Development of β‐carotene aerosol formulations using a modified spray dryer

Abstract

Abstract The objective of this study was to develop β‐carotene inhalable powders through a modified spray drying process. The conventional spray dryer nozzle was replaced with a nebulizer. The core (β‐carotene) to wall (HPβCD) ratio was varied (1:10, 1:25, and 1:50) to determine its effect on physical properties, aerosolization, and morphology of the powders. Scanning electron microscopy images of particles confirmed the formation of spherical particles with porous surface, with geometric diameters ranging from 2.9 to 3.8 μm. The particles exhibited low density and excellent flowability. Core to wall ratios showed a narrow range of mass median aerodynamic diameters of 3.02, 2.82, and 2.85 μm for 1:10, 1:25, and 1:50, respectively. Around 73–81% of powder was emitted from the dry powder inhaler for all core to wall ratios. The in vitro release of β‐carotene inhalable powder was studied with TRIS buffer for 12 h; it was found that in 1:50 formulation powders, the release was slow and sustained as compared to other formulations, and the release was found to be via diffusion. This approach can be used for developing a range of bioactive inhalable powders for dry powder inhalation applications. Practical Applications Development of β‐carotene inhalable powder by modified spray dryer is helpful in achieving the required aerodynamic properties. By using this method nutrients can be supplemented through lungs in the form of aerosol for effective absorption of the same in blood. This approach can be used for developing a range of bioactive inhalable powders for dry powder inhalation applications.