1304 Full
1304 Full
Introduction
Powder Inhalers Today
Unit-Dose Devices
Multi-Dose Devices
Factors That Impact Performance and Patient Acceptance
DPI Development
Future DPI Developments
Summary
Dry powder inhalers (DPIs) are a widely accepted inhaled delivery dosage form, particularly in
Europe, where they currently are used by a large number of patients for the delivery of medications
to treat asthma and chronic obstructive pulmonary disease. The acceptance of DPIs in the United
States after the slow uptake following the introduction of the Serevent Diskus in the late 1990s has
been driven in large part by the enormous success in recent years of the Advair Diskus. This
combination of 2 well-accepted drugs in a convenient and simple-to-use device has created an
accepted standard in pulmonary delivery and disease treatment that only a few years ago could not
have been anticipated. The DPI offers good patient convenience, particularly for combination
therapies, and also better compliance. The design and development of any powder drug-delivery
system is a highly complex task. Optimization of the choice of formulation when matched with
device geometry is key. The use of particle engineering to create a formulation matched to a simple
device is being explored, as is the development of active powder devices in which the device inputs
the energy, making it simpler for patients to receive the correct dose. Patient interface issues are
also critically important. However, one of the most important factors in pulmonary delivery from
a DPI is the requirement for a good-quality aerosol, in terms of the aerosol’s aerodynamic particle size,
and its potential to consistently achieve the desired lung deposition in vivo. Key words: dry powder inhaler,
DPI, lactose, aerosol, asthma, bronchodilator, chronic obstructive pulmonary disease, COPD, corticosteroids,
drug delivery. [Respir Care 2005;50(10):1304 –1312. © 2005 Daedalus Enterprises]
Paul J Atkins PhD presented a version of this article at the 36th RESPI-
RATORY CARE Journal Conference, Metered-Dose Inhalers and Dry Pow- Correspondence: Paul J Atkins PhD, Oriel Therapeutics, PO Box 14087,
der Inhalers in Aerosol Therapy, held April 29 through May 1, 2005, in 630 Davis Drive, Research Triangle Park NC 27709. E-mail:
Los Cabos, Mexico. [email protected].
first combination of a long-acting  agonist (salmeterol) inspiration (a limitation of MDIs) because DPIs are essen-
and a corticosteroid (fluticasone propionate) in a conve- tially breath-actuated. However, this breath-actuation is
nient multi-dose DPI (Advair Diskus, GlaxoSmithKline, also one of their disadvantages. Some DPIs require in-
Research Triangle Park, North Carolina).1 spiratory flow of ⱖ 60 L/min to effectively de-aggregate
Key to all inhalation dosage forms (either MDI or DPI) the powder,6,7 which cannot always be achieved by all
is the need to generate the optimum “respirable dose” asthmatic patients, particularly infants. All the currently
(particles ⬍ 5.0 m) of a therapeutic agent that will reach available DPIs suffer from this potential drawback and can
the site of action (ie, the lung). This is a critical perfor- be characterized as “passive” inhalers (ie, the patient pro-
mance feature in the rational design and selection of a vides the energy to suck the drug from the device). This
pulmonary delivery system. Historically, MDIs have has prompted several companies to evaluate ways of pro-
achieved lung deposition of 5–15% of the delivered dose. viding energy in the inhaler, which is leading to the de-
Current DPIs have similar efficiency, but they have a num- velopment of several “active” DPIs, although none of these
ber of advantages over MDIs, including the fact that they are currently available commercially.
are breath-actuated and therefore require less coordination
than a conventional press-and-breathe MDI. Furthermore, Unit-Dose Devices
they do not contain chlorofluorocarbon propellants, which
have been implicated in atmospheric ozone depletion2 and With a single-dose DPI, a powder-containing capsule is
are being phased out. In addition, the more recently de- placed in a holder inside the DPI, the capsule is opened
veloped multi-dose DPIs have either a dose counter or within the device, and then the powder is inhaled. The
indicator that tells the patient how much medication re- spent capsule must be discarded after use and a new cap-
mains in the inhaler, which is another feature that differ- sule inserted for the next dose. The concept of the first
entiates DPIs from currently available MDIs. capsule-based device (the Spinhaler) was first described in
DPIs do, however, suffer from some inherent disadvan- the early 1970s, by Bell and colleagues,8 who had devel-
tages, including the fact that they require moderate inspira- oped this device for the administration of powdered so-
tory effort to draw the formulation from the device; some dium cromoglycate. Briefly, the drug mixture, which often
patients are not capable of such effort. Furthermore, there includes a bulk carrier to aid powder flow, is pre-filled into
is only a limited number of drugs available in a multi-dose a hard gelatin capsule and loaded into the device. After
format, with some drugs being available only in unit-dose activation of the device, which pierces the capsule, the
formats. These unit-dose devices are perceived as complex patient inhales the dose, which is dispensed from the vi-
and confusing for patients.3 In a recent review, Frijlink and brating capsule by means of inspired air. This product is
De Boer claimed that “well designed DPIs are highly ef- no longer available in the United States.
