Innovative Drug Delivery System Oral Fast Dissolving Film:
A Comprehensive Review
Akash Rathod*, Mitesh Sonawane, Kirti Pawar, Vikash Nikam, Akash Tamboli
Loknete Dr. J. D. Pawar College of Pharmacy, Manur, Kalwan, Nashik. 423501.
*Corresponding Author E-mail: akashrathod5848@gmail.com
ABSTRACT:
In an effort to guarantee patient acceptability, safety, efficacy, and compliance, companies and researchers have been working on developing innovative drug delivery methods for the past few decades. The creation of new drugs takes a lot of money, effort, and time these days, but the trend is toward innovative medication delivery methods. Through a variety of methods, this delivery system facilitates both local and systemic drug response. The oral fast-dissolving film preparation (OFDFs) using this innovative method aids patients who are immobile, elderly, and pediatric. The goal of this review study is to provide information about potential therapeutic candidates and polymers for use in OFDFs, as well as specifics about the creation, information and examination of OFDFs. It also focuses on both positive aspects and drawbacks that have an impact on the film's formulation. These films have good patient compliance, are pharmacoeconomic, and can be administered on their own. Oral fast dissolution films can be formulated using a variety of methods, the best of which being the solvent casting process. Buccal films are often made of hydrophilic polymers and other excipients, which dissolve fast and release the integrated APIs in a matter of seconds. There is potential for market and business development with oral fast dissolving films since they have many advantages in terms of accessibility, administration and withdrawal, retentivity, low enzymatic movement, economy, and high patient compliance. The mechanism of action, benefits, composition, formulation, evaluation, packaging and marketed formulations of oral fast dissolving films are highlighted in this prepared review. covers the topics around cutting-edge quick-solving methods as well.
KEYWORDS: Oral Fast Dissolving Film, Composition If Formulation, Manufacturing Technique, Evaluation Parameters, and Packaging.
INTRODUCTION:
Proteins and carbohydrates make up the thirty to forty cell thick stratum that makes up the mucosal epithelium of oral cavity. The gel-like substance known as mucus is released by the mucosal epithelium. It's made primarily of water (90-99%), with the other components including enzymes, nucleic acids, glycoproteins, and electrolytes that are not soluble in water. Conversely, every 60 seconds, 1-2 milliliters of saliva are secreted by the glands that produce saliva near the sublingual canals, which is released via the salivary ducts along with parotid. Saliva serves as a barrier and is composed of coagulation factors, mucus, mineral salts, immunoglobulin, lysozymes, water and amylase. There are two sections of the mucosal epithelial layer: a lipophilic and a hydrophilic section. The mucosa membrane present in mouth cavity has about four to four thousand times more penetrating capacity than the skin and is more permeable than the gut and epidermis. There are two ways that medications can be absorbed through the mucosal epithelial layer: through the cell to cell (transcellular) and through intracellular space (paracellular pathways). The ability of medications to be absorbed is determined by their amphiphilic, hydrophilic, or hydrophobic properties. The polarity of the intracellular environment promotes hydrophilic drug penetration, whereas lipid-based structure promotes pharmaceutical compounds possessing a significant coefficient of partition1,2.
The oral method is the most effective and recommended method for administering medication to people in order to relieve pain. It also helps a number of drug candidates achieve their desired effects additionally ensure patient compliance. Oral drug delivery systems are used in the preparation of medications intended to be taken orally. This method of administering drugs allows for easier manufacturing at a lower cost because it does not require sterility condition3,4. There are a number of manufactured pharmaceutical products on the market right now that come in tablet, powder, liquid, capsule, granule, and syrup form. Patients who are young, old, or paralyzed may find it difficult to take pills or capsules because of swallowing issues that make it impossible to provide medications in solid dose forms5. In order to address these issues, a novel dosage form that delivers medications orally without the use of water has been developed with the goal of doing so rapidly and effectively. We have called this new dosage form the OFDFs drug delivery technique. By delivering medications towards location of action more rapidly additionally in effective way with quick disintegration and dissolution without requiring swallowing and chewing, this strategy helps to ensure patient compliance 6.
Oral films with rapid disintegration have replaced oral tablets as the preferred mode of drug delivery for oral medications. This innovative drug delivery technique allows for drug release with a modified dosage form. Oral films may be stored for extended periods of time and are flexible, making them easier to handle and handle than regular tablets, which readily broke down as well as necessitate extensive taking care of packaging, keeping, additionally shipping7. Oral fast dissolving films, as defined by the Formulations are listed in the European Pharmacopoeia, ninth edition (Ph. Eur) meant the for oral administration of medication through the mouth cavity. According to the Ph. Eur., the primary component of OFDFs is a polymer that has the capacity to films, which functions as a drug carrier or active ingredient in pharmaceuticals. Additionally, plasticizers are employed to guarantee the prepared films' flexibility 8.
Oral fast dissolving films (OFDFs) are a kind of dose form that a patient can take without the need for water. This is because OFDFs are made of polymers that break down quickly in the saliva and dissolve quickly, making them easy to dissolve and absorb through the tongue or oral cavity. Following mucosal absorption, the medication passes through the mouth cavity's thin membranes and becomes instantly accessible because of the quick Flow of blood. The FDA refers to OFDFs as Forms of dosage that include more than one APIs and are sufficiently flexible to promptly dissolve in saliva when applied to the buccal cavity. Because the buccal mucous membrane possesses numerous blood arteries and a thinner membranes layer features which promote high bioavailability it has a greater ability to penetrate. The drug's components become more systemically bioavailable as it penetrates the body, avoiding the first pass metabolism. OFDFs are often constructed of a thin polymer layer that can be manufactured with or without plasticizers. They are also typically flexible. They reduce discomfort in order to increase patient compliance. Across a wide range of problems with traditional dosage forms, OFDFs have been shown in the literature to reduce dosage frequency, enhance duration of effects, improve early medication effects, and aggregate pharmacological efficacy. Drug side effects are decreased, drug metabolism is boosted, this novel drug delivery technique (film technology) increases drug bioavailability and improves absorption. This is the most significant benefit. OFDFs enhance the stability of medication formulations and offer quick dissolving and suitable drug loading capacities. Moreover, they are biodegradable, biocompatible, and non-toxic9-12.
