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Solubility enhancement of a poorly water-soluble anti-malarial drug: experimental design and use of a modified multifluid nozzle pilot spray drier.

A modified multifluid nozzle spray drier was used to prepare drug containing microparticles of a poorly water-soluble anti-malarial drug, artemisinin (ART) with the aim of improving its solubility. We investigated the spray drying of ART with maltodextrin (MD) via a full factorial experimental design considering the effect of drying temperature, feed ratio (ART:MD), feed flow rate and pressure on the physical properties and solubility of spray-dried ART. Characterization of the ART powder, spray-dried ART microparticles and spray-dried ART-MD were analyzed by scanning electron microscopy (SEM), differential scanning calorimetry (DSC), Fourier transform infrared (FT-IR) spectroscopy, X-ray diffraction (XRD) and solubility. DSC and XRD studies suggested that the crystallinity of spray-dried particles was decreased with increasing inlet temperatures and flow rate. The particle size of spray-dried ART microparticles was found to be dependent on inlet temperature, flow rate, pressure and feed ratio. The solubility of spray-dried ART particles in composites was markedly increased as compared to commercial ART. A solubility surface-response model was regressed and statistically assessed before elucidating the significant and direct relationships between inlet temperature and feed rate on one hand and solubility on the other. An optimal pressure condition was observed while feed ratio had relatively reduced effect on solubility. The model was also used in an optimization exercise identifying the optimal solubility to be 66.2 +/- 7.17 microg/mL under the calculated spray drying conditions of: inlet temperature = 140 degrees C, feed ratio (ART:MD) = 0.1, feed flow rate = 250 mL h(-1), and pressure = 1.38 bar.