Active Pharmaceutical Ingredient Particles Research Articles

Determining the Impact of Roller Compaction Processing Conditions on Granulate and API Properties: Impact of Formulation API Load.

Previous work demonstrated that roller compaction of a 40%w/w theophylline-loaded formulation resulted in granulate consisting of un-compacted fractions which were shown to constitute between 34 and 48%v/v of the granulate dependent on processing conditions. The active pharmaceutical ingredient (API) primary particle size within the un-compacted fraction was also shown to have undergone notable size reduction. The aim of the current work was to test the hypothesis that the observations may be more indicative of the relative compactability of the API due to the formulation being above the percolation threshold. This was done by assessing the impact of varied API loads in the formulation on the non-granulated fraction of the final granulate and the extent of attrition of API particles within the non-granulated fraction. The influence of processing conditions for all formulations was also investigated. The results verify that the observations, both of this study and the previous work, are not a consequence of exceeding the percolation threshold. The volume of un-compacted material within the granulate samples was observed to range between 34.7 and 65.5% depending on the API load and roll pressure, whilst the API attrition was equivalent across all conditions.

Analysis of Factors Related to Variation in Dissolution Profiles Estimated from Continuously Conducted Dissolution Tests of Generic Products.

The development of generic pharmaceuticals involves a bioequivalence study to ensure the therapeutic equivalence of the test formulation to the original innovative product. The formulation characteristics of generic products are expected to be maintained in the long term after approval. This study analyzed the factors contributing to the changes in the dissolution profiles of approved products during their life cycles. Cumulative data on the dissolution similarity of 1675 products of 127 ingredients tested by official laboratories in Japan were assessed according to Japanese bioequivalence guidelines with slight modifications. The products showing dissimilarities in dissolution profiles were analyzed for reporting year, therapeutic category, co-development, physical properties of the active pharmaceutical ingredient (API), and suspected reasons for dissolution change. The increase in the number of dissimilar products is related to the co-development of generic products. Although the solubility of the API was not associated with the dissolution change in the analysis of the total dissolution data, control of the API particle size is suggested to be important for drugs with poorly soluble APIs. Additionally, a risk factor for dissolution changes in the test solutions at a certain pH was the presence of acidic or basic residues. These results indicate the importance of proper development through a thorough evaluation of the formulation and process factors affecting the dissolution properties throughout the product lifecycle.

Determination of the Solid Content of Active Pharmaceutical Ingredient Powders in Suspension-Type Pharmaceutical Oral Jelly Using Time-Domain NMR.

This study determined the content of solid active pharmaceutical ingredient (API) powders dispersed in suspension-type pharmaceutical oral jellies using a low-field time-domain NMR (TD-NMR). The suspended jellies containing a designated API content were prepared and tested. Acetaminophen (APAP), indomethacin (IMC) and L-valine were used as test APIs. First, this study measured the T2 relaxation rate (the reciprocal of T2 relaxation time) by the Carr-Purcell-Meiboom-Gill (CPMG) pulse sequence, and then evaluated whether the API content could be determined by the acquired T2 relaxation rate. The T2 relaxation rate negatively correlated with API content to a certain extent, but their correlation was not sufficient for achieving a precise determination. Subsequently, the solid-echo pulse sequence measurement was adopted for this study. We found that NMR signals corresponding to solid components strongly correlated with API content. Thus, this method achieved a precise determination of API contents in suspended jellies. In addition, this study confirmed the effect of API particle size on the T2 relaxation rate by using an L-valine-containing jelly: the T2 relaxation rate became faster when a smaller API size was incorporated into the suspended jelly, while there was no difference in terms of the NMR signals measured by solid-echo pulse sequence. From these findings, TD-NMR could be a powerful tool for evaluating the API dispersion state in suspended oral jellies.

A novel mixing rule model to predict the flowability of directly compressed pharmaceutical blends

In the pharmaceutical industry, powder flowability is an essential manufacturability attribute to consider when selecting the suitable manufacturing route and formulation. The selection of the formulation is usually based on the physical and chemical properties of the Active Pharmaceutical Ingredient (API) under consideration. Current industrial practice heavily relies on experimental work, which often results in significant labor and API consumption that results in higher costs. In this study we describe the development of a mixing rule to predict powder blend flowability from the flow properties of the individual components for industrial formulations manufactured via Direct Compression (DC). The mixing rule assumes that the granular solids’ interactions are dominated by cohesive forces but are pragmatic to calibrate from the perspective of the typical data collated in an industrial environment. The proposed model was validated using a range of different APIs and the results show that the model can effectively predict the flowability properties of any formulation across the space of DC-relevant formulation compositions. Finally, a connection between the model and APIs properties (shape and size) was investigated via a linear correlation between the API particle properties and interparticle forces.

