Artificial Intelligence-Enabled Quality by Design and Regulatory
Science for Apixaban Orodispersible Tablets: A Critical Review of Clinical
Rationale, Formulation Strategy, and Submission-Ready Documentation for Stroke
Prevention
Gururaj S Kulkarni¹, Mithun N², Anna Balaji³
¹Department of Pharmaceutics (HOD), The Oxford College
of Pharmacy, Bengaluru, Karnataka, India
²Department of Pharmaceutics (PG Student), The Oxford College of
Pharmacy, Bengaluru, Karnataka, India
³Principal, The Oxford College of Pharmacy, Bengaluru,
Karnataka – 560068, India
*Correspondence: tocpceutics@gmail.com
DOI: https://doi.org/10.71431/IJRPAS.2026.5307
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Article
Information
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Abstract
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Review Article Received: 22/03/2026
Accepted:26/03/2026
Published:31/03/2026
Keywords
Apixaban; Artificial Neural Networks; eCTD; Genetic
Algorithms; Orodispersible Tablets; Quality by Design; Stroke Prevention
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Stroke is a leading global cause of death and
acquired disability, affecting millions annually. Among post-stroke patients,
36–51% experience oropharyngeal dysphagia, rendering conventional film-coated
tablets of apixaban – a direct factor Xa inhibitor – difficult or unsafe to
administer. This review critically examines the evidence base for developing
an apixaban Orodispersible Tablet (ODT) formulation across three converging
domains: (1) global stroke burden and dysphagia-related adherence barriers in
dysphagic, geriatric, and paediatric populations; (2) apixaban's
biopharmaceutical constraints – particularly poor aqueous solubility (~40
µg/mL) and BCS Class II/IV designation – mapped onto ODT manufacturing
approaches (direct compression, lyophilisation, sublimation) and excipient
selection strategies; and (3) the integration of Artificial Intelligence (AI)
within a formal Quality by Design (QbD) framework, detailing how Artificial
Neural Networks (ANNs) and Genetic Algorithms (GAs) can optimise Critical Quality
Attributes and resolve multi-objective formulation trade-offs. The review
further maps AI-generated data streams onto eCTD Modules 2, 3, and 5 in
alignment with FDA, EMA, and ICH requirements for data integrity (ALCOA+),
model lifecycle management, and audit trail compliance.
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INTRODUCTION
Global Stroke Burden and the Dysphagic Patient
Stroke
represents a persistent global health emergency, ranking as the second-leading
cause of death worldwide and the third-leading cause of death and disability
combined as measured by disability-adjusted life years (DALYs).[1]
The
2019 Global Burden of Disease (GBD) study documented 12.2 million incident
strokes (95% uncertainty interval [UI] 11.0–13.6 million), 101 million
prevalent strokes, and 6.55 million stroke-related deaths globally.[6]
While
age-standardised stroke incidence and mortality rates declined between 1990 and
2019, absolute numbers increased dramatically due to population ageing and
growth: incident strokes increased by 70.0%, prevalent strokes by 85.0%, and
DALYs by 32.0%. Critically, among individuals younger than 70 years, prevalence
rates increased by 22.0% and incidence rates by 15.0%, signalling an
epidemiological shift toward younger populations.[6][7]
Without
urgent primary prevention and improved acute care delivery, projections
indicate that by 2050 there will be over 200 million stroke survivors,
approximately 300 million stroke-related DALYs, 25 million new strokes
annually, and 13 million deaths from stroke each year.[6]
Oropharyngeal
dysphagia – impaired swallowing efficiency and safety – is a prevalent and
clinically significant complication of acute stroke. A prospective study of 201
stroke patients documented dysphagia prevalence of 42.8% during
hospitalisation.[1]
Meta-analysis of Asian stroke populations revealed a pooled dysphagia
occurrence rate of 36.3% (95% CI 33.3%–39.3%),[3]
while Chinese epidemiological surveys reported 51.14% prevalence among stroke
patients.[2]
Figure 1.
Global stroke incidence, prevalence, mortality, and DALY trends from 1990–2019,
with projections to 2050. Adapted from GBD 2019 Stroke Collaborators.
