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INTRODUCTION OF PHARMACEUTICAL AEROSOL :

 AEROSOL :

An aerosol is defined as a suspension system of solid or liquid particles in a gas. An aerosol includes
both the particles and the suspending gas, which is usually air. Frederick G. Donnan  presumably first
used the term aerosol during World War I to describe an aero-solution, clouds of microscopic particles in
air. This term developed analogously to the term hydrosol, a colloid system with water as the dispersed
medium. Primary aerosols contain particles introduced directly into the gas, secondary aerosols form
through gas-to-particle conversion.

Aerosols are unique among the pharmaceutical dosage forms because they depend on the function
of a container, its valve assembly, and propellants for the physical delivery of the ingredients. The aerosol
container is referred to as a pressurized package. The pressure inside the package is created by the
presence of one or more liquefied or gaseous propellants. When the valve is actuated, the pressure forces
the contents of the package out through the opening in the valve. The physical form of the expelled
contents is a function of the product formulation and the type of valve employed.

Aerosols used to provide an airborne mist are called space sprays and include room disinfectants
and deodorizers. This group of aerosols produce particles that are usually less than 50 μm in size. This will
ensure that the dispersed droplets or particles will remain airborne for a prolonged period of time. A one-
second burst from a typical space spray will produce 120 million particles, of which a substantial number
will remain airborne for an hour.

Aerosols intended to carry the active drug to a surface are called surface sprays or surface coating
sprays. This class of sprays includes products such as deodorant sprays, hair sprays, perfume and cologne
sprays, shaving lathers, paint sprays, and various household products such as spray starch, waxes,
polishes, and cleaners.

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Comparison of Space Sprays, Surface Sprays, and Foam Aerosols

Property Space Sprays Suface Sprays Foam Aerosols


Product Concentrate (%) 2 - 20 20 - 75  
Propellant (%) 70 - 98 25 - 80 6 - 10
Pressure (psig at 70°F) 30 - 40 25 - 55 35 - 55
Particles (μm) <1 - 50 50 - 200  

Pharmaceutical aerosols emit liquid or solid materials in a gaseous medium when they are
actuated. The contents may be a fine mist, a course wet or dry spray, a steady stream, or a stable or fast-
breaking foam. Pharmaceutical aerosols are intended to deliver active drugs for inhalation, nasal, buccal,
and sublingual administration. Aerosols are also available for topical, rectal, and vaginal administration.

Some general advantages of pharmaceutical aerosols include:

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.
Many pharmaceutical aerosols are used for oral (i.e., buccal and
sublingual), nasal, or inhalation administration of vaccines, antiviral compounds, and hormones. These
aerosols provide the advantage of a rapid onset of action and avoid the first pass effect and gastrointestinal
tract degradation.  In some cases, lower drug dosages can be used, which have the additional benefit of
minimizing adverse reactions. 

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AEROSOL FORMULATION :

An aerosol formulation consists of two components: the product concentrate and the
propellant. The product concentrate is the active drug combined with additional ingredients or co-solvents
required to make a stable and efficacious product. The concentrate can be a solution, suspension,
emulsion, semisolid, or powder. The propellant provides the force that expels the product concentrate
from the container and additionally is responsible for the delivery of the formulation in the proper form
(i.e., spray, foam, semisolid).

Active Pharmaceutical Ingredient :-

Active pharmaceutical ingredient first checked for preformulation studies and particle size (D 97)
should be below 10 µm in case of suspension formulation.

Propellants :-
The propellant is used to provide the energy to generate a fine aerosol of drug particles and to
expel the concentrate from the container and deliver to lung. The liquefied compressed gases are mainly
used because discharge of aerosol undergoes evaporation of propellant to give aerosol of very small
particles. A compressed liquefied gas gives consistent pressure throughout the use of content.

A propellant is a chemical with a vapor pressure greater than atmospheric pressure at 40°C
(105°F). Types of propellants commonly used in pharmaceutical aerosols include

 Chlorofluorocarbons
 Hydrocarbons
 Hydrochlorofluorocarbons and hydrofluorocarbons
 Compressed gases

 Chlorofluorocarbon (CFC) propellants

For many years, the chlorofluorocarbon (CFC) propellants P-11, P-12, and P-114 were used in
aerosol products. Their use has been severely curtailed due to their role in depleting the ozone layer of the
atmosphere. Since January 1996, worldwide production of these CFCs has been reduced to only the
amount needed for aerosols used in the treatment of asthma and chronic obstructive pulmonary disease.
Alternatives to P-12 (i.e., P-134a and P-227) have now been developed and are being incorporated in
aerosol formulations. Currently, there are not alternatives for P-11 and P-114. Small amounts of P-11 are

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required in most aerosol suspensions to make a slurry of the active drug and other ingredients. It also is
used to dissolve surfactants in some formulations.

P-11, P-12, and P-114 are the CFCs of choice for oral, nasal, and inhalation aerosols. These
particular chlorofluorocarbon propellants are well accepted due to their relatively low toxicity and
inflammability. The chlorofluorocarbons as a class are inert but P-11 is subject to hydrolysis and will form
hydrochloric acid in the presence of water. The acid increases the corrosion of the container and may be
irritating when applied to membranes. If water is present, P-12 or a mixture of P-12 and P-114 are used.

