Effect of lubricants type and particle size on the rheological properties and aerosolization behavior of dry powder inhalers

A commonly used strategy to improve aerosolization behavior of carrier-based dry powder inhalers (DPIs) is the addition of magnesium stearate as a lubricant, yet it may also negatively affect properties of DPIs. Thus, the aim of this study was to find lubricants that could be used as alternatives of magnesium stearate and meanwhile verify the applicability of using powder rheological properties to predict the performance of different lubricants in DPIs. Here, using fluticasone propionate as a model drug, LH200 as the carrier, influence of lubricants type and particle size, including magnesium stearate, sodium stearate, Leucine, sodium stearate fumarate, Compritol® 888 ATO, and Compritol® HD5 ATO, on the physicochemical properties, powder rheology and aerosolization behavior of the DPI formulations was characterized. Further, the relationship between powder rheological parameters and in-vitro drug deposition parameter, fine particle fraction (FPF), were explored, and the contribution of powder flowability and adhesion was evaluated using principal component analysis (PCA). The results showed that magnesium stearate, sodium stearate and smaller sized leucine significantly reduced the basic flowability energy, aeration energy and Permeability of the DPI formulations, leading to improved aerosolization behavior. A robust linear correlation was established between rheological parameters and FPF. PCA showed that in lubricants containing formulations, the contribution of flowability (74.69%) was greater than that of adhesion (25.31%). In conclusion, sodium stearate and smaller particle size Leucine can be considered as substitutes of magnesium stearate in DPI formulations.