OFDFs are now widely used, more widely accepted, and acknowledged as practical oral drug carriers in the pharmaceutical sector. The development of a wide variety of OFDFs has been facilitated by the availability of several polymers and production technology. According to the European Medicines Agency (EMA), OFDFs have quick bioavailability and dissolve readily in the mucosal layer when they come into contact with saliva, taking anywhere from a few seconds to a minute 10.
Table 1. OFDFs are marketed as over-the-counter and prescription medications.
Brand Name |
API |
OFDF Use |
Category |
Reference |
Risperidon hexal |
Risperidone |
For treating schizophrenia |
R x |
1 |
Gas-X Thin Strips |
Simethicone |
For reducing bloating |
O T C |
10 |
Chloraseptic Sore Throat Relief Strips |
Benzocaine |
For sore throat relief |
O T C |
15 |
Orajel Kids Sore Throat Relief Strips |
Benzocaine |
For children’s sore throat relief |
O T C |
16 |
Snoreeze Oral Strips |
Peppermint oil, vitamin E |
For snoring relief |
O T C |
16 |
Benadryl Allergy quick dissolve strip |
Diphenhydramine HCL |
For allergy |
O T C |
16 |
Pedia-Lax Quick Dissolve Strip |
Sennosides |
For treating constipation |
O T C |
17 |
Supress Cough Strips |
Menthol |
For cough |
O T C |
18 |
Sudafed PE |
Phenylephrine HCL |
For relief of stuffy nose |
O T C |
19 |
Theraflu Thin Strips multi symptom |
Diphenhydramine HCL |
For the common cold |
O T C |
18 |
Zuplenz |
Ondansetron |
For nausea and vomiting |
R x |
16 |
NiQuitin |
Nicotine |
For nicotine withdrawal symptoms |
R x |
19 |
Zolmitriptan oral film |
Zolmitriptan |
For migraine |
R x |
19 |
Sildenafil Sandoz Orodispersible Film |
Sildenafil |
For treating erectile dysfunction |
R x |
20 |
IvyFilm |
Hedera helix extract |
For relief of productive cough |
O T C |
20 |
Clobazam OSF |
Clobazam |
Used to treat seizures |
R x |
20 |
The first prescription OFDF, which uses API as an ondansetron (Zuplenz), was approved by the Food and Drug Administration in 2010. Suboxone was the second OFDF to receive approval from the FDA. Listerine OFDFs have now gained popularity all over the world and are now sold as breath fresheners. There are a number of OFDFs on the market right now, and physicians recommend them. Table 1 contains a list of some of the OFDFs that are marketed as over-the-counter and prescription medications. OFDFs are produced as big sheets that be trimmed to the appropriate size and dosage13. OFDFs for a variety of medications with either systemic or local activity have been developed. OFDFs are utilized for oral ulcers, cold sores, toothaches, and local anesthesia 14. They are used to treat pain, nausea, vomiting, gastrointestinal problems, sore throats, coughs, and central nervous system illnesses.
Figure 1. Diagram showing the administration and release of oral fast dissolving film (OFDF) (A) Opening the sealed ODF container, applying it to the upper side of tongue without any fluids, and telling the user to avoid mastication (B) Salivation aquation, breaking down, and ODF dissolution (C): Due to the pH variation of the gastro-intestinal tract, Saliva naturally ingests dissolved ODF, which then makes its way to the stomach for systemic absorption126.
Oral Fast Dissolving Films (ofdf):
A dosage form can instantly hydrate, adhere, and dissolve to deliver the medication when it is placed on the surface of the tongue or in the oral cavity. This kind of dosage form is called as a strip or film and is typically made of a hydrocolloid, though it can also be a bioadhesive polymer21,22. They are also known as oral-dissolving, fast-melting, quick-dispersing, and fast-dissolving films23. OFDF can offer a practical and efficient way to get active substances, like medicinal compounds and breath fresheners, into the mucosa of both people and animals24. It makes it possible to administer the medication sublingually, buccally, or intragastrically to the bloodstream25. Rapid medication absorption through the sublingual route is possible as soon as OFDF are taken, which ultimately results in a speedy beginning of pharmacological action. When creating OFDF, it is essential to select the right one integrated excipient and or ingredients because OFDF must dissolve and/or disintegrate rapidly in the buccal cavity. Based on its intended purpose, the formulation may contain additional ingredients in addition to the water-dissolving polymer26, namely.
Figure 2. OFDF127.
Special Features of OFDF27,28
1. An elegantly thin narrow or film.
2. Comes in a variety of shapes and sizes.
3. Unobtrusive.
4. Enhanced adherence of mucosa.
5. Quick breakdown and disintegration.
6. Fast drug release.
7. Avoid first pass effect.
Merits and Demerits:
Merits29,30,31,32,33
1. The medication directly reaches the systemic circulation, avoiding the first-pass impact. Many medications, including peptides steroids and other proteins, and insulin may not stable when they come into contact with the gastrointestinal tract's digestive secretions. Moreover, Neither the speed at which food is consumed nor the timing of stomach emptying influences the rate of drug absorption.
2. A greater surface area in the mouth cavity promotes quick dissolution and disintegration.
3. Oral films are less fragile than OFDTs because they are more flexible. Transportation, as well as the processing and storage of consumers, are thereby made simpler.
4. The bitter flavor is concealed by using the flavor-masking technique of medications and achieve a pleasant taste instead. Therefore, these are used in pediatrics.
