Optimisation of spray-drying process variables for dry powder inhalation (DPI) formulations of corticosteroid/cyclodextrin inclusion complexes

This study aims to develop and characterise a beclomethasone diproprionate:γ-cyclodextrin (BDP:γ-CYD) complex and to optimise the variables on the spray-drying process, in order to obtain a powder with the most suitable characteristics for lung delivery. The spray-dried powder – in a mass ratio of 2:5 (BDP:γ-CYD) – was physically mixed with three carriers of different particle sizes and in different ratios.Particle-size distribution, shape and morphology, moisture content, and uniformity in BDP content of formulations were studied. In vitro aerolisation behaviour of the formulations was evaluated using the Rotahaler, and the performance was characterised based on the uniformity of emitted dose and aerodynamic particle-size distribution (respirable fraction (RF), as a percentage of nominal dose (RFN) and emitted dose (RFE)).The most suitable conditions for the preparation of BDP:γ-CYD complexes were obtained with the solution flow of 5 ml/min, Tin of 70 °C and Tout of 50 °C.Statistically significant differences in the aerodynamic performances were obtained for formulations containing BDP:γ-CYD complexes prepared using different solution flows and different Tin (p < 0.05). RFN and RFE vary in direct proportion with Tin, while an inverse relationship was observed for the solution flow. A direct correlation between the RFE and the Tout was identified.Performance of the formulations was compared with an established commercial product (Beclotaide Rotacaps 100 μg) with improved performance of RF: formulations with respitose carrier attained RFN and RFE twofold greater, and formulations based on 63–90 μm fraction lactose and trehalose achieved a threefold improvement; also, all formulations showed that the percentage of dose of BDP deposited in the “oropharynx” compartment was reduced to half.