Abstract:
A unit dosage form, such as a capsule or the like for delivering drugs into the body in a sustained release fashion similar to that produced by INDERAL® LA indicated for the treatment of cardiovascular diseases, comprises two populations of propranolol-containing particles (beads, pellets, granules, etc.). Each bead population exhibits a pre-designed rapid release profile (i.e., substantially complete release within 60 minutes) or sustained release profile over a period of 24 hours. Such a cardiovascular drug delivery system is designed by combining immediate release (IR) beads and sustained release (SR) beads. SR beads may be obtained by membrane coating IR beads with a water-insoluble polymer such as ethylcellulose or a mixture of a water insoluble polymer and a water-soluble polymer such as hydroxypropylcellulose at a ratio of from about 65/35 to 95/5.

Description:
TECHNICAL FIELD  
         [0001]    This invention relates to extended release dosage forms of propranolol hydrochloride suitable for oral administration for the treatment of cardiovascular diseases, exhibiting in vitro and in vivo release profiles matching that of INDERAL® LA (an extended release propranolol hydrochloride dosage form), and more particularly to extended release propranolol HCl capsules, 60, 80, 120, and 160 mg, comprising immediate release (IR) beads releasing the drug within 60 minutes and sustained release (SR) beads releasing the drug over 24 hours when dissolution tested by the United States Pharmacopoeia dissolution test method for propranolol hydrochloride extended release capsules.  
         BACKGROUND OF THE INVENTION  
         [0002]    Propranolol hydrochloride-containing non-pareil seeds (sugar spheres) require a coating of water insoluble ethylcellulose of less than 2% by weight to mimic the drug release profile of INDERAL® 0  LA when applied from a 98/02 acetone/purified water solution. Due to extremely low spray time, a significant batch to batch variability in drug release profile can occur. There was thus a desire to minimize batch to batch variability in drug release profile. Batch to batch variability may be improved by incorporating a water soluble film forming agent in the ethylcellulose membrane such that a significantly higher coating level, less susceptible to batch to batch variation, would be desired to provide a drug release profile mimicking that of INDERAL® LA.  
           [0003]    U.S. Pat. No. 4,138,475 to McAinsh et al. discloses controlled release oral formulation comprising coated spheroids of propranolol or a pharmaceutically acceptable salt thereof, each spheroid coated with a mixture of 80 to 100% by weight of ethylcellulose, preferably having a viscosity of 50 cps at 20° C., 20 to 0% by weight of hydroxypropyl methylcellulose and optionally up to 20% plasticizer based on the total weight of the membrane. These spheroids prior to membrane coating comprise 40 to 65% by weight propranolol or a pharmaceutically acceptable salt thereof and 35 to 60% by weight of microcrystalline cellulose and are prepared by extrusion and spheronization. The ratio of ethylcellulose to hydroxypropylcellulose and coating thickness depend upon the desired controlled release characteristics.  
           [0004]    U.S. Pat. No. 4,587,118 issued to Hsiao discloses a controlled release theophylline oral formulation comprising coated micropellets; each pellet is designed to release theophylline at an approximately constant rate. The pellet comprises a drug containing core, which is then coated with a mixture of about 90-70% by weight of ethylcellulose and about 10-30% by weight of hydroxypropyl cellulose. The ratio of ethylcellulose to hydroxypropylcellulose and coating thickness depend upon the desired control release characteristics.  
           [0005]    U.S. Pat. No. 4,752,470 issued to Mehta teaches the art of making a controlled release indomethacin formulation comprising coated pellets of indomethacin; each pellet is designed to release indomethacin in both immediate and sustained release form. The pellet comprises a drug-containing core, which is then coated with a mixture of plasticized ethylcellulose and hydroxypropyl cellulose or hydroxypropyl methylcellulose. The loaded pellets are preferably composed of 5-30% by weight of indomethacin and coated with 0.5-10% by weight of ethylcellulose and hydroxypropylcellulose or hydroxypropyl methylcellulose, the ratio of ethylcellulose to hydroxypropylcellulose/hydroxypropyl methylcellulose depending upon the desired control release characteristics.  
           [0006]    U.S. Pat. No. 4,957,745 issued to Jonsson et al. describes the art of making a controlled release formulation of a salt of metoprolol comprising a multitude of metoprolol cores prepared by layering the drug onto inert silicon dioxide beads, wherein the core is coated with a metoprolol permeable membrane of essentially ethylcellulose or a mixture of hydroxypropyl methylcellulose and ethylcellulose, the ratio of ethylcellulose to hydroxypropyl methylcellulose depending upon the desired control release characteristics.  