Anticoagulation Imperatives and Conventional Dosage
Form Limitations
Atrial
fibrillation-related cardioembolic stroke and venous thromboembolism prevention
require sustained oral anticoagulation. Apixaban, a selective direct factor Xa
inhibitor, is a guideline-recommended first-line agent for stroke prevention in
nonvalvular atrial fibrillation and treatment/prevention of deep vein
thrombosis and pulmonary embolism.[5][14]
The drug is currently marketed as film-coated tablets (Eliquis®) in 2.5 mg and
5 mg strengths.[4][5]
For
dysphagic stroke patients, conventional tablets present multiple adherence and
safety barriers including swallowability constraints, administration delays
when crushed for tube feeding, adherence barriers in elderly (≥75 years) and
paediatric populations, and limitations related to onset and bioavailability.[2][15]
Apixaban
exhibits approximately 50% oral bioavailability with time to maximum
concentration (Tmax) of 3–4 hours and a half-life of approximately 12 hours,
with food-independent absorption.[15]
Orodispersible Tablets: A Patient-Centred Solution
Orodispersible
tablets (ODTs) are solid dosage forms designed to disintegrate rapidly in the
oral cavity (typically <30 seconds) without requiring water.[16][17][18]
ODTs offer multiple patient-centred advantages: rapid disintegration and
buccal/sublingual absorption pathways; elimination of swallowing barriers
enabling administration in dysphagic patients, children, and the elderly;
improved adherence through ease of administration and palatability enhancement;
and suitability for emergency and field settings where water availability is
limited.[19]
The Role of Artificial Intelligence in Pharmaceutical
Development and Regulatory Science
Traditional
pharmaceutical development employs one-factor-at-a-time (OFAT) experimentation
or classical Design of Experiments (DoE) to optimise formulation composition
and manufacturing processes. AI and machine learning (ML) techniques –
particularly artificial neural networks (ANNs) and evolutionary algorithms such
as genetic algorithms (GAs) – offer transformative capabilities for non-linear
modelling, multi-objective optimisation, and data efficiency.[20][21]
ANN-GA
hybrid workflows reduce experimental burden by training surrogate models on
limited datasets and guiding subsequent experimentation toward optimal regions.
Despite these advantages, pharmaceutical applications of AI face regulatory
scrutiny regarding validation, data integrity, model interpretability, and
human oversight.[11][12][22]
Objectives and Scope
This
review critically synthesises the evidence base for apixaban ODT development
through three integrated lenses: (1) clinical imperative – quantifying stroke
burden, dysphagia prevalence, and adherence barriers; (2) formulation science
and QbD – characterising apixaban's biopharmaceutical properties and evaluating
manufacturing methods; and (3) AI-driven development and regulatory readiness –
mapping ANN and GA applications to QbD and aligning with FDA/EMA/ICH eCTD
expectations.[18][23]
Global and Regional Stroke Epidemiology: Burden,
Trends, and Vulnerable Populations
Overall Stroke Burden and Mortality (2019 Baseline)
The
most recent comprehensive global stroke surveillance derives from the GBD 2019
study, which documented 12.2 million incident strokes (95% UI 11.0–13.6
million) and 101 million prevalent strokes worldwide.[6]
Stroke
accounted for 6.55 million deaths (6.00–7.02 million), representing 11.6% of
all global deaths in 2019, ranking stroke as the second-leading cause of
mortality after ischaemic heart disease. Combined death and disability burden
reached 143 million DALYs, making stroke the third-leading cause of DALYs
globally.[6][24]
From
1990 to 2019, absolute stroke burden increased dramatically despite declining
age-standardised rates. Incident strokes increased by +70.0% (95% UI
67.0–73.0%); prevalent strokes by +85.0% (83.0–88.0%); deaths by +43.0%
(31.0–55.0%); and DALYs by +32.0% (22.0–42.0%). This paradox – rising absolute
burden amid falling age-standardised rates – reflects population ageing and
growth as dominant epidemiological drivers.[6][7]
Stroke Subtypes and Geographic Disparities
Ischaemic
stroke predominated in 2019, accounting for 62.4% of incident strokes (7.63
million cases, 95% UI 6.57–8.96 million), followed by intracerebral haemorrhage
(27.9%, 3.41 million cases) and subarachnoid haemorrhage (9.7%, 1.18 million
cases). This distribution differs markedly from paediatric patterns, where
approximately 50% of strokes are haemorrhagic.[6][25]
Geographic
inequities are profound. Age-standardised stroke mortality rates in World Bank
low-income countries were 3.6 times higher (95% UI 3.5–3.8) than in high-income
countries. In absolute terms, 86% of all stroke deaths and 89% of
stroke-related DALYs occurred in lower-income and lower-middle-income countries
in 2019.[6][26][7]
Figure 2.