5. Because there is less discomfort, there is greater patient compliance associated with injections, the ability to provide drugs to unconscious or the patients under coma, and the convenience of intake of medicine in comparison to an injection and medicine.
6. The low water demand and ease of swallowing have led to higher levels of acceptability among dysphagic patients.
7. Beneficial for situations where a quick response is necessary, such motion sickness, sudden allergic reactions, coughing, bronchitis, or asthma.
8. Increase buccal bioavailability of substances which are affected by first-pass metabolism.
9. Reducing the dosage by avoiding the first-pass metabolism may lessen the adverse effects of the compounds.
10. OFDFs are easier for geriatric, paediatric, and paralyzed patients to ingest without water and without choking hazards, which increases patient compliance.
11. Remain stable for a longer period of duration or time because the medication is consumed in a solid dosage form. till it is finished.
12. Lowering the dosage improves the medication's safety and efficacy while minimizing negative effects.
Demerits29,30,31,34
1. There is no way to incorporate high doses.
2. Rapid drug clearance for local action is brought on by continual salivation (0.5-2L/day), which subsequently dilutes the medication and requires frequent administration.
3. Because OFDFs are water-soluble and prone to degradation, they are difficult to protect.
4. They require particular packing and storage equipment.
5. OFDFs are unable to contain medications that are absorbed through active diffusion.
6. Consumption of food and drinks could be restricted.
7. Drugs that irritate the mucosa, this route cannot be used to deliver anything bitter, disagreeable, or odorous.
Classification of OFDF35
Flash release wafer.
Mucoadhesive melt-away wafer.
Mucoadhesive sustained release wafer.
Mechanism of buccal absorption:
The process of buccal medication absorption is primarily driven by concentration gradients and involves nonionized molecules passively diffusing across the intercellular pores in the epithelium. Passive transfer of not-ionic molecules is the primary pathway of transport through the lipid membrane of the buccal cavity. The mucosa of the mouth has been described as a lipoidal barrier to drug transit, similar to many other mucosal membranes; the more quickly a drug molecule is absorbed, the more lipophilic it is. A first order rate method could appropriately characterize the kinetics of medication absorption via the mucosa of the buccal cavity. Medication absorption via the buccal mucosa could be inhibited by a number of possible factors. Salivary secretion alters, according to Dearden and Tomlison (1971) the concentration of medication in the mouth, which subsequently impacts the buccal absorption kinetics of drug solution. Linear relationship between salivary secretion and time represents the following equation.36
-dm Kc
---------- = -----------
dt ViVt
Where,
M - At time t, Drug mass in the oral cavity.
K - Constant proportionality.
Vi - quantity of the solution administered orally.
Vt - The rate of salivary secretion.
C - concentration of medicine in the oral cavity over time.
Table 2. Classification of OFDF and their characteristics.
Property/sub type |
Flash release wafer |
Mucoadhesive melt- away wafer |
Mucoadhesive sustained release wafer |
Area (cm2) |
2-8 |
2-7 |
2-4 |
Thickness (mm) |
20-70 |
50-500 |
50-250 |
Structure |
Single layer |
Single and multilayer system |
Multilayer system |
Excipient |
Soluble, highly hydrophilic polymer |
Soluble, hydrophilic polymers |
Low/non-soluble polymers |
Drug phase |
Solid solution |
Solid solution or suspended drug particles |
Suspension and/or solid solution |
Application |
Tongue (upper palate) |
Gingival or buccal Region |
Gingival, (another region in the oral cavity) |
Dissolution |
Maximum 60 seconds |
Disintegration in a few minutes, forming gel |
Maximum 8-10 hours |
Site of action |
Systemic or local |
Systemic or local |
Systemic or local |
Aspects of physiology that affect buccal bioavailability:37
a. Epithelial penetration: Epithelial penetration: The mucosal epithelial cell of the gut and the skins of epithelial cells, which are very particular for barrier function, it has an extremely particular adsorptive ability, have permeabilities that are roughly similar. The buccal mucosa in the cavity mouth has a lower permeability than the sublingual mucosa.
b. Epithelium thickness: The oral epithelium varies greatly in thickness in every part of the oral cavity. The thickness of the oral mucosa ranges from five hundred to eight hundred micrometer.
c. Blood supply: Because the mouth cavity has adequate supply of blood and a network of lymphatic system in the lamina propria, medications that cross the epithelial cell of mouth and enter the circulation swiftly.
d. Metabolic activity: Adsorbed drug moiety through the mouth epithelial membrane bypass the first-pass metabolic actions of the gut wall and liver and enter the bloodstream directly. For enzymatically labile medications, such as therapeutic some proteins and peptides, oral mucosal delivery may therefore be particularly desirable.
e. Saliva and mucous: The function of the salivary gland suggests that a continuous stream of saliva, ranging from 0.5 to 5 liters daily, is pressed up against the oral mucosal surfaces. Due to increased salivary flow, the sublingual region can enhance the solubility of medications and hence increase their bioavailability.
f. Retention of delivery system: Because of its smooth and typically immobile surface, the oral mucosa is a great option for retentive delivery systems.
g. Species differences: For the purpose of examining buccal drug delivery, rats are not suitable animal models due to their highly keratinized epithelium.
h. Routes and mechanisms of transportation: Beyond the epithelial barrier, drugs can enter the body through two main pathways:
1. The paracellular pathway: via neighboring epithelial cells.
2. The transcellular pathway: This can be achieved by endocytic processes, carrier-mediated transport, or passive diffusion across epithelial cells.
Composition of the Formulation:
OFDFs need to taste good, be the right size, and be packaged with the right materials. API and other excipients need to be stable, the necessary permeability and solubility, as well as the dosage of theincluded API It has to be minimal with a low weight molecular structure (MW) in order to guarantee all these qualities. The intended active component, a proactive pharmaceutical ingredient, or an active neutraceutical, along with excipients (stabilizers, thickeners, plasticizers, sweeteners, and film formers) can be used to manufacture a suitable OFDF38.