The CFCs are gases at room temperature that can be liquefied by cooling them below their boiling
point or by compressing them at room temperature. For example, dichlorodifluoromethane (P-12) will
form a liquid when cooled to -21.6°F or when compressed to 84.9 psia at 70°F (psia = pounds per square
inch absolute). These liquefied gases also have a very large expansion ratio compared to the compressed
gases (e.g., nitrogen, carbon dioxide). The usual expansion ratio for liquefied gases is about 1 to 240
which means that 1 mL of liquefied gas will occupy a volume of approximately 240 mL if allowed to
vaporize. Compressed gases have an expansion ratio of about 3 to 10.

Properties of Chlorofluorocarbon Propellants


V.P. 
B.P. Liquid Density 
Name Formula No. @70°F
°F (1 atm) @70°F (g/mL)
(psia)a

Trichloromonofluoromethane CCl3F 11 13.4 74.7 1.485

Dichlorodifluoromethane CCl2F2 12 84.9 -21.6 1.325

Dichlorotetrafluoroethane CClF2ClF2 114 27.6 39.4 1.468

a
psia (pounds per square inch absolute) = psig (pounds per square inch gauge +
14.7)
 Hydrocarbons

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.

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Properties of Hydrocarbon Propellants

V.P. B.P. Liquid Density 


Name Formula No.
@70°F (psia) °F (1 atm) @68°F (g/mL)

Propane C3H8 A-108 124.7 -43.7 0.50

Isobutane C4H10 A-31 45.1 10.9 0.56

Butane C4H10 A-17 31.2 31.1 0.58

Hydrochlorofluorocarbons (HCFC) and Hydrofluorocarbons (HFC)

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.

Properties of Hydrochlorofluorocarbon and Hydrofluorocarbon Propellants

Liquid
V.P.
B.P. Density 
Name Formula No. @70°F
°F (1 atm) @70°F
(psia)
(g/mL)

Chlorodifluoromethane CHClF2 22 -135.7 -41.4 1.21

Trifluoromonofluoroethane CF3CH2F 134a 85.8 -15.0 1.21


Chlorodifluoroethane CH3CCIF2 142b 43.8 14.4 1.12
Difluoroethane CH3CHF2 152a 76.4 -12.5 0.91
Heptafluoropropane CF3CHFCF3 227 57.7 2.3 1.41

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 Compressed Gases

Gases such as nitrogen, nitrous oxide, and carbon dioxide have been used as aerosol propellants for
products dispensed as fine mists, foams, or semisolids. But due to their low expansion ratio, the sprays are
fairly wet and the foams are not as stable as produced by liquefied gas propellants. However, using a
compressed gas that is insoluble in the product concentrate (e.g., nitrogen) will emit the product
concentrate in essentially the same form as it was placed in the container.

The pressure of the compressed gas contained in the headspace of the aerosol container forces the
product concentrate out of the container. But unlike aerosols prepared with liquefied gas propellants, there
is no propellant reservoir. So higher gas pressures are required in these aerosols and the pressure
diminishes as the product is used. These gases have been used for the most part to dispense food products,
dental creams, hair preparations, and ointments.

Properties of Compressed Gases

V.P. B.P. Gas Density 


Name Formula
@70°F (psia) °F (1 atm) @70°F (g/mL)

Nitrogen N2 492 -320 0.97


Nitrous Oxide N2O 735 -127 1.53
CO2 CO2 852 -109 1.53
Solution aerosols are two phase systems consisting of the product concentrate in a propellant, a
mixture of propellants, or a mixture of propellant and solvent. Solvents may also be added to the
formulation to retard the evaporation of the propellant. Solution aerosols can be difficult to formulate
because many propellant or propellant-solvent mixtures are nonpolar and are poor solvents for the product
concentrate. Also, there is a limited number of solvents that can be used. Ethyl alcohol is the most
commonly used solvent but propylene glycol, dipropylene glycol, ethyl acetate, hexylene glycol, and
acetone have also been used.

Stabilizing Agent :-

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Surfactants are used to stabilize the suspension formulation. It also helps in solubilising drug and
prevents crystal growth during the storage period. It improves valve lubrication. Surfactants such as oleic
acid, sorbitan trioleate and soya derived lecithin are highly soluble in CFC but are not soluble in HFAs,
therefore co-solvent are used to dissolve these surfactants in the HFA propellants.

Co-solvent :-

Surfactants are highly soluble in CFC but are not soluble in HFA therefore co-solvent is used to
dissolve the surfactants in the HFA propellants. Ethanol is one of the most commonly used cosolvents in
pMDI formulation. It lowers pressure of HFA propellants which produce smaller particle and more
respirable drug fractions. It can even increase the solubility of certain APIs which the vapour regard to
non-combustibility, toxicological safety, availability and technical suitability in terms of physicochemical
characteristics.

INHALER:-

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An inhaler (puffer or pump) is a medical device used for delivering medication into the body via
the lungs.

It is mainly used in the treatment of asthma and chronic obstructive pulmonary disease.

 Zanamivir, used to treat influenza, must be administered via inhaler.

To reduce deposition in the mouth and throat, and to reduce the need for precise synchronization of
the start of inhalation with actuation of the device, MDIs are sometimes used with a
complementary spacer or holding chamber device.

History

The idea of directly delivering medication into the lungs was based on ancient traditional cures that
involved the use of aromatic and medicinal vapours. These did not involve any special devices beyond the
apparatus used for burning or heating to produce fumes. Early inhalation devices included one devised by
John Mudge in 1778.

