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Review Article
Sterilization of Glucocorticosteroids for Inhalation Delivery
*Chandrashekhar Laxman Bhingare, Sampada Dhaval Dalvi, Suhas Vasudeo Joshi, Vibhuti Ashok
Mishra
ABSTRACT
Sterile drug products are defined as those products that are free from all viable microorganisms. They
provide a number of benefits, both medically and economically. Glucocorticoid (GC) is a class of steroid
hormones that bind to the glucocorticoid receptor (GR), which is present in almost every vertebrate
animal cell. The name glucocorticoid (glucose + cortex + steroid) derives from their role in the regulation
of the metabolism of glucose, their synthesis in the adrenal cortex, and their steroidal structure. Steroids
in powder form are not stable at temperatures above 600 C. The major problems are related to the high
temperatures of the sterilization process and to the consequent thermal instability of the drug substance
that frequently leads to degradation with modification of the impurities profile and of the
physicochemical characteristics of the drug. For solid drug substances suitable for inhalation delivery to
be suspended in aqueous formulations, the particle size distribution, as well as its preservation during the
shelf life of the finished product, is particularly crucial parameters. The main focus of this review article is
to provide different processes for the sterilization of a powdered form of a glucocorticosteroid and use
thereof in the treatment of an allergic &/or inflammatory conditions of the nose or lungs.
Received 28 June 2013 Received in revised form 21 July 2013 Accepted 23 July 2013
INTRODUCTION
The administration of drugs through treatment of respiratory diseases,
inhalation has been used for many years glucocorticosteroids such as
and is the mainstay of treatment of diseases beclomethasone dipropionate (BDP),
which limit airflow, such as asthma and dexamethasone, flunisolide, budesonide,
chronic bronchitis. fluticasone propionate are of great
Furthermore, a number of inhalator importance. They can be administered in
formulations have been marketed for some the form of a finely divided, i.e. micronized
years for the administration of steroidal powder, formulated as suspension in an
anti-inflammatory, decongestant and anti- aqueous phase containing any necessary
allergic agents for the topical treatment of surfactants and/or co-solvents. When
rhinitis and/or sinusitis. One of the intended to be administered in the form of
advantages of the inhalator route over the metered doses of aerosol spray, they should
systemic one is the possibility of delivering also contain a low boiling propellant. The
the drug directly at the action site, so effectiveness of the administration form
avoiding any systemic side-effects. Said way depends on the deposition of an adequate
of administration allows achieving a more amount of particles at the action site. One of
rapid clinical response and a higher most critical parameters determining the
therapeutic index. Among the different proportion of inhalable drug which will
classes of drugs which are usually reach the lower respiratory tract of a
administered by inhalation for the patient is the size of the particles emerging
from the device. In order to ensure an addition to the control of the physical and
effective penetration into the bronchiole chemical stability of the sterilized drug, it is
and alveoli and hence ensure a high then crucial to prevent any unacceptable
respiration fraction, the mean aerodynamic change in particle size due to possible re-
diameter (MMAD) of the particles should be crystallization of the drug, which is
lower than 5-6 microns (Pm). For nasal consequent to many known sterilization
administration, particles with higher MMAD methods [1].
are required. Terminology
Other important characteristics for a Sterilization
correct administration and therefore for the Sterilization is a process performed to
therapeutic efficacy, are the size ensure that there is complete freedom from
distribution and the homogeneous microbial contamination. Sterilization is
dispersion of the particles in the especially done for pharmaceutical
suspension. The process for sterilizing formulations which are to be directly
powdered forms of water insoluble drug introduced into the body and its cavities.
substance to be suspended into a sterile Such formulations explicitly include
aqueous vehicle suitable for the pulmonary ophthalmic preparations, nasal
administration, such as non-electrolyte preparations, ocular preparations,
corticosteroids, glucocorticoid and the like, injections, transdermal patches, depot
is still a critical process. The major preparations and the like. Such sterilized
problems are related to the high preparations involve two main methods of
temperatures of the sterilization process preparation. First route is that the active
and to the consequent thermal instability of ingredient is sterilized and the formulation
the drug substance that frequently leads to is prepared aseptically or the final is
degradation with modification of the prepared, packed in the desired container
impurities profile and of the and then sterilized. The second route is
physicochemical characteristics of the drug. known as a terminal sterilization technique.