           [0007]    U.S. Pat. No. 5,133,974 issued to Paradissis et al. discloses a controlled release formulation comprising a mixture of approximately 0-50% immediate release particles containing a drug, an inert substrate, a binder coated with talc, and up to 100% of extended release particles comprising the immediate release particles coated with a dissolution modifying system containing plasticizers and a film forming agent. Optionally, a drug is included in the coating. Film forming agents include ethylcellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose and mixtures thereof.  
           [0008]    U.S. Pat. No. 5,472,708 issued to Chen discloses the art of making a tablet which rapidly disintegrates in the aqueous environment of use, comprising a plurality of pellets embedded in the tablet comprising drug containing cores and a swelling agent having a dissolution rate controlling polymer membrane of a mixture of water-insoluble ethylcellulose and a water soluble film forming polymer, and a permeability reducing agent. The water-soluble polymer is selected from a group containing cellulose acetate phthalate, hydroxypropyl methylcellulose, and polyvinylpyrrolidone, the polymer exhibiting greater solubility at alkaline pH&#39;s being preferred. The swelling agent has the property of increasing in volume on exposure to the aqueous environment of use, thus causing rapid release of the drug following bursting of the bead.  
           [0009]    Propranolol [1-(isopropyl amino)-3-(1-naphthyloxy)-2-propanol] is a beta-adrenergic blocking agent and as such is a competitive inhibitor of the effects of catecholamines at beta-adrenergic receptor sites. The principal effect of propranolol is to reduce cardiac activity by diminishing or preventing beta-adrenergic stimulation. By reducing the rate and force of contraction of the heart, and decreasing the rate of conduction of impulses through the conducting system, the response of the heart to stress and exercise is reduced. These properties are used in the treatment of angina in an effort to reduce the oxygen consumption and increase the exercise tolerance of the heart. Propranolol is also used in the treatment of cardiac arrhythmias to block adrenergic stimulation of cardiac pacemaker potentials. Propranolol is also beneficial in the long-term treatment of hypertension. Other uses of propranolol are in the treatment of migraine and anxiety.  
           [0010]    Propranolol is normally administered as propranolol hydrochloride tablets or as long acting INDERAL® LA.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention provides a sustained release multi-particulate dosage form comprising a two-bead population of propranolol hydrochloride—one IR (immediate release) bead and the other SR (sustained release) bead. Alternatively, the dosage form may comprise only SR beads. The IR bead population, comprising in one embodiment an inert core coated with one or more layers of propranolol HCl and a binder, rapidly releases the active upon oral administration while the SR bead population comprises an IR bead population having a sustained release coating of a water insoluble polymer (e.g., ethylcellulose) or a combination of a water insoluble polymer and a water soluble polymer, such as hydroxypropylcellulose (e.g., HPC, Klucel LF) or hydroxypropyl methylcellulose (e.g., HPMC, Methocel E5). The weight ratio of water insoluble polymer to water soluble polymer may vary from 100:0 to 65:35. The weight of the SR coating may vary from approximately 1 to 10%, preferably from about 1.5 to 4.0% based on the total weight of the coated beads, and most preferably the SR coating level is approximately 1.8 to 4.4 weight % based on the weight of the SR beads.  
           [0012]    In accordance with one embodiment of the present invention unit dosage forms of extended release propranolol hydrochloride are provided that will release the drug into an aqueous environment in a fashion mimicking that of INDERAL® LA when tested under in vitro or in vivo conditions. It is an embodiment of the present invention to provide unit dosage forms such as hard gelatin capsules comprising two types of beads—one bead population (IR beads) comprising sugar spheres drug layered from an aqueous solution of propranolol hydrochloride with polyvinylpyrrolidone as the binder and a second bead population (SR beads) comprising an immediate release bead population having a sustained release membrane of approximately 1.5 to 6%, more particularly 1.8 to 4.4% by weight of a water insoluble polymer alone or in combination with a water soluble film forming polymer, wherein the ratio of IR beads to SR beads as well as the ratio of water insoluble polymer to water soluble polymer is optimized to obtain release profiles similar to that of INDERAL® LA, when both reference product and the long acting capsules of the present invention are tested by the United States Pharmacopoeia method for Propranolol Hydrochloride Extended Release Capsules. It is another embodiment of the present invention to provide unit dosage forms to be bioequivalent to INDERAL® LA when compared on an mg-by-mg basis. It is yet another embodiment of the present invention to provide physically and chemically stable dosage forms (i.e., exhibiting drug release profiles and degradation profiles statistically similar to that at the initial time point) when subjected to stability studies per ICH Guidelines. These and other embodiments, advantages and features of the present invention become clear when detailed description and examples are provided in subsequent sections. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 illustrates non-reproducibility in drug release profiles for commercial scale batches of extended release propranolol HCl Capsules (duplicate bead batches coated with an ethylcellulose membrane at 2.0%, 1.9%, and 1.8% based on the weight of the coated beads as described in Example 1).  
