Hot Melt Coating of Pellets
for a Water Soluble Drug using Combination of Waxes
Pramod Salve*, Sushat Dubey, Nikhil Bali
University Department of Pharmaceutical Sciences,
Rashtrasant Tukadoji Maharaj Nagpur University Campus, Mahatma Jyotiba Fuley
Shaikshanik Parisar, Amravati Road, Nagpur-440033, (M.S), India.
*Corresponding Author E-mail: pramodsalve77@yahoo.com
ABSTRACT:
Waxes retards drug release from dosage form based on
their lipophilic characteristics. In this study, the effect of hot melt spray
coated Verapamil pellets with composition of stearic acid, carnauba wax;
glyceryl monostearate and polyethylene glycol on drug release and release
kinetics were investigated. The verapamil pellets containing 70%
microcrystalline cellulose (Avicel PH101) were prepared by
extrusion-spheronization technique and spray coated with molten wax at various
ratios and thickness in a hot-melt spray coating instrument. In-vitro drug
release was studied using test method for Extended Release tablets USP 24. The
drug release was decreased with increase in stearic acid concentration and
addition of 5 % carnauba wax to stearic acid minimized initial burst release
but it also retarded drug release. Glyceryl monostearate 30 %w/w as release
modifier at 20 %w/w coating level provided desired drug release while PEG 6000
provided similar results at 2.5 %w/w concentration. The plot of log fraction
drug unreleased versus time showed a good linear relationship. Glycerol
monostearate at 30 %w/w as release
modifier showed higher release rate in initial hours which declined with time
and also R2 value for first order release kinetics was found to be
nearest to one indicating drug release was dependent on initial concentration
present in pellets. A zero order release profile was obtained from verapamil
HCl sustained release pellets prepared by hot melt spray coating of stearic
acid with sitable combination of carnuba wax and PEG 6000.
KEYWORDS: Hot-melt spray coating; pellets; sustained release dosage form.
INTRODUCTION:
Conventional
pharmaceutical dosage forms are being replaced by novel drug delivery systems
which are safe, more efficacious and providing more patient compliance.
Sustained release dosage forms are designed in such a way that they provide
rapid onset of action and therapeutic response is maintained for prolonged
period due to controlled release of drug from dosage form to maintain desired
drug concentration in body fluids (7,8).
Various
techniques have been utilized for development of sustained release dosage
forms. Amongst various techniques available extrusion spheronization is one of
most successful methods which came increasingly into use in late 1970s (10).
Pellets having spherical shape are gaining more attention in designing extended
release and controlled release preparations due to inherent advantages (19).
The film coating
technology although most widely used for coating of granules, pellets and
tablets to produce sustained release dosage forms but has several
disadvantages. Film coating processes often require solvents. The use of
organic solvents may lead to environmental problems, solvent residues and
excessive costs of recovery. The aqueous solvent generally prolongs the
duration of the coating process. In
present environment of global competition and cost containment in
pharmaceutical industry, it is necessary to develop novel coating process which
is simple, efficient, precise and cost-effective and allow easy compliance with
regulatory requirements. Under such demanding circumstances, promise of hot
melt coating is attractive and provides various advantages (1) as it avoids the
use of organic solvents and thus it is eco-friendly, has high application rate
and shorter processing time.
The hydrophobic
coating materials which are suitable for application in hot melt coating
comprises waxes, fatty acid bases and hydrogenated vegetable oils. Due to low
melting points, waxes are of interest for preparation of controlled release
system by means of melt granulation, melt extrusion, melt pelletization, melt
dispersion or spray congealing (46) which does not require use of organic
solvents. The choice of coating agents depends primarily on its function such
as retardation of drug release rate (13,15), prevention of environmental degradation,
and masking of unpalatable taste in dosage form.
Verapamil HCl,
the first calcium-channel blocker to be introduced for clinical use is a major
drug used for the treatment of systemic hypertension. Due to its short
half-life, Verapamil was originally administered 3 to 4 times daily. It is a
relatively water soluble agent. Most of water soluble drugs, if not formulated
properly, may readily release the drug at a faster rate, and are likely to
produce toxic concentration of drug on oral administration. (14,21)
The objective of
present study was to develop Verapamil HCl sustained release pellets by hot
melt coating of waxes.