Geographic distribution of stroke burden (deaths and DALYs) by World Bank
income classification. Data from GBD 2019 and young stroke scoping review.
Young Adult and Paediatric Stroke: Emerging
Epidemiological Shift
Among
individuals younger than 70 years, GBD 2019 data revealed a concerning reversal
of favourable age-standardised trends: prevalence rates increased by 22.0% (95%
UI 21.0–24.0%) and incidence rates increased by 15.0% (12.0–18.0%) between 1990
and 2019.[6]
A
comprehensive scoping review of stroke in individuals ≤30 years analysed 471
articles from 50 countries, identifying heterogeneous incidence reporting and
risk factor profiles. In perinatal stroke, leading risk factors were
infections, cardiac conditions, and intrapartum factors; in paediatric stroke,
vasculopathies and infections predominated; and in young adult stroke, chronic
conditions including diabetes and hypertension were most frequently reported.[28]
The
Young ESUS Longitudinal Cohort Study enrolled 535 participants ≤50 years of age
from 41 stroke centres in 13 countries and documented a recurrent ischaemic
stroke and death rate of 2.19 per 100 patient-years. Prior stroke or TIA
(hazard ratio 5.3), diabetes (HR 4.4), and coronary artery disease (HR 10) were
associated with recurrent events.[29]
Stroke and SARS-CoV-2 in Paediatric Populations
An
international survey during March–May 2020 identified SARS-CoV-2 infection in 8
of 971 (0.82%) hospitalised paediatric patients with stroke.[30]
A
subsequent cohort study (June–December 2020) documented SARS-CoV-2 positivity
in 23 of 335 acute arterial ischaemic stroke cases tested (6.9%). Elevated
inflammatory markers occurred in 77.3% of SARS-CoV-2-positive stroke cases,
suggesting infection-mediated vasculopathy as a plausible mechanism.[31]
Dysphagia in Acute and Post-Stroke Populations:
Prevalence, Prognostic Implications, and Medication Administration Barriers
Prevalence of Oropharyngeal Dysphagia in Stroke
Oropharyngeal
dysphagia is characterised by impaired efficiency (prolonged bolus transit,
incomplete oral clearance) and safety (aspiration, penetration) of swallowing.[32]
A
prospective cohort study of 201 stroke patients admitted to a dedicated Stroke
Unit documented oropharyngeal dysphagia prevalence of 42.8% (86 patients)
during acute hospitalisation. Dysphagic patients exhibited significantly higher
National Institutes of Health Stroke Scale (NIHSS) scores at admission, higher
pneumonia incidence, and worse functional outcomes at 90 days.[1]
Meta-analysis
of 40 studies (43 observations) from Asian stroke populations yielded a pooled
dysphagia occurrence rate of 36.3% (95% CI 33.3%–39.3%).[3]
A population-based cross-sectional survey in China (5,943 participants across
14 provinces) identified dysphagia prevalence of 51.14% among stroke patients,
compared to 19.2% in healthy older adults ≥65 years. Multivariable analysis
confirmed that stroke patients were significantly more likely to exhibit
dysphagia (odds ratio 2.27, p<0.01) compared to age-matched controls.[2]
Figure 3.
Prevalence of oropharyngeal dysphagia across stroke and related populations.
Bar chart comparing dysphagia rates in acute stroke patients (36.3–51.1%),
healthy elderly ≥65 years (19.2%), neurodegenerative disease patients (48.3%),
and head/neck cancer patients (34.4%).
