title: Impact of formulation and process variables on solid-state stability of theophylline in controlled release formulations.
abstract: Understanding the impact of pharmaceutical processing, formulation excipients and their interactions on the solid-state transitions of pharmaceutical solids during use and in storage is critical in ensuring consistent product performance. This study reports the effect of polymer viscosity, diluent type, granulation and granulating fluid (water and isopropanol) on the pseudopolymorphic transition of theophylline anhydrous (THA) in controlled release formulations as well as the implications of this transition on critical quality attributes of the tablets. Accordingly, 12 formulations were prepared using a full factorial screening design and monitored over a 3 month period at 40 °C and 75%. Physicochemical characterization revealed a drastic drop in tablet hardness accompanied by a very significant increase in moisture content and swelling of all formulations. Spectroscopic analysis (ssNMR, Raman, NIR and PXRD) indicated conversion of THA to theophylline monohydrate (TMO) in all formulations prepared by aqueous wet granulation in as early as two weeks. Although all freshly prepared formulations contained THA, the hydration-dehydration process induced during aqueous wet granulation hastened the pseudopolymorphic conversion of theophylline during storage through a cascade of events. On the other hand, no solid state transformation was observed in directly compressed formulations and formulations in which isopropanol was employed as a granulating fluid even after the twelve weeks study period. The transition of THA to TMO resulted in a decrease in dissolution while an increase in dissolution was observed in directly compressed and IPA granulated formulation. Consequently, the impact of pseudopolymorphic transition of theophylline on dissolution in controlled release formulations may be the net result of two opposing factors: swelling and softening of the tablets which tend to favor an increase in drug dissolution and hydration of theophylline which decreases the drug dissolution.
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA.
authors.forename: Maxwell
authors.initials: M
authors.lastname: Korang-Yeboah
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA.
authors.forename: Ziyaur
authors.initials: Z
authors.lastname: Rahman
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA.
authors.forename: Dhaval
authors.initials: D
authors.lastname: Shah
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA.
authors.forename: Adil
authors.initials: A
authors.lastname: Mohammad
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA.
authors.forename: Suyang
authors.initials: S
authors.lastname: Wu
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA.
authors.forename: Akhtar
authors.initials: A
authors.lastname: Siddiqui
authors.affiliation: Division of Product Quality Research, Center for Drug Evaluation and Research, Food and Drug Administration, MD, USA; Rangel College of Pharmacy, Texas A&M Health Science Center Reynolds Medical Building, Suite 159, College Station, TX 77843-1114, USA. Electronic address: mkhan@pharmacy.tamhsc.edu.
authors.forename: Mansoor A
authors.initials: MA
authors.lastname: Khan
mesh_terms: D001993:Bronchodilator Agents / Q000008:administration & dosage* / Q000737:chemistry; D002626:Chemistry, Pharmaceutical / Q000379:methods*; D003692:Delayed-Action Preparations; D004355:Drug Stability; D004356:Drug Storage; D005079:Excipients / Q000737:chemistry*; D006244:Hardness; D011108:Polymers / Q000737:chemistry; D012995:Solubility; D013057:Spectrum Analysis; D013607:Tablets; D013806:Theophylline / Q000008:administration & dosage* / Q000737:chemistry; D014783:Viscosity
chemical_list: D001993:Bronchodilator Agents; D003692:Delayed-Action Preparations; D005079:Excipients; D011108:Polymers; D013607:Tablets; D013806:Theophylline
keywords: Dissolution; Pseudopolymorphic transition; Solid-state stability; Theophylline