Sensitivity of Pharmacokinetics to Differences in the Particle Size Distribution for Formulations of Locally Acting Mometasone Furoate Suspension-Based Nasal Sprays.

To assess bioequivalence of locally acting suspension-based nasal sprays, the U.S. FDA currently recommends a weight-of-evidence approach. In addition to in vitro and human pharmacokinetic (PK) studies, this includes a comparative clinical endpoint study to ensure equivalent bioavailability of the active pharmaceutical ingredient (API) at the site of action. The present study aimed to assess, within an in vitro/in vivo correlation paradigm, whether PK studies and dissolution kinetics are sensitive to differences in drug particle size for a locally acting suspension-based nasal spray product. Two investigational suspension-based nasal formulations of mometasone furoate (MF-I and MF-II; delivered dose: 180 μg) differed in API particle size and were compared in a single-center, double-blind, single-dose, randomized, two-way crossover PK study in 44 healthy subjects with oral charcoal block. Morphology-directed Raman spectroscopy yielded volume median diameters of 3.17 μm for MF-I and 5.50 μm for MF-II, and dissolution studies showed that MF-II had a slower dissolution profile than MF-I. The formulation with larger API particles (MF-II) showed a 45% smaller Cmax and 45% smaller AUC0-inf compared to those of MF-I. Systemic bioavailability of MF-I (2.20%) and MF-II (1.18%) correlated well with the dissolution kinetics, with the faster dissolving formulation yielding the higher bioavailability. This agreement between pharmacokinetics and dissolution kinetics cross-validated both methods and supported their use in assessing potential differences in slowly dissolving suspension-based nasal spray products.

Controlling Microparticle Morphology in Melt-Jet Printing of Active Pharmaceutical Ingredients through Surface Phenomena.

Achieving homogeneity and reproducibility in the size, shape, and morphology of active pharmaceutical ingredient (API) particles is crucial for their successful manufacturing and performance. Herein, we describe a new method for API particle engineering using melt-jet printing technology as an alternative to the current solvent-based particle engineering methods. Paracetamol, a widely used API, was melted and jetted as droplets onto various surfaces to solidify and form microparticles. The influence of different surfaces (glass, aluminum, polytetrafluoroethylene, and polyethylene) on particle shape was investigated, revealing a correlation between substrate properties (heat conduction, surface energy, and roughness) and particle sphericity. Higher thermal conductivity, surface roughness, and decreased surface energy contributed to larger contact angles and increased sphericity, reaching a near-perfect micro-spherical shape on an aluminum substrate. The integrity and polymorphic form of the printed particles were confirmed through differential scanning calorimetry and X-ray diffraction. Additionally, high-performance liquid chromatography analysis revealed minimal degradation products. The applicability of the printing process to other APIs was demonstrated by printing carbamazepine and indomethacin on aluminum surfaces, resulting in spherical microparticles. This study emphasizes the potential of melt-jet printing as a promising approach for the precise engineering of pharmaceutical particles, enabling effective control over their physiochemical properties.

A comparative study of dry and wet top-down milling approaches for the preparation of microparticle suspensions

Top-down milling methods are widely used in the pharmaceutical industry for the micronisation of active pharmaceutical ingredients (APIs). In this work, jet milling (dry milling) and microfluidisation (wet milling) were compared for the comminution of indomethacin and naproxen. A design of experiments (DoE) approach was used to setup the experimental work and determine the parameters that affect the average particle size of the API particles. The same API, excipient combinations, concentration and particle size were targeted to constitute the suspensions with both techniques, and the resultant particle size stability, solid state, and morphology were studied. Both techniques were successful in producing suspensions with a particle size of 1–10 μm and the most stable API solid form. The key parameters to mill particles to the target particle size, and a protocol to produce crystalline particle suspensions were established in this work highlighting the differences between methods.

