of topics addressed in this text. Fundamental considerations are the foundation for the adoption
of technologies to treat specific diseases. Knowledge gained from these experiences can be integrated to establish gen-
eral principles that may be used prospectively in transferring the drug molecule from its starting environment to the prox-
imity of its biological target. Many of the intervening steps are controlled either in manufacturing or in patient training.
nebulizers to smaller, more efficient vibrating mesh nebu-               This systematic method ideally accounts for the drug molecule
lizers and ultimately to handheld soft mist inhalers (SMIs).             from its starting environment, accounting for adjacencies, to
   As progress has been made to apply the fundamental                    its presentation to the molecular therapeutic target, control-
understanding of the dosage forms and the route of adminis-              ling as many of the intervening variables as possible.
tration to the context of specific diseases, an integrated body
of knowledge can now be drawn together to make general                   REFERENCES
observations about the foundation of technology available
and its impact on certain aspects of disease.                               1. Fuchs N. The Mechanics of Aerosols. Mineola, NY:
   The complexity of inhaled products and the multitude of                     Dover Press, 1989.
factors that affect their performance requires a quality by                 2. Davies C. Aerosol Science. New York: Academic
design (QbD) approach if overall quality is to be ensured.                     Press, 1966.
The spatial (chemical and physical structure) and tempo-                    3. Mercer T. Aerosol Technology in Hazard Evaluation.
ral (motion and disposition) behaviors of the product are                      New York: Academic Press, 1973.
subject to change by a range of variables, and each variable                4. Reist PC. Aerosol, Science and Technology.
requires sufficient monitoring and control to meet product                     New York: McGraw-Hill, 1993.
specifications and regulatory approval. The efficacy and                    5. Hinds W. Aerosol Technology. Properties, Behavior
safety of the product are linked to quality metrics, since the                 and Measurement of Airborne Particles, 2nd ed.
characteristic therapeutic needs of each disease are matched                   New York: John Wiley & Sons, 1999.
to the performance of the drug product.                                     6. Kulkarni P, Baron P, Willeke K. Aerosol Measurement:
   Subsequent chapters of the book will guide the reader                       Principles, Techniques, and Applications, 3rd ed.
through the fundamentals (Part I) into specific disease con-                   New York: John Wiley & Sons, 2011.
siderations with translation to precision pulmonary medicine                7. Ruzer L, Hartley N. Aerosols Handbook:
(Part II) from which integrated expositions on the nature of                   Measurement Dosimetry and Health Effects, 2nd ed.
technology and the impact of disease considerations will be con-               Boca Raton, FL: CRC Press, 2012.
cluded. The importance of developing products in a controlled               8. Finlay W. The Mechanics of Inhaled Pharmaceutical
environment and the ways in which this might be translated                     Aerosols. An Introduction. New York: Academic
into a uniform therapeutic outcome are discussed (Part III).                   Press, 2001.
                                                                                                      Introduction xvii
 9. Tougas T, Mitchell J, Lyapustina S, Eds. Good            14. Smyth H, Hickey A. Controlled Pulmonary Drug
    Cascade Impactor Practices, AIM and EDA for Orally           Delivery. New York: Springer, 2011.
    Inhaled Products. New York: Springer, 2013.              15. Colombo P, Traini D, Buttini F. Inhaled Drug Delivery:
10. Purewal T, Grant D. Metered Dose Inhaler                     Techniques and Products. New York: Wiley-
    Technology. Boca Raton, FL: CRC Press, 1997.                 Blackwell, 2013.
11. Srichana T. Dry Powder Inhalers. Formulation, Device     16. Newman S. Respiratory Drug Delivery: Essential Theory
    and Characterization. Hauppauge, NJ: Nova Science            and Practice. Richmond, VA: RDD Online, 2009.