         [0014]    [0014]FIG. 2 shows drug release profiles for Extended Release Propranolol HCl Capsule, 160 mg (80% SR beads/20% IR beads) as described in Example 2.  
         [0015]    [0015]FIG. 3 illustrates drug release profiles for Extended Release Propranolol HCl Capsule, 160 mg (80% SR beads/20% IR beads) as described in Example 3.  
         [0016]    [0016]FIG. 4 provides drug release profiles for Extended Release Propranolol HCl Capsules on stability at 40° C./75% RH as described in Example 4.  
         [0017]    [0017]FIG. 5 shows drug release profiles for Extended Release Propranolol HCl Capsules on stability at 40° C./75% RH as described in Example 5. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]    All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.  
         [0019]    As used herein, the term “propranolol” includes the base, pharmaceutically acceptable salts thereof, stereoisomers thereof and mixtures thereof.  
         [0020]    The active core of the dosage form of the present invention may be comprised of an inert particle or an acidic or alkaline buffer crystal, which is coated with a drug-containing film-forming formulation and preferably a water-soluble film forming composition to form a water-soluble/dispersible particle. The amount of drug in the core will depend on the drug, the dose, and the capsule size. Those skilled in the art will be able to select an appropriate amount of drug for coating onto the core to achieve the desired dosage. In one embodiment, the inert core may be a sugar sphere, cellulose sphere, silicon dioxide or a buffer crystal or an encapsulated buffer crystal such as calcium carbonate, sodium bicarbonate, fumaric acid, tartaric acid, etc. which alters the microenvironment of the drug to facilitate its release.  
         [0021]    The drug-containing particle may be coated with a water insoluble polymer or a combination of a water insoluble polymer and a water soluble polymer to provide SR beads. The water insoluble polymer and said water soluble polymer may be present at a weight ratio of from about 100/0 to 60/40 more particularly at a weight ratio of from about 95/5 to 65/35, preferably at a weight ratio of from 85/15 to 75/25. The membrane coating typically comprises from approximately 1% to 10%, preferably approximately 1.5 to 6%, most preferably approximately 1.8 to 4.4% by weight of the coated beads.  
         [0022]    The unit dosage form according to one aspect of the present invention comprises two bead populations, one bead population, which provides an immediate release component of the active to act as a bolus dose and the other, a sustained release bead population, which releases propranolol over a period of 24 hours. In accordance with another embodiment, the dosage form comprises only SR beads.  
         [0023]    The invention also provides a method of making a sustained release dosage form which comprises a mixture of two or more bead populations. In accordance with one aspect of the present invention, the method includes the steps of:  
         [0024]    1. coating an inert particle such as a non-pareil seed, an acidic buffer crystal or an alkaline buffer crystal with a drug and polymeric binder to form an active drug particle (IR beads), which may be present in the unit dosage form to act as a bolus dose;  
         [0025]    2. coating the active drug particle with a solution or suspension of a water insoluble polymer or a mixture of water soluble and water insoluble polymers to form a sustained release coated drug particle (SR beads);  
         [0026]    3. filling into a hard gelatin capsule SR beads and IR beads at a proper ratio ranging from 95/5 to 70/30 (SR beads/IR beads) to produce an extended release capsule exhibiting a drug release profile similar to that of INDERAL® LA when tested under identical conditions.  
         [0027]    In accordance with certain embodiments of the present invention, the extended release capsule exhibits an in vitro dissolution profile substantially corresponding to the following pattern when tested according to United States Pharmacopoeia dissolution test method for Propranolol Hydrochloride Extended Release Capsules (USP Apparatus 1, Baskets @ 100 rpm, Drug Release Test 1 using 900 mL of pH 1.2 buffer for 1.5 hours followed by testing in 900 mL of pH 6.8 at 4, 8, 14, and 24 hours):  
         [0028]    after 1.5 hours, not more than about 30% of the total propranolol is released;  
         [0029]    after 4 hours, about 45±15%, preferably about 45±10%, of the total propranolol is released;  
         [0030]    after 8 hours, about 65±15%, preferably about 65±10%, of the total propranolol is released;  
         [0031]    after 14 hours, about 80±15%, preferably about 80±10%, of the total propranolol is released;  
         [0032]    after 24 hours, not less than about 85% of the total propranolol is released.  