A Novel Technique to Assess Drug Substance Particle Size in a Complex Inhaled Formulation

Dry powder inhalers, comprising an active pharmaceutical ingredient (API) and carrier excipients, are often used in the delivery of pulmonary drugs. The stability of the API particle size within a formulation blend is a critical attribute for aerodynamic performance but can be challenging to measure. The presence of excipients, typically at concentrations much higher than API, makes measurement by laser diffraction very difficult. This work introduces a novel laser diffraction approach that takes advantage of solubility differences between the API and excipients. The method allows insight into the understanding of drug loading effects on API particle stability of the drug product. Lower drug load formulations show better particle size stability compared with high drug load formulations, likely due to reduced cohesive interactions.

Understanding the role of magnesium stearate in lowering punch sticking propensity of drugs during compression

The sticking of active pharmaceutical ingredient (API) to the surfaces of compaction tooling, frequently referred to as punch sticking, causes costly downtime or product failures in commercial tablet manufacturing. Magnesium stearate (MgSt) is a common tablet lubricant known to ameliorate the sticking problem, even though there exist exceptions. The mechanism by which MgSt lowers punch sticking propensity (PSP) by covering API surface is sensible but not yet experimentally proven. This work was aimed at elucidating the link between PSP and surface area coverage (SAC) of tablets by MgSt, in relation to some key formulation properties and process parameters, namely MgSt concentration, API loading, API particle size, and mixing conditions. The study was conducted using two model APIs with known high PSPs, tafamidis (TAF) and ertugliflozin-pyroglutamic acid (ERT). Results showed that PSP decreases exponentially with increasing SAC by MgSt. The composition of material stuck to punch face was also explored to better understand the onset of punch sticking and the impact of possible MgSt-effected punch conditioning event.

Sorbitol-coated indomethacin and naproxen particles produced by supercritical CO2-assisted spray drying

Co-spraying active pharmaceutical ingredients (APIs) with excipients is a strategy to create excipient matrices containing API particles to address formulation challenges such as the reconstitution of powders into homogeneous suspensions. In this work, indomethacin and naproxen were co-sprayed with/without sorbitol using supercritical CO2-assisted spray drying (SASD), followed by particle collection in a filter paper, and resuspension in an aqueous excipient solution. SASD yielded particles in the range of 0.4–7.6 µm, naproxen crystalline Form 1 particles in an amorphous sorbitol matrix, and a partially crystalline indomethacin-sorbitol mixture. Most naproxen-sorbitol mixtures successfully constituted homogenous microparticle suspensions where sorbitol matrix dissolved upon contact with water releasing naproxen particles, while indomethacin-sorbitol mixtures were not reconstitutable and not studied further. The API-sorbitol interactions were studied in detail by thermal analysis and COSMO-RS modelling. Overall, the work presented herein provides a better understanding of co-spraying of APIs with excipients for the formulation of reconstitutable dried microparticles.

Determination of the physical and mechanical indicators of the polymer base and the optimal method of introducing active pharmaceutical ingredients into the base composition

Treatment of wounds and wound infection remains an urgent medical problem today, especially in conditions of constant hostilities. Hydrogel bandages are quite effective means for local treatment of wounds, which are able to have a complex therapeutic effect and do not require frequent replacement in the process of medical supply to military personnel. Taking into account the relevance of this topic, our research is aimed at developing a hydrogel bandage with lidocaine hydrochloride, ceftriaxone and metronidazole. Aim. To study the physical and mechanical parameters of the polymer base and determine the optimal method for introducing active pharmaceutical ingredients (APIs) into the base composition. Materials and methods. The study materials were APIs (lidocaine hydrochloride, ceftriaxone, metronidazole) and excipients. Physical and mechanical research methods were used in the work. Results and discussion. In order to develop the optimal technology for obtaining the polymer mass and determining technological indicators, we studied the indicators of physical and mechanical properties. Indicators of breaking force and relative elongation depend on such technological characteristics as homogeneity, uniformity of application on the substrate, the absence of air bubbles. It was found that the higher the physical and mechanical parameters, the higher the quality of the polymer mass applied to the substrate. Therefore, after obtaining a homogeneous mass it is necessary to deaerate air bubbles by centrifugation (No. 1-5) at 3000 rpm for 5-10 min. During the study of the ease of application of the polymer mass on the polyethylene terephthalate substrate, it was found that the drying process was affected by the thickness of the layer. It was proven that samples No. 1-5 had a uniform, adhesive layer and could be used for further research. The main technological indicators were the layer thickness of 0.40 mm, the centrifugation time of 5-10 min at 3000 rpm, homogeneity (mixing for 15 min at 36 rpm, an anchor stirrer). It was experimentally found that to obtain a layer thickness of 0.40 mm, it was necessary to apply 0.03 g of the sample per 1 cm2 of the substrate. We proved that polymers in the concentration of 10 % provided the optimal technological indicators. To confirm this, the dependence of the viscosity of the forming solution on the concentration / ratio of polymers was studied. We found that the technological indicators of homogeneity and uniformity directly affected the quality of the resulting product. Taking into account the fact that it was possible to introduce poorly soluble substances into the composition of model samples we conducted an experiment on their sedimentation in a polymer solution. It was found that APIs introduced into the polymer solution had different values of the sedimentation rate (time), which was probably related to the degree of solubility. In addition, the polymer concentration in the forming solutions also affected the sedimentation rate of API. The higher the viscosity, the slower the API particles settled. Conclusions. It has been found in the course of the study that satisfactory indicators of physical and mechanical parameters can ensure the quality of the polymer mass production technology as the base for choosing a polymer coating for obtaining a hydrogel with anesthetic, antibacterial, and antimicrobial effects. The main technological indicators determined are the layer thickness (0.40 mm), the centrifugation time (5-10 min at 3000 rpm), homogeneity (mixing for 15 min at 36 rpm, anchor stirrer). The results obtained will be used to develop the composition and the manufacturing technology for a pharmaceutical composition with lidocaine hydrochloride, ceftriaxone and metronidazole.

