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PulmoCraft™

Accelerating pulmonary drug development through particle engineering, formulation expertise and device-focused development.

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PulmoCraft™

Drug Delivery to the Lung

Drug delivery into the lung is one of the fastest growing, yet technically challenging areas of pharmaceutical development. Producing a successful pulmonary drug product requires expertise in formulation development, particle engineering and device selection. Inhalation product testing capabilities are also vital to ensure that the developed product can effectively deliver the target dose into the correct region of the lung.

When to use PulmoCraft

PulmoCraft™ is ideally suited to:

Dry Powder Inhaler (DPI) development
Nebulised formulations
Pulmonary biologics
Poorly soluble compounds
Particle engineering programmes
Device-selection studies
Early-stage pulmonary development

What you receive

Data-driven recommendations that support pulmonary formulation development and progression towards clinical studies.

Formulation strategy recommendation
Device selection guidance
Aerodynamic performance assessment
Particle engineering strategy
Development roadmap
Clinical progression recommendations

PulmoCraft™

Liquid and Dry Powder Formulation Development

When developing a pulmonary drug product, the first key decision will be whether the product should be a Liquid or Dry Powder formulation. This choice will be dependent on several factors including speed to clinic, solubility and stability profile of the API, and the target dose to be delivered.

Drug product development includes two equally important aspects:

Formulation Development: Producing a stable dry powder or liquid formulation, with the correct physical properties for successful delivery, such as viscosity, for liquid formulations, or particle size for dry powder formulations.

Delivery Performance: Ensuring that the target delivered dose is achieved from the selected device and that the aerodynamic performance will result in the deposition in the target region of the lung.

PulmoCraft™ and Spray Drying

Aerodynamic particle engineering

Spray drying enables precise control over particle size, morphology and density for inhalation products.

Deep lung delivery

Engineered particles designed to achieve optimal aerodynamic performance and target deposition within the lungs.

DPI Development

Designed to support dry powder inhaler formulations from feasibility through clinical manufacture.

Pulmonary biologics

Specialist capabilities supporting the development of biologics for delivery to the lungs.

Development of pulmonary products

API

PSD, Morphology
Chemical stability

Formulation

API loading/excipient levels
Target region, deposition profile, PSD.
Lactose blend or spray dried powder

Device

Single dose or multi dose
Capsule versus blister

Dry Powder Inhalers (DPI)

Successful development of a Dry Powder Inhaler (DPI) formulation requires a good understanding of the physicochemical properties of the API, extensive testing of the dry powder formulation, and its performance when delivered from the selected device.

The key to the successful development of a DPI formulation is the development of formulated drug substance particles with the correct aerodynamic size for pulmonary delivery. At Upperton this is achieved through two basic approaches: Pharmaceutical Spray Drying and Jet Milling.

Pharmaceutical Spray Drying is one of the most flexible and versatile particle engineering techniques and Upperton has over twenty years of experience in developing formulations and spray drying processes to create microparticles with the correct aerodynamic properties for deep lung delivery.

Once optimised spray drying processing parameters have been defined, the Upperton spray dryers can produce kilo quantities of engineered microparticles that can be precision filled into capsules or directly into a DPI.

Drug delivery to the lung

API

Aqueous solubility
Physiochemical properties

Formulation

Osmolality, pH, viscosity
Buffers, preservatives
Solution or suspension
Chemical and physical stability of liquid formulation

Device

Nebuliser type (jet versus mesh)
Pharmacy versus home use
Container closure system

Liquid Formulations

Many customers initially enter the clinic with a liquid formulation for delivery via a nebuliser. The use of a liquid formulation is often seen as a ‘quick’ route into clinic as it avoids the need for more extensive dry powder formulation development timelines.

Successful development of liquid (nebulised) formulations requires a thorough investigation into the properties of the API, the formulated liquid product and the performance of the formulation in the device.

Pulmonary dosage form development

Analytical Testing

Generating stability and performance data on both liquid and dry powder pulmonary dosage forms require significant know-how and technical capability. Meaningful and reproducible performance data is critical to successful product development.

Upperton has a range of analytical capabilities to support development activities, including particle size by laser diffraction, spray pattern and plume geometry, microscopy including scanning electron microscopy, aerodynamic particle size distribution by cascade impactor (NGI), emitted dose and content uniformity.