Formulation and processing of solid self-emulsifying drug delivery systems (HME S-SEDDS): A single-step manufacturing process via hot-melt extrusion technology through response surface methodology

The objective of the current study is the formulation development and manufacturing of solid self-emulsifying drug delivery systems (HME S-SEDDS) via a single-step continuous hot-melt extrusion (HME) process. For this study, poorly soluble fenofibrate was selected as a model drug. From the results of pre-formulation studies, Compritol & REG; HD5 ATO, Gelucire & REG; 48/16, and Capmul & REG; GMO-50 were selected as oil, surfactant and co -surfactant respectively for manufacturing of HME S-SEDDS. Neusilin & REG; US2 was selected as a solid carrier. The design of experiments (response surface methodology) was employed to prepare formulations via a continuous HME process. The formulations were evaluated for emulsifying properties, crystallinity, stability, flow properties and drug release characteristics. The prepared HME S-SEDDS showed excellent flow properties, and the resultant emulsions were stable. The globule size of the optimized formulation was 269.6 nm. The DSC and XRD studies revealed the amorphous nature of the formulation and FTIR studies showed no significant interaction between fenofibrate and excipients. The drug release studies showed significant (p < 0.05) improvement in solubility compared to the pure drug (DE15 = 45.04 for the optimized formulation), as >90% of drug release was observed within 15 min. The stability studies for the optimized formulation were conducted for 3 months at 40 degrees C/75% RH.

Automated summary

The aim of this study was to develop and manufacture solid self-emulsifying drug delivery systems (HME S-SEDDS) using a single-step continuous hot-melt extrusion (HME) process. The formulation was prepared with selected excipients, and the emulsifying properties, crystallinity, stability, flow properties, and drug release characteristics were evaluated. The results showed that the prepared HME S-SEDDS had excellent flow properties, stable emulsions, and improved drug solubility. The optimized formulation exhibited a globule size of 269.6 nm and >90% drug release within 15 minutes. Stability studies were conducted for 3 months at 40 degrees C/75% RH.