Needles to Spheres: Evaluation of inkjet printing as a particle shape enhancement tool

Active pharmaceutical ingredients (APIs) often reveal shapes challenging to process, e.g. acicular structures, and exhibit reduced bioavailability induced by slow dissolution rate. Leveraging the API particles’ surface and bulk properties offers an attractive pathway to circumvent these challenges. Inkjet printing is an attractive processing technique able to tackle these limitations already in initial stages when little material is available, while particle properties are maintained over the entire production scale. Additionally, it is applicable to a wide range of formulations and offers the possibility of co-processing with a variety of excipients to improve the API’s bioavailability. This study addresses the optimization of particle shapes for processability enhancement and demonstrates the successful application of inkjet printing to engineer spherical lacosamide particles, which are usually highly acicular. By optimizing the ink formulation, adapting the substrate-liquid interface and tailoring the heat transfer to the particle, spherical particles in the vicinity of 100 µm, with improved flow properties compared to the bulk material, were produced. Furthermore, the particle size was tailored reproducibly by adjusting the deposited ink volume per cycle and the number of printing cycles. Therefore, the present study shows a novel, reliable, scalable and economical strategy to overcome challenging particle morphologies by co-processing an API with suitable excipients.

Influence of PLGA End Groups on the Release Profile of Dexamethasone from Ocular Implants.

The present study deals with the development of dexamethasone (DM)-loaded implants using ester end-capped Resomer RG 502 poly(lactic acid-co-glycolic acid) (PLGA) (502), acid end-capped Resomer RG 502H PLGA (502H), and a 502H:502 mixture (3:1) via hot melt extrusion (HME). The prepared intravitreal implants (20 and 40% DM loaded in each PLGA) were thoroughly investigated to determine the effect of different end-capped PLGA and drug loading on the long-term release profile of DM. The implants were characterized for solid-state active pharmaceutical ingredient (APIs) using DSC and SWAXS, water uptake during stability study, the crystal size of API in the implant matrix using hot-stage polarized light microscopy, and in vitro release profile. The kinetics of PLGA release was thoroughly investigated using quantitative 1H NMR spectroscopy. The polymorph of DM crystal was found to remain unchanged after the extrusion and stability study. However, around 3 times reduction in API particle size was observed after the HME process. The morphology and content uniformity of the RT-stored samples were found to be comparable to the initial implant samples. Interestingly, the samples (mainly 502H) stored at 40 °C and 75% RH for 30 d demonstrated marked deformation and a change in content uniformity. The rate of DM release was higher in the case of 502H samples with a higher drug loading (40% w/w). Furthermore, a simple digital in vitro DM release profile derived for the formulation containing a 3:1 ratio of 502H and 502 was comparable with the experimental release profile of the respective polymer mixture formulation. The temporal development of pores and/or voids in the course of drug dissolution, evaluated using μCT, was found to be a precursor for the PLGA release. Overall, the release profile of DM was found to be dependent on the PLGA type (independent of subtle changes in the formulation mass and diameter). However, the extent of release was found to be dependent on DM loading. Thus, the present investigation led to a thorough understanding of the physicochemical properties of different end-capped PLGAs and the underlying formulation microstructure on the release profile of a crystalline water-insoluble drug, DM, from the PLGA-based implant.

