Excipients make the difference! Dr. Felicitas Guth Global Technical Service Excipients Pharma Ingredients & Services BASF SE

Excipients make the difference! Dr. Felicitas Guth Global Technical Service Excipients Pharma Ingredients & Services BASF SE

Paradigm shift in pharmaceutical development Traditional medicinal products Trial & error Drug delivery systems Quality by Design Increased functionality and understanding of excipients. 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 2

Innovation in excipients Standard excipients used in combination with innovative technologies Co-processed excipients (a combination of two or more excipients designed to physically modify their properties in a manner not achievable by simple physical mixing, and without significant chemical change) Novel excipients (new chemical entities, mostly polymers with a specific functionality) 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 3

Standard excipients & innovative technologies Copovidone in pharmaceutical melt extrusion 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 4

The solubility challenge H Trans, S Trans H Sub,S Sub H Solv, S Solv H S, S S Zimmermann, I.: Pharmazeutische Technologie. Springer Verlag Berlin, Heidelberg, 1998 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 5

Relevant types of solid dispersions Drug crystalline amorphous dissolved Polymer amorphous amorphous amorphous Thermoynamic stability almost stable unstable (kin. Controlled) stable (below satur. solubility) 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 6

Polymers in pharmaceutical melt extrusion Instant release Enteric Sustained release Copovidone* PEG** Povidone PVA-PEG HPMC HPC Poloxamers Amino methacrylate copolymer Methacrylic acid copolymer HPMCAP HPMCAS PVAc PVP/ PVAc EC Ammonio methacrylate copolymer * Kaletra (Actives: Ritornavir & Lopinavir; copovidone matrix) ** Gris-PEG, Novartis (Active: Griseofulvin, PEG matrix) 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 7

Principle of pharmaceutical melt extrusion Die Tempering Cylinder Screw Powder Extrudate Engine Shaping Mixing Melting according to Reitz (2007) Temperature: above T g of polymer (80 180 C) Residence time: variable (0.5 5 min) 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 8

Performance characteristics Long term stability Targeted release profile Glass transition temperature Hygroscopicity Drug + Polymer Melt viscosity Physicochemical properties of active Thermostability of drug & polymer Solution & solubilizing capability Not all relevant parameters may be covered by the standard specification of the excipient! 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 9

Copovidone Copovidone is a copolymer consisting of 6 parts of N-vinylpyrrolidone and 4 parts of vinyl acetate. Pharmacopeia monographs in JPE, Ph.Eur and USP/NF Traditional use: Wet binder and film forming agent CH CH 2 N O CH O C CH 2 O n CH 3 m 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 10

Copovidone in melt extrusion processes Requirements Thermoplastic behavior Copovidone Suitable Tg and melt viscosity Tg: 101 C Good thermal stability between 50 & 180 C Low water content and hygroscopicity to prevent re-crystallization Safety High [or no] solubilization capacity Water content: max. 5% Self affirmed GRAS 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 11

Melt viscosity as a function of temperature Viscosity [Pa s] 1000000 100000 10000 1000 Kollicoat Kollicoat MAE 100 MAE P Kollidon 30 Kollidon 12 PF Kollidon SR Kollidon VA 64 Kollidon 12 PF Kollidon 30 Kollidon SR Shear stress controlled rotational rheometer (Rheometrics SR5) Plate plate geometry Angular frequency: 1.6 rad/s 100 Kollidon VA 64 120 140 160 180 200 220 240 Temperature [ C] 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 12

Melt viscosity as a function of shear rate 10000000 1000000 Shear stress controlled rotational rheometer (Rheometrics SR5) Plate plate geometry Temperature: 170 C Viscosity [Pa*s] 100000 10000 1000 Kollidon SR Kollicoat MAE 100 P Kollidon VA64 100 Kollidon 12 0.01 0.1 1 10 100 10 Angular Frequency [rad/s] 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 13

Processes run at high temperatures Hot melt extrusion Steam sterilization 80 150 C/ 0.5-5 min Non aqueous environment Potential reactions: Hydrolysis, oxidation, elimination of water Relatively new process; few approved drug products 121 C/ 2 bar/ 15 min Aqueous environment Potential reactions: Hydrolysis Process well known by excipient users and health authorities Low Probability of significant degradation due to short process times! 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 14

Thermal stability of copovidone Test parameter Requirements Results Powder Results Extrudates Vinyl acetate max. 10mg/kg <10mg/kg < 10mg/kg Vinyl pyrrolidone max. 10mg/kg <2mg/kg < 2mg/kg Acetaldehyde max. 500mg/kg <10mg/kg <10mg/kg Peroxide max. 400mg/kg <20mg/kg <20mg/kg 2-Pyrrolidone max. 0.5g/100g 0.06g/100g 0.06g/100g Saponification value [mg KOH/g] ph-value (10% in Solution) K-value (1% aqueous solution) 230-270 246 237 min. 3.0 max. 7.0 min. 25.2 max. 30.8 4.1 4.1 27.0 26.6 Polymers for pharmaceutical melt extrusion.ppt/15 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 15