For solid drug substances suitable for Certain formulations such as respules or
inhalation delivery to be suspended in aqueous nasal preparations, ophthalmic
aqueous formulations, the particle size preparations and the like that involve
distribution, as well as its preservation steroids as the active ingredient are usually
during the shelf-life of the finished product, prepared by the first method described
is particularly crucial parameters. The above [2-7].
particle size influences, in fact, the Pharmaceutical Importance of
distribution of the drug into the lung and, as Sterilization
a consequence, the activity and Moist heat sterilization is the most
effectiveness of the drug itself. It is efficient biocide agent. In the
generally accepted that the mean diameter pharmaceutical industry it is used for:
of the particles in a formulation for Surgical dressings, Sheets, Surgical and
inhalation delivery must be less than 10 diagnostic equipment, Containers,
microns, preferably about 5 microns or less. Closures, Aqueous injections, Ophthalmic
Solid non-electrolyte corticosteroids, preparations and Irrigation fluids etc.
steroids as well as non-steroid drugs for use Dry heat sterilization can only be used
in aqueous suspensions are usually for thermo stable, moisture sensitive or
sterilized in different ways, for example by moisture impermeable pharmaceutical
exposure to gases, or by aseptic and medicinal. These include products
crystallisation, drug heat sterilization, or by like; Dry powdered drugs, Suspensions of
irradiation. The sterilizing treatment can drug in non aqueous solvents, Oils, fats
cause adverse physical and chemical waxes, soft hard paraffin silicone, Oily
changes of the drug substance and all injections, implants, ophthalmic
parameters have to be checked and ointments and ointment bases etc.
investigated in the preliminary phase of the Gaseous sterilization is used for
process development. In the case of drug sterilizing thermo-labile substances like;
substances intended for inhalation use, in
counter. They also interfere with some of the agent to a saturated solution of sodium
the abnormal mechanisms in cancer cells, so chloride in water at 100C and then heating
they are used in high doses to treat cancer. the mixture at 100-130C. This method is
This includes mainly inhibitory effects on not suitable for suspensions of fine particles
lymphocyte proliferation (treatment of of steroids, which are intended for
lymphomas and leukaemia) and mitigation inhalation because the water, and the
of side effects of anticancer drugs. GCs cause heating and cooling involved, produce
their effects by binding to the glucocorticoid unfavourable changes in the size of
receptor (GR). The activated GR complex, in particles. Indeed it can lead to the formation
turn, up-regulates the expression of anti- of bridges between the fine particles
inflammatory proteins in the nucleus and producing large, hard aggregates, which will
represses the expression of pro- not disaggregate into the desired fine
inflammatory proteins in the cytosol by particles upon administration.
preventing the translocation of othe- 3. Dry heat sterilization. According to the
r transcription factors from the cytosol into European Pharmacopoeia (1996, pp. 283-4)
the nucleus (transrepression). Glucocorti- a normal heat sterilization process runs at
coids are distinguished from mineralo- 180C for 30 min or at a minimum of 160C
corticoids and sex steroids by their specific for at least 2 hours. According to
receptors, target cells, and effects. In Pharmacopeia Nordica (1964, pp.16) such
technical terms, "corticosteroid" refers to sterilization can be carried out at 140C for
both glucocorticoid and mineralocorticoids 3 hours. However at the temperatures of
(as both are mimics of hormones produced these processes glucocorticosteroids suffer
by the adrenal cortex), but is often used as a significant degradation and are subject to
synonym for "glucocorticoid". Cortisol (or changes in their surface structure. These
hydrocortisone) is the most important procedures on climbs industrialist foresee a
human glucocorticoid. It is essential for life, validation work of the process and of the
and it regulates or supports a variety of sterilization heater much gives a complex,
important,cardiovascular, metabolic, immu in how much be necessary show that the
nologic, and homeostatic functions. Various temperature of sterilization is reached in
synthe-tic glucocorticoid are available; every point of the product and maintained
these are used either as replacement for the necessary time.
therapy in glucocorticoid deficiency or to 4. Sterilization by irradiation is also known.
suppress the immune system. Examples of When such irradiation is used to sterilize
glucocorti-costeroids are hydrocortisone, certain finely divided, e.g., micronized
dexameth-asone, budesonide, methyl- steroids such as glucocorticosteroids, they
prednisolone, prednisolone sodium are significantly degraded.