ficient systems for pulmonary drug delivery. However, A similar DPI (Rotahaler, GlaxoSmithKline), which has
they are also complicated systems, the performance of also been available for many years, delivers albuterol. With
which relies on many aspects, including design. . . , pow- the Rotahaler, the drug mixture is also in a hard capsule.
der formulation, and airflow generated by the patient.”4 The capsule is inserted into the device, broken open inside
This paper will review the currently available DPIs, fo- the device, and the powder is inhaled through a screened
cusing primarily on the United States market, evaluate the tube (Fig. 1).9,10 Again, this product is no longer available
key performance variables of these DPIs, including patient in the United States.
preferences, and provide some insights into potential fu- Although these single-dose devices have performed well
ture developments of DPIs for the delivery of agents to in clinical use for many years, the main criticism of them
treat respiratory diseases and systemic diseases. is the cumbersome nature of loading the capsule, which
might not be easily accomplished by a patient who is
Powder Inhalers Today undergoing an asthma attack and requires immediate de-
livery of the drug. This is clearly very relevant for devices
Today there are essentially 2 types of DPI: those in that deliver short-acting bronchodilators. In addition, el-
which the drug is packaged into discrete individual doses derly patients may not have the manual dexterity to ac-
(in a gelatin capsule or a foil-foil blister) and those that complish all the necessary maneuvers to take the capsule
contain a reservoir of drug from which doses are metered from the package, load it, and pierce the capsule in the
out.5 Both are now widely available around the world and device. However, despite the perception that unit-dose de-
are gaining broad acceptance as suitable alternatives to vices are not patient-friendly and are not easy to use, sev-
MDIs. There is clearly considerable interest in these de- eral introductions of single-dose DPIs have occurred over
vices, because they do not require chlorofluorocarbon pro- the last few years using similar designs (eg, Foradil Aerol-
pellant to disperse the drug and are therefore ozone-friendly. izer, made by Novartis/Schering-Plough, and Spiriva
Furthermore, DPIs obviate coordination of actuation and HandiHaler, made by Boehringer Ingelheim/Pfizer).11,12
Resistance
Inhaler Manufacturer
(H2O/L/s)
Rotahaler GlaxoSmithKline 0.015
Spinhaler Sanofi-Aventis 0.016
Diskhaler/Diskus GlaxoSmithKline 0.032
HandiHaler Boehringer Ingelheim 0.042
Turbuhaler AstraZeneca 0.044
Fig. 3. Schematic of the Diskus powder inhaler. (From Reference 20, with permission.)
Fig. 4. Serevent Diskus (left) and Advair Diskus (right) powder inhalers. (Courtesy of GlaxoSmithKline.)
such as inspiratory flow, patient inhalation technique, and training with ease of use. In many device-handling stud-
device resistance. ies the simple conclusions are that patients find device
One of the key factors with DPIs is that the various A better than device B, although often the criteria eval-
DPIs require different techniques to achieve an appro- uated have been extremely subjective. In a recent study26
priate therapeutic dose, unlike MDIs, with which, in conducted in Germany and Holland, it was shown that
general, the inhalation technique is the same. Thus, ease in elderly patients (mean age 60 years), approximately
of use and clear, concise instructions are required. In a two thirds (n ⫽ 254) were able to use the Diskus suc-
recent publication by Melani and colleagues,25 some cessfully, without any problems, compared with less
interesting observations were made linking patient- than 30% of the patients using HandiHaler. This is at-
tributable to the complex nature of the unit-dose system formulation from moisture effects. Hence, many of the
versus the simpler multi-dose system. In contrast, the DPIs now available have secondary packing (a foil over-
study by Melani et al25 showed that adherence to in- wrap) to protect them from moisture effects until just prior
structions was poorer with the Diskus and Turbuhaler to use.
