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Propellant (%) 70 - 98 25 - 80 6 - 10
apsia (pounds per square inch absolute) = psig (pounds per square inch gauge + 14.7)
The hydrocarbons are used in topical
pharmaceutical aerosols because of their
environmental acceptance and their low toxicity and
nonreactivity. They are also useful in making three
phase (two layer) aerosols because of their density
being less than 1 and their immiscibility with water.
The hydrocarbons remain on top of the aqueous
layer and provide the force to push the contents out
of the container. However, they are flammable and
can explode. They contain no halogens and
therefore hydrolysis does not occur making these
good propellants for water based aerosols.
Propane, butane, and isobutane are the most
commonly used hydrocarbons. They are used alone
or as mixtures or mixed with other liquefied gases
to obtain the desired vapor pressure, density, and
degree of flammability. The flammability hazard has
been substantially reduced by using mixtures of
propellants and with the development of newer
types of dispensing valves (i.e., valve with vapor
tap).
V.P. Liquid
Name of Propellants Formula No. B.P.
@70°Fa °F (1 Density
(psia) atm) @70°F
(g/mL)
apsia (pounds per square inch absolute) = psig (pounds per square inch gauge + 14.7)
The hydrochlorofluorocarbons (HCFC) and
hydrofluorocarbons (HFC) differ from CFCs in that
they may not contain chlorine and have one or more
hydrogen atoms. These compounds break down in the
atmosphere at a faster rate than the CFCs resulting in a
lower ozone depleting effect. P-22, 142b, and 152a are
used in topical pharmaceuticals. These three propellants
have a greater miscibility with water and therefore are
more useful as solvents compared to the other
propellants. They are also slightly more flammable than
the other propellants but this is not perceived as a
disadvantage.
V.P. Liquid
Name of Propellants Formula No. B.P.
@70°Fa °F (1 Density
(psia) atm) @70°F
(g/mL)
apsia (pounds per square inch absolute) = psig (pounds per square inch gauge + 14.7)
The Valve Assembly: The effectiveness of a pharmaceutical
aerosol depends on achieving the proper combination of
product concentrate formulation, container, and valve
assembly. The primary purpose of the valve is to regulate the
flow of product concentrate from the container. But the valve
must also be multifunctional and regulate the amount of
emitted material (metered valves), be capable of delivering
the product concentrate in the desired form, and be easy to
turn on and off. The valve must withstand the pressure
required by the product concentrate and the container, be
corrosive resistant, and must contribute to the form of the
emitted product concentrate. Among the materials used in the
manufacture of the various valve parts are plastic, rubber,
aluminum, and stainless steel.
The basic parts of a valve assembly can be described as:
1. Actuator: The actuator is the button which the user presses to
activate the valve assembly and provides an easy mechanism of
turning the valve on and off.
2. Stem: The stem supports the actuator and delivers the
formulation in the proper form to the chamber of the actuator.
3. Gasket: The gasket, placed snugly with the stem, serves to
prevent leakage of the formulation of the valve is in the closed
position.
4. Spring: The spring holds the gasket in place and also is the
mechanism by which the actuator retracts when pressure is
released thereby returning the valve to the closed position.
5. Mounting Cup: The mounting cup which is attached to the
aerosol container serves to hold the valve in place. If necessary,
it may be coated with an inert material to prevent an undesired
interaction.
6. Housing: The housing located directly below the
mounting cup serves as the link between the dip tube
and the stem and actuator. With the stem, its orifice
helps to determine the delivery rate and the form in
which the product is emitted.
7. Dip Tube: The dip tube which extends from the
housing down into the product concentrate serves to
bring the formulation from the container to the valve.
The viscosity of the product and its intended delivery
to rate dictate the inner dimensions of the dip tube and
housing for a particular product.
Spray valves are used to obtain fine to coarse wet sprays.
Depending on the formulation and the design of the valve and
actuator, the particle size of the emitted spray can be varied.
The spray is produced as an aerosol solution passes through a
series of small orifices which open into chambers that allow
the product concentrate to expand into the proper particle
size.
Vapor tap valves are used with powder aerosols, water based
aerosols, aerosols containing suspended materials, and other
agents that would tend to clog a standard valve. This valve is
basically a standard valve except that a small hole has been
placed into the valve housing. This allows vaporized
propellant to be emitted along with the product concentrate
and produces a spray with greater dispersion. These valves
are used with aqueous and hydro alcoholic product
concentrates and hydrocarbon propellants.
Foam valves have only one orifice that leads to a single
expansion chamber. The expansion chamber also serves as the
delivery nozzle or applicator. Foam valves are used for
viscous product concentrates such as creams, ointments and
are used to dispense rectal and vaginal foams.