It had a pewter mug with a hole allowing attachment of a flexible tube. Mudge used it for the
treatment of coughs using opium. These devices evolved with modifications by Wolfe, Mackenzie (1872)
and better mouth attachments such as by Beigel in 1866. Many of these early inhalers needed heat to
vapourize the active chemical ingredient.

The benefits of forced expiration and inspiration to treat asthma were noted by J. S. Monell in
1865. Chemicals used in inhalers included ammonia, chlorine, iodine, tar, balsams, turpentine camphor
and numerous others in combinations. Julius Mount Bleyer used a variation in 1890 in New York.

 1968, Robert Wexler of Abbott Laboratories developed the Analgizer, a disposable inhaler that
allowed the self-administration of methoxyflurane vapor in air for analgesia.[7] The Analgizer consisted of
a polyethylene cylinder 5 inches long and 1 inch in diameter with a 1 inch long mouthpiece. The device
contained a rolled wick of polypropylene felt which held 15 milliliters of methoxyflurane.

Drugs and therapeutic agents administered by inhalation

Inhalational Bronchodilators Antihypertensives Anti-


anesthetic agents inflammatories

 aliflurane  Arformoterol  Amyl nitrite  Beclometha


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 chloroform  Bitolterol  Iloprost (Prostacyclin) sone

 cyclopropan  Epinephrine  Nitric oxide  Budesonide


e  Fenoterol  Ciclesonide
 desflurane  Formoterol  Cromolyn
 diethyl ether  Ipratropium  Dexamethas
 halothane  Isoetharine one

 isoflurane  Isoproterenol  Flunisolide

 methoxyflur  Levalbuterol  Fluticasone


ane  Metaproterenol  Mometason
 methoxypro e
 Pirbuterol
pane  Nedocromil
 Procaterol
 nitrous oxide  Triamcinolo
 Racepinephrine (ra
 roflurane ne
cemic epinephrine)
 sevoflurane  Salbutamol
 teflurane  Salmeterol
 trichloroethy  Terbutaline
lene
 Tiotropium
 vinyl ether
 xenon

Antimicrobials Pulmonary surfactants Sympathomimetic amines Miscellaneous

 Pentamidine  Beractant  Amphetamine (Benzedr  Aromatic


 Ribavirin  Calfactant ine) ammonia

 Tobramycin  Colfosceril  Levomethamphetamine   Dornase alfa

 Zanamivir  Poractant alfa (Vicks Vapor Inhaler)  Glutathione


 Propylhexedrine (Benze  Insulin
drex)  Methacholin
e

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o Metered-dose inhaler

The most common type of inhaler is the pressurized metered-dose inhaler (MDI) which is made up of 3
standard components- a metal canister, plastic actuator, and a metering valve. H&T Presspart, based in
Blackburn, UK, provide over 75% of the world's can and actuator components to the pharmaceutical
market. The metering valve is supplied by a number of companies including Aptar and Coster. In MDIs,
medication is typically stored in solution in a pressurized canister that contains a propellant, although it
may also be a suspension.[1] The MDI canister is attached to a plastic, hand-operated actuator. On
activation, the metered-dose inhaler releases a fixed dose of medication in aerosol form. The correct
procedure for using an MDI is to first fully exhale, place the mouth-piece of the device into the mouth,
and having just started to inhale at a moderate rate, depress the canister to release the medicine. The
aerosolized medication is drawn into the lungs by continuing to inhale deeply before holding the breath
for 10 seconds to allow the aerosol to settle onto the walls of the bronchittus and other airways of the lung.
Some inhalers are made to act instantly in case of an asthma attack, and others are made to act later.

o Dry powder inhalers

Dry powder inhalers (DPI) release a metered or device-measured dose of powdered medication that is
inhaled through a DPI device.

o Nebulizers

Nebulizers — supply the medication as an aerosol created from an aqueous formulation.

o Nasal

Nasal inhalers contain decongestant drugs to relieve nasal congestion in the upper respiratory tract. The


active ingredient in most decongestants is either pseudoephedrine or phenylephrine. Many are sold over-
the-counter without a prescription

TYPES OF INHALER :

 Pressurized metered dose inhaler (pMDIs)

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 Dry power inhaler (DPIs)


 Nebulizer

Pressurized metered dose inhaler (pMDIs):-

A metered-dose inhaler (MDI) is a device that delivers a specific amount of medication to


the lungs, in the form of a short burst of aerosolized medicine that is usually self-administered by the
patient via inhalation. It is the most commonly used delivery system for treating asthma, chronic
obstructive pulmonary disease (COPD) and other respiratory diseases. The medication in a metered dose
inhaler is most commonly a bronchodilator, corticosteroid or a combination of both for the treatment of

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asthma and COPD. Other medications less commonly used but also administered by MDI are mast cell
stabilizers, such as cromoglicate or nedocromil.

 A metered-dose inhaler consists of three major components; the canister which is produced in
aluminium or stainless steel by means of deep drawing, where the formulation resides; the metering valve,
which allows a metered quantity of the formulation to be dispensed with each actuation; and an actuator
(or mouthpiece) which allows the patient to operate the device and directs the aerosol into the patient's
lungs.The formulation itself is made up of the drug, a liquefied gas propellant and, in many cases,
stabilising excipients. The actuator contains the mating discharge nozzle and generally includes a dust cap
to prevent contamination.

History

Before the invention of the MDI, asthma medication was delivered using a squeeze
bulb nebulizer which was fragile and unreliable. [7] The relatively crude nature of these devices also meant
that the particles that they generated were relatively large, too large for effective drug delivery to the
lungs.[2] Nonetheless these nebulizers paved the way for inhalation drug delivery providing the inspiration
for the MDI.