Functional Oral Intake Stratification and Prognostic
Associations
The
Functional Oral Intake Scale (FOIS) stratifies swallowing capacity into seven
levels from tube-feeding dependency (FOIS 1–3) through oral feeding requiring
food consistency modifications (FOIS 4–5) to normal oral intake without
restrictions (FOIS 6–7). In the prospective Stroke Unit cohort, FOIS 6–7 was a
protective factor against disability (modified Rankin Scale ≥3): OR 0.17 (95%
CI 0.005–0.56, p=0.004). Tube feeding use at discharge significantly increased
risk of disability (mRS ≥3): OR 14.97 (95% CI 2.68–83.65, p=0.002) and 90-day
mortality: OR 9.79 (95% CI 2.21–43.4, p=0.003).[1]
Nutritional Consequences and Percutaneous Endoscopic
Gastrostomy Outcomes
A
retrospective study of 158 patients with post-stroke dysphagia requiring PEG
documented high prevalence of malnutrition markers at admission: 41.6% had low
body mass index, 62.3% had low serum albumin, 68.6% had low serum transferrin,
and 59.6% had low serum cholesterol. Low albumin and transferrin were more
prevalent in patients who underwent PEG >2 months after stroke, suggesting
progressive nutritional decline. Mortality remained high: 12.9% at 1 month,
27.7% at 3 months, and 40% at 12 months post-PEG.[33]
Implications for Oral Anticoagulant Administration
For
dysphagic stroke patients requiring oral anticoagulation, conventional
film-coated tablets present multiple challenges: aspiration risk, crushing and
bioavailability uncertainty, adherence barriers, and onset delays in emergency
settings. In the Chinese dysphagia survey, dysphagic participants were at
significantly greater risk of malnutrition (OR 1.91, p<0.01),[2]
and malnutrition is independently associated with medication non-adherence.
Apixaban: Pharmacological Profile and
Biopharmaceutical Properties Relevant to Orodispersible Tablet Development
Mechanism of Action and Clinical Pharmacology
Apixaban
(brand name Eliquis®) is a selective, reversible inhibitor of factor Xa (FXa),
a serine protease enzyme in the coagulation cascade that converts prothrombin
to thrombin.[14]
By inhibiting FXa, apixaban reduces thrombin generation and fibrin clot
formation without requiring antithrombin III as a cofactor and without
affecting existing thrombin activity. Apixaban is indicated for stroke and
systemic embolism prophylaxis in patients with nonvalvular atrial fibrillation;
treatment of deep vein thrombosis (DVT) and pulmonary embolism (PE);
prophylaxis of recurrent DVT and PE; and prophylaxis of VTE in patients
undergoing hip or knee replacement surgery.[4][5][14]
The
recommended dosing for stroke prevention in atrial fibrillation is 5 mg twice
daily, with dose reduction to 2.5 mg twice daily in patients meeting at least
two of the following criteria: age ≥80 years, body weight ≤60 kg, or serum
creatinine ≥1.5 mg/dL.[5]
Pharmacokinetics and ADME Properties
Apixaban
is rapidly absorbed following oral administration, with time to maximum plasma
concentration (Tmax) occurring at 3–4 hours. Absolute oral bioavailability is
approximately 50%. Food does not have a clinically meaningful impact on
bioavailability, enabling flexible administration with or without meals – a
feature advantageous for dysphagic patients requiring texture-modified diets or
enteral feeding. Apixaban has an elimination half-life of approximately 12
hours, supporting twice-daily dosing.[15]
Apixaban
is metabolised primarily via CYP3A4/5, with minor contributions from CYP1A2,
CYP2C8, CYP2C9, CYP2C19, and CYP2J2. This metabolic pathway necessitates
attention to drug–drug interactions with strong CYP3A4 inhibitors (e.g.,
ketoconazole, ritonavir) and inducers (e.g., rifampin, carbamazepine).[14]
Physicochemical Properties and BCS Classification
Apixaban
has the molecular formula C₂₅H₂₅N₅O₄ and a molecular weight of 459.5 g/mol.[34][9]
Aqueous solubility is reported as 40 µg/mL (0.04 mg/mL) across the
physiological pH range, classifying apixaban as poorly water-soluble.[34][9]
Caco-2 apparent permeability (Papp) is reported as 0.9 × 10⁻⁶ cm/s. Based on
low solubility and variable permeability data, apixaban is classified as BCS
Class II or Class IV.[9][10]
Apixaban
is described as a white to pale yellow non-hygroscopic crystalline powder.