A typical composition contains the following:
API: 5 to 30% w/w
Aqueous soluble polymers: 45% w/w
Plasticizers: 0 to 20% w/w
Saliva stimulating agent: 2 to 6% w/w
Thickening agent: 5% w/w
Super disintegrant: 5 to 8% w/w
Sweeteners: 3 to 6% w/w
Filler, colour, flavour (colour <1% w/w) (flavour 5 to 10% w/w)
Surfactant: qs % w/w
Water: qs % w/w
Drug:
A drug candidate's classification in BCS class 1, high permeability, solubility, low MW, and low dose-adjustability are the most important factors for usage in an OFDF. However, researchers and companies are currently working to produce OFDFs using medications from BCS classes 2 and 3. In an effort to improve patient compliance, researchers are also working to create medications that have better tastes or that hide undesirable tastes. Table 3 presents a list of medication candidates with low molecular sizes and dosages. Predicted medication dosages for OFDF preparation typically fall between 0.3 and 100mg12. In addition to pharmaceutical component films, plant leaf extracts with medicinal properties, such as cannabinoids, have also been used to create OFDFs. Although the processes for preparing OFDFs appear simple, there are two challenging aspects: the taste of the medications and the consistency of the dosage39. When it comes to patient compliance, patients' taste preferences are the primary problem. OFDFs include medications directly into the film, however after dissolving and being absorbed on the tongue, irritating tastes may lead to patient noncompliance. An obstructive technique is applied to cover or mask the unpleasant taste in order to increase patient compliance. The bitter taste of the medicine is hidden by blocking it. Examples include the use of cholestyramine resin to prevent the effects of ketoprofen, as well as the use of cooling, taste-blocking, and sweetening chemicals. Sodium hydroxide and bicarbonate were used to cover the sour taste of sildenafil citrate. OFDFs of dimenhydrinate were recently synthesized by researchers employing sulfobutylether-β-cyclodextrin as a mask, and an electronic taste-sensing system was used to verify the mask's taste 40. Another way to achieve taste masking is to change the makeup of the film (drugs and film-formers at a 9:1 ratio). Masking taste also aids in lowering medication burden. Nonetheless, it is simple to hide the taste of bitter medications by employing obscuration techniques. Drug agglomeration is a significant issue with OFDF formulation since it leads to irregularity. Several companies have employed multilayer formulations to get around this problem after making numerous fruitless attempts to address it. But creating multilayer films requires a lot of money and effort 41.
Table 3. The medications that could be included in OFDF formulations and their dosages.
Drug |
Drug class |
BCS class |
Dose (mg) |
Category |
Chlorpheniramine |
Antihistamine |
1 |
4-12 |
OTC |
Loratadine |
Antihistamine |
1 |
5-10 |
OTC |
Diphenhydramine |
Antihistamine |
1 |
12.5–60 |
Rx |
Dextromethorphan |
Antitussives |
2 |
10-30 |
OTC |
Sildenafil |
PDE inhibitors |
1 |
25-100 |
Rx |
Ketoprofen |
NSAID |
2 |
12.5-25 |
OTC |
Sumatriptan |
SSRA |
3 |
35-70 |
Rx |
Zolmitriptan |
SSRA |
3 |
2.5 |
Rx |
Loperamide |
ANTIDIARRHEAL |
2 |
2 |
OTC |
Famotidine H2 |
H2 blockers |
3 |
5-10 |
Rx |
Nicotine |
NCA |
1 |
1-15 |
Rx |
Pseudoephedrine |
Nasal decongestants |
1 |
15-60 |
OTC |
Atorvastatin |
HMG-CoA |
2 |
5-80 |
Rx |
Valdecoxib |
Cox-2 inhibitor |
2 |
5-20 |
Rx |
Amlodipine |
CCB |
1 |
2.5-10 |
Rx |
Rofecoxib |
NSAID |
2 |
5-25 |
Rx |
Setraline |
SSRI |
2 |
10-100 |
Rx |
Ziprasidone |
Antipsychotics |
2 |
20-80 |
Rx |
Eletriptan |
SSRI |
1 |
10-40 |
Rx |
Nitroglycerin |
Vasodilators |
|
0.3-0.6 |
Rx |
Phenylephrine |
Antihistamine |
|
5-10 |
OTC |
BCS (Biopharmaceutical classification system), OTC (Over the counter), Rx (Prescription), PDE (Phosphodiesterase), NSAID (Non-steroidal anti-inflammatory drug), SSRI (Selective serotonin receptor agonists), NCA (Nicotinic cholinergic agonist), HMG-CoA RI (HMG-CoA reductase inhibitor), H2 (Histamine-2), COX-2 (Cyclooxygenase-2 inhibitor), CCB (Calcium channel blocker).
Excipient:
Among every excipient used in the formulation process of OFDFs, the film developer is an essential ingredient and plays a significant function. Because molecular weight has an impact on the properties of polymers, it is important to keep the mechanical characteristics of OFDFs and disintegration times in balance, concentrations, polymers and kinds42,43. Cellulose derivatives, pullulan and Polyvinyl alcohol (PVA) are the most widely used polymers in film preparation44-46. Examples of polymer combinations utilized in OFDFs include hypromellose and methacrylic acid47, PVA and croscarmellose48, as well as povidone and macrogol-PVA49. Plasticizers are a class of compounds that facilitate the production of films and help to give them flexibility. Researchers have examined the effects of plasticizers on the manufacture of OFDF in the literature, and choosing the right kind and quantity is essential50. The purpose of OFDFs, or quickly disintegrating films, is to dissolve or break down in the buccal cavity when applied over the surface of tongue. The development of this innovative drug delivery method is significantly inhibited by the bitter tastes of some medications; however, flavor maskers can also be utilized as excipients while making OFDFs. Polymers retain their tensile strength and are helpful in the production of OFDFs. The most of the polymers used in film formulations come from natural sources, and these polymers are used entirely in over-the-counter films for cough, breath fresheners, and sore throats. Oral films can also make use of plant-based gums (agar, pectin, and carrageenan)38,51.