Metered dose inhaler (MDI) valves are used to accurately
deliver a dose of medication. Metered valves are used for all
oral, inhalation, and nasal aerosols. The metered valves
reproducibly deliver an amount of product concentrate
accurately from the same package and also allow for the same
accuracy between different packages. Two basic types of
metering valves are available; one for inverted use and the
other for upright use. Generally the valves for upright use are
used with solution type aerosols and contain a thin capillary
dip tube. Suspension or dispersion aerosols use the valve
intended for inverted use that does not contain a dip tube.
Aerosol containers are generally made of glass, metals (e.g.,
tin plated steel, aluminum, and stainless steel), and plastics.
The selection of the container for a particular aerosol product
is based on its adaptability to production methods,
compatibility with the formulation, ability to sustain the
pressure necessary for the product, the design and aesthetic
appeal, and the cost.
Glass containers would be the preferred container for most
aerosols. However, glass containers must be precisely
engineered to provide the maximum pressure safety and
impact resistance. Therefore, glass containers are used in
products that have lower pressures and lower percentages of
propellants. When the pressure is below 25 psig and less than
50% propellant is used, coated glass containers are considered
safe.
To increase the resistance to breakage, plastic coatings
are commonly applied to the outer surface of glass
containers. These plastic coatings serve many purposes:
1) prevent the glass from shattering into fragments if
broken;
2) absorb shock from the crimping operation during
production thus decreasing the danger of breakage around
the neck;
3) protect the contents from ultraviolet light;
4) act as a means of identification since the coatings are
available in various colors.
Glass containers range in size from 15 to 30 mL and are
used primarily with solution aerosols.
Tin-plated steel containers are light weight and relatively
inexpensive. For some products the tin provides all the
necessary protection. However when required, special
protective coatings are applied to the tin sheets prior to
fabrication so that the inside of the container will be protected
from corrosion and interaction between the tin and the
formulation. The coating usually is an oleoresin, phenolic,
vinyl, or epoxy coating. The tin plated steel containers are
used in topical aerosols.
Aluminum is used in most MDIs and many topical aerosols.
This material is extremely light weight and is less reactive
than other metals. Aluminum containers can coated with
epoxy, vinyl, or phenolic resins to decrease the interaction
between the aluminum and the formulation. The container
themselves available in sizes ranging from 10 mL to over
1,000 mL.
Stainless steel is used when the container must be
chemically resistant to the product concentrate. The
main limitation of these containers is their high cost.
Plastic containers have limited success because of
their inherent permeability problems to the vapor
phase inside the container. Also, some drug-plastic
interactions have limited the efficacy of the product.
Filling and Packaging Operations: Two methods
are used to manufacture aerosols: The cold fill
process and The pressure fill process.
Cold filling method : Two methods are involved: v In the first
method, the product concentrates are chilled to a temperature of
– 30 to – 400 F. The chilled product concentrates are added to the
chilled aerosol container. The chilled propellant is added through
an inlet valve present under side of the valve of the aerosol
container. v In the second method, both the product concentrate
and the propellant are chilled to – 30 to – 400 F. Then the mixture
is added to the chilled container. In both the above methods,
after the aerosol containers are filled, the valves are set in its
place and the filled aerosol containers are passed through a water
bath in which the contents of the containers are heated to 130 0 F
to test for leaks and strength. Then the containers are air dried,
capped and labelled. Cold filling method is advantageous for the
filling of metering valve containing aerosol container. The
pressure filling method is more prominent than cold filling
method as most of the formulations cannot be cooled to very low
temperatures
Pressure filling is carried out essentially at room
temperature. The product concentrate is placed in
the container, the valve assembly is inserted and
crimped into place, and then the liquefied gas, under
pressure, is added through the valve. After the
filling operation is complete, the valve is tested for
proper function. This spray testing also rids the dip
tube of pure propellant prior to consumer use.
Pressure filling is used for most pharmaceutical
aerosols.
A. Flammability and combustibility:
1. Flame extension
2. Flash point
B. Physiochemical characteristics:
1. Vapor pressure
2. Density
3. Moisture content
4. Identification of propellant(s)
C. Performance:
1. Aerosol valve discharge rate
2. Spray pattern Dosage with metered valves
3. Net contents
4. Uniformity of delivered dose
5. Particle size determination
6. Leakage
D. Stability testing
Flame extension: This test indicates the effect of an
aerosol formulation on the extension of an open flame.
Product is sprayed for 4 sec. into flame. Depending on
the nature of formulation, the flame is extended, and
exact length was measured with ruler. 20cm for
combustible and 45cm for flammable.