    Publishers, 2016.                                        17. Jacob B, O’Driscoll B, Dennis J. Practical Handbook of
12. Zeng X, Martin G, Marriott C. Particulate Interactions       Nebulizer Therapy. Boca Raton, FL: CRC Press, 2003.
    in Dry Powder Formulations for Inhalation. New York:     18. Gradon L, Marijnisson J. Optimization of Aerosol
    CRC Press, 2000.                                             Drug Delivery. New York: Springer, 2003.
13. Hickey A. Pharmaceutical Inhalation Aerosol              19. Dhand R, Rothen-Rutishauser B, Hickey A. ISAM
    Technology, 2nd ed. New York: Marcel Dekker,                 Textbook of Aerosol Medicine. New Rochelle, NY:
    2004.                                                        ISAM-Mary Ann Liebert, 2015.
                                                                                                        I
                                                                                                 Part    
Fundamentals
BORIS SHEKUNOV
Introduction: Physicochemical particle properties and                  Solid-state chemistry of crystalline and amorphous
inhaler performance                                            3       materials                                                 15
Major factors affecting particle aerosolization                5       Lactose carriers and adhesive blends                      18
   Aerodynamic diameter and Stokes number                      5       Engineered solid particles                                19
   Particle aggregate strength                                 7       Liposomes                                                 23
   Modeling of dry powder dispersion                           9       pMDI solutions and suspensions                            24
   Atomization of droplets                                    13    Conclusions and future perspective                           25
Drug solubility and mechanism of particle dissolution         14    Nomenclature                                                 27
Formulation aspects of respiratory drug delivery              15    References                                                   28
INTRODUCTION: PHYSICOCHEMICAL                                       drug dissolution and particle uptake rates. Particle inertial
PARTICLE PROPERTIES AND INHALER                                     deposition is typically associated with the fine particle frac-
PERFORMANCE                                                         tion (FPF) between 1 and 5 μm in terms of the aerodynamic
                                                                    diameter, dA, with maximum deposition in alveoli region
Drug delivery by inhalation can be considered as a sequence         between 1 and 2 μm. It is also known that particles with
of three equally important stages: particle aerosolization          dA ≈ 100 nm also exhibit a peak related to the deposition
within an inhaler device (as solid particles or liquid drop-        by Brownian diffusion mechanism (1), although generating
lets); particle deposition/distribution in the airways and,        such nanosize aerosols is rather hypothetical. Particles in the
finally, drug release/particle uptake/clearance at the site of      micron, and especially the submicron, range are very cohe-
action. The anatomy of respiratory tract presents a natural         sive. Small variations in size, surface and morphology, and
barrier to any particulate matter and, if particles penetrate       some environmental conditions can significantly affect the
into the deeper lungs, they tend to be rapidly removed by one       powder aerosolization leading to low or, even worse, incon-
of the physiological defense mechanisms (1,2). Consequently         sistent FPF. Particles that deposit into the alveolar region
a major goal of respiratory drug delivery is to optimize            are removed by phagocytosis, which may influence the effi-
physicochemical particle properties in order to achieve the         cacy of drug formulation (2,7). For this uptake, the volume-
maximum efficacy and safety of these dosage forms. The phys-        weighted particle diameter, d, and surface-to-volume shape
icochemical properties of respiratory formulations can also         factor, αsv, are important: for example, spherical particles
be classified in accordance with their material characteriza-       1–5 μm are taken at a greater extent than smaller or larger
tion level and in relationship with their biopharmaceutical         particles, or particles of acicular shape, or those with modi-
effects as illustrated in Table 1.1. This table also contains       fied surface and charge. By using different means of particle
information pertinent to regulatory considerations during           engineering it is therefore theoretically possible to optimize
development, quality control and bioequivalence studies of          most drug delivery characteristics. There are, however, very
inhalation drug products (3–6). Particle size distribution, in      significant practical limitations to that imposed by the inher-
combination with the particle density and shape factor, is the      ent material properties of active pharmaceutical ingredients
most important critical attribute for any respiratory formula-      (APIs) and carriers, their toxicology, the inhaler design, the
tion and at each drug delivery stage: it determines the abil-       patient variability, as well as by the stringent requirements
ity of formulation to be efficiently aerosolized at predefined      of drug product manufacturing and pharmaceutical quality
inspiratory flow rates, controls the particle deposition profile,   control.
