Stability Studies of Amorphous Ibrutinib Prepared Using the Quench-Cooling Method and Its Dispersions with Soluplus^®

The successful development of an amorphous form of a drug demands the use of process conditions and materials that reduce their thermodynamic instability. For the first time, we have prepared amorphous ibrutinib using the quench-cooling method with very high process efficiency. In the presented study, different formulations of amorphous active pharmaceutical ingredient (API) with Soluplus (SOL) in various weight ratios 1:9, 3:7, and 1:1 were prepared. The obtained samples were stored under long-term (25 ± 2 °C/60%RH ± 5% RH, 12 months) and accelerated (40 ± 2 °C/75%RH ± 5% RH, 6 months) storage conditions. The physical stability of amorphous ibrutinib and ibrutinib-Soluplus formulations was analyzed using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), powder X-ray diffraction analysis (XRPD), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM). The lack of significant interactions between the ingredients of the formulation was confirmed by FTIR analysis. An increase in moisture content with an increasing SOL weight ratio was observed under accelerated aging and long-term conditions. Additionally, a slight increase in the moisture content of the stored sample compared to that at the initial time was observed. The results revealed the physical strength of the polymeric systems in the presence of high humidity and temperature. The observed high thermal stability allows the use of various technological processes without the risk of thermal degradation.