Hot-melt extrusion in the pharmaceutical industry: toward filing a new drug application

The pharmaceutical development of amorphous solid dispersions (ASDs) by hot-melt extrusion (HME) is briefly reviewed. A systematic step-by-step approach is presented, where thermodynamics, polymer screening, multivariate statistics and process optimization are combined, to increase the success of HME-based drug product development. The quality by design (QbD) concept is introduced and applied to HME. Steps and tools for its effective implementation are provided, including risk assessment highlighting crucial points. The technical and scientific specificities of HME-based ASDs are discussed in light of the current paradigm of drug development and in-line with regulatory guidelines from the ICH regions. Case studies of recently approved HME products are presented.