                                                                                                                                  3
4 Physicochemical properties of respiratory particles and formulations
 Table 1.1 Different levels of physicochemical functionality in relationship to major biopharmaceutical and drug delivery
 characteristics, combined with its regulatory considerations for development, bioequivalence, and quality control of
 inhalation drug products
                                                       Affected biopharmaceutical
 Physicochemical characteristics                               parameters                      Related regulatory considerations
 Solid State
 Molecular structure, impurities; crystal        Physical and chemical stability,             Physicochemical characterization of
   form/crystallinity/amorphous content;           potency, safety; systemic                    API(s) and excipients relevant to
   equilibrium solubility, intrinsic               bioavailability and/or local drug            their functionality in drug product;
   dissolution rate; hygroscopicity /              concentration; bioequivalence (for           compatibility with diluentsc; effects
   moisture content                                generics)                                    of environmental moisturea,b, low
                                                                                                temperatureb; temperature
                                                                                                cyclingb,d; moisture contenta,b;
                                                                                                sameness/therapeutic equivalence
                                                                                                of API (generics).
 Formulation
 Type of formulation, dosage form and      Mode of administration; immediate,           Assay, mean delivered dose vs. label
   packaging presentation; carrier(s)a,b,   sustained or controlled drug delivery;        claima,b,d; DCUa,b,d; dose
   composition and coatinga,b; dispersion   dose metering, devise retention; dose         proportionality (for different
   mediab,c,d; powder triboelectric charge, uniformity/consistency; systemic              strengths and/or APIs); formulation/
   bulk and tapped densitya; aggregate      bioavailability and/or local drug             inhaler robustness; drug product
   structure, density and strength; impact  concentration; therapeutic efficacy and       stability; qualitative (Q1) sameness
   of processing/mixing; bulk flow          therapeutic index; ADME; safety/              and quantitative (Q2) equivalence of
   properties/powder handling/fillinga.     toxicology/ irritability; storage stability/ excipients and media
                                            shelf life; bioequivalence (for generics).    physicochemical similarityc (generics).
 a   DPIs.
 b   pMDIs.
 c   Nebulizers.
 d   Non-pressurized metered-dose inhalers; otherwise generally applicable.
    The medical science of respiratory drug delivery is                  DPIs certainly belong to the cutting technological edge, due to
 iscussed in the following chapters of this book. The present
d                                                                        the wide range of different active ingredients, doses, formula-
chapter is concerned with material science—physicochemical               tions as well as current and potential therapeutic applications
particle properties that directly impact formulation and inhaler         (8). They also present the greatest challenges in pharmaceuti-
design, especially for dry powder inhalers (DPIs). Although              cal development, and from the regulatory viewpoint, are con-
other type of devices such as pressurized metered-dose inhal-            sidered one of the most complex drug products (4). Since the
ers (pMDIs), nebulizers and non-pressurized metered-dose                 early application of DPIs in the 1960s, there has been a great
inhalers/soft mist inhalers are very important; the range of             body of work done and literature accumulated for this technol-
material science issues with them is much narrower. The fun-             ogy, but there are still many unresolved fundamental issues.
damental reasons for this observation will also be discussed.            In recent reviews, for example, it has been pointed out that
                                                                                      Major factors affecting particle aerosolization 5
lack of understanding of powder dispersion mechanisms is a              requires a purposeful experimental methodology to determine
major obstacle to improved inhaler performance (9). Several             the key material and fluid dynamic parameters, rather than sta-
misconceptions are highlighted in relationship to optimal               tistical correlations.