MDIs were first developed in 1955 by Riker Laboratories, now a subsidiary of 3M Healthcare. At
that time MDIs represented a convergence of two relatively new technologies, the CFC propellant and the
Meshburg metering valve which was originally designed for dispensing perfume. The initial design by
Riker used a glass canister coated with a vinyl plastic to improve its resilience. By 1956 Riker had
developed two MDI based products, the Medihaler-Ept containing epinephrine and the Medihaler-Iso
containing Isoprenaline. Both products are agonists which provide short term relief from asthma
symptoms and have now largely been replaced in asthma treatment by salbutamol, which is more
selective.

Lifespan and replacement

The deposition of the content of drug formulation on the canister surface can result in a shorter
shelf life of an MDI inhaler. Applying a suitable surface coating to the components helps to extend this
shelf life. Over the years a range of coating processes have been developed that can be applied to both the
canister and valve to protect the contents from deposition and degradation. Gas plasma processing is an
industrial technique that is carried out in a vacuum to coat the entire MDI inhaler and involves constant or

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pulsed excitation of gas by either Radio Frequency (RF) or microwave field to produce an energetic
plasma. This coating ensures that the drug formulation does not stick to the interior wall of the
MD inhaler and results in the patient receiving the prescribed dose of medication, whilst also extending
the product's shelf-life.

Propellants

One of the most crucial components of a MDI is its propellant. The propellant provides the force to
generate the aerosol cloud and is also the medium in which the active component must be suspended or
dissolved. Propellants in MDIs typically make up more than 99% of the delivered dose, [11] so it is the
properties of the propellant that dominate more than any other individual factor. This is often overlooked
in literature and in industry because so few propellants are used and their contribution is often taken for
granted. Suitable propellants must pass a stringent set of criteria, they must:

 Have a boiling point in the range -100 to +30 °C. 


 Have a density of approximately 1.2 to 1.5 g cm−3 (approximately that of the drug to be
suspended or dissolved) .
 Have a vapour pressure of 40 to 80 psig.
 Have no toxicity to the patient.
 Be non-flammable  .
 Be able to dissolve common additives (active ingredients should be either fully soluble or fully
insoluble).

Solution and suspension formulations of P MDI


Sr. No. Brand Name Active Dose Type of
Ingredient Formulation
1 Serovent Salmeterol 25μg/dose Suspension
2 Ventoline Albuterol sulfate 100 μg/dose Suspension
3 Qvar Beclomethasone 50 μg/dose Solution

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Dipropionate
100 μg/dose Solution
4 Fluvent HFA Fluticasone 50 μg/dose Suspension
Propionate
125 μg/dose

250 μg/dose
5 Atrovent Ipratropium 20 μg/dose Solution
Bromide

Uses

Metered-dose inhalers are only one type of inhaler, but they are the most commonly used type. The
replacement of chlorofluorocarbons propellants with hydrofluoroalkanes (HFA) resulted in the redesign of
metered-dose inhalers in the 1990s. For one variety of beclomethasone inhaler, this redesign resulted in
considerably smaller aerosol particles being produced, and led to an increase of potency by a factor of 2.6.

 Asthma inhalers contain a medication that treats the symptoms of asthma.


 Metered-dose inhalers can be used to treat COPD, both in stable state and during lung attacks. 
 Dry powder inhalers involve micronised powder often packaged in single dose quantities
in blisters or gel capsules containing the powdered medication to be drawn into the lungsby the user's own
breath. These systems tend to be more expensive than the MDI, and patients with severely compromised
lung function, such as occurs during an asthma attack, may find it difficult to generate enough airflow to
get good function from them.
 A nicotine inhaler allows cigarette smokers to get nicotine without using tobacco, much like
nicotine gum or a nicotine patch. Nicotine inhalers that are marketed as nicotine replacement
therapy should not be confused with electronic cigarettes, which produce vapour. Nicotine inhalers are
also known by their nickname of “the puffer”. These devices are made of thin plastic, sometimes
resembling a cigarette, or a cylinder shape. It contains a porous nicotine filled plug, located in the base of
the product. When you puff on the inhaler, nicotine vapor is inhaled and absorbed in the mouth’s lining.
Every inhaler delivers almost four hundred puffs of this nicotine vapor. It is also healthier than the
traditional cigarette. The nicotine inhaler is also temperature sensitive. In cooler weather, less nicotine is
delivered. The Nicotine Inhaler is considered easier to use than the electronic cigarette as it is usually
disposable, and contains fewer parts than the electronic cigarette. The evidence suggests that the US Food
and Drug Administration (FDA) accepted products such as a nicotine inhaler may be a safer way to give
nicotine than e-cigarettes.

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Dry power inhaler (DPIs):-

A dry-powder inhaler (DPI) is a device that delivers medication to the lungs in the form of a dry
powder. DPIs are commonly used to treat respiratory diseases such
as asthma, bronchitis, emphysema and COPD although DPIs (such as inhalable insulin Afrezza) have also
been used in the treatment of diabetes mellitus.