However, forced degradation studies demonstrated that apixaban exhibits high
degradability under both acidic and basic conditions, with a pH-independent
hydrolysis degradation impurity identified. This chemical instability profile
necessitates careful excipient selection (avoiding acidic or basic pH
modifiers) and moisture control during ODT manufacturing.[8][37]
Table 1.
Physicochemical and Pharmacokinetic Properties of Apixaban
|
Property
|
Value
|
Reference
|
Clinical/Formulation Implication
|
|
Molecular formula
|
C₂₅H₂₅N₅O₄
|
34,9
|
—
|
|
Molecular weight
|
459.5 g/mol
|
34,9
|
Suitable for oral delivery
|
|
Ionisation
|
Non-ionisable
|
15
|
Minimal pH-dependent solubility
variation
|
|
pKa
|
Not available in retrieved sources
|
—
|
Evidence gap; regulatory documents may contain data
|
|
Aqueous solubility
|
40 µg/mL (0.04 mg/mL)
|
34,9
|
Poorly water-soluble; requires
solubility enhancement
|
|
XLogP (lipophilicity)
|
1.81
|
36
|
Moderate lipophilicity; limited buccal absorption expected
|
|
Caco-2 Papp
|
0.9 × 10⁻⁶ cm/s
|
15
|
Low permeability per BCS criteria
|
|
BCS classification
|
Class II or Class IV
|
9,10
|
Dissolution- and/or permeability-limited absorption
|
|
Hygroscopicity
|
Non-hygroscopic
|
37
|
Facilitates moisture-sensitive ODT processing
|
|
Chemical stability
|
High degradability under acidic/basic conditions
|
8
|
Requires neutral pH excipients; moisture control
|
|
Appearance
|
White to pale yellow crystalline powder
|
37
|
—
|
|
Tmax
|
3–4 hours
|
15
|
Moderate absorption rate
|
|
Half-life (t½)
|
~12 hours
|
15
|
Supports twice-daily dosing
|
|
Oral bioavailability
|
~50%
|
15
|
Food-independent; enables flexible administration
|
|
Metabolism
|
CYP3A4/5 (primary);
CYP1A2/2C8/2C9/2C19/2J2 (minor)
|
14
|
Drug-drug interaction monitoring
required
|
|
DSC melting point
|
Not available
|
—
|
Evidence gap; critical for ASD and sublimation processing
|
|
TGA moisture content
|
Not available
|
—
|
Evidence gap
|
Formulation Strategies for Apixaban Orodispersible
Tablets: Manufacturing Methods, Excipient Selection, and Critical Process
Parameters
Manufacturing Methods: Decision Criteria and
Mechanism-Oriented Comparison
Orodispersible
tablets can be manufactured via three primary approaches: direct compression, lyophilisation
(freeze-drying), and sublimation. Each method offers distinct advantages and
constraints for apixaban ODT development, informed by the drug's
biopharmaceutical properties (low solubility, non-hygroscopic, chemically
labile under acidic/basic conditions).[38][16]
Direct Compression
Direct
compression involves blending drug and excipients directly and compressing into
tablets without granulation or complex post-processing. Its advantages for
apixaban include simplicity and scalability, cost-effectiveness, moisture
avoidance (no aqueous granulation, advantageous for apixaban's chemical
stability),[8]
and extensive regulatory precedent. Studies on fast disintegrating tablets
demonstrated that crospovidone combined with sodium starch glycolate yielded
optimal disintegration with acceptable hardness.[39]
Lyophilisation (Freeze-Drying)
Freeze-drying
creates a three-dimensional porous network with high surface area, enabling
rapid disintegration (typically <10 seconds). However, lyophilised tablets
are mechanically fragile, moisture-sensitive, and require capital-intensive
manufacturing. Apixaban's chemical lability under acidic/basic conditions[8]
may be exacerbated by residual water-catalysed hydrolysis during extended freeze-drying
cycles.