inhaler performance with the air-flow independent therapy                   The major objective of this chapter is not to review pre-
(8), device resistance and application of high-resistance devices       vious developments of inhalation particle technology or
by patients with reduced lung function (8,10). It was noted that        formulations, an extensive topic already covered by mul-
surprisingly little attention has been given to the improvement         tiple recent publications (e.g., 1,8,10,11,14–17). Although
of inhaler designs and new integrated device-          formulation     a comprehensive assessment is also difficult to accomplish
systems, with most modern inhalers still delivering only                in a single chapter, the main intention here is to provide
20%–30% FPF of the label claim (10). For the carrier-based              the reader with a systematic quantitative description of the
formulations, the consensus is that the relationship between            key physicochemical parameters and, when possible, relate
properties of the starting materials, the mixing process, and           these parameters to the inhaler performance using analyti-
dispersion performance is not well understood and constitutes           cal concepts developed for this work. In what follows, the
a mostly empirical endeavor (11). This list of misconceptions           definitions are introduced and mechanisms discussed by
can further be extended to other areas of inhalation material           which the physicochemical properties of solid particles and
science including, for example, mechanisms of interparticle             liquid drops are translated into the drug delivery character-
interaction, dispersion, particle dissolution and solid-state sta-      istics of pharmaceutical aerosols, most important, the FPF.
bility of amorphous formulations, as discussed in this chapter.         This is concluded with a brief review of different formulation
    Although the complexity of interactions within the triad            approaches and optimization strategies, and future perspec-
“formulation—airflow—inhaler design” should not be underes-             tives in this important and fast-growing therapeutic field.
timated, in the author’s opinion many of these gaps are method-
ological. For instance, one may consider independence of FPF            MAJOR FACTORS AFFECTING PARTICLE
from the airflow as a desirable characteristic for any respiratory      AEROSOLIZATION
formulation, but this point needs to be clarified in conjunction
with a specific inhaler design. If formulation is readily fluidiz-      Aerodynamic diameter and Stokes number
able and dispersible at any flow rate, this implies a low “threshold
energy” (or, more precisely, minimal stresses required for pow-         Particles for inhalation may not only have different geometric
der disaggregation, see the section called “Major factors affect-       size (usually defined through the volume-equivalent diam-
ing particle aerosolization”) with very high FPF approaching            eter, d, [18]) but also exhibit different shape, density/porosity
the ideal 100%. Also for such particles, the inertial impaction         and aggregate structure. In order to standardize the fluid
parameter is sufficiently small to bypass deposition in the upper       dynamic equations for different kinds of particles, the con-
respiratory tract resulting in low in vivo variability (12). In prac-   cept of aerodynamic diameter, dA, is introduced. It is defined
tice, however, neither formulation nor inhaler are perfect, so          as the diameter of spheres of unit density, which undergo
if FPF increases steadily with flow or pressure drop, this most         the same acceleration in the air stream as non-spherical par-
likely indicates a cohesive formulation and variable dispersion         ticles of arbitrary density, therefore moving along the same
mechanism, whereas a steady but low FPF value may suggest a             streamlines. Following this definition, the general dynamic
problem with either formulation or inherent inhaler design and          equation leads to the following relationship:
may, in fact, be attributed to the fundamental properties of tur-
bulent flow, as shown below. A significant issue here is that flow                              ρ 1 Cd ( Re A ) Cc ( Re )
rate, pressure drop and inhaler resistance are usually not related                     dA = d                                        (1.1)
                                                                                                ρ1 α sv Cd ( Re ) Cc ( Re A )
quantitatively to the material characteristics of the formulation
(e.g., particle adhesion/cohesion and aggregate strength), flow
regime (character and intensity of turbulence) or the inhaler           where 𝜌1 is the unit density (e.g., 1 g/cm3) and 𝜌 is the particle
performance in terms of FPF or other measurable aerosoliza-             density. Cd is the particle drag coefficient which is a function
tion parameters. Indeed, the most widely used approach con-             of the particle Reynolds number, Re = ud/υ, where υ is the air
sists of an array of empirical studies, oriented towards proving        kinematic viscosity, u is the particle (slip) velocity relative to
how certain formulation properties are important for better             the air stream. ReA and Re denote numbers for particles with
inhaler performance. Even when supported by the design of               diameters dA and d, respectively. Cc is the Cunningham slip
experiments (DoE), these studies often lead to contradictory            correction factor dependent on the particle diameter (18,19).
