A modified thin film method for large scale production of dimeric artesunate phospholipid liposomes and comparison with conventional approaches

Dimeric artesunate phospholipid (ART-GPC), an amphiphilic derivative of artemisinin dimer reported in our previous work, can be applied to treat malaria effectively. The objective of this study is to develop a facile method for the industrial production of ART-GPC liposomes. Conventional methods including thin film hydration (TFH), ethanol injection (EI), and freeze drying (FD) were used to prepare ART-GPC liposomes, and the resultants presented poor physicochemical properties. Fortunately, a modified thin film hydration method (MTFH) by forming thin film of ART-GPC composed of fine lipid bilayer structure in the vials showed promise for the liposomes production. A quality design strategy (solvents, pressure, hydration time, and temperature) was performed to obtain optimal physicochemical characteristics and production conditions. Thereafter, ART-GPC liposomes are produced under GMP conditions with the size of 176.32 nm, PDI of 0.17, zeta potential of −25.79 mV, and osmotic pressure of 297.33 mOsm/kg, confirming the scalability and reproductivity of the MTFH technology. It is the first report that the MTFH method allows liposomes to be preserved in a dry film state and in-situ hydrated in injection vials with excellent performance. Conclusively, the MTFH method is a promising technology for the large-scale production of ART-GPC liposomes.