Flash point: Determined by using standard Tag Open
Cap apparatus. PROCEDURE: Aerosol product is
chilled to temperature of - 25 0 F and transferred to the
test apparatus. Temperature of test liquid increased
slowly, and the temperature at which the vapors ignite
is taken a flash point.
Vapor pressure: Determined by pressure gauge.
Variation in pressure indicates the presence of air in
headspace.
Density: Determined by Hydrometer or a
Pycnometer. Procedure: A pressure tube is fitted
with metal fingers and hoke valve, which allow for
the introduction of liquids under pressure. The
hydrometer is placed in to the glass pressure tube.
Sufficient sample is introduced through the valve to
cause the hydrometer to rise half way up the length
of the tube. The density can be read directly.
Moisture content: (Karl Fischer method): Iodine
produced at anode reacts with the water present in the
sample. When all has been consumed, excess of iodine
is detected electrometrically and that is the indication
of end point. For propellants 10ppm.
Identification of propellants: By using G.C, I.R
spectrophotometry.
Dosage with Metered valves: Dosage with Metered
valves Weigh accurately the filled container. Dispense
no. of doses. Reweigh the container & calculate the
weight difference. Weight diff/ No. of times dose
dispensed gives avg. dose. We should note the time of
the each dose dispensed also. Dose is measured in
gms/sec.
Spray pattern: By TLC
Net content: weigh ten full containers, empty each container
through the valve, open each container and wash thoroughly
and dry each container, valve and all associated parts. Weigh
the containers, valves and all associated parts. The difference
in the weight of the full container and tarred container gives
the content in the container. Net wt. = gross wt. – Tare wt.
Foam stability: Foam stability It can be determined by visual
examination Time for given mass to penetrate the foam Time
for given rod that is inserted in the foam to fall. Use of
rational viscometers.
Particle size determination: Particle size determination It is
done by microscopy, cascade impactor, glass impinger, time
of flight, laser diffraction, phase doppler analysis, optical
particle counter & light scatter decay methods.
Leakage test: Leakage test Aerosol containers are
completely immersed in hot water bath until temp.
reaches 54.4ºc and is tested for leakage. Leakage rate =
365 x 24/T x (W1 – W2) and Net fill weight = (w1 – w3)
The requirements are met if the average leakage rate of
12 containers is not more than 3.5% of the net fill
weight per year and none of the containers leaks more
than 5% of the net fill weight per year. If one container
leaks more than 5% per year, and none of the containers
leaks more than 7% per year, leakage rate of additional
24 containers is determined. Not more than 2 out of 36
containers should leak more than 7% of net fill weight
per year.
1. Aerosols are easy to use. Medication is dispensed at the push
of a button. No ancillary equipment is needed.
2. Aerosol application is a clean process which requires minimal
patient cleanup after using the product.
3. A portion of medication may be easily withdrawn without
contaminating the remaining material. If the product is sterile,
sterility can be maintained throughout the product's shelf life.
4. The active drug is protected from oxygen and moisture. The
usual aerosol container is opaque, which also protects the drug
from light.
5. By proper formulation and valve control, the physical form
and the particle size of the emitted product may be controlled.
6. If the dosage must be regulated, a metered dose valve can be
used which will control the accuracy of the administered dose.
Aerosols are used to deliver active drugs to the pulmonary
airways, the nasal passages, or the oral cavity. They are also
used to administer drugs topically and into body cavities such
the vagina and rectum.
Inhalation therapy: (i.e., drug delivery to the pulmonary
airways and nasal passages): MDIs are the most commonly
used product for inhalation therapy. Nasal aerosols deliver
the drug directly to the nasal mucosa. The most common
nasal aerosols contain steroids used to treat nasal congestion,
sneezing, and running nose associated with hay fever,
allergies, and rhinitis. Aerosols used to deliver drugs to the
oral cavity generally administer the product sublingually.
One such product is a sublingual nitroglycerin formulation
that is sprayed under the tongue and delivers 0.4 mg of
nitroglycerin per actuation.
Topical aerosol formulations are available for local
anesthetics, antiseptics, germicides, first aid
preparations, and spray on protective films. These
aerosols deliver particles that are larger and more
course than the inhalation aerosols. Topical aerosols
deliver the active drug in the form of a powder, a wet
spray, a stream of liquid, or an ointment like product.
Vaginal and rectal foams are available that contain
estrogens, contraceptives, and anti-inflammation
agents. These products are packaged in containers that
have an application device which is filled with foam
when the valve is actuated and then the device is placed
in the vagina or rectum and the foam is instilled with
the device plunger.