Polymers:
A variety of film-forming polymers, including hydroxypropyl cellulose (HPC), sodium alginate, pectin, carboxymethyl cellulose (CMC), starch, pullulan and hydroxypropyl methylcellulose (HPMC), are found in these OFDFs. The appropriate strip properties can be achieved by combining or using these water-soluble polymers alone. They guarantee the integrity of the films by providing their physical framework. The kind and quantity of polymers utilized inside the strip formulation affect the durability of the strip52.
Polymers are chosen for films based on their rate of dissolution as well as the physical characteristics they provide. The rate of drug delivery is determined by the inverse relationship between a dissolving polymer's molecular weight and its rate of dissolution. The mostly important and essential element of the oral film is the film making polymer, which acts as its platform. Accordingly, at least 45% w/w of the polymer should be present in the dry oral film depending on its overall weight53.
Plasticizers:
The mixture can have plasticizers added to it to improve its mechanic characteristics, such as tensile strength and elongation. Plasticizers' concentration-dependent mechanical characteristic. Plasticizers including polyethylene glycols, di-butyl phthallate, and glycerol are frequently used54.
Surfactant:
Surfactants facilitate the instant the therapeutic ingredient's release and the quick dissolution of the film in formulations by acting as a dispersion, wetting, or solubilizing agent. Tweens, benzalkonium chloride, and sodium lauryl sulfate are a few of the most often utilized. Poloxymer 407 is a necessary surfactant that functions as a solubilizing, dispersion and wetting agent55.
Sweetening Agent:
Natural sweeteners: Sweeteners are now a necessary part of both medications that dissolve in the mouth and nutraceuticals. The most often used sweeteners are isomaltose, fructose, dextrose, glucose, and sucrose. Mannitol is less sweet than fructose and sorbitol, which are often used as sweeteners. It is possible to combine polyhydric alcohols that have a pleasant mouthfeel and cooling effect, including isomalt, mannitol, and sorbitol 56.
Artificial sweeteners:
Artificial sweeteners are becoming more and more common in pharmaceutical and culinary applications. There are two categories of artificial sweeteners: Sweeteners of the first and second generations. Sucralose is 600 times sweeter than acesulfame-K, which is 200 times sweeter. Compared to sucrose, neotame and alitame have the ability to sweeten food over 2000 and 8000 times, respectively. Produced with the South American herb Stevia rebaudiana, which is over two hundred and three hundred sweeter than sugar, rebiana is a naturally occurring sweetener57.
Saliva stimulating agent:
Salivary stimulants, like acids used in food preparation, may be included in rapid dissolving film formulations because increased saliva production facilitates a faster disintegration rate. Citric acid is the most widely used of the salivary stimulants, which also include malic, lactic, ascorbic, and tartaric acids58.
Flavors:
You can add any flavor which are permitted by the (FDA) US Food and Drug Administration, including sweet confectionary flavors, sour fruit flavors, and strong mint flavors15. The amount needed to cover the flavor depends on the kind and intensity of the taste59.
Table 4. excipients and their function in the creation of OFDF1,3,16,40,42,43,60-67
Excipient |
Role of excipient |
Example of excipient |
Film-forming polymers |
They provide shape, elasticity, fast disintegration, and mechanical strength in films |
Sodium carboxy methyl cellulose, hydroxyl ethyl cellulose, hydroxyl propyl methyl cellulose, pectin, pullulan, gelatin, sodium alginate, starch, maltodextrin, methacrylic acid, xanthan gum, guar gum, locust bean gum, carrageenan, chitosan, polyvinyl pyrrolidone, polyvinyl alcohol, polyethylene oxide, polyvinyl acetate, polyvinyl pyrrolidone |
Plasticizers
|
They provide elongation, tensile strength, and plasticity; improve absorption and solubility; prevent crushing; and reduce brittleness and glass transition temperature |
Mannitol, glycerol, sorbitol, citric acid macrogol, propylene glycol, polyethylene glycols, phthalate derivatives (dibutyl, diethyl, dimethyl), citrate derivatives (triacetin, acetyl citrate, triethyl, tributyl) |
Sweetening agents |
They are used to improve the taste of films for patient compliance |
Glucose, fructose, sucrose, sucralose, maltose, sorbitol, mannitol, stevioside sodium, ribose, cyclamate salts, aspartame, thaumatin, xylose, ribose, flavored essences, cyclamate, oleoresins |
Saliva stimulants |
They increase saliva production |
Ascorbic acid, citric acid, tartaric acid, malic acid, lactic acid |
Taste maskers |
They are used to mask nauseating and bitter tastes for patient compliance |
Hydroxypropyl-β-cyclodextrin, maltodextrin, sulfobutylether-β-cyclodextrin |
Surfactants |
They help to disintegrate films in seconds and allow dispersion and solubilization |
Poloxamer, sodium lauryl sulfate, polysorbate, laureth-a, sucrose esters, dodecyl maltoside, cetyl trimethylammonium bromide |
Methodology for Preparation of Oral Fast Dissolving Film:
Numerous methods, including solvent casting, rolling, hot-melt extrusion, semi-solid casting, and solid dispersion extrusion, have been developed to make OFDFs because it is a challenging process. Researchers and industry most commonly employ two processes for making films: hot-melt extrusion and solvent casting68-70.
