The effect of lactose micro-spherical crystals prepared by conditioning with supercritical fluid on salbutamol sulphate inhalation performance

In this study, lactose crystalline powder was produced to improve its stability. The effect of micronised crystalline lactose on a dry powder inhalation formulation was investigated. Supercritical carbon dioxide (scCO2) modified with menthol was used for the conditioning of spray-dried amorphous lactose and salbutamol sulphate to generate micro-spherical crystalline powders. The optimum processing conditions, which include: menthol concentration, temperature and processing time, were determined by experimental design to produce crystalline and a desired particle size. The average particle size of spray-dried amorphous lactose decreased from 8.15 ± 0.28 μm to 7.60 ± 0.10 μm after conditioning with modified CO2 at 150 bar and 50 °C for a period of 5 h. The SEM results shows that these particles kept their micro-spherical shape, however, the particle surface became rough due to crystallisation. This particle size reduction was most likely due to increasing surface roughness, which decreased agglomeration between particles. The blend of this fine powder and coarse crystalline lactose enhanced salbutamol sulphate inhalation performance. The emitted fine particle fraction of salbutamol sulphate was enhanced to 40 ± 0.3% compare to the samples that contained only coarse lactose (38.2 ± 0.6%) or conditioned lactose (24.6 ± 0.4%).

Graphical abstractFigure optionsDownload full-size imageDownload as PowerPoint slideHighlights► Conditioning of amorphous lactose with scCO2 and menthol has created crystalline spherical particles of lactose. ► The blend of this conditioned lactose (fine particles) and coarse crystalline lactose enhanced the salbutamol sulphate inhalation performance. ► We developed an environmentally friendly technique as no organic solvent was used.