Materials and methods
Materials
Stearic acid (S.D. Fine Chem. Ltd. India), Carnauba
wax (S.D. Fine Chem. Ltd., India),
Glyceryl monostearate, [GMS] (S.D. Fine
Chem. Ltd., India) and Polyethylene glycol, [PEG] (S.D. Fine Chem. Ltd., India) were used
as waxes in coating composition. Verapamil hydrochloride (ZIM Laboratories,
India) and microcrystalline cellulose (Avicel PH101, Asahi Chemical, Japan)
were used as a model drug and a spheronizing aid respectively. Starch and PVP
K-30 used as binder were procured from ZIM Laboratories, India
Preparation of Verapamil HCl core pellets
Microcrystalline
cellulose and Verapamil HCl were passed through sieve # 60 and accurately
weighed. All the powders were blended by geometric dilution method using mortar
and pestle. Aqueous binder solution of PVP K-30 was added to powder blend in
gradual manner and after each addition, it was kneaded thoroughly in order to
get optimum wet mass. The damp mass was extruded through extruder. Extrudates
were spheronized in a spheronizer. The resulting pellets were dried at 45-55 °C
for 24 hours. The composition of core pellets is shown in Table 1.
Table 1 Composition of core
pellets
|
Sr. No. |
Formulation batch |
Binder |
Concentration
of aqueous solution (%w/v) |
Verapamil HCl (gm) |
Avicel PH
101 (gm) |
|
1 |
C1 |
Starch Paste |
3 |
15 |
35 |
|
2 |
C2 |
Starch Paste |
4 |
15 |
35 |
|
3 |
C3 |
PVP K30 |
3 |
15 |
35 |
|
4 |
C4 |
PVP K30 |
4 |
15 |
35 |
Preparation
of wax coated pellets
Figure
1: Schematic diagram of Hot Melt Spray Coating Device
A hot melt spray coating instrument was
developed in our laboratory. The schematic diagram of instrument used for wax
coating is shown in figure 1. The wax coating instrument consists of a round
baffled coating pan, jacketed reservoir for molten wax with thermostat mounted
on top of a spray gun, electrical heating element for heating atomization air
and a compressor to provide air under pressure. A temperature regulator and a
pressure regulator were used to control temperature and pressure of hot air
respectively.(23)
Specified quantities of pellets in the
coating pan were preheated using hot air. The molten wax above its melting
point along with hot air was then sprayed onto the ladling pellets with
intermittent heating. The cycle of spraying and heating was continued till
desired weight gain was achieved. The parameters for wax coating are shown in
the Table 2.
Table 2 Constant parameters
for wax coating
|
Sr.
No. |
Parameters |
Values |
|
1 |
Spray rate |
2 (gm/min) |
|
2 |
Atomization air pressure |
5 (lb/in2) |
|
3 |
Temperature of hot air through nozzle |
70 °C |
|
4 |
Distance of spray nozzle from pellet bed |
5 cm |
|
5 |
Temperature of molten wax inside reservoir |
80-85 °C |
|
6 |
Batch size |
30 gm |
|
7 |
Pan rotation speed |
35 rpm |
The formulation batches as per coat
composition and coating levels are shown in Table 3.
Table
3 Formulation batches as per coat composition and coating level
Formulation batch |
Coat Composition (%w/w) |
Coating Level (%w/w) |
|||
|
Stearic acid |
Carnauba wax |
Glyceryl
monosterate |
Polyethylene
glycol 6000 |
||
|
F1 |
100 |
- |
- |
- |
5 |
|
F2 |
100 |
- |
- |
- |
10 |
|
F3 |
100 |
- |
- |
- |
20 |
|
F4 |
95 |
5 |
- |
- |
10 |
|
F5 |
95 |
5 |
- |
- |
20 |
|
F6 |
92.5 |
5 |
2.5 |
- |
10 |
|
F7 |
90 |
5 |
5 |
- |
10 |
|
F8 |
92.5 |
5 |
2.5 |
- |
20 |
|
F9 |
90 |
5 |
5 |
- |
20 |
|
F10 |
85 |
5 |
10 |
- |
20 |
|
F11 |
80 |
5 |
15 |
- |
20 |
|
F12 |
65 |
5 |
30 |
- |
20 |
|
F13 |
92.5 |
5 |
- |
2.5 |
20 |
|
F14 |
90 |
5 |
- |
5 |
20 |
Evaluation of pellets
Size distribution
Mean pellet diameter of pellets was determined by
sieve analysis of samples. It was carried out by shaking 10, 14 and 20 sieves #
arranged on automatic sieve shaker at a frequency of 60 Hz for 5 minutes with a
load of 40 gm of pellets on topmost sieve.