Solvent Casting Method:
This is one of the older techniques for creating OFDFs is solvent casting. This process is hydrous, and it is used to create medicines that are available in dose forms that are both thermostable and thermolabile71. In order to prepare plant extracts or active pharmaceutical ingredients, active ingredients must first be soluble in purified water or another evaporative solvent that the pharmaceuticals drugs may readily dissolve in. The mixture is then thoroughly mixed with a magnetic stirrer to ensure consistency. The qualities of the active substances are taken into consideration when choosing solvents. These characteristics include temperature sensitivity, solvent–drug compatibility, polymorphism, and interaction of the active ingredient with excipients, particularly polymeric materials that form films. Each of the necessary excipients, plasticizer, coloring agent, and film-forming polymer is produced separately in purified water. The necessary liquid solution is prepared, then to guarantee homogeneity it is stirred once more. This substance is referred to as the "film dope." After applying the film dope on laboratory-scale Petri plates, the dishes are heated to between 40 and 50 °C for a full day. The films are taken out, cut off to the appropriate sizes, and kept in aluminum foil for characterisation once they have completely dried. On an impregnated paper roll, on an industrial scale, solvent cast film deposition procedures are used to apply the film dope. To remove the solvents, the spread medium is put through a convection chamber. The films are split into tiny pieces when they have dried, and they are either individually wrapped in aluminum foil or sealed in airtight containers. To prevent the impacts of moisture, certain precautions are taken when packing films. One of the things that affects a film's mechanical qualities and stability is moisture. Moreover, solutions' viscosity can only be maintained by managing the temperature 72-78. As volatile ingredients require lower temperatures to be removed from the films, the solvent casting approach works best to prepare active molecules that are responsive to light and heat. However, there are certain drawbacks to this approach. While preparation, small quantities of solvents may remain, which impairs compendial acceptance. Furthermore, extra precautions must be taken while handling volatile or flammable solvents, such as ethanol and methanol, to prevent fire79.
Figure 3. description of solvent casting method 128
Hot-Melt Extrusion Method:
Solvent casting was the procedure formerly used to make oral thin films. While this particular method of film preparation allows for flexibility, consistency, clarity, and the appropriate thicknesses to help in drug loading, it is restricted by increased tensile strength and lower elasticity80. Another limitation of films made by solvent casting techniques is the usage of solvents that are organic for some polymer compounds that have a low liquid solubility. solvents that are organic are dangerous, and their traces make it difficult to dispose of garbage, which leads to a number of environmental problems81,82. The pharmaceutical industry needed a different approach to address these problems, and it was discovered that the hot-melt extrusion technology offered a number of benefits. First off, no solvents are needed for the processing of oral films. Additionally, this procedure is cost-effective since it produces extrudates in a single step, eliminating the need to compress medications and excipients throughout processing. Drug bioavailability is enhanced by the uniform distribution of particles made possible by the liquid condition of active ingredients and polymers after mixing83. In the past, sustained drug releasing tablets and granules were made using the hot-melt extrusion method for transmucosal as well as transdermal delivery systems for drugs, such as skin patches84.
Several researchers have reported using this method to produce OFDFs. But in the past few decades, this technique of producing OFDFs has become more and more widespread. Using this method, it is simple to extrude one or more medications to create the appropriate dose forms for drug delivery. Rather than employing the solvent casting procedure, excipients inside a film for medicinal delivery85. The hot-melt extruded process produces strip by mixing the medication, hydrophilic polymers which form film, plasticizing agent, surface active agents, and further necessary ingredients in the proper quantities to achieve equal blending. After blending, the extruded material is sent to a heated barrel via a hopper to create consistent films that are thinner than one millimeter. In order to guarantee that films adhere to the mucosal surface, ingredients are occasionally additionally added during the first processing86. Future potential to develop films for gastroretentive delivery of drugs as well as multiple-layered films for transdermal medicine release applications will result from the hot-melt extrusion method of film manufacturing. Hot-melt extrusion techniques can be used in medical devices to include medications into biodegradable stents and catheters. These viewpoints could boost commercialization, innovation, and research in academic institutions, research centers, and the biotechnology and pharmaceutical businesses.
Figure 4 Description of Hot melt extrusion method 129.
Semi-solid Casting Method:
The development of OFDFs also employs the semi-solid casting technique. This approach involves first preparing film-forming and water-soluble solutions, which are then mixed into a polymer slurry that is insoluble in acid. To get the desired gel mass, plasticizers are proportionately incorporated to the previously generated solution. The resulting gelatinous mass is carefully controlled and cast into films between 0.015 and 0.05 inches thick87.
Rolling Method:
Another method for preparing OFDFs is rolling, which involves rolling drug solutions on a drum. Either distilled water or an alcohol and water mixture is used to dissolve the drugs. On the rolling device, the already mixed solutions are rolled, and then After drying, the thin film is sliced into the required sizes. The already mixed solution is made up of the film-forming polymer, polar solvent, active agent, and required excipients, which is then added to the tank. To achieve the required thickness, a controlled valve pump feeds the fluid with the intended dose 88.
Figure 5 Description of rolling method130.
3-D Printing Method
In recent years, scientists have also attempted to create OFDFs through the use of a novel method called 3D printing. This method, which is additive in nature, depends on the deposition of several ingredient layers89. Researchers have manufactured OFDFs through the use of 3D printing techniques; in the last stage of production, liquid or semi-solid components solidify to form the final product. The most popular way to create medication delivery systems using 3D printing is by extrusion technologies with fused deposition90. The creation of aripiprazole OFDFs is one instance of this process. The first step in the preparation of aripiprazole filaments is hot-melt extrusion, followed by PVA mixing and ethanol moistening before drying. An extruder is used in the preparation of the film filaments. A steady pace is used to feed and extrude the mixed powder through the die. After that, the film filament is gathered and utilized once more to create 3D-modeled OFDFs. The lengths, widths, and depths of the manufactured OFDFs are specified91.
Solid Dispersion Extrusion:
When amorphous hydrophilic polymers are available, the process of dispersing one or more APIs in an inert carrier using methods like hot melt extrusion is known as "solid dispersion extrusion". This procedure involves the extrusion of the medication along with soluble ingredients, resulting in the solid dispersions. Die-cutting machines are then employed to form the film from the solid dispersions92.