Co-Crystallization Approach to Enhance the Stability of Moisture-Sensitive Drugs.

Stability is an essential quality attribute of any pharmaceutical formulation. Poor stability can change the color and physical appearance of a drug, directly impacting the patient's perception. Unstable drug products may also face loss of active pharmaceutical ingredients (APIs) and degradation, making the medicine ineffective and toxic. Moisture content is known to be the leading cause of the degradation of nearly 50% of medicinal products, leading to impurities in solid dose formulations. The polarity of the atoms in an API and the surface chemistry of API particles majorly influence the affinity towards water molecules. Moisture induces chemical reactions, including free water that has also been identified as an important factor in determining drug product stability. Among the various approaches, crystal engineering and specifically co-crystals, have a proven ability to increase the stability of moisture-sensitive APIs. Other approaches, such as changing the salt form, can lead to solubility issues, thus making the co-crystal approach more suited to enhancing hygroscopic stability. There are many reported studies where co-crystals have exhibited reduced hygroscopicity compared to pure API, thereby improving the product's stability. In this review, the authors focus on recent updates and trends in these studies related to improving the hygroscopic stability of compounds, discuss the reasons behind the enhanced stability, and briefly discuss the screening of co-formers for moisture-sensitive drugs.

The Rat Continuous Intestine Model Predicts the Impact of Particle Size and Transporters on the Oral Absorption of Glyburide

Oral drug absorption is known to be impacted by the physicochemical properties of drugs, properties of oral formulations, and physiological characteristics of the intestine. The goal of the present study was to develop a mathematical model to predict the impact of particle size, feeding time, and intestinal transporter activity on oral absorption. A previously published rat continuous intestine absorption model was extended for solid drug absorption. The impact of active pharmaceutical ingredient particle size was evaluated with glyburide (GLY) as a model drug. Two particle size suspensions of glyburide were prepared with average particle sizes of 42.7 and 4.1 μm. Each suspension was dosed as a single oral gavage to male Sprague Dawley rats, and concentration-time (C-t) profiles of glyburide were measured with liquid chromatography coupled with tandem mass spectrometry. A continuous rat intestine absorption model was extended to include drug dissolution and was used to predict the absorption kinetics of GLY depending on particle size. Additional literature datasets of rat GLY formulations with particle sizes ranging from 0.25 to 4.0 μm were used for model predictions. The model predicted reasonably well the absorption profiles of GLY based on varying particle size and varying feeding time. The model predicted inhibition of intestinal uptake or efflux transporters depending on the datasets. The three datasets used formulations with different excipients, which may impact the transporter activity. Model simulations indicated that the model provides a facile framework to predict the impact of transporter inhibition on drug C-t profiles. Model simulations can also be conducted to evaluate the impact of an altered intestinal lumen environment. In conclusion, the rat continuous intestine absorption model may provide a useful tool to predict the impact of varying drug formulations on rat oral absorption profiles.

Magnesium stearate surface coverage on tablets and drug crystals: Insights from SEM-EDS elemental mapping

Scanning electron microscopy-based energy dispersive X-ray spectroscopy (SEM-EDS) is proposed as a versatile tool for quantifying surface area coverage (SAC) by magnesium stearate (MgSt) on pharmaceutical tablets and particles. Our approach involved fast elemental mapping and subsequent SAC quantitation by image analysis. The study was conducted using a multi-component system, but the particle-level mapping was limited to active pharmaceutical ingredient (API) crystals. For both tablets and API particles, the calculated SAC against MgSt loading afforded a positive linear correlation over the range of MgSt levels examined in this work. On the tablet surface, MgSt was found to be preferentially concentrated at or in the close vicinity of grain boundaries, supporting the idea of compression-driven migration and relocation of MgSt within the tablet. On the particle surface, only discrete aggregates of MgSt were observed, as opposed to the widely accepted phenomenon of the formation of a thin lubricant film around host particles. The selection of proper SEM-EDS operating conditions and the challenges confronted in particle surface mapping are discussed in detail.

