Following the April 2022 expiration of GSK's Diskus dry powder inhaler (DPI) filling equipment patent, 3P Innovation has announced the market availability of its next-generation DPI filling technology. The new system promises to revolutionize the production of inhalable therapeutics with significantly improved speed and handling capabilities.
The Warwick, UK-based automation company specializes in high-precision liquid and powder drug filling systems and has developed an enhanced equivalent to the original high-speed powder filling system used in GSK's Diskus DPI, which later became integral to the GSK Ellipta inhaler.
Technical Advancements in DPI Filling
3P Innovation's new technology offers several significant advantages over existing alternatives in the market. The system can fill inhalers with dry powder up to five times faster than current options, representing a substantial improvement in production efficiency.
Beyond speed, the technology demonstrates enhanced capabilities in handling challenging powder formulations. It provides increased containment for highly potent and dusty powders, addressing a critical safety concern in pharmaceutical manufacturing. Additionally, the system can process magnesium stearate and powders containing lubricants, which opens opportunities for developing novel DPI formulations that combine active pharmaceutical ingredients, lactose, and magnesium stearate.
Tom Bailey, Founder of 3P Innovation and the leading developer behind the original GSK Diskus DPI filling system, explained: "The expiry of the Diskus DPI patent will enable lower cost medications and improved access to an increased number of therapeutic options. 3P Innovation has now created an equivalent high-speed powder filling system which is far more cost-effective and faster than market alternatives."
Custom Solutions for Pharmaceutical Manufacturers
The company plans to bespoke build each new enhanced filling system according to the specific requirements of developers, pharmaceutical firms, or contract manufacturers. This customization approach ensures that the technology can be adapted to various production needs and formulation challenges.
The technology will be available to all manufacturers looking to produce generic versions of the original Diskus and Ellipta products. With these generic inhalable therapeutic products expected to launch in 2029, 3P Innovation anticipates installing commercial lines within the next 12 months.
Industry Expertise Driving Innovation
A key factor in 3P Innovation's technological advancement is the expertise of team members who were part of the original engineering team behind GSK's Diskus DPI filling technology patent in 2002. These engineers have accumulated an additional 23 years of experience since the original patent filing, allowing them to significantly improve upon the original design.
With 20 years of experience in custom-built automation and technologies for drug delivery devices and containers, 3P Innovation brings considerable expertise to this market advancement.
Growing Demand for Inhalable Therapeutics
The launch comes at a time when therapeutic developers are increasingly focusing on more efficient drug delivery methods. Inhalable therapies are gaining attention due to their rapid onset of action and ability to bypass the harsh conditions of the gastrointestinal tract, potentially enhancing treatment effectiveness while reducing required dosages.
"Demand for these inhalable products is also growing, driven by the increasing incidence of respiratory diseases. Coupled with advancements in biologic therapies, this trend is expected to lead to a rise in the number of treatments administered via inhalation in the coming years," Bailey noted.
Impact on Healthcare Access
The development of this technology is expected to have significant implications for healthcare systems globally. By enabling more efficient production of generic inhalable medications, the technology could contribute to reducing costs and improving access to respiratory treatments.
Bailey emphasized that this represents "a considerable commercial and growth opportunity for 3P Innovation" that will also "have considerable benefits for patients of respiratory conditions as well as for healthcare systems internationally."
For manufacturers interested in learning more, 3P Innovation has published a whitepaper titled "Optimizing DPI Production: Filling Technologies For Precision And Performance" with additional technical details about their DPI filling technology.
