Formulation and Characterization of Acetaminophen Nanoparticles in Orally Disintegrating Films

The purpose of this study is to prepare acetaminophen loaded nanoparticles to be cast directly, while still in the emulsion form, into Orally Disintegrating Films (ODF). By casting the nanoparticles in the films, we expected to keep the particles in a stable form where the nanoparticles would be away from each other to prevent their aggregation. Once the films are applied on the buccal mucosa, they are supposed to dissolve within seconds, releasing the nanoparticles. Then the nanoparticles could be directly absorbed through the mucosa to the blood stream and deliver acetaminophen there.;The oral cavity mucosa is one of the most attractive sites for systemic drug delivery due to its high permeability and blood supply. Furthermore, it is robust and shows short recovery times after stress or damage, and the drug bypasses first pass effect and avoids presystemic elimination in the GI tract.;Nanoencapsulation increases drug efficacy, specificity, tolerability and therapeutic index. These Nanocapsules have several advantages in the protection of premature degradation and interaction with the biological environment, enhancement of absorption into a selected tissue, bioavailability, retention time and improvement of intracellular penetration. The most important characteristics of nanoparticles are their size, encapsulation efficiency (EE), zeta potential (surface charge), and the drug release profiles. Unfortunately, nanoparticles tend to precipitate or aggregate into larger particles within a short time after preparation or during storage. Some solutions for this problem were mentioned in literature including lyophilization and spray drying. These methods are usually expensive and give partial solutions that might have secondary problems; such as low re-dispersion efficacy of the lyophilized NPs. Furthermore, most of the formulations of NPs are invasive or topical. Few formulas are available to be given orally.;Fast disintegrating films (ODFs) are rapidly gaining interest in the pharmaceutical industry. These thin films are designed to dissolve within a few seconds without the need for water or chewing. The introduction of fast disintegrating dosage forms has solved some problems encountered in the administration of drugs to pediatric and elderly patients. This convenience provides both marketing advantages and higher patient compliance. Acetaminophen was chosen to be the model drug due to its safety. The amount of acetaminophen in each film is much below the therapeutic dose, but the purpose of using acetaminophen is to be an analytical tracer only.;Films were formulated using hydroxypropyl methyl cellulose (HPMC) as film forming polymer, polyethylene glycol 400 (PEG) as a plasticizer and polyvinyl alcohol (PVA) as a NPs stabilizer. First of all, the effect of different Methocel grades and concentration, PEG 400 concentration and PVA 80% concentration on the films were determined. Ingredients that gave best physico-mechanical properties to the films were used in the formulation of ODFs that are loaded with the NPs.;Nanoparticles were prepared by the emulsion-solvent evaporation method where acetone phase containing the drug and NPs forming polymers were added to water phase containing other additives. Three types of NPs were prepared: empty, loaded and loaded in ODF dispersion. The size, polydispersity index (PI), zeta potential and drug entrapment efficacy (EE) of NPs were measured. The effect of addition rate, agitation rate, viscosity of the continuous phase, PVA hydrolization, PLGA polymerization and the PLGA to PVA ratio on NPs properties was investigated. The nanoemulsions were cast to form films which were studied in vitro and ex-vivo. Furthermore, the mechanism of drug appearance in the receiver of a Franz cell was explored. Films were placed on a pork buccal membrane using a Franz cell and samples were withdrawn at specific time intervals. Samples were divided into two portions; one of them was extracted while the other was not extracted before analysis. The amount of drug in extracted and non-extracted samples was different which indicated that the NPs diffused through the membrane.;The primary screening showed that films with 6% of HPMC E15, 2% PVA 80% and 5% PEG 400 had good properties; 1018.5 N/m2, 750 N and 37 s for TS, FB and DT, respectively. Therefore, these film ingredients were used in later steps to prepare nanoparticles in films.;The nanoparticles physical properties and drug release from the nanoparticles showed a high sensitivity to the materials used and methods of preparation. The prepared NPs size ranged from 180 to 645 nm. The particle size was not changed as the addition rate increases till we get to 2.0 drop/s. In other words, as the hydrolyzation increases the particle size increases. The particle size did not show a pattern that's related to PLGA polymerization. Both the agitation rate and the ratio of PLGA to PVA had a negative effect on the particles size.;In general, all NPs have negative zeta potential ranged between -7.07 and -0.98. Zeta potential was found to decrease (become more negative) when PLGA polymerization increases, PVA hydrolyzation increases or the ratio of PLGA to PVA decreases.;EE was almost constant and not affected by formulation variables and recorded high values (above 90%). EE recorded a huge drop when acetaminophen was dissolved in the aqueous phase rather than being dissolved in the acetone phase.;All films disintegrated in less than one minute, but acetaminophen was not free in the dissolution media, even after 6 days. These results indicate that although the nanoparticles immediately released from the films when impressed in solution, the drug is retained in the nanoparticles for a longer time. The release from the NPs was related to PVA hydrolyzation, PLGA polymerization and the PLGA to PVA ratio.;Finally, from the results we got ex-vivo, and by comparing the extracted and non-extracted samples we were able to estimate the amount of NPs diffused through the membranes. The appearance of the free drug was a factor of two processes; the diffusion through the buccal membrane and the diffusion through NPs. The order of these two processes was related to the NPs properties which were related to PVA hydrolyzation, PLGA polymerization and the PLGA to PVA ratio.;In conclusion, casting PLGA NPs into films could be a new method to introduce NPs into the mouth cavity where the NPs are released within seconds from the films. Then the NPs diffuse through the membrane to the blood stream where they release the drug in a controlled manner.