Budesonide

Liposomes are promising carriers for pulmonary drug delivery due to their biocompatibility and controlled-release properties. However, their stability in aqueous suspension is limited, leading to aggregation and reduced therapeutic efficiency. Converting liposomal dispersions into dry powders for inhalation (DPIs) is a potential strategy to overcome these limitations. Spray-drying (SD) is particularly attractive for this purpose, offering precise control over particle properties along with speed, cost-efficiency, and scalability. Yet, the thermal and mechanical stresses involved in this process and their effects on liposomal integrity remain poorly understood, limiting its broader application. In this study, we developed a systematic framework integrating Design of Experiments (DOE) with scale-up-oriented processing, combining supercritical fluid technology (PGSS) for liposome formation with subsequent spray-drying of high solid content suspensions. Two complementary DoE approaches were applied: DOE_A optimized drying parameters and carbohydrate type, testing trehalose and hydroxypropyl-β-cyclodextrin (HPβCD), while DOE_B assessed the effects of active pharmaceutical ingredients (APIs) hydrophobicity, lipid composition (1,2-Distearoyl-sn-glycero-3-phosphoethanolamine-N-[methoxy(polyethylene glycol)-₂₀₀₀ (DSPE-PEG₂₀₀₀) percentage), and carbohydrate-to-liposome ratio. Optimized spray-dried powders exhibited preserved liposome structure (mean diameter < 200 nm, narrow polydispersity index (PdI), near-neutral zeta potential (ZP)), favorable aerodynamic properties (∼3 µm, extra-fine particle fraction (eFPF) > 20% and fine particle fraction (FPF) > 60%), low residual moisture (<5%), and high drying yields (>75%). Mechanistic insights revealed that HPβCD significantly protects liposomes during atomization, while drug retention was governed by PEGylated lipid content, lipid-to-carbohydrate ratio, and API hydrophobicity. Co-encapsulation of clinically relevant drug combinations (formoterol/budesonide and ciclesonide/indacaterol) produced uniform powders with efficient aerosolization, highlighting the therapeutic potential of these formulations. Collectively, these results establish a robust, scalable, and reproducible approach for designing liposomal DPIs, balancing formulation composition, excipient selection, and process parameters. This study demonstrates that strategic integration of scalable technologies can reconcile structural stability, aerodynamic performance, and manufacturability, paving the way for the industrial translation of liposomal dry powders for targeted pulmonary therapies, including asthma and chronic obstructive pulmonary disease (COPD).

Oral drug delivery is a widely used method of drug administration; however, achieving localized drug release at specific regions of the gastrointestinal (GI) tract is generally accomplished by using broad environmental differences. The GI tract is a complex system with regional differences in composition, such as selective expression of mucin glycoproteins in different organs. Here, we identify small molecule ligands that can selectively bind to the different mucins to localize drug delivery to the small intestine and stomach. We demonstrate up to a 10-fold increase in particle binding to these organs and up to a 4-fold increase in selectivity compared to chitosan. Additionally, we observe up to a 9-fold increase in budesonide concentration in the small intestine and a 25-fold increase in tetracycline concentration in the stomach. These results show that we have developed a versatile platform capable of sequestering a variety of drugs in certain GI tract organs.