conclusions and, by their nature, cannot result in generalized          Experimentally, the aerodynamic particle size distribution
models (13). Of course, such studies may solve some short-term          (APSD) is typically measured using cascade impactor devices
problems of industrial development or commercial produc-                such as Andersen cascade impactor, next generation cascade
tion. On the other hand, more recent applications of compu-             impactor (NGI) and muti-stage liquid impinger (MSLI), all
tational fluid dynamics (CFD) predominantly concentrate on              of which operate on the principle of particle classification by
the description of aerodynamic flow fields, but usually do not          using a series of jets and collection plates with different Stokes
contain principal closure equations of particle aerosolization          numbers (see below). APSD can also be measured using time-
and dispersion. Understanding of these mechanisms, in turn,             of-flight (TOF) techniques (18).
6 Physicochemical properties of respiratory particles and formulations
    Surface-to-volume shape factor, αsv, is the ratio of the char-   the ratio of the characteristic particle relaxation time under
acteristic particle cross-section with equivalent diameter, ds,      the drag, to the characteristic flow time around the obstacle
to that of the particle with volume-equivalent diameter, d:          (20). At small Stke << 1, a particle follows the fluid stream-
                                                                     lines whereas at Stke >> 1, particle follows its initial trajec-
                                           2
                                   d                               tory and impact the obstacle. This definition depends on the
                            α sv =  s                      (1.2)   particle Re number (20,21):
                                   d 
Equations (1.1) and (1.2) define this shape factor through                                 Stk e =ψ ( Re ) Stk                  (1.5)
the particle geometry, whereas the drag coefficients are
written for the spherical particles, thus decoupling these           where Stk is this number in the Stokesian flow regime
quantities. This definition is different from the dynamic            (ψ = 1):
shape factor considered elsewhere (18,19). The advantage
is that it can be determined experimentally from micro-                                               ρd A2 u
                                                                                              Stk =                             (1.6)
scopic image analysis, or from other measurements given                                               18 µ L
independent assessment of both d and d s. These param-
eters are usually measured through a combination of laser            μ = υ𝜌0 is the dynamic air viscosity and L is the character-
diffraction and microscopic imaging studies. For solid               istic dimension of an obstacle. The non-Stokesian particle
particles with density 𝜌p, it is useful to define αsv (for ran-      drag correction factor, ψ, can be calculated numerically (21).
domly oriented particles) through the specific surface area          The importance of the Stokes number is that it can describe
(SSA) which are related through the well-known Cauchy                at least three categories of events:
theorem stipulating that the mean projected area is equal
to quarter of the surface area, leading to the following             1. Deposition by inertial impaction in the upper air-
expression:                                                             ways defining the fine particle dose (FPD) delivered
                                                                        to the lungs. The “inertial impaction parameter,” dA2Q
                              1                                         (according to Eq. [1.6]), is often used to describe the
                        α sv = SSA ρ p d                     (1.3)
                              6                                         mouth-throat deposition (12).
                                                                     2. Measurements of the aerodynamic particle diameters
whereby SSA can be determined from the Brunauer–                        (e.g., mass-median aerodynamic diameter [MMAD])
Emmett–Teller (BET) gas adsorption measurements.                        and fine particle fraction (FPF) with different cascade
    The general equation (1.1) is solved numerically and                impactors or liquid impingers, typically used for in vitro
equally applicable to droplets, solid particles, porous par-            R&D studies and industrial quality control of different
ticles and aggregates provided that the particle density (or            inhalers; and applied for recalibration of impactor cut-
void fraction for aggregates) and particle shape factor are             off diameters at different flow rates Q (18).
known. The flow regimes applicable to respiratory delivery           3. Efficiency of particle deaggregation within the DPIs,
or measurements can be defined as Stokesian (Re < 0.1)                  in particular those purposely designed for particle
and ultra-Stokesian (0.5 < Re < 100). For the spheri-                   impaction.
cal particles in the Stokesian flow regime, the drag coef-
ficient assumes the well-known relationship: Cd = 24/Re.