         [0033]    An aqueous or a pharmaceutically acceptable solvent medium may be used for preparing drug containing core particles. The type of film forming binder that is used to bind the water-soluble drug to the inert sugar sphere is not critical but usually water-soluble, alcohol-soluble or acetone/water soluble binders are used. Binders such as polyvinylpyrrolidone (PVP), polyethylene oxide, hydroxypropyl methylcellulose (HPMC), hydroxypropylcellulose (HPC), and polysaccharides, such as dextran and cornstarch, typically are used at concentrations of 0.5 to 10 weight % based on the coating formulation. The drug substance may be present in this coating formulation in the solution form or may be suspended at a solid content up to 35 weight % or lower, depending on the viscosity of the coating formulation.  
         [0034]    The active containing cores (beads, pellets or granular particles) thus obtained may be coated with one or more layers of polymers to obtain desired release profiles. The membrane coating, which largely controls the rate of drug release by diffusion following imbibition of water or body fluids into the core, comprises a water insoluble polymer or a water insoluble polymer in combination with a water-soluble polymer. The water insoluble polymer is selected from the group which includes ethylcellulose, cellulose acetate, and ammonio methacrylic acid copolymers sold under the trademarks EUDRAGIT RL and EUDRAGIT RS. The water-soluble polymer is selected from the group consisting of low viscosity (approximately 200 cps or less when tested as a 2% solution) HPMC, HPC, methylcellulose, polyethylene glycol (PEG of molecular weight &gt;3000), and polyvinylpyrrolidone. The water insoluble polymer to water-soluble polymer ratio may typically vary 100/0 to 60/40, more particularly from 95/5 to 65/35, preferably from 85/15 to 75/25, at a thickness of from about 1% to 10%, preferably of approximately 1.5 to 6%, most preferably of approximately 1.8 to 4.4%, by weight of coated beads and depending on whether a polymer solution in an organic solvent or an aqueous polymer dispersion is used for membrane coating.  
         [0035]    The membranes described herein may also include one or more plasticizers. Representative examples of plasticizers that may be used to plasticize the membranes include triacetin, tributyl citrate, triethyl citrate, acetyl tri-n-butyl citrate, diethyl phthalate, castor oil, dibutyl sebacate, acetylated monoglycerides and the like or mixtures thereof. The plasticizer may comprise about 3 to 30 wt. % and more typically about 10 to 25 wt. % based on the polymer.  
         [0036]    In general, it is desirable to prime the surface of the active containing particle before applying the sustained release membrane coating by applying a thin hydroxypropyl methylcellulose (HPMC) film. A particularly useful plasticized HPMC seal coat is OPADRY® Clear available from Colorcon. While HPMC is typically used, other primer or seal coats such as hydroxypropyl cellulose (HPC) can also be used.  
         [0037]    The present invention relates to multi-dose forms, i.e., drug products in the form of multi-particulate dosage forms (pellets, beads, granules or mini-tablets) or in other forms suitable for oral administration.  
         [0038]    The following non-limiting examples illustrate the capsule dosage forms manufactured in accordance with the invention, which exhibit in vitro drug release profiles, similar to that predicted by performing modeling exercises, and in vitro and plasma concentrations following circadian rhythm pharmacodynamic profile of angina attacks.  
       EXAMPLE 1:  
       [0039]    Propranolol HCl (168 kg) was slowly added to an aqueous solution of polyvinylpyrrolidone (8.8 kg Povidone K-30) and mixed well. 25-30 mesh sugar spheres (117.2 kg) were coated with the drug solution in a Glatt fluid bed granulator. The drug containing pellets were dried, and a seal coat of Opadry Clear (6.0 kg) was first applied. Duplicate batches of sustained release beads with a membrane coating with ethylcellulose having a viscosity of 10 cps at 25° C. at a thickness of 1.8%, 1.9% and 2.0% w/w (batch size: 275 kg) were manufactured. The SR coating was followed by the application of an Opadry Clear seal coating at 2% w/w. The SR beads prepared in accordance with Example 1 were filled into hard gelatin capsules and were characterized by the following properties:  
         [0040]    Drug loading: 56% w/w based on core composition (corresponds to approximately 54% drug based on coated bead weight for bead batches having an SR coating of 1.8, 1.9, and 2.0%).  