DPIs are an alternative to the aerosol-based inhalers commonly called metered-dose inhaler (or


MDI). The DPIs may require some procedure to allow a measured dose of powder to be ready for the
patient to take. The medication is commonly held either in a capsule for manual loading or a proprietary
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from inside the inhaler. Once loaded or actuated, the operator puts the mouthpiece of the inhaler into their
mouth and takes a sharp, deep inhalation (ensuring that the medication reaches the lower parts of the
lungs), holding their breath for 5–10 seconds. There are a variety of such devices. The dose that can be
delivered is typically less than a few tens of milligrams in a single breath since larger powder doses may
lead to provocation of cough.

Most DPIs rely on the force of patient inhalation to entrain powder from the device and
subsequently break-up the powder into particles that are small enough to reach the lungs. For this reason,
insufficient patient inhalation flow rates may lead to reduced dose delivery and incomplete deaggregation
of the powder, leading to unsatisfactory device performance. Thus, most DPIs have a minimum
inspiratory effort that is needed for proper use and it is for this reason that such DPIs are normally used
only in older children and adults.

Three types of dry powder inhalers:

 Turbuhaler
 Accuhaler
 Ellipta devices

Lactose

Some powder inhalers use lactose to:

1. Carry the fine particles of the active component (which must be fine to reach its target).
2. Improve the flow-ability of the powder during manufacturing and help handling.
3. Act as a bulking agent.
4. Aid in powder uptake from the device during inhalation and aerosolization.

It has been suggested that such lactose may be harmful to lactose intolerant people, and some


doctors advise patients not to use lactose containing DPIs  to minimize the risk of hypersensitivity
reactions.

Storage

DPI medication must be stored in a dry place in a temperature of not more than 25 °C (77 °F) and
humidity between 40–50% in a sealed packaging, since exposure of the powder to moisture degrades the
ability of the device to disperse its medication as a fine powder upon inhalation. Some medication also
needs photo protection.

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Nebulizer :-

In medicine, a nebulizer or nebuliser (see spelling differences) is a drug delivery device used to


administer medication in the form of a mist inhaled into the lungs. Nebulizers are commonly used for the
treatment of cystic fibrosis, asthma, COPD and other respiratory diseases or disorders.

Analytical nebulizers are another form of nebulizer and are used primarily in laboratory settings
for elemental analysis.

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Nebulizers use oxygen, compressed air or ultrasonic power to break up solutions and suspensions


into small aerosol droplets that can be directly inhaled from the mouthpiece of the device. An aerosol is a
mixture of gas and solid or liquid particles.

History

The first "powered" or pressurized inhaler was invented in France by Sales-Girons in 1858. This


device used pressure to atomize the liquid medication. The pump handle is operated like a bicycle pump.
When the pump is pulled up, it draws liquid from the reservoir, and upon the force of the user's hand, the
liquid is pressurized through an atomizer, to be sprayed out for inhalation near the user's mouth.

In 1864, the first steam-driven nebulizer was invented in Germany. This inhaler, known as
"Siegle’s steam spray inhaler", used the Venturi principle to atomize liquid medication, and this was the
very beginning of nebulizer therapy. The importance of droplet size was not yet understood, so the
efficacy of this first device was unfortunately mediocre for many of the medical compounds. The Siegle
steam spray inhaler consisted of a spirit burner, which boiled water in the reservoir into steam that could
then flow across the top and into a tube suspended in the pharmaceutical solution. The passage of steam
drew the medicine into the vapor, and the patient inhaled this vapor through a mouthpiece made of glass.

The first electrical nebulizer was invented in the 1930s and called a Pneumostat. With this device,
a medical liquid (typically epinephrine chloride, used as a bronchial muscle relaxant to reverse
constriction) was made aerosol by the power from an electrical compressor. As an alternative to the
expensive electrical nebulizer, many people in the 1930s continued to use the much more simple and
cheap hand-driven nebulizer, known as the Parke-Davis Glaseptic.

In 1956, a technology competing against the nebulizer was launched by Riker Laboratories (3M),
in the form of pressurized metered-dose inhalers, with Medihaler-iso (isoprenaline) and Medihaler-epi
(epinephrine) as the two first products. In these devices, the drug is cold-fill and delivered in exact doses
through some special metering valves, driven by a gas propellant technology (i.e. Freon or a less
environmentally damaging HFA).

In 1964, a new type of electronic nebulizer was introduced: the "ultrasonic wave nebulizer". Today
the nebulizing technology is not only used for medical purposes. Ultrasonic wave nebulizers are also used
in humidifiers, to spray out water aerosols to moisten dry air in buildings.

Some of the first models of electronic cigarettes featured an ultrasonic wave nebulizer (having
a piezoelectric element vibrating and creating high-frequency ultrasound waves, to cause vibration and
atomization of liquid nicotine) in combination with a vapouriser (built as a spray nozzle with an
electric heating element).The most common type of electronic cigarettes currently sold, however, omit the
ultrasonic wave nebulizer, as it was not found to be efficient enough for this kind of device. Instead, the

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electronic cigarettes now use an electric vaporizer, either in direct contact with the absorbent material in
the "impregnated atomizer," or in combination with the nebulization technology related to a "spraying jet
atomizer" (in the form of liquid droplets being out-sprayed by a high-speed air stream, that passes through
some small venturi injection channels, drilled in a material absorbed with nicotine liquid).