Mean pellet diameter (davg) of pellets was determined using
the following formula:
davg
=
![]()
Surface topography studies
Surface topography of coated pellets from optimized
formulations was studied by scanning electron microscopy [SEM] (Phillips 500,
Germany). The pellet sample before and after dissolution study was used. Gold
sputter coating (Bio-Rad, Germany) of samples was done by using 18 mA current
at 2.5 kV.
Drug content
Accurately weighed quantity of wax coated pellets
equivalent to 120 mg of Verapamil HCl was added to 1 liter pH 1.2 buffer and
heated to 65 °C to melt the wax and magnetically stirred for 24 hours to
extract the drug. The solution was filtered and drug content was determined
spectrophotometrically at 278 nm.
In-vitro drug release studies
In-vitro drug release from wax coated pellets was
done using USP dissolution test apparatus I in pH 1.2 buffer for 1 hour and in
pH 6.8 phosphate buffer for 2-8 hours. Dissolution medium 5 ml was withdrawn at
regular intervals of 1 hour. The volume withdrawn was replaced by fresh volume
of dissolution medium to maintain sink conditions. The filtered samples were analyzed
spectrophotometrically at 278 nm and cumulative percentage of drug released was
calculated.
Application
of release kinetics
To describe kinetics of drug release from
wax coated pellets, mathematical models: zero order, first order and Higuchi square
root of time model were used. The criteria for selecting most appropriate model
were based on goodness of fit test.
Differential
scanning calorimetric studies
Differential scanning calorimetric thermograms of (a)
Stearic acid (b) Carnauba wax (c) Glyceryl
monostearate (d) Polyethylene glycol 6000 (e) Physical mixture I of Stearic
acid, Carnauba wax and Glyceryl monostearate (as in coat composition) (f)
Physical mixture II of Stearic acid, Carnauba wax and Polyethylene glycol 6000
(g) Molten mixture I of Stearic acid, Carnauba wax and Glyceryl monostearate
(as in coat composition) and (h) Molten mixture II of Stearic acid, Carnauba
wax and Polyethylene glycol 6000 were studied using Mettler Toledo S R system
at a heating rate of 5 °C per minute from 30 to 150 °C.
RESULTS
AND DISCUSSION:
Preparation of Verapamil core
pellets
Core pellets containing 30 %w/w Verapamil HCl
alongwith microcrystalline cellulose were prepared.
Evaluation of Verapamil
pellets
Size distribution
Size distribution studies of uncoated pellets has
shown that PVP K30 at 3 %w/v concentration provided pellets with higher yield
as 75 % pellets were in region of 10/14
sieve size. Mean pellet diameter of formulation batches C1, C2,
C3 and C4 were found to be 1.363, 1.541, 1.478 and 1.602
mm respectively. The size distribution of uncoated pellets is shown in Table 4.
Table 4: Size distribution of
uncoated pellets
|
Sr. No. |
Formulation batch |
Size Distribution |
|
|
Yield (%) |
Mean Pellet Diameter (mm) |
||
|
1. |
C1 |
75 |
1.363 |
|
2. |
C2 |
71 |
1.541 |
|
3. |
C3 |
68 |
1.478 |
|
4. |
C4 |
62 |
1.602 |
Surface topography studies
Morphological details of coated pellets were observed
under SEM. Photographs of sectioned and intact pellets before dissolution and
after dissolution studies are shown in Figure 2. In sectioned pellets, a
continuous layer of wax on pellet surface was observed indicating efficiency of
hot melt spray coating process.
Figure
2. SEM photograph of sectioned and intact pellets
Figure
3. Surface topography of pellets
In surface topography studies at 500x magnifications
(Fig.3), formation of cracks were observed after dissolution studies on initial
smooth pellets of formulation batch F12 while the pellets of
formulation batch F13 showed formation of small pores. This
indicates that drug might have released through the cracks or pores formed
during dissolution studies.
Drug content
The drug content of pellet batches was found to be
within range of 94% to 98.67%.The crushing strength was found to be between 3
to 5 kgs.The values for drug content and crushing strength are shown in Table
5.
