Pressurized metered dose inhalers and pharmaceutical aerosol formulations

Abstract: Provided are pressurized metered dose inhalers containing stable formulations of a β-agonist drug. Also provided are aerosol formulations suitable for inhalation therapy containing a β-agonist drug.

Description: 1. Field of the Invention. The invention relates to pressurized metered dose inhalers and aerosol formulations for inhalation therapy. 2. Background of the Invention. Because of environmental considerations, chlorohydrocarbon and chlorofluorocarbon propellants for aerosol formulations for medical uses have been largely replaced by hydrofluoroalkanes such as 1,1,1,2-tetrafluoroethane ("HFA-134a") and 1,1,1,2,3,3,3,-heptafluoropropane ("HFA-227ea") that have been identified as safe for use in pressurized metered dose inhalers. Such medicinal aerosol formulations are generally of the solution or suspension type. Each type is composed of, at least, the medicament and the propellant. Some formulations also include one or more special purpose adjuvants such as a cosolvent or a surfactant (EP O 372777). Conventional aerosol solution formulations contain low concentrations of a cosolvent more polar than the propellant. Conventional aerosol suspension formulations contain a surfactant rather than a cosolvent on a theory that the surfactant would prevent agglomeration of the particles, their adhesion to the walls of the aerosol container, and provide for lubrication of the dispensing valve ("actuator"). (US 3,014,844). EP 0 504 112 discloses aerosol formulations comprising a non-ionic surfactant selected from the group consisting of monoacetylated or diacetylated monoglycerides and a propellant which does not contain any separating chlorine atoms. WO 96/19198 discloses aerosol formulations comprising a hydrofluoroalkane propellant and a surfactant selected from a C 8 - C 16 fatty acid or salt thereof, a bile salt, a phospholipid or an alkyl saccharide. WO 97/47286 discloses aerosol formulations comprising formoterol, or an acid addition salt thereof, ethanol, HFA 134a, HFA 227 or a mixture thereof and optionally a surfactant other than a monoacetylated or diacetylated monoglyceride. Ethanol has been used as a cosolvent. However, previous teachings (see, e.g., EP 0 616525) have taught away from using concentrations of ethanol greater than 5% for solution aerosol formulations for β-agonists. Historically, ethanol concentrations greater than 5% have been used only for steroid-based formulations with hydrofluoroalkane propellants. The β-agonist drug, formoterol ("eformoterol" in Europe) and its derivatives, have proven difficult to formulate in conventional aerosols. Such formulations have exhibited short shelf-lives and require refrigeration. Refrigeration is undesirable because many patients are required to carry the aerosol canisters on their persons. There remains, therefore, an important need for aerosol formulations for β-agonist drugs such as formoterol and its derivatives that remain chemically and physically stable during storage at ambient conditions of temperature and humidity. SUMMARY OF THE INVENTION An objective of the present invention is to provide a pressurized metered dose inhaler that contains a stable formulation of formoterol which does not require the use of refrigeration. Another objective of the present invention is to provide a stable formulation of that is suitable for use as an aerosol, which formoterol does not require the use of refrigeration. The above objectives are surprisingly achieved by the following. The invention provides a pressurized metered dose inhaler comprising a container equipped with a metering valve and containing a pressurized aerosol formulation formulated from a composition comprising: particles of formoterol or a salt with a weak acid ; at least one fluoroalkane propellant; and a surfactant that is capable of forming a suspension of the particles of β-agonist drug, i.e. diethylene glycol monoethyl ether. Said aerosol formulation is adapted for use in a pressurized aerosol container. The aerosol formulation is surprisingly stable under conditions up to about 40°C and about 75% relative humidity for at least about four weeks. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 illustrates a chromatogram of formoterol fumarate formulated as a suspension; and Fig. 2 illustrates a chromatogram of the formoterol fumarate after storage for 28 days at 40°C and 75% relative humidity. DETAILED DESCRIPTION OF THE INVENTION It has been unexpectedly discovered that stable aerosol formulations of suspensions of particles of formoterol can be formed by utilizing formoterol in combination with diethylene glycol monoethyl ether. The term "formoterol" is hereinafter understood to mean the base form of formoterol as well as the weak acid form of formoterol, unless stated otherwise. A preferred weak acid form of formoterol is formoterol fumarate. Any fluoroalkane propellant that is suitable for inhalation can be used. Examples of suitable fluoroatkanes include HFA-134a, HFA-227ea, HFA-125 (pentafluoroethane), HFA-152a (1,1-difluoroethane), and HFA-32 (difluoromethane). Hydrocarbon and/or aliphatic gases may be added to modify propellant