Evaluation and Characterization:
It is important to characterize and evaluate prepared OFDFs. A variety of techniques, including mechanical properties, transparency, contact angle, to assess prepared OFDFs in line with planned goals and objectives, tests for DT (disintegration time), moisture content, visual surface pH assessment, swelling index, dissolution, and content homogeneity have been established93-100.
Organoleptic Evaluation:
One method of assessing taste that can be done in vitro or in vivo is organoleptic evaluation. Specialized, regulated Human tasting panels are employed in its execution. While regarding the taste examination approach, in vivo evaluation uses human subjects, electronic taste sensors are used to evaluate the taste of films in vitro40. Commercially available taste sensing devices like α sstree (Alphamos) and TS-5000Z (Insent) are used for OFDF evaluation. Seven lipid membrane sensors, one for each of the following taste attributes: salty, sour, umami, astringent, and bitter, are installed in the TS-5000Z system. The alternative system, α astree, has seven ChemFET-sensors intended for use in pharmaceutical applications101,102. Due to the fact that bad taste lower elderly patient and therapy compliance, pediatric, and bedridden patients, taste-sensing devices have drawn attention in the pharmaceutical industry. These artificial tongues offer a novel way to screen drug-filled films for unpleasant or poor tastes. The taste of dose forms can be evaluated using in vitro taste sensing techniques. Tastes of formulations and the amount of sweetener in taste masking formulations are evaluated using both in vitro and in vivo techniques103.
The Morphology of Surfaces:
OFDFs' surface morphology or visual examination can provide information on their transparency, uniformity, and color96. SEM (scanning electron microscopy) and LM (light microscopy) have been employed for this. Because of its development and uniform surfaces absent of pores, SEM performance can be utilized to evaluate the superior quality of OFDFs. Films of one centimeter square were positioned over a glass slide on a microscope stage, allowing for the micro-level observation of the film's structure; a deeper look at the structure of the film was obtained using SEM104.
Disintegration Time:
Many disintegration instruments are mentioned in pharmacopoeias for use in calculating film disintegration times (DTs). Since DT varies with formulations, DT depends on the film's composition. OFDFs often break down after 5–30 seconds. There are currently no clear pharmacopeial guidelines available for figuring out what the DTs of OFDFs are94. The Petri dish method is the approach most investigators use to determine the DTs of OFDF formulations, however there are two ways available: slide frame methods and Petri dish method105.
Slide Frame Technique:
Films are put on a Petri dish or a glass slide frame when using the slide frame method. After being applied to the film, the duration of time it takes for pure distilled water droplets to disintegrate is noted100.
Petri Dish Method:
Using this procedure, First, add 10 milliliters of warm distilled water to the Petri plate, then add 2 cm2 films to it. After that, given the Petri dish a little shake to determine how long the film will take to dissolve. The total duration of time the strip takes to breakdown is known as the disintegration time. The identical procedure should be carried out three times for optimal results, and the averages and standard deviations of the outcomes should be noted106.
In Vitro Dissolution Test:
In vitro film dissolving times have been measured using two authorized paddles as well as basket apparatus. Sink conditions have to be kept consistent during the dissolving experiment. Testing became challenging when the film occasionally floats above the medium during disintegration. Since paddle apparatuses are the main source of this issue, the basket apparatus approach is recommended. The study used pure water, 0.1 Normal HCL, phosphate-buffered solutions having pH of 6.8, stomach and intestinal fluids, and purified water in both apparatuses. Five milliliter aliquots were taken six times a minute, at 8, 10, 12, 16, 20, and 30 minutes. A UV- spectrophotometer was used to evaluate the extracted samples107.
Swelling Properties:
Polymers are employed to create films that are hydrophilic in nature, which determines the swelling properties of OFDFs108. For the release of medications, the rate and degree of film swelling are important. However, these characteristics are typically taken into consideration to examine drug release patterns and film mucoadhesion109. Films' swelling profile has been enhanced by the application of simulated saliva solution. The percentage of hydration was used to evaluate the swelling of the films. In order to do this, films were first weighed (W1) and immersed for a specific period of time in simulated saliva. Following that, the samples were removed, the surfaces were cleared of any extra water, and they were weighed once more (W2). The following formula was used to determine the % hydration110,111:
W2 -W1
Hydration (%) = -------------------- x 100
W1
To measure the amount of swelling is present, Wi (the film was first weighed) and after that it was placed on a wire mesh and dipped in medium. The weight of the film was recorded until regular periods of time passed and no further Wf weight growth was noticed. The amount of swelling was measured with the use of the equation described below43:
Wf -Wi
Degree of swelling = -----------
Wi
Surface Ph:
The surface of the oral cavity has a pH range of 5.5 to 7.4. Given that OFDF formulations with very acidic or alkaline pHs irritate mucosal tissues, OFDF pH values must fall between the range of the mouth cavity pH. This is because OFDFs are meant to dissolve rapidly inside the mouth cavity after being positioned on the tip of the tongue. Films were chosen at random to measure the pH of their surfaces. Since it is impossible to estimate the pH of a dry film, first, the films were dissolved in two milliliters of purified water in order to measure the pH and alter the film state. After allowing the pH value to stabilize for ten minutes, The electrode that is part of the pH meter was positioned on the surface of the fluid, and the reading was noted112.
Moisture Loss and Moisture Uptake:
The film is weighed and then dried within a desiccator with for three days, the calcium carbonate was used to determine the percentage of moisture loss. Following a three-day period, after removing the films and weighing them again, the moisture loss is calculated using the following formula:
Initial weight –final weight
% Moisture loss = --------------------------------------- x100
Initial weight
The percentage moisture uptake of a film can be measured using the method described below, when it has been exposed for a period of seven days to a room temperature environment having a humidity level of 75% 113:
Final weight -Initial weight
% Moisture uptake = ----------------------------------- x100
Initial weight
Mechanical Properties:
The mechanical parameters of OFDFs have been determined using the results for tensile strength, Young's modulus, folding endurance, percent elongation, and tear resistance114. Studies has shown that fragile and softer polymers have lower values of Young's modulus, tensile strength and elongation than do their strong and hard counterparts115. Moreover, the mechanical characteristics of films are changed by production processes.