Thermal stability of copovidone 0.90 0.80 0.70 0.60 Kollidon VA 64 LOT 76964875L0 extruded 160 C Kollidon VA 64 LOT 76964875L0 w(log(m)) 0.50 0.40 0.30 0.20 0.10 0.00 1,000 10,000 100,000 1,000,000 10,000,000 M/Da 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 16

Innovation potential & challenges Pharmaceutical melt extrusion with selected thermo-stable polymers proved to be a potent technology to overcome limitations in bioavailability. But: The technology usually involves exposure to higher temperatures and requires excipient doses which significantly exceed the amount in previously approved medicinal products Users and suppliers have to jointly define relevant performance characteristics and evaluate the safety of the excipient. 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 17

Novel excipients PEG-PVA Copolymer (Kollicoat IR) 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 18

Desired functionality Target: Cost efficient coating process Good stability and rapid dissolution of the active ingredient Requirements Processing of coating suspensions with a high solid content Flexible and elastic film that dissolves quickly Excipient properties Low viscosity & low surface tension of the polymer solution High solubility & high flexibility of the polymer 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 19

Kollicoat IR - Polymer structure & properties ~ 25 %PEG & ~75% PVA units Mw: ~ 45 000 The polyvinyl alcohol moiety provides good film-forming properties The polyethylene glycol part acts as an internal plasticizer The polymer quickly dissolves in water, weak acids and bases as well as in diluted ethanol. It is practically insoluble in organic solvents 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 20

Viscosity of aqueous polymer solutions 60 50 Dynamic viscosity [mpas] 40 30 20 Kollicoat IR: 17% PVA: 11% HPMC 603: 10% HPMC 606: 6% 10 0 25 35 45 55 65 75 85 Temperature [ C] Equipment: ThermoFisher Scientific, Haake RheoWin 322 Kollicoat IR PVA 5-88 HPMC type 603 HPMC type 606 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 21

Viscosity of aqueous polymer solution 3000 Temperature: 25 C 2500 Dynamic viscosity [mpas] 2000 1500 1000 Kollicoat IR PVA HPMC 3 type 603 HPMC 6 type 606 500 0 0 5 10 15 20 25 30 Equipment: Haake Rotovisko RV1 Polymer concentration [%] 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 22

Dissolution of polymer films Modified dissolution tester Orifice (35x23 mm) Film 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 23

Solubility and dissolution of polymer films 240 180 Time [s/100µm] 120 60 0 HPMC type 603 HPMC type 606 PVA Kollicoat IR Beginning dissolution of the film Complete dissolution of the film 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 24

Elongation at break Texture Analyzer TA-XT2i HR Stable Micro Systems 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 25

Elongation at break 70 60 50 Strain [N/mm²] 40 30 20 10 0 0 50 100 150 200 250 Elongation at break [%] Kollicoat IR PVA HPMC 3 cp HPMC 6 cp 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 26

Applications Application Instant release coating Binder Pore former in sustained release applications API loaded films Film former in sprays Functionality Protects against unpleasant taste or odor Improves appearance Makes tablets easier to swallow Protects sensitive active ingredients For very rapidly dispersible/ soluble granules or tablets Highly flexible and hydrophilic pore former allows to adjust release rates Polymer carrier Extremely flexible texture 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 27

Novel excipients the regulatory challenge Novel excipients are very welcome at R&D departments,... Precedence of use Pharmacopoeia monograph..., but who wants to be the first to file a drug application? Generic companies in less regulated markets use novel products first 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 28

Kollicoat IR a commitment to innovation 2003 2004 2005 2006 2007 2008 2009 2010 Product launch 1 st Approved drug product EU (Ger) Japan USA Draft Ph.Eur. Monograph PE 20/ 3 Draft NF. Monograph PF 35 (2) Today, Kollicoat IR is also approved and used in several other countries all over the world! Since 1998 BASF has sucessfully introduced 13 new excipients. Two of them were new chemical entities. 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 29

Conclusion We believe that the challenges in drug delivery can only be overcome with new technologies and new excipients. New and highly functional excipients can help to reduce drug dosages, minimize side effects and therefore make medicines better and safer. New excipients can contribute to a cost effective and efficient manufacture of drug products and offer the possibility to differentiate. Excipients make the difference! 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 30

Thank you for your attention! Data: Dr. Karl Kolter, Nils Rottmann, Thorsten Cech Dr. Felicitas Guth Global Technical Service Excipients BASF SE G-EMP/ME Pharma Ingredients & Services Care Chemicals Phone: + 49 (0) 621 / 60 28707 Fax: + 49 (0) 621 / 60 66 28707 Mail: Internet: felicitas.guth@basf.com www.pharma-solutions.basf.com 29.04.2009 Excipients make the difference F.Guth PharmSciFair 2009 31