than with another unit-dose device (the Aerolizer). In- Some years ago Brown28 alluded to the complexities
deed, in that study, which examined over 1,400 patients involved in the design and development of a DPI. In much
in Italy, the authors concluded that adherence to correct the same way as for an MDI, the combination of formu-
inhaler use was similar across DPIs and, indeed, be- lation (drug and carrier), the way that it is presented to the
tween the DPIs studied (Aerolizer, Turbuhaler, and Dis- device, and the design of the dosing device itself all con-
kus) and an MDI. This was attributed in part to appro- tribute to the overall performance of the dosage form. The
priate training prior to product use. Thus, one of the requirement to use micronized drug with small particles, to
critical factors in ensuring that patients receive the ap- achieve good aerodynamic properties of the dispersed pow-
propriate medication from the currently available pas- der, is confounded by the need to develop formulations
sive DPIs is the provision of appropriate training and that fill easily and accurately.29 It is also important that
device education by the health-care provider. changes in the physical nature of the formulation on trans-
portation and storage are studied and do not adversely
DPI Development affect the product performance.
The development of DPIs has traditionally linked a spe-
Historically, drug particles for inhalation have been pro- cific formulation to a particular device geometry that then
duced by a milling (micronization) process that creates creates a pneumatic dispersion of the powder to overcome
particles of 1.0 –3.0 m (this is absolutely necessary for the interparticulate forces and create the aerosol.30 How-
inhalation). Of critical importance in the development of ever, in the past decade, the notion of producing particles
DPI products is the evaluation, optimization, and control of a specific size, density, and morphology has evolved,
of flow and dispersion (de-aggregation) characteristics of and has the potential to lead to important advances in
the formulation. These typically consist of micronized drug pulmonary drug delivery. This advance was recently re-
blended with a carrier (eg, lactose). The properties of these viewed by Peart and Clarke31 and by Koushik and
blends are a function of the principal adhesive forces that Kompella.32 The underlying principle is that enhanced per-
exist between particles, including van der Waals forces, formance can be controlled by formulation changes (eg,
electrostatic forces, and the surface tension of adsorbed generating highly porous particles with large geometric
liquid layers.27 Particle size distribution of the drug and diameters but small aerodynamic diameters), an approach
the excipient (lactose) are optimized during early formu- characterized as “particle engineering.” These complex for-
lation development studies to ensure consistent aerosol mulations are then coupled with a simple delivery device.
cloud formation during subsequent clinical evaluation. This is clearly a subject of interest for formulation scien-
The efficiency of dispersion of DPI aerosols, relative to tists as they strive to develop more efficient powder de-
the various geometric diameters of the particles, may also livery systems.
be an important factor. Specifically, dispersion requires The goal of delivering micronized powders is a chal-
the powder to overcome interparticulate forces that bind lenging one. Because of their very nature, these types of
particles in bulk powder and to become entrained as single powders are highly cohesive. Their high inter-particulate
particles in the inhalatory air stream. Interparticulate forces forces make them difficult to de-aggregate: hence, the need
are dominated by the van der Waals force for particles in for high inspiratory flow and turbulent airflow within DPIs.
the respiratory size range. All other factors being equal, Inclusion of a carrier can aid in the de-aggregation pro-
the van der Waals force will decrease as the geometric cess, but it can also lead to problems with absorption of
particle size increases. Thus, in general terms, the proba- atmospheric moisture. The alternative approach to achiev-
bility of deposition in the deep lung is at odds with effi- ing efficient dispersion of these highly cohesive powders
ciency of dispersion for DPIs. is to provide an energy source for dispersion within the
Environmental factors, especially temperature and hu- device itself, and a number of companies are pursuing this
midity, are key factors that can impact DPI formulation approach. An outline review of some of these approaches
stability and performance. The impact of these are studied is provided below as part of a prediction of future DPI
in early development studies, and often the humidity ef- developments.
fects negatively impact the formulation (particularly for
lactose blends), making it more cohesive and therefore Future DPI Developments
more difficult to disperse. This will be to some extent
dependent on the device/formulation combination, and typ- The delivery of powdered medication for the treatment
ically reservoir devices have a poorer ability to protect the of lung ailments has been known for centuries, is well
Group. Inhalation technique and variables associated with misuse of 31. Peart J, Clarke MJ. New developments in dry powder inhaler tech-
conventional metered-dose inhalers and newer dry powder inhalers nology. Am Pharm Rev 2001;4(3):37–45.
in experienced adults. Ann Allergy Asthma Immunol 2004;93(5): 32. Koushik K, Kompella UB. Inhalation engineering. Drug Deliv Tech-
439–446. nol 2004;4(2):40–50.