Types of nebulizers:-

I. Mechanical

I. Soft mist inhaler :

The medical company Boehringer Ingelheim also invented a new device named Respimat Soft


Mist Inhaler in 1997. This new technology provides a metered dose to the user, as the liquid bottom of the
inhaler is rotated clockwise 180 degrees by hand, adding a build up tension into a spring around the
flexible liquid container. When the user activates the bottom of the inhaler, the energy from the spring is
released and imposes pressure on the flexible liquid container, causing liquid to spray out of 2 nozzles,
thus forming a soft mist to be inhaled. The device features no gas propellant and no need for battery/power
to operate. The average droplet size in the mist was measured to a somewhat disappointing 5.8
micrometers, which could indicate some potential efficiency problems for the inhaled medicine to reach
the lungs. Subsequent trials have proven this was not the case. Due to the very low velocity of the mist,
the Soft Mist Inhaler in fact has a higher efficiency compared to a conventional pMDI. In 2000, arguments
were launched towards the European Respiratory Society (ERS) to clarify/expand their definition of a
nebulizer, as the new Soft Mist Inhaler in technical terms both could be classified as a "hand driven
nebulizer" and a "hand driven pMDI".

II. Electrical

1.Jet nebulizer :
The most commonly used nebulizers are jet nebulizers, which are also called "atomizers". [11] Jet nebulizers
are connected by tubing to a compressor, that causes compressed air or oxygen to flow at high velocity
through a liquid medicine to turn it into an aerosol, which is then inhaled by the patient. Currently there
seems to be a tendency among physicians to prefer prescription of a pressurized Metered Dose
Inhaler (pMDI) for their patients, instead of a jet nebulizer that generates a lot more noise (often 60 dB
during use) and is less portable due to a greater weight. However, jet nebulizers are commonly used for
patients in hospitals who have difficulty using inhalers, such as in serious cases of respiratory disease, or
severe asthma attacks. The main advantage of the jet nebulizer is related to its low operational cost. If the
patient needs to inhale medicine on a daily basis the use of a pMDI can be rather expensive. Today several

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manufacturers have also managed to lower the weight of the jet nebulizer down to 635 grams (22.4 oz),
and thereby started to label it as a portable device. Compared to all the competing inhalers and nebulizers,
the noise and heavy weight is however still the biggest draw back of the jet nebulizer. Trade names for jet
nebulizers include Maxin.

1. Ultrasonic wave nebulizer:


Ultrasonic wave nebulizers were invented in 1965 [14] as a new type of portable nebulizer. The technology
inside an ultrasonic wave nebulizer is to have an electronic oscillator generate a high frequency ultrasonic
wave, which causes the mechanical vibration of a piezoelectric element. This vibrating element is in
contact with a liquid reservoir and its high frequency vibration is sufficient to produce a vapor mist. [15] As
they create aerosols from ultrasonic vibration instead of using a heavy air compressor, they only have a
weight around 170 grams (6.0 oz). Another advantage is that the ultrasonic vibration is almost silent.
Examples of these more modern type of nebulizers are: Omron NE-U17 and Beurer Nebulizer IH30.

2. Vibrating mesh technology :


A new significant innovation was made in the nebulizer market around 2005, with creation of the
ultrasonic Vibrating Mesh Technology (VMT). With this technology a mesh/membrane with 1000-7000
laser drilled holes vibrates at the top of the liquid reservoir, and thereby pressures out a mist of very fine
droplets through the holes. This technology is more efficient than having a vibrating piezoelectric element
at the bottom of the liquid reservoir, and thereby shorter treatment times are also achieved. The old
problems found with the ultrasonic wave nebulizer, having too much liquid waste and undesired heating
of the medical liquid, have also been solved by the new vibrating mesh nebulizers. Available VMT
nebulizers include: Pari eFlow, Respironics i-Neb, Beurer Nebulizer IH50, and Aerogen Aeroneb. As the
price of the ultrasonic VMT nebulizers is higher than models using previous technologies, most
manufacturers continue to also sell the classic jet nebulizers

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QUALITY CONTROL OF PHARMACEUTICAL AEROSOLS :

QUALITY CONTROL TESTS : It includes the testing of:-

1. Propellents

2. Valves, Actuator, Dip Tubes

3. Containers

4. Weight Checking

5. Leak Testing

6. Spray Testing

1.Propellents:- All Propellents are accompanied by Specification sheet. 

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Identification – Gas Chromatography.

Purity – Moisture, Halogen, Non-Volatile Residue Determination.

2.Valves, Actuator, Dip-tubes: –

Sampling is done according to standard procedure as found in Military Standards “MIL-STD-


105D”.
For metered dose aerosols test methods was developed by ‘Aerosol Specification Committee’
‘Industrial Pharmaceutical Technical Section ‘Academy Of Pharmaceutical Sciences. The object of this
test is to determine magnitude of valve delivery & degree of uniformity between individual valves.
Standard test solutions were proposed to rule out variation in valve delivery.

Testing Procedure:- Take 25 valves & placed on containers. Filled with specific test solution Actuator
with 0.020-inch orifice is attached. Valve is actuated to fullest extent for 2 sec. Repeat this for total 2
individual delivery from each 25 test units.

 Valve delivery per actuation in µL= Individual delivery wt in mg / Specific gravity of test sol.

 Valve Acceptance:-

54 µL or less –  ± 15%

55 to 200 µL –  ± 10%

 Of 50 delivery

 If 4 or more are outside limits:- valves are rejected

 If 3 delivery are outside limits:- another 25 valves are tested : lot is rejected if more than 1 delivery
outside specification

 If 2 delivery from 1 valve are beyond limits:- another 25 valves are tested : lot is rejected if more
than 1 delivery outside specification.