Thickness:
To ensure that the medication contents are consistent, the film thickness is measured using a micrometer, also known as a screw gauge. The precision of the drug dosage is dependent on the consistency of the film thickness. Film thicknesses were measured from the center of each film as well as from its four corners, and average values were recorded116.
Dryness:
To determine whether films adhere to a piece of paper, tests called tack or dryness tests are conducted. Tack is the term used to describe the persistence of films as seen when there's a piece of paper placed in between them. A few beneficial phases of film drying are Set-to-touch, dry-to-recoat, dry-through, tack-free, dry-print, and dry-to-touch and dry-hard. Film dryness has been evaluated using this test93,94.
Tensile strength:
One of the most important mechanical tests for determining the strength and flexibility of films is the tensile strength (TS) test. Strength of tensile in the OFDFs refers to the maximum force and pressure that a film can bear before breaking. The force that breaks a film is divided by the film's original size to determine the total stress (TS)117.
Percentage Elongation:
Any object that is under stress will change in size and shape a process known as elongation 18. It can be as determined through a texture analyzer which helps in the prediction of the flexibility of polymers utilized in formulations. The percentage of elongation indicates a film's capacity to stretch before breaking down; yet, simply matching the film's length at breakage to its initial length will yield the percentage of elongation 118,119. It can be computed by using the formula in mathematics120.
Change in length at break
% Elongation = --------------------------------------- x 100
Initial length
Young’s Modulus:
The degree of stiffness or flexibility in the film is reflected in Young's modulus. It can be found by graphing the relationship and connection between the slopes representing Young's moduli and the stress-strain curves. It describes resistance to deformation films. The tensile modulus increases with increasing slope and vice versa121. In other words, films that are hard and brittle have greater Young's modulus values. the applied stress to strain ratio, which may be calculated using the formula22, can be used to display the results.
Slope
Young’s modulus = ------------------------------- x 100
Film thickness x speed
Folding Endurance:
An evaluation test called to assess the mechanical properties; FE (folding endurance) is employed of OFDFs. When it comes to delivering the patient the dosage form precisely and without breaking, this is an important parameter. With FE, measuring a film's elasticity is simple. The method of calculation involves repeatedly folding a sheet at 180° angles until cracks show up. There is a clear correlation between FE and film mechanical power. The mechanical strength will increase with a higher FE value and vice versa. However, because the quantity of plasticizer is used in the film's composition influences mechanical strength, the FE value is indirectly impacted by plasticizer concentration. Tests should be conducted three times for improved outcomes122,123.
Content Uniformity:
Pharmacopoeias provide a standard assay method that can be used to calculate the content uniformity of formulations. It is estimated that drug content in films is examined 94. First, dissolve the 1 cm2 OFDF in buffer solution of quantity 100ml for this test. Make 2mL aliquots out of that mixture and dilute them up to 10mL with buffer solution. The diluted sample should next be measured with an ultraviolet-visible spectrophotometer, and the absorbance adjusted in accordance with the active component that was utilized. In order to verify drug content homogeneity, The amount of drug present in the film can be estimated with the aid of the absorbance value124.
Packaging of Films:
Appropriate film packaging is necessary to preserve the mechanical properties of OFDF formulations and ensure their stability during storage. The packing material acts as a barrier to keep moisture out, light, heat, and oxygen. Film storage can be achieved with commercially available packaging materials such as foil sheets, plastic pouches, blister packs, and aluminum pouches. But none of them are good at keeping film products stable while they are being stored100. The most popular and effective packaging for films is aluminum foil packaging, which protects the OFDFs from deterioration, light, heat, and moisture. In order to establish airtight conditions, films require not only primary packing but also secondary packaging containers for storage18. Commercially, OFDFs and basic films in sizes 1 × 2cm2, 2 × 2 cm2, and 3 × 2 cm2 are offered on the market124. OFDFs may be packaged in pouches to hold films of any size and shape, and the process is inexpensive, safe, and simple while taking some time to complete125. There are many films on the market that come in single or multiple unit dose packs. Pfizer Consumer Healthcare sells a single-dose film for breath freshening under the brand name PocketpaksTM. In a similar vein, APR-Labtec introduced a packaging method for Rapid® films it has 6 films and is available in multiple dosages124. The different film packing approach uses an automated process that is computer-driven designed to boost patient compliance and simplicity of usage18.
Conclusions and Future Perspective:
Over the past ten years, OFDFs have gained popularity as a medication delivery mechanism. Patients' adherence to conventional dosage forms is reduced by a number of issues related to administration, bioavailability, solubility, and taste. However, to improve adherence, a unique drug delivery method employing oral thin films composed of synthetic, natural, and semi-synthetic polymers has been developed. Films for the oral route can be created utilizing a variety of procedures, and we can also use these techniques to create films for the rectal, vaginal, ophthalmic, and transdermal routes of drug delivery. As a result, innovative films can be utilized as substitutes for traditional dosage forms and can readily address the issues related to traditional dosage forms. There are several difficulties in the formulation and manufacturing of the unique dosage film formulation, but these have all been resolved by formulation optimization. Film technology appears to have a bright future in delivery of drugs, providing a means of overcoming the limitations correlated with traditional technologies.
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Received on 24.07.2024 Revised on 19.11.2024 Accepted on 15.02.2025 Published on 09.05.2025 Available online from May 12, 2025 Res. J. Pharma. Dosage Forms and Tech.2025; 17(2):149-163. DOI: 10.52711/0975-4377.2025.00022 ©AandV Publications All Right Reserved
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