characteristics as required. Preferably, the aerosol formulation is substantially free of chlorofluorocarbons. However, if desired chlorofluorocarbons can be utilized. The propellant in suspension aerosol formulations can be utilized in amounts up to 99.9% by weight, based on the total weight of the aerosol formulation. The amount of formoterol utilized in the aerosol formulation will depend on the type of drug selected. For formoterol fumarate, the concentration utilized is usually about 1 % by weight or less, preferably about 0.01% to about 0.02% by weight, based on the total weight of the aerosol formulation. The particle size of formoterol should be suitable for inhalation into the nose or lung. Suitable average particle sizes are 100µm and less, preferably 20µm and less, and more preferably in the range of 1 to 10µm. The surfactant is usually present in an amount of 1% by weight or less. Pressurized metered dose inhalers are now well known in the art. Any pressurized metered dose inhaler that is suitable for application of drugs to the lungs or nose of a patient can be used. Pressurized metered dose inhalers usually are equipped with a metering valve having a spray orifice diameter of about 460µm. Based on the disclosure provided herein, one skilled in the art will be able to adjust the component composition to deliver a desired dose for the selected metered valve, without undue experimentation. For example, the composition may be altered to adjust the vapor pressure of the formulation. The aerosol formulation and metering valve are usually selected to provide a therapeutically effective amount of formoterol per activation. An example of a therapeutically effective amount of formoterol fumarate is 12 µg per activation. The following examples are presented merely as comparative examples and not to limit the claims which are supported by the entire specification. Examples 1-3 Three suspension aerosols according the present invention were formulated by combining the components shown in Table 1, using the following steps: 1. Weighing the surfactant into a plastic coated glass bottle or an aluminum canister. 2. Adding the weighed drug. 3. Camping a valve upon the bottle or canister. 4. Adding a known amount of propellant through the valve into the bottle or canister. 5. Sonicating the formulation for about 5 minutes. A Presspart, 19 mL, aluminum metered dose inhaler canister with a Bespak BK357,63 µL metered valve was used, unless otherwise stated. The properties of the Example aerosol formulations were tested using one or more of the following: appearance (no external signs of leaking or deformation should be present); leakage to meet United States Pharmacopeia 23 and National Formulary 18 standards; canister contents to be within 10% of the mean; drug per container to be within 25% of the mean; chemical assay to be within 90.0-110% of label claim; weight per metered dose; unit spray content and content uniformity to meet Pharmacopeial Forum, vol. 22, no. 6 standards; and aerodynamic size distribution and water determination. The test results are shown in Table 1. By comparing the percent deposition in Stage 2, it was determined that formulations containing Brij 30 and Tween 20 were superior to those containing PEG 300. In addition, the data demonstrated that the Tween 20 formulation deposited a greater amount of drug on the actuator. Therefore, in order to minimize deposition on this type of actuator, Brij 30 was a more useful surfactant in these formulations than was Tween 20. solution aerosol formulations showed no signs of chemical deterioration. Examples 4-7 Four suspension aerosols according to present invention were formulated by combining the components shown in Table 2, using the method described in Example 1 To determine the stability of the suspension aerosol formulations, Examples 6 and 7, were maintained for 1 month (28 days) at 40°C and 75% relative humidity, which are considered herein as accelerated conditions. The suspension aerosol formulations were equilibrated at room temperature overnight before testing: The properties of the suspension aerosol formulations were measured as in Example 1 and the results are shown in Table 2. After 28 days storage, the dose delivered (by unit spray determination) in Examples 6 and 7 was less than that obtained with the initial Examples 4 and 5, but not reduced by the same degree as with the solution formulation examples. Examples 8-11 Four suspension aerosols according to present invention were formulated by combining the components shown in Table 3, using the method described in Example 1. To determine the stability of the suspension aerosol formulations, Examples 10 and 11 were maintained for 1 month (28 days) at 40°C and 75% relative humidity, which are considered herein as accelerated conditions. The suspension aerosol formulations were equilibrated at room temperature overnight before testing. The properties of the suspension aerosol formulations were measured as in Example 1 and the results are shown in Table 3. The test data demonstrates that there was about a 10% loss of drug after storage under accelerated conditions in Examples 10 and 11, relative to the initial Examples 8 and 9. This