                                                                     One may consider possible deviations introduced in
Also, taking Cc ≈ 1 for the micron particle size range (the
                                                                     Eqs. (1.1) and (1.5) in the ultra—Stokesian flow regime.
estimated error <10% for particles approximately 2 μm in
                                                                     Although the particle Re is much smaller than correspond-
size [19]), Eq. (1.1) leads to the simplified expression for
                                                                     ing numbers for airflow within both the human respiratory
Stokes aerodynamic diameter widely used in the aerosol
                                                                     system and inhalation devices, it can reach levels suffi-
literature:
                                                                     ciently high to introduce non-Stokesian corrections. For
                                                1/2                  example, for a turbulent flow (at least at the peak airflow
                                      ρ 
                   d A (Stokes ) = d                       (1.4)   rate) in the mouth-throat, Re ≈ 1, for particles below 10 μm,
                                      α sv ρ 1                     which give the value of ψ ≈ 0.9, so the effect on the throat
                                                                     deposition is likely to be minimal. However, for the turbu-
Thus non-spherical particles and porous particles have a             lent flow within the inhaler itself, and for larger aggregates,
smaller aerodynamic diameter than solid spherical particles          Re may reach one or two orders of magnitude higher (see
of the same mass. For liquid aerosols, such as nebulizer and         the section called “Modelling of dry powder dispersion”),
pMDIs sprays, the droplet particle shape is also not com-            thus ψ ≈ 0.4–0.8, introducing a significant correction, for
pletely spherical due to deformation by air stresses, as will        example, in assessing the particle impaction on an inhaler
be discussed in the following sections.                              grid. Similarly, calculations of the precise cut-off diameters
    The dimensionless Stokes number (given here as the               in the cascade impactors may require application of com-
generalized effective Stokes number, Stke), can be viewed as         plete Eqs. (1.1) and (1.5) (18).
                                                                                Major factors affecting particle aerosolization 7
characteristic dimension, d, it can be seen (Figure 1.1) that      4. For binary mixtures consisting large carrier particles,
coordination number on the edges, Ke, is generally smaller            such as lactose crystals, the aggregates mostly consist
that coordination number, Kb, in the bulk, whereas the                of a carrier with adhered drug particles. According
mean coordination number for the entire cross-section can             to Eqs. (1.10) through (1.11), the carrier-drug bond
be calculated as:                                                     increases by a factor of 2, given the same W and con-
                                                                      tact cross-section, compared to the bond between drug
                     K = Ke +
                                (Kb − Ke )                 (1.9)
                                                                      particles themselves. However, the balance of strength
                                 d0 
                                          2                           for such aggregates depends on the drug-carrier surface
                                1 +                                 coverage and packing order of drug particles.
                                   d 
                                                                   5. Both parameters, K and σT , become dependent on the
                                                                      aggregate (or cross-section) size when they are compa-
The mean interparticle cohesive force, F, depends on sev-             rable to the size of primary particles. In particular, K
eral factors, including the particle shape and surface                has a smaller value for the fracture cross-sections close
roughness; however the analytical equations are only avail-           to the aggregate surface (Eq. 1.9).
able for smooth elastic spheres under attractive (usually
van-der-Waals) contact forces. For example, a well-accepted        Note that the current model does not assume an increase of
Johnson-Kendall-Roberts (JKR) (30) relationship reads:             aggregate porosity with their size, as in the fractal descrip-
                                                                   tion (26,28), because there is no physical basis by which this
                             3
                        F = − π Wd p                      (1.10)   porosity should increase with size given that all aggregates
                             8                                     are produced from the same powder bed.