26. Moore AC, Stone S. Meeting the needs of patients with COPD: 33. Sanders M. Inhalatorium. http://inhalatorium.com. Accessed April
patients’ preference for the Diskus inhaler compared with the Handi- 30, 2005.
haler. Int J Clin Pract 2004;58(5):444–450. 34. Anderson PJ. History of aerosol therapy: liquid nebulization to MDIs
27. Concessio NM, Hickey AJ. Descriptors of irregular particle morphology to DPIs. Respir Care 2005;50(9):1139–1149.
and powder properties. Adv Drug Deliv Rev 1997;26(1):29–40. 35. Nowak-Wegrzyn A, Shapiro GG, Beyer K, Bardina L, Sampson HA.
28. Brown K. The formulation and evaluation of powders for inhalation. Contamination of dry powder inhalers for asthma with milk proteins
In: Ganderton D, Jones TM, editors. Drug delivery to the respiratory containing lactose (letter). J Allergy Clin Immunol 2004;113(3):
tract 1987. Chichester, England: Ellis Horwood.1987:119–123. 558–560.
29. Crowder TM, Rosati JA, Schroeter JD, Hickey AJ, Martonen TB. Fun- 36. Chuchalin AG, Manjra AI, Rozinova NN, Skopkova O, Cioppa GD,
damental effects of particle morphology on lung delivery: predictions of Till D, et al. Formoterol delivered via a new multi-dose dry powder
Stokes’ law and the particular relevance to dry powder inhaler formu- inhaler (Certihaler) is as effective and well tolerated as the formot-
lation and development. Pharm Res 2002;19(3):239–245. erol dry powder inhaler (Aerolizer) in children with persistent asthma.
30. Crowder TM, Louey MD, Sethuraman VV, Smyth HD, Hickey AJ. J Aerosol Med 2005;18(1):63–73.
An odyssey in inhaler formulations and design. Pharm Technol 2001; 37. Crowder TM. Vibration technology for active dry-powder inhalers.
25(7):99–113. Pharm Technol 2004:2–6.
Discussion probably about 10% or less, will not MacIntyre: I was struck by Tony’s
be able to use Diskus or other DPIs. [Hickey] comment during his presen-
Amato:* Do you think if Advair was That doesn’t answer your question di- tation that there will probably not be
introduced as an MDI, it would be as rectly, but I think there is probably a generic DPIs. But you showed 2 de-
popular as the DPI is? Is its popularity preference in some places for Diskus vices that are being used as generic
related more to the device or to the drug? or other DPIs over MDI, but the MDI DPIs. Help me reconcile those 2 state-
is going to be around for a while. ments. Can you build a “generic” DPI
Atkins: As to whether the device or and then find a product to disperse
the drug drives physician choice, I Smaldone: I think a lot of it has to with it?
think it is usually the drug. I can tell do with the market. In the United States
you that, in France, with fluticasone there was no heavy competition for Hickey: It’s a question of how you
at the same price per dose, patients the combination product. My answer consider generic products to perform.
preferred Diskus over HFA MDI, 65% to Mike’s question would be that an If you do it based on performance,
to 35%. Another aspect is that some MDI version of Advair probably which is how the Europeans are look-
small percentage of the population, would have been as popular. If you ing at it, then it’s possible. If you do it
compare the Diskus against the MDI, based on componentry equivalence,
the Diskus might win, but if the Dis- which is the way we look at it in the
* Michael T Amato, American Respiratory Care
kus wasn’t there, I don’t think the com- United States, it’s absolutely impossi-
Foundation, Irving, Texas; Monaghan Medical/ pany would have been any less suc- ble, because all these devices are dif-
Trudell Medical International, Syracuse, New York. cessful with an MDI version. ferent.