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1. Containers: –

 Containers are examined for defects in lining. Q.C aspects includes degree of conductivity of
electric current as measure of exposed metals. Glass containers examined for Flaws.

4. Weight Checking: – 
It is done by periodically adding tared empty aerosol container to filling lines which after filling
with concentrate are removed & weighed. Same procedure is used for checking weight of Propellents.

5. Leak Test:- 

It is done by measuring the Crimp’s dimension & comparing. Final testing of valve closure is done
by passing filled containers through water bath.

6. Spray Testing:-

It is done for:

 To clear dip tube of pure propellant & concentrate,

 To check for defects in valves & spray pattern.


 

EVALUATION TEST :

EVALUATION Flammability & Combustibility Flash Point Flame extension, including flashback
Physicochemical Characteristics Vapor pressure Density Moisture content Identification of propellant (s)
Concentrate-propellant ratio Performance Aerosol valve discharge rate Spray pattern Dosage with metered
valves Net contents Foam stability Particle Size determination Leakage Biologic Characteristics

1. Flammability & combustibility: –

 Flash point

 Flash Projection

2. Physicochemical characteristics: –

 Vapor pressure

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 Density

 Moisture content

 Identification of Propellents

3. Performance:-

 Aerosol valve discharge rate

 Spray pattern

 Dosage with metered valves

 Net contents

 Foam stability

 Particle size determination

4. Biological testing:-

 Therapeutic activity

 Toxicity studies
Flame Projection : 
Flame Projection Effect of an aerosol formulation on an open flame. The product is sprayed for
about 4 sec into a flame Depending on the nature of the formulation, the flame is extended, the exact
length is measured with a ruler.

Flash Point : 
Flash Point Determined by using the Standard Tag Open Cup Apparatus. The aerosol product is
allowed to chilled to a temp of about -250F & transferred to test apparatus. The test liquid is allowed to
increase slowly in a temperature & the temp at which the vapor ignites is taken as the flash point.
Calculated for flammable components, which in case of topical hydrocarbons.

Measurement Of Vapor Pressure : 


Measurement Of Vapor Pressure To determine pressure variation from container to container.
Determine by pressure gauge or can puncturing device. Variation in pressure indicates the presence of air
in headspace.

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Measurement Of Density : 
Measurement Of Density Determination 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.

Identification of Propellants : 
Identification of Propellants GC & IR spectroscopy. These methods are used for the identification
as well as measurement for proportion of each components in blend. Moisture Karl Fischer Method GC .

Aerosol Valve Discharge Rate : 


Aerosol Valve Discharge Rate This is determine by taking an aerosol product of known weight and
discharge the content for a given period of time using standard apparatus. By reweighing the container
after the time limit has expired, the change in weight per time dispensed is the discharge rate, which can
then be expressed as grams per second. I

Spray pattern : 
Spray pattern Method is based on the impingement of the spray on a piece of paper that has been
treated with a dye-talc mixture. Depending on the nature of the aerosol, an oil-soluble or water-soluble
dye is used. The particles that strike the paper cause the dye to go into solution and to be absorbed onto
the paper. These gives the record of the spray, which can then be used for comparison.

Dosage With Metered Valve : 


Dosage With Metered Valve Reproducibility of dosage each time the valve is depressed. Amount
of medication actually received by the patient. It is done by assay method. Either by spraying the content
into the solvent or on the material which absorb the API. Which then assay for the content uniformity.

Net content : 
Net content Weight of empty container =W1 gm Weight of the filled container = W2gm
Difference in the weight = W1-W2gm net content. Distractive method: weight the filled container,
dispensing the content and than contents are weigh.

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Foam Stability : 
Foam Stability Visual evaluation Time for a given mass to penetrate the foam Time for a given rod
that is inserted into the foam to fall Rotational viscometer.

Particle Size Determination : 


Particle Size Determination Cascade impector. Operates on the principle that in a stream of
particles projected through a series of nozzles and glass slides at high velocity, larger particles became
impacted first on the lower velocity stages and the smaller particles pass on and are collected at higher
velocity stages. Particle size = 2-8 µ.

Light Scatter Decay : 


Light Scatter Decay As the aerosol settles under turbulent conditions, the change in the light
intensity of a Tindal beam is measured.

Leakage : 
Leakage Select 12 pressurized containers at random, and record the date and time to the nearest
half-hour. Weigh each container to the nearest mg, and record the weight, in mg, of each as W1. Allow the
container to stand in an upright position at room temperature for not less than 3 days, and again weigh
each container, recording the weight, in mg, of each as W2 . 

AEROSOL PACKAGING :

 The Valve Assembly:-

The effectiveness of a pharmaceutical aerosol depends on achieving the proper combination of


product concentrate formulation, container, and valve assembly. The valve mechanism is the part of the
product package through which the contents of the container are emitted. 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.

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.
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:

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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. In some actuators, mechanical breakup devices are also
included. It is the combination of the type and quantity of propellant used and the actuator design and
dimensions that determine the physical form of the emitted product concentrate.

Stem –
The stem supports the actuator and delivers the formulation in the proper form to the chamber of
the actuator.

Gasket –
The gasket, placed snugly with the stem, serves to prevent leakage of the formulation of the valve
is in the closed position.

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.

Mounting Cup –
The mounting cup which is attached to the aerosol container serves to hold the valve in place.
Because the undersigned of the mounting cup is exposed to the formulation, it must receive the same
consideration as the inner part of the container with respect to meeting criteria of compatibility. If
necessary, it may be coated with an inert material to prevent an undesired interaction.

