Deagglomeration of selected high-load API-carrier particles in swirl-based dry powder inhalers

Dry powder inhalers' performances rely on the optimal combination of the therapeutic efficacy of the drug (pharmaceutical research) and the effectiveness of the delivery system (device engineering and design). The respirability requirement of API poses serious challenges associated with their poor flowability, so coating of larger carrier particles with hydrodynamic conditions for subsequent deaggregation is often a solution. The presence of high loading on the carrier increases the probability of insufficient deagglomeration or possible reagglomeration. Advanced CFD–DEM simulations are utilized to investigate API deaggregation in a swirl-based DPI from four carrier particles coated with 5% and 10% relative loading. The analysis of the FPF reveals the influence of API dosage and initial location of the particles. The effect of the cohesive/adhesive balance is investigated as well, by comparing budesonide and salbutamol as API. Highly loaded salbutamol is shown to be delivered more effectively, in agreement with previous experimental findings.