Numerical investigation of powder dispersion mechanisms in Turbuhaler and the contact electrification effect

Powder dispersion in dry powder inhalers (DPI) is affected by factors such as device design and flow rate, but also electrification due to particle–particle/device collisions. This work presented a CFD-DEM study of powder dispersion in Turbuhaler®, aiming to understand the effect of electrostatic charge on the dispersion mechanisms. The device geometry was reconstructed from CT-scan images of commercial Turbuhaler device. Different work functions were applied to the active pharmaceutical ingredient (API) powder and the device wall. Electrostatic charges were accumulated on the API particles due to contact potential difference (CPD) between the particles and the device wall. Results showed that both the chamber and the spiral mouthpiece played an important role in de-agglomeration of powders caused by particle–wall impactions. With increasing flow rates, the performance of the device was improved with higher emitted dose (ED) and fine particle fractions (FPF). The electrostatic charging of the particles was enhanced with higher CPD and higher flow rates, but the electrostatic charging had a minimum effect on powder dispersion and deposition with slight reduction in ED and FPF. In conclusion, the van der Waals force is still the dominant adhesive inter-particle force, and the dispersion efficiency is affected by the flow rate rather than contact electrification of particles. Future work should focus on the effect of highly charged particles emitted from the inhaler on the deposition in the airway.

Varied Bulk Powder Properties of Micro-Sized API within Size Specifications as a Result of Particle Engineering Methods.

Micronized particles are commonly used to improve the content uniformity (CU), dissolution performance, and bioavailability of active pharmaceutical ingredients (API). Different particle engineering routes have been developed to prepare micron-sized API in a specific size range to deliver desirable biopharmaceutical performance. However, such API particles still risk varying bulk powder properties critical to successful manufacturing of quality drug products due to different particle shapes, size distribution, and surface energetics, arising from the anisotropy of API crystals. In this work, we systematically investigated key bulk properties of 10 different batches of Odanacatib prepared through either jet milling or fast precipitation, all of which meet the particle size specification established to ensure equivalent biopharmaceutical performance. However, they exhibited significantly different powder properties, solid-state properties, dissolution, and tablet CU. Among the 10 batches, a directly precipitated sample exhibited overall best performance, considering tabletability, dissolution, and CU. This work highlights the measurable impact of processing route on API properties and the importance of selecting a suitable processing route for preparing fine particles with optimal properties and performance.

Assessing microstructural critical quality attributes in PLGA microspheres by FIB-SEM analytics.

The distribution of the active pharmaceutical ingredient (API) within polymer-based controlled release drug products is a critical quality attribute (CQA). It is crucial for the development of such products, to be able to accurately characterize phase distributions in these products to evaluate performance and microstructure (Q3) equivalence. In this study, polymer, API, and porosity distributions in poly(lactic-co-glycolic acid) (PLGA) microspheres were characterized using a combination of focused ion beam scanning electron microscopy (FIB-SEM) and quantitative artificial intelligence (AI) image analytics. Through in-depth investigations of nine different microsphere formulations, microstructural CQAs were identified including the abundance, domain size, and distribution of the API, the polymer, and the microporosity. 3D models, digitally transformed from the FIB-SEM images, were reconstructed to predict controlled drug release numerically. Agreement between the in vitro release experiments and the predictions validated the image-based release modelling method. Sensitivity analysis revealed the dependence of release on the distribution and size of the API particles and the porosity within the polymeric microspheres, as captured through FIB-SEM imaging. To our knowledge, this is the first report showing that microstructural CQAs in PLGA microspheres derived from imaging can be quantitatively and predictively correlated with formulation and manufacturing parameters.

Modelling Deaggregation Due to Normal Carrier–Wall Collision in Dry Powder Inhalers

Powder deaggregation in Dry Powder Inhalers (DPI) with carrier-based formulations is a key process for the effectiveness of drug administration. Carrier-wall collisions are one of the recognised mechanisms responsible for active pharmaceutical ingredient (API) aerosolisation, and DPI geometries are designed to maximise their efficacy. The detachment of fine and cohesive API particles is investigated at a fundamental level by simulating with DEM the normal collision of a carrier sphere with an API particle attached. The impact velocity at which detachment occurs (escape velocity) is determined as a function of key parameters, such as cohesiveness, coefficient of restitution, static and rolling friction. An analytical model for the escape velocity is then derived, examining the role of the initial position of the particle, cohesion model and particle size. Finally, the results are framed in the context of DPI inhalers, comparing the results obtained with impact velocities typically recorded in commercial devices.