Sublimation (Preferred Method for Apixaban)
In
sublimation, a volatile subliming agent (e.g., camphor, menthol, ammonium
bicarbonate) is incorporated into the tablet blend, compressed, and then
removed by controlled heating, leaving a porous tablet matrix. The comparative
study of atenolol and atorvastatin mouth-disintegrating tablets concluded that
sublimation is superior to direct compression and effervescent methods across
all evaluated parameters.[16]
Sublimation
is the preferred manufacturing method for apixaban based on: moisture avoidance
critical for apixaban's acid/base lability;[8]
and optimised porosity–hardness balance. A study on quetiapine fumarate ODTs
via sublimation achieved 18.66-second disintegration time, 3.5 kg/cm² hardness,
and <1% friability using 5% camphor and 3–5% Indion 414 super disintegrant,
with sublimation at 50°C for 6 hours.[38]
Figure 4.
Comparative schematic of three ODT manufacturing methods: (A) Direct
compression; (B) Lyophilisation; (C) Sublimation. Diagrams illustrate process
flow, equipment requirements, and resulting tablet microstructure.
Excipient Selection: Functional Roles, Concentration
Ranges, and Apixaban-Specific Considerations
Super Disintegrants
Crospovidone
(Polyplasdone XL, Kollidon CL) exhibits rapid swelling without gel formation. A
comparative study of super disintegrants at 2% w/w demonstrated that
crospovidone achieved the fastest disintegration and dissolution kinetics,[40]
making it the preferred super disintegrant for apixaban ODTs at 3–6% w/w.
Croscarmellose sodium (Ac-Di-Sol) swells 4–8 times its original volume in water
at 2–5% w/w[40]
while sodium starch glycolate requires 4–8% w/w for comparable effect.[39][41]
Fillers/Diluents
Microcrystalline
cellulose (MCC, Avicel PH-102) is the preferred primary filler. A study on
amorphous solid dispersion tablets demonstrated that MCC is preferred over
mannitol for moisture-sensitive drugs because MCC's hydrophobic nature
minimises recrystallisation risk.[42]
Mannitol (Pearlitol SD-200) can be used at 10–20% w/w in combination with MCC for
taste improvement. Lactose is not recommended for apixaban ODTs due to
recrystallisation concerns and lactose intolerance contraindication.[42]
Binders
Polyvinylpyrrolidone
(PVP K-30) serves a dual role as binder and solubiliser. A study on lamotrigine
ODTs (a BCS Class II drug analogous to apixaban) used PVP K-30 in solid
dispersions combined with super disintegrants to achieve 15-second
disintegration and >80% drug release in 10 minutes.[41]
HPMC has been used in apixaban formulation studies for solubility enhancement.[10]
Subliming Agents
Camphor
exhibits sublimation at 50–60°C; optimal concentration 5–15% w/w. A 3²
factorial design study demonstrated that porosity increased from 12.76% to
41.01% as camphor concentration increased from 3% to 15%, with optimal
concentration identified as 5–7% w/w to balance rapid disintegration (18.66 seconds)
with acceptable friability (0.33%).[38][16]
Table 2.
Excipient Selection for Apixaban Orodispersible Tablets: Functional Roles and
Recommended Concentrations
|
Excipient Category
|
Examples
|
Functional Mechanism
|
Range (% w/w)
|
Selection Rationale for Apixaban ODTs
|
|
Super disintegrant
|
Crospovidone (Kollidon CL-F)
|
Rapid water uptake; swelling without gel
formation
|
3–6
|
Fastest disintegration kinetics [40];
compatible with non-hygroscopic drugs
|
|
|
Croscarmellose sodium (Ac-Di-Sol)
|
Swelling (4–8×) + wicking
|
2–5
|
Alternative if crospovidone supply constraints
|
|
|
Sodium starch glycolate (Primojel)
|
Swelling via carboxymethyl starch
|
4–8
|
Less effective; requires higher
concentration [39]
|
|
Filler/Diluent
|
MCC (Avicel PH-102)
|
Directly compressible; minimises ASD recrystallisation
|
30–60
|
Preferred primary filler; supports mechanical strength and ASD
stability [42]
|
|
|
Mannitol (Pearlitol SD-200)
|
Sweet taste; cooling sensation; good
compressibility
|
10–20
|
Secondary filler; enhances
taste/mouthfeel [42]
|
|
Binder
|
PVP K-30
|
Amorphisation-inducing; solubility enhancer; inter-particulate
adhesion
|
1–5 (DC); 10–30 (ASD)
|
Dual-function: binding + solubilisation; proven for BCS Class II
drugs [41]
|
|
|
HPMC (K15M)
|
Controlled-release at high conc.;
binding at low conc.