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.

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

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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 hydroalcoholic 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. The chamber is the appropriate volume to allow the product
concentrate to expand into a ball of foam. Foam valves are used for viscous product concentrates such as
creams and ointments because of the large orifice and chamber. Foam valves also are used to dispense
rectal and vaginal foams. If the size of the orifice and expansion chamber are appropriately reduced, a
product concentrate that would produce a foam will be emitted as a solid stream. In this case, the ball of
foam begins to develop where the stream impinges on a surface.

-Metered dose inhaler (MDI) valves (metering 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.

In general, valves should retain the material in the metering chamber for fairly long periods. However, it is
possible for the material in the chamber to slowly return back to the container. The degree to which this
occurs depends on the construction of the valve and length of time between actuations of the valves. Some
valves have been fitted with a "drain tank" to overcome this problem.

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Containers: -

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.

Pressure Limitations of Aerosol Containers


Container Maximum Temperature
Material Pressure (psig) (oF)

Tin-plated steel 180 130

Uncoated glass < 18 70

Coated glass < 25 70

Aluminum 180 130

Stainless Steel 180 130

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Plastic < 25 70

Glass containers would be the preferred container for most aerosols. Glass presents fewer problems with
respect to chemical compatibility with the formulation compared to metal containers and is not subject to
corrosion. Glass is also more adaptive to design creativity and allows the user to view the level of contents
in the container.

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.
Glass containers are generally not used with suspension aerosols because the visibility of the suspended
particles presents an aesthetic problem. All commercially available containers have a 20 mm neck finish
which adapts easily to metered valves.

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
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phenolic resins to decrease the interaction between the aluminum and the formulation. The aluminum can
also be anodized to form a stable coating of aluminum oxide. Most aluminum containers are manufactured
by an impact extrusion process that make them seamless. Therefore, they have a greater safety against
leakage, incompatibility, and corrosion.

Aluminum containers are made with a 20 mm neck finish that adapts to the metered valves. For special
purposes and applications, containers are also available that have neck finishes ranging from 15 to 20 mm.
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 had 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 METHODS OF PHARMACEUTICAL AEROSOL :

Two methods are used to manufacture aerosols:

The cold fill process and the pressure fill process. The cold fill process takes advantage of the property
that some ingredients will liquefy when cooled, and the pressure fill process uses the property that some
ingredients will liquefy when placed under pressure.

Cold filling Method :

In cold filling method the product concentrate are chilled to temperature of -30 to -40°F. The chilled
product concentrate 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. In this method cold temperatures are
used to convert the drug formulation to a liquid phase. Initially, active pharmaceutical ingredient (API)
and solvent are mixed to form either a homogenous suspension or a solution. Simultaneously, the
propellant is placed into a pre-chilled vessel. The low temperature ensures that the propellant is in liquid
form in the batching vessel. The concentrate is then transferred into the manufacturing vessel and the
entire formulation is mixed. In the next step of the cold filling process formulation is dispensed into
appropriate sized canisters by pumping the formulation to a filling head and feeding a predetermined
portion of the chilled liquid formulation into an open canister. The valve is placed on top of each canister
and then crimped into place.

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Pressure filling Method

In this method the product concentrate is filled to the aerosol container through the metering pressure
filling burette at room temperature. In contrast to cold filling, the pressure fill process uses pressure
instead of low temperature to condense the propellant. Pressure filling manufacturing can follow two
methods. In one method, known as two stage pressure filling method, the drug concentrate is placed in an
open canister. A valve is then placed on top of the canister and crimped into position to form the seal. The
propellant is then driven under pressure through the valve and into the canister. Using this method, the
mixing of the concentrate and propellant actually happens in the canister. The other method of pressure fill
manufacturing is referred as single-stage pressure filling. In this process the API and propellant are mixed
and held under pressure in the vessel. An empty canister is then fed onto the filling table and a valve is
placed on top and crimped into place. The complete formulation is then filled under pressure into the
canister.

CONCLUSION:-

An aerosol can have variations in formulation as per the area of application and intention of use. In
short aerosol formulations are the best NDDS for dispensing Active Pharmaceutical Ingredients (API’s) to
the systemic circulation as well as faster local action as compared to OSD. As this dosage form is applied
topically, it does not affect the major organs of the body. It has been concluded that it does not show or
shows minimum hypersensitivity to locally applied area. It shows best bioavailability as compared to the
OSD & desired pharmacological effect. Now a days, new excipients are being used to used get the better
formulation efficacy and for batter patient’s compliance. According to the formulation to be processed, we

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should use specific excipients as conformed by the assay procedure in respective furmularary or
pharmacopoeia. From various excipients like colorants, disintigrants, antiadherants, lubricants,
sweeteners, binders, flavourin agents, glidants, sorbents, preservatives and vehicles, various dosage forms
were formulated as per target and bioavailability. The present review is based on the excipients used in
topical pharmaceutical aerosols and its variations.

The advantages of aerosol administration of drugs and vac- cines for TB treatments are supported
by the different aspects presented in this review. These include:

(1) higher drug con- centrations at the main site of infection limiting systemic side effects, and

(2) enhanced protection with the convential vaccines and possible vaccine strategy using subunit vaccines
for immune- compromised patients. These advantages are not only clinical, but also pharmaceutical
offeringmore stable formulations and dosage forms that can be stored without refrigeration for their use in
regions of the world where the burden of TB infection is high.

REFERENCE :

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