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Identifying Optimal Drug Loading in Stable Amorphous Solid Dispersion Formulations: A Rheological Approach.

Sagar Narala1, Fengyuan Yang2, Kapish Karan1

  • 1Ashland Specialty Ingredients, Wilmington, DE, 19808, United States of America.

AAPS Pharmscitech
|May 12, 2026
PubMed
Summary
This summary is machine-generated.

Formulation scientists can determine optimal polymer/API ratios for stable amorphous drug systems using rheological studies. This research highlights how drug solubility in copovidone impacts the physical stability of amorphous nifedipine formulations.

Keywords:
amorphous solid dispersioncopovidonehomogeneitymiscibilityrheologystability

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Area of Science:

  • Pharmaceutical Sciences
  • Materials Science

Background:

  • Synthetic polymers like copovidone enhance drug formulations via controlled release, bioavailability, and stability.
  • Hot-melt extrusion (HME) uses copovidone to improve solubility of active pharmaceutical ingredients (APIs).
  • Challenges include optimizing copovidone/API ratios and ensuring long-term stability of amorphous APIs.

Purpose of the Study:

  • To assess the solubility and miscibility of crystalline nifedipine in copovidone.
  • To develop stable amorphous polymer/API systems.
  • To determine the optimal copovidone/API composition for nifedipine formulations.

Main Methods:

  • Produced amorphous copovidone/nifedipine extrudates (10-60% w/w) using HME.
  • Characterized extrudates using differential scanning calorimetry (DSC) and X-ray diffraction (XRD).
  • Evaluated extrudate stability and homogeneity via rheological temperature cycles.

Main Results:

  • All extrudates were amorphous, confirmed by DSC and XRD, irrespective of drug loading.
  • Rheological studies indicated homogeneity at low drug loads, heterogeneity at medium loads, and API nucleus formation at high loads.
  • Higher drug loads resulted in poor physical stability and API recrystallization during storage.

Conclusions:

  • Rheological studies aid in creating semi-phase diagrams for optimal polymer/API composition.
  • Thermodynamic stability is formulation-dependent, emphasizing the need to determine API solubility in the polymer.
  • Optimal formulation composition is critical for achieving stable amorphous drug systems.