                                                                       The magnitude of aggregate strength can be assessed as
In case of particles of different diameters, dp1 and dp2, the      follows, taking typical parameters: dp = 2 μm; 𝜌 = 0.3 g/cm3;
interactive diameter can be taken as the harmonic mean:            𝜌max = 1 g/cm3; 𝜌p = 1.4 g/cm3; Kb = 3; W = 20 mJ/m2 (22). One
                                                                   then obtains: σT = 3.2 kPa for large aggregates, σT = 1.6 kPa for
                         2   1    1
                           =    +                         (1.11)   small aggregates according to this model; whereas the compu-
                        d p d p1 d p 2                             tation using other models gives: σT = 3.6 kPa (29); σT = 0.3 kPa
                                                                   (25). Thus, the present model suggests the aggregate strength
Eqs. (1.7) through (1.11) are sufficient to describe practically   just below that predicted by Rumpf but significantly above
all effects related to interactions of particles in aggregates     that following from the model by Kendell. One should also
and also to make a quantitative assessment of the aggregate        consider rather unreliable predictions of the bonding force,
tensile strength:                                                  F, based on the assumption of idealized geometry of smooth
                                                                   elastic spheres, which is used in the JKR model, as well as in
1. The aggregate strength is inversely proportional to dp,         all other similar models of particle interactions. In reality the
   although the magnitude of interparticulate bonds is             rough particle surface and non-spherical morphology ensure
   directly proportional to dp according to Eq. (1.10). This       that the effective contact area would be significantly reduced
   comes from the fact that tensile strength is defined by the     below that for the smooth sphere in most cases but flat contacts.
   force per unit area of cross-section in Eq. (1.7). In par-      Also, these models assume uniform distribution of particle
   ticular larger “porous” particles of the same aerodynamic       defects, whereas the breakup would first occur in planes with
   diameter form weaker aggregates than solid particles.           the weakest σT, as observed experimentally (27). Practically
2. Small surface irregularities (also called asperities or         that means that Eq. (1.10) would have a significantly smaller
   corrugated surfaces [22]) can significantly decrease            numerical coefficient dependent on the particle shape, albeit
   both the interparticle bond and aggregate strength (by          the dependence on volume diameter and work of adhesion
   a factor ~2y/dp where y is the diameter of asperity for a       in this equation would likely hold from the fundamental con-
   single contact). For multiple contacts with number, q,          siderations, at least for the mean values of these parameters.
   the mean interparticulate bond increases to ~2qy/dp,            In this connection, it should also be mentioned that the work
   but may still be below the value for smooth particles if        of adhesion, W, is often confused in literature with the sur-
   y << dp. This effect can be calculated based on geometry        face energy (or, more precisely, with the specific surface free
   for specific packing.                                           energy) of a solid, γs. W is defined by the minimum of energy
3. For binary mixtures consisting of nanoparticles, the            per unit area required to separate two surfaces in mechanical
   same applies as for asperities. The mean interparticu-          contact (25), whereas the surface energy is defined thermody-
   late bond and aggregate strength both decrease with             namically as the specific free energy created by the new solid
   increasing concentration of nanoparticles, reaching a           surface, for example, in the processes of crystal nucleation,
   minimum at a certain surface coverage corresponding             growth or cleavage (31) (the analogue for liquids is surface
   to approximately a single particle-nanoparticle-particle        tension). Both definitions are only equivalent for a perfect
   contact within the entire lattice, after which the aggre-       contact between similar and ideally smooth (on the atomic
   gate strength increases again due to increasing number          level) surfaces, which is never the case for particles, although
   of such contacts.                                               these quantities relate to each other progressively.
                                                                                 Major factors affecting particle aerosolization 9
residence time, requires an independent assessment of the                unit mass (m2/s3) and Cb is the proportionality constant
aerodynamic stress, σ.                                                   in this breakage kernel (28).
   Considering the mass balance of breakable aggregates,              2. Stress defined by the inertial forces above λK, whereby:
unbreakable agglomerates and fine particles before and
                                                                                                        2/3
after dispersion process:                                                                   C α ρ                                 ε d 
                                                                                                                                             2 /3
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