         [0041]    Drug Release Testing: The drug release profiles were generated by dissolution testing per US Pharmacopoeia method for Propranolol Hydrochloride Extended Release Capsules (USP Apparatus 1, Baskets @ 100 rpm, Drug Release Test 1 using 900 mL of pH 1.2 buffer for 1.5 hours followed by testing in 900 mL of pH 6.8 at 4, 8, 14, and 24 hours). The profiles obtained are shown in FIG. 1, which demonstrates potential batch to batch variability. Although ethylcellulose applied from a solvent solution provides less than ideal reproducibility, sustained release membranes containing ethylcellulose as described above are within the scope of the present invention.  
       EXAMPLE 2:  
       [0042]    Propranolol HCl (168 kg) was slowly added to an aqueous solution of polyvinylpyrrolidone (8.8 kg Povidone K-30) and mixed well. 25-30 mesh sugar spheres (117.2 kg) were coated with the drug solution in a Glatt fluid bed granulator. The drug containing pellets were dried, and a seal coat of Opadry Clear (6.0 kg) was first applied at a weight gain of 2% to form IR beads. Duplicate batches of sustained release beads were prepared by membrane coating IR beads (3750 g) with a sustained release coating comprising ethylcellulose (148 g) having a viscosity of 10 cps at 25° C. and hydroxypropylcellulose (Klucel LF; 47.3 g) having a viscosity of 75-150 cps when tested on a 5% aqueous solution at 25° C. (ratio of ethylcellulose to Klucel: 75/25) for a weight gain of approximately 5% w/w (batch size: 3947 g). The coated beads were cured at 60° C. for 4 hours. Propranolol Hydrochloride Extended Release Capsules, 160 mg, were produced by filling IR and SR Beads at a ratio of 20/80. The drug release from these capsules is presented in FIG. 2.  
       EXAMPLE 3:  
       [0043]    Propranolol HCl (168 kg) was slowly added to an aqueous solution of polyvinylpyrrolidone (8.8 kg Povidone K-30) and mixed well. 25-30 mesh sugar spheres (117.2 kg) were coated with the drug solution in a Glatt fluid bed granulator. The drug containing pellets were dried, and a seal coat of Opadry Clear (6.0 kg) was first applied to form IR beads. Duplicate batches of sustained release beads were prepared by membrane coating IR beads (3750 g) with ethylcellulose (152.5 g) having a viscosity of 10 cps at 25° C. and hydroxypropyl methylcellulose (Methocel E5 from Dow Chemicals; 26.9 g) having a viscosity of 5 cps when tested on a 2% aqueous solution at 25° C. (ratio of ethylcellulose to Methocel E5: 85/15) for a weight gain of approximately 5% w/w (batch size: 3947 g). The coated beads were cured at 60° C. for 4 hours. Propranolol Hydrochloride Extended Release Capsules, 160 mg, were produced by filling IR and SR Beads at a ratio of 20/80. The drug release from these capsules is presented in FIG. 3.  
       EXAMPLE 4:  
       [0044]    Ethylcellulose-Klucel based extended release capsules of Example 2 were packaged in induction sealed HDPE bottles and placed on accelerated stability (i.e., at 40° C./75% RH). The drug release profiles at 1, 2, 3, and 6-month stability time points are shown in FIG. 4. These dissolution data as well as the chemical stability data demonstrate that the product is stable.  
       EXAMPLE 5:  
       [0045]    Ethylcellulose-HPMC based extended release capsules of Example 3 were packaged in induction sealed HDPE bottles and placed on accelerated stability (i.e., at 40° C./75% RH). The drug release profiles at 1, 2, 3, and 6-month stability time points are shown in FIG. 5. These dissolution data as well as the chemical stability data demonstrate that the product is stable.  
       EXAMPLE 6:  
       [0046]    Propranolol HCl (168 kg) was slowly added to an aqueous solution of polyvinylpyrrolidone (8.8 kg Povidone K-30) and mixed well. 25-30 mesh sugar spheres (117.2 kg) were coated with the drug solution in a Glatt fluid bed granulator. The drug containing pellets were dried, and a seal coat of OPADRY Clear (6.0 kg) was first applied to provide IR beads. IR beads (255.8 kg) were membrane coated with a sustained release coating comprising ethylcellulose (14.4 g) and hydroxypropyl methylcellulose (4.8 g) at a ratio of 75/25 for a weight gain of approximately 5% w/w (batch size: 275 kg). The coated beads were cured at 60° C. for 4 hours. Propranolol Hydrochloride Extended Release Capsules, 60, 80, 120, and 160 mg were produced by filling IR and SR Beads at a ratio of 20/80. The drug release from these capsules mimics that of INDERAL® LA.