Table 5 Drug content and
Crushing strength of wax coated pellets
|
Sr. No. |
Formulation batch |
Drug content (%)
(Mean ± SD) |
Crushing strength (Kg) (Mean ± SD) |
|
1 |
F1 |
98.20±0.32 |
3.00±0.23 |
|
2 |
F2 |
97.00±1.31 |
3.40±0.20 |
|
3 |
F3 |
95.10±2.31 |
3.52±0.30 |
|
4 |
F4 |
98.13±0.51 |
4.32±0.34 |
|
5 |
F5 |
94.73±1.61 |
5.00±0.28 |
|
6 |
F6 |
98.67±0.63 |
4.20±0.24 |
|
7 |
F7 |
94.53±1.35 |
4.18±0.22 |
|
8 |
F8 |
95.23±2.28 |
4.82±0.27 |
|
9 |
F9 |
96.17±2.51 |
4.78±0.27 |
|
10 |
F10 |
95.87±1.83 |
4.42±0.30 |
|
11 |
F11 |
95.38±1.43 |
4.16±0.35 |
|
12 |
F12 |
94.04±1.10 |
3.58±0.23 |
|
13 |
F13 |
97.17±0.63 |
4.94±0.25 |
|
14 |
F14 |
97.31±0.51 |
4.78±0.27 |
|
|
(n= 3) |
(n=20) |
|
In-vitro drug release studies
Effect of coating level
Figure
4. Effect of coating level on in-
vitro drug release
As shown in Fig. 4, formulation batch F1
has shown more than 90 % drug release in 2 hours indicating 5 %w/w coating of
stearic acid was insufficient to retard drug release from pellets.
The formulation batch F2 has shown 75% drug
release in 8 hours but more than 40 % drug was released in 2 hours which might
be due to initial bursting of pellets. After dissolution studies it was
observed that some pellets were totally intact while others burst out due to
internal stress.
The formulation batch F3 released only 40%
drug in 8 hours and as compared to F2 high retardation in drug
release was observed due to higher coating level.
Effect of carnauba wax
Figure 5. Effect of
carnauba wax on in- vitro drug
release
As shown in Fig. 5, the addition of 5% carnauba wax to
stearic acid in formulation batch F4 minimized initial burst release
from pellets but it also retarded drug release from pellets as only 60 % drug
was released in 8 hours.
Carnauba wax also improved coat stiffness as shown in
crushing strength studies in Fig. 5.
Formulation batch F5 significantly retarded drug release from
pellets and only 25% drug release was observed in 8 hours.
Effect of Release modifier
Figure 6. Effect of glyceryl
monostearate on in-vitro drug release
at 10 % w/w coating level
The effect of release modifiers glyceryl monostearate
and polyethylene glycol 6000 is shown in Fig. 6.
Glyceryl monostearate
The formulation batch F6 and F7
were prepared with glyceryl monostearate as release modifier at 2.5 and 5 %w/w
concentration respectively at 10 % w/w coating level.
Formulation batch F6 has shown about 70% drug release
in 8 hours with no initial burst release, whereas, formulation batch F7
has shown 80 % drug release in 8 hours but about 50 % drug was released in 2
hours. Formulation batch F7 was failed to comply USP drug release
test I of Verapamil HCl.
Coat stiffness provided by 10 %w/w coating might be
insufficient to withstand internal stress developed in pellets and was
responsible for high drug release rate from pellets in initial hours.
Figure 7: Effect of
glyceryl monostearate on in-vitro drug
release at 20 % w/w coating level
Fig. 7 shows influence of various concentrations of
glyceryl monostearate such as 2.5, 5, 10, 15 and 30 % on drug release from
formulation batches F8, F9, F10, F11
and F12 respectively at 20 %w/w coating level.
No significant improvement in drug release was
observed with increase in proportion of glyceryl monostearate up to 15 %w/w
level. The formulation batch F12 with a 30 %w/w concentration of GMS
as release modifier have shown 88 % release in 8 hours. The formulation batch F12
complied USP drug release test I for Verapamil HCl at all time points.
Polyethylene glycol 6000
Figure
8. Effect of polyethylene glycol 6000 on in-vitro
drug release
Formulation batch F13 and F14 were
prepared with PEG 6000 as release modifier at 2.5 and 5 %w/w concentration
levels. Formulation batch F13 released 93 % drug in 8 hours and also
complied USP drug release test I for Verapamil HCl. The high drug release rates
from F13 and F14 might have occurred due to water soluble
nature of polyethylene glycol 6000.