phosphate and prednisone [8]. 5. Terminal sterilization of pharmaceutical
Methods of sterilization of glucocorti- formulations, especially suspensions, e.g.,
costeroids for inhalation delivery: [9- 22] aqueous suspensions, of glucocorti-
1. Cold sterilization of micronized costeroids has all proved unsatisfactory.
glucocorticosteroids using mixtures of Such suspensions cannot normally be
ethylene oxide and carbon dioxide. sterilized by sterile filtration as most of the
However, ethylene oxide is toxic and when particles of glucocorticosteroids will be
it is used to sterilize glucocorticosteroids it retained on the filter. The sterilizing
has been found that the residual amounts of filtration, in case of the suspensions, is little
the ethylene oxide contravene practicable because its requested the use of
pharmaceutical guidelines, which require filters with a dimension of the pores not
very low levels of residual ethylene oxide. superior to 0,2 micron, under the diameter
Accordingly this method has been found to of the most particles present in the active
be unsuitable for producing therapeutically principle, so most of them are blocked by
acceptable glucocorticosteroids and the filter. Moist heat sterilization, e.g., steam
formulations thereof. treatment of glass vials containing the
2. Production of sterile isotonic solutions of product, leads to an unacceptable change in
medicinal agents, which comprises adding particle size. The standard treatments of
introducing the active ingredient into a performed directly in the preparation vessel
pressure vessel or other sealed container (turbo homogenizer working as an
along with one or surfactants and water. autoclave); in this way the bulk preparation
The pressure vessel is preferably fitted with and the transfer of bulk to the filling
a hydrophobic vent filter and a hydrophobic machine can be carried out without any
cartridge filter. The sterilization is contact with the environment (aseptic
preferably done at temperatures ranging condition). As a consequence, qualification
from 100-140C for 3-30 mins at varying and controls of preparative area, personnel
pressures. gowning and training as well as cleaning
Preferred combinations of temperature- procedures, result to be less heavy in terms
time-pressure including the following: of costs and timing. no significant
(a) 121C for 20 mins at 103 kPa (15 psi) differences were found in crystal growth
(b) 132C for 3 mins at 186 kPa (27 psi) and size distribution between formulations
(c) 115C for 30 mins at 69 kPa (10 psi), prepared with steam sterilised
But other combinations can be used if glucocorticoid and with non-sterilised
desired. Generally, the higher the glucocorticoid, after storage under
temperature and pressure, the shorter the accelerated conditions, for 50 days at 40C
time required for adequate sterilization. A 75% R.H.
wet mass comprising steroid, surfactants 10. Heat treating the glucocorticosteroid in
and water is, for example, placed in a the form of a powder at a temperature of
pressure vessel or other sealed container. from 100 to 130 0 C. The process is
This vessel or container is then preferably preferably carried out at a temperature of
placed in an autoclave, and then from about 110 to 120 0 C., more preferably
sterilization takes place. This differs from at about 1100 C., preferably upto 24 hrs,
other methods in which material containing more preferable up to 10 hrs, e.g. from 1 to
the active of interest is placed in an 10 hrs.. The process is conveniently carried
autoclave and sterilized directly. The out under atmospheric conditions, i.e. in air,
present methods confer the advantage of but may also be carried out under an inert
being able to transfer the sterilized mass gas atmosphere.
directly to the main bulk of the final CONCLUSION
formulation (for example, a nasal spray or Sterile drug products provide a no. of
respules formulation) without intermediate benefits, both medically and economically.
steps, in particular without using Form the literature it was known that
sterilization chambers. sterilization by supercritical CO2 is
9. A process for the steam sterilisation of expensive and unfeasible. Sterilization by
steroid, comprising heating a mixture of irradiation produces significant
water and micronized steroid at a degradation; sterilization with heat
temperature ranging between 100 and produces significant degradation and is
130C for a time sufficient to sterilise the subjected to changes in their surface
mixture with a minimum S.A.L. (Sterility structure. Ethylene oxide is toxic and the
Assurance Level) of 10-6, the mixture being residual levels are often above the
a mixture of steroid and water only. The pharmaceutically acceptable limits as per
micronized steroid: water ratio can range by most regulatory agencies. So far filtration
between 2.5:100 and 100:2. Mixtures of the is the best method that can be used for
steroid and water at different ratios were filtration. It is a simple, economic process.
prepared and the mixtures were steam Use of this process in industrial plants,
sterilised at a temperature of about 120 C allows an easier and less expensive
for a time ranging from 15 to 30 minutes. manufacturing process. Qualification and
Preferably steam sterilization was carried controls of prepared area, personnel
out at 121C for 20 minutes. Its a simple gowning and training as well as cleaning
and economic process. Use of said process procedures result to be less heavy in terms
in industrial plants allows an easier and less of costs and timing. No degradation,
expensive manufacturing process. The production of toxic substances or change in
sterilisation of the active ingredient can be surface structure is observed.