Polynomial models were constructed for the optimisation process by employing a 29-run, 4-factor, 3-level Box–Behnken design using Design Expert software to develop and optimise the inhalable EGCG nano-liposome formulation. The Box–Behnken design was selected, as it demands fewer runs in the case of 3 or 4 independent variables compared with the centre composite design, and its avoids factor extremes, since the range of these factors was determined on the basis of the literature and our screening experiments to be the best acceptable range to achieve our formulation goal [41 ]. Four independent variables were evaluated, namely (A) the total lipid concentration (the total concentration of the two included lipids and cholesterol in the liposome solution, mg/mL), (B) the pH of the dispersion media (the rehydration solution), (C) the molar percentage of cholesterol, and (D) the D/L molar ratio, which is also known as “loading capacity” [42 (
link)]. The 3 levels of each factor were represented as −1, 0, and +1, as depicted in
Table 1.
The variables were selected on the basis of data compiled from a literature review [31 (
link),41 ,43 (
link)]. For example, it was reported that the total lipid concentration affected the encapsulation efficiency in some liposomal formulations [44 (
link)], and that the pH of the dispersion media in the liposome formulations affected their sizes [45 (
link)]. In addition, it was reported that the percentage of cholesterol in the liposome formulations affected the liposomes’ physical stability, including the PDI [43 (
link),46 (
link)]. The D/L molar ratio is considered to be a critical factor that expresses the actual capacity of the liposome to accommodate the drug. Maximising the D:L molar ratio can optimise a liposomal formulation [42 (
link)].
In this research, the range of total lipid concentration (A) was 5–15 mg/mL, since the total concentration of lipids in the majority of liposome formulations in medicines falls within this range [47 (
link)]. The range of pH of the dispersion media (B) was chosen to be between 3 and 6.5 because this range is suitable for the inhalation route [48 (
link)]. The molar percentage of cholesterol (C) in the range of 0–20% was chosen to measure the impact of cholesterol on the stability of the formulation, the encapsulation efficiency, and other independent factors. The molar ratio of DPPG was kept the same (20%) for all the tested formulations in this design, as the presence of the negatively charged lipid, DPPG, ensured a sufficiently negative zeta potential and thus prevented agglomeration of the liposome [49 ,50 ]. When the molar ratio of cholesterol was 0, 10, and 20, the DPPC molar ratio used was 80, 70, and 60, respectively. The D/L molar ratio (D) within the 8–11 range was used, as a higher ratio was shown to formulate unstable liposomes. As was shown in our screening experiments, when the D/L molar ratio for this formulation was higher than 11, agglomeration of the liposomes occurred. The selected responses were as follows: R1, liposome size (z-average, nm); R2, polydispersity index (PDI); R3, encapsulation efficiency (%); R4, zeta potential; R5, PDI after 1 month. The centre point (CP) was run four times to measure the curvature and precision of the production process. All 29 formulations that were proposed by the Design Expert software, as shown in
Table 2, were prepared to generate, evaluate, and analyse the model. Polynomial equations that described the correlation between the dependent and independent variables were obtained.
Haddad F., Mohammed N., Gopalan R.C., Ayoub Y.A., Nasim M.T, & Assi K.H. (2023). Development and Optimisation of Inhalable EGCG Nano-Liposomes as a Potential Treatment for Pulmonary Arterial Hypertension by Implementation of the Design of Experiments Approach. Pharmaceutics, 15(2), 539.