Cumulative percentage drug release from formulation
batch F12 and F13 complied with percentage release range
of USP drug release test I at all time points as shown in Table 6.
Table 6: Comparison of drug
release with USP criteria
|
Time (Hour) |
Cumulative % drug released |
||
|
USP test I |
Formulation batch F12 |
Formulation batch F13 |
|
|
1 |
10-21 |
11.6 |
13.7 |
|
2 |
18-33 |
21.3 |
18.3 |
|
3.5 |
35-60 |
54.5 |
43.5 |
|
5 |
50-82 |
71.3 |
63.7 |
|
8 |
NLT 85 |
87.3 |
93.0 |
Drug release kinetics
Results of goodness of fit test for drug release
models are shown in Table 7
Table 7: R2 value
of various release models for formulation batch F12 and F13
|
Model |
R Value |
|
|
Batch F12 |
Batch F13 |
|
|
Zero-order |
0.9695 |
0.9961 |
|
First-order |
0.9911 |
0.9302 |
|
Higuchi |
0.9562 |
0.9326 |
In-vitro dissolution profile of formulation batch
F12 containing 30 %w/w glycerol monostearate as release
modifier has shown higher release rate in initial hours which decline with time
and is shown in figure 9. Also R2 value for first order release
kinetics was found to nearest to one indicating drug release from formulation
batch F12 was dependent on initial drug concentration present in
pellets.
R2 value for formulation batch F13
has shown zero-order release kinetic model as best fit model shown in figure
10. In-vitro dissolution profile of formulation batch F13 containing
2.5 %w/w PEG 6000 as release modifier showed gradual increase in release rate
with time indicating concentration independent drug release from coated
pellets.
Differential Scanning
Calorimetric Studies
The DSC thermograms of
waxes individually (Fig.11, 12, 13, 14), the physical mixtures I (Fig.
15) and II (Fig. 16) and molten mixture I (Fig. 17) and II (Fig. 18) are shown
respectively.
Figure
11. DSC thermogram of stearic acid
Figure
12. DSC thermogram of carnauba wax
Figure
13. DSC thermogram of glyceryl monostearate
Figure 14. DSC thermogram of
polyethylene glycol 6000
Figure
15. DSC thermogram of physical mixture I
Figure
16. DSC thermogram of physical
mixture II
Figure
17. DSC thermogram of molten
mixture I
Figure
18. DSC thermogram of molten
mixture II
All waxes individually as well as their physical
mixtures I and II and molten mixtures I and II showed single endothermic peak,
indicating formation of single homogenous phase. Molten mixture I and II showed
shifting of endothermic peaks by approximately 1 °C towards lower temperature side as
compared to stearic acid might be due to formation of low melting wax crystals
after solidification of molten mixture.
CONCLUSION:
In the present studies, sustained release pellets of
Verapamil HCl were prepared using a solvent less hot melt lipid spray coating
technique. The pellets containing 30 %w/w Verapamil HCl were prepared by
extrusion spheronization using microcrystalline cellulose, starch paste and
PVP-30 as binder. Stearic acid owing to its lipophilic properties and low
melting point was selected as coating material. Stearic acid coating, 5 %w/w
has not provided sustained release while 10 %w/w and 20 %w/w coatings provided
sustained release but desired drug release profile was not obtained. Carnauba
wax 5 %w/w was added to stearic acid to improve coat strength and to minimize
burst effects of pellets. It was found that waxes did not show a functional
coating and other materials have to be added to improve drug release. Glyceryl
monostearate and PEG 6000 were added to improve drug release. Formulation batch
with 30 %w/w GMS as release modifier at
20 %w/w coating level provided desired drug release while PEG 6000 provided
similar results at 2.5 %w/w concentration only which might be due to its water
soluble nature. Drug release kinetics
has shown that formulations containing GMS as release modifier followed first
order release kinetics, while formulation batch with PEG followed zero order
release kinetics.
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Received on 14.05.2016
Modified on 25.05.2016
Accepted on 28.05.2016 ©
RJPT All right reserved
Research J. Pharm. and Tech. 2016; 9(6): 741-749
DOI: 10.5958/0974-360X.2016.00141.4