Electrostatic powder deposition to prepare films for drug delivery

An electrostatic powder deposition (ESPD) method was developed to prepare free films for drug delivery. Films were prepared using polyethylene oxide (PEO), a physical mixture of PEO and acetaminophen (APAP), and co-processed PEO and APAP particles. Compositions were charged by an electrostatic spray gun and deposited onto a grounded stainless steel coupon. The deposited powders were cured and free films were peeled from the substrate. Average drug content of the active films was 97% of theoretical. Films prepared using the physical mixture of the powders showed greater variability with an RSD of 11.9% compared to 1.8% from films prepared using co-processed particles. Mechanical testing of the prepared films showed lower puncture strength than commercially available Listerine (R) strips, but exhibited greater elongation prior to break. Active films showed up to 15% elongation compared to 1.6% from Listerine (R) strips and 3.8% from PEO films, due primarily to the plasticizing effect of APAP on PEO in the drug containing films. Both active films exhibited greater than 85% drug release in 2 min. This study is the first to demonstrate the application of ESPD to prepare free films for drug delivery; however, future studies of this technology are needed to determine its full potential. (C) 2015 Elsevier B.V. All rights reserved.