value is within acceptable limits and was in the area of 100% material balance (canister contents - drug per canister). In addition, the USP accepted method for determining particle size (Andersen impacter) was employed. The results showed that there was no chemical (as appearance of a known degradation reduced or loss of parent compound) or physical instability after storage including (1) as an increase in particle size (MMAD - mass median aerodynamic diameter), (2) change in the distribution (GSD - geometric standard deviation), (3) change in fine particle dose, or (4) change in fine particle fraction. Examples 12 and 13 Two suspension aeroso!s according to present invention were formulated by combining the components shown in Table 4 using the method described in Example 1. The properties of the suspension aerosol formulations were measured as in Example 1 and the results are shown in Table 4. Example 14 A suspension aerosol formulation was formed by combining 99.96 % by weight of HFA-134a, 0.02 % by weight formoterol fumarate, and 0.02 % by weight of Brij 30, using the method described in Example 1. HPLC chromatograms of the suspension aerosol, before and after storage for 28 days at 40°C and 75% relative humidity, were obtained as Figs. 1 and 2 respectively. In each Figure, only a single peak, representing the intact drug, was observed. No peaks representing breakdown products of the drug (expected to be at about 13 minutes) were found. Thus, the formoterol suspension aerosol exhibited long term stability. Test Example 12 Example 13 Unit Spray Content Drug per Dose (mcg) 10.67 9.55 Material Balance (%) 89.0 78.5 Shot Weight (mg) 78.6 78.0 Shot Number 6-7 71-72 Unit Spray Content Drug per Dose (mcg) 10.51 12.90 Material Balance (%) 86.0 104.8 Shot Weight (mg) 78.7 78.9 Shot Number 8-9 73-74 Andersen Impactor Valve (mcg) 5.93 9.14 Actuator/Adapter (mcg) 28.91 29.02 Induction Port/Cone (mcg) 30.03 20.18 Stage 0 (mcg) 1.33 0.96 Stage 1 (mcg) 1.64 1.32 Stage 2 (mcg) 228 1.72 Stage 3 (mcg) 9.54 8.45 Stage 4 (mcg) 29.37 27.25 Stage 5 (mcg) 27.71 27.52 Stage 6 (mcg) 3.27 3.38 Stage 7 (mcg) 0.00 0.00 Stage F (mcg) 0.68 0.00 Total S0-S7 (mcg) 75.14 70.60 Total Drug Recovered (mcg) 140.69 128.93 Material Balance (%) 107.7 103.8 MMAD 2.3 2.5 GSD 1.6 1.5 Fine Particle Dose (mcg) 73 68 Fine Particle Fraction (%) 69 75 Andersen Impactor Valve (mcg) 5.64 - Actuator/Adapter (mcg) 25.58 - Induction Port/Cone (mcg) 23.56 - Stage 0 (mcg) 1.13 - Stage 1 (mcg) 1.56 - Stage 2 (mcg) 1.97 - Stage 3 (mcg) 9.95 - Stage 4 (mcg) 30.04 - Stage 5 (mcg) 27.51 - Stage 6 (mcg) 3.05 - Stage 7 (mcg) 0.00 - Stage F (mcg) 0.00 - Total S0-S7 (mcg) 75.21 - Total Drug Recovered (mcg) 132.98 - Material Balance (%) 103.3 - MMAD 2.5 - GSD 1.5 - Fine Particle Dose (mcg) 73 - Fine Particle Fraciion (%) 74 - Formulation HFA-134a 12.8169 12.6705 Brij 30 0.00230 0.00220 Formoterol fumarate 0.002044 0.001970 While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to those of ordinary skill in the art that various changes and modifications can be made to the claimed invention without departing from the scope thereof.

Claims: A pressurized metered dose inhaler comprising a container equipped with a metering valve and containing a pressurized aerosol formulation comprising (a) particles of formoterol or a salt with a weak acid; (b) at least one fluoroalkane propellant; and (c) a surfactant that is capable of forming a suspension of said particles of β-agonist drug, wherein the surfactant is diethylene glycol monoethyl ether. The inhaler according to claim 1, wherein said metering valve is suitable to provide metered doses of formoterol or its salt in an amount of 12 µg per actuation of said metering valve. The inhaler according to claim 1, wherein said fluoroalkane comprises 1, 1, 1,2-tetrafluoroethane. The inhaler according to claim 1, wherein the formulation is substantially free of chlorofluorocarbons. The inhaler according to claim 1, wherein propellant (b) is present in an amount up to 99.9% by weight. The inhaler according to claim 1, wherein the formoterol salt is formoterol fumarate. The inhaler according to claim 6, wherein formoterol fumarate is present in an amount of 1% by weight or less, based on the total weight of said aerosol formulation. The inhaler according to claim 7, wherein formoterol fumarate is present in an amount of 0.01 to 0.02% by weight, based on the total weight of said aerosol formulation. The inhaler according to claim 1, wherein formoterol or its salt has an average particle size of less than 100 µm. The inhaler according to claim 9, wherein formoterol or its salt has an average particle size of less than 20 µm. The inhaler according to claim 10, wherein formoterol or its salt has an average particle size of from 1 µm to 10 µm. The inhaler according to claim 1, wherein diethylene glycol monoethyl ether is present in an amount of from 0.002% to 1% by weight, based on the total weight of said aerosol composition.

Inventors: BLONDINO FRANK E, BRUCATO MICHAEL, BUENAFE MARIA W, BLONDINO, FRANK E., BRUCATO, MICHAEL, BUENAFE, MARIA W.
Applicants: IVAX RESEARCH INC, IVAX RESEARCH, INC.
Application year: 1999
Main classification: A61K9
IPC codes: A61K47, A61K31, A61K9