|
2–5
|
Used in apixaban formulation studies
[10]
|
|
Lubricant
|
Magnesium stearate
|
Hydrophobic metallic soap; reduces friction
|
0.5–1
|
Standard lubricant; controlled blending time (<3 min)
critical
|
|
Subliming Agent
|
Camphor
|
Sublimes at 50–60°C; creates porous
network
|
5–15
|
Preferred: proven efficacy at 50°C/6h
[38]; complete removal validated
|
|
|
Menthol
|
Sublimes at 40–50°C; cooling sensation; mint flavour
|
5–10
|
Alternative; dual taste-masking benefit
|
|
Sweetener
|
Sucralose
|
High-intensity sweetener (600× sucrose);
thermally stable
|
0.2–0.5
|
Preferred: heat stability for
sublimation [38]; superior palatability
|
Critical Process Parameters and Their Impact on Tablet
Quality Attributes
Critical
process parameters (CPPs) are manufacturing variables that must be controlled
within defined ranges to consistently achieve target critical quality
attributes (CQAs). A Box-Behnken optimisation study of carbamazepine ODTs
identified compression pressure as the dominant factor affecting friability,
disintegration behaviour, and drug release.[18]
Optimal
compression force for ODTs is typically 10–15 kN (equivalent to 50–100 N
hardness).[38][18]
The sublimation temperature and duration must be validated: camphor sublimation
at 50°C for 6 hours achieves complete removal (validated by GC) without drug
degradation.[38]
Super disintegrant concentration (3–6% w/w for crospovidone) and
blending/lubrication time (<3 minutes) are the remaining CPPs governing
disintegration and mechanical integrity.[17]
Figure 5.
Impact of critical process parameters on apixaban ODT quality attributes.
Multi-panel chart showing: (A) Compression force vs. hardness and
disintegration time; (B) Camphor concentration vs. porosity and friability; (C)
Super disintegrant concentration vs. disintegration time; (D) Lubrication time
vs. disintegration time.
Quality Attribute Evaluation and Clinical Relevance
for Stroke Prevention
Weight Variation and Content Uniformity
For
apixaban 2.5 mg and 5 mg ODTs (both <25 mg), content uniformity testing per
USP <905> is mandatory. Anticoagulants have narrow therapeutic indices;
dose variability directly impacts bleeding risk (overdosing) or thromboembolic
event risk (underdosing). Content uniformity ensures that each tablet delivers
95–105% of label claim (USP specification: 85–115% with acceptance value
≤15.0).[43]
Hardness and Friability
Acceptable
hardness range for ODTs is 50–100 N (equivalent to 3–5 kg/cm²).[38][18]
Friability specification per USP <1216> is <1% mass loss after 100
rotations at 25 rpm. For stroke patients with limited manual dexterity
(hemiparesis, tremor), tablets must withstand handling without crumbling.
Studies on ODTs consistently achieve friability <1% with optimised
formulations.[38][17][18]
Wetting Time and Disintegration Time
Wetting
time for ODTs should typically be <30 seconds and correlates with in vivo
disintegration onset velocity.[38]
Disintegration time (USP <701>) specification for ODTs is typically
<30 seconds; some formulations target <10 seconds for lyophilised
tablets. Disintegration time is the most critical quality attribute for
dysphagic patients: ODTs disintegrate in the oral cavity within seconds,
enabling swallowing of a drug–saliva suspension rather than a solid bolus,
drastically reducing aspiration risk. A study on carbamazepine ODTs optimised
via QbD achieved disintegration times as low as 18.66 seconds with acceptable
hardness and friability.[18]
In Vitro Dissolution and Release Kinetics
Testing
conditions for apixaban ODTs should include pH 1.2 (0.1 N HCl), pH 4.5 (acetate
buffer), pH 6.8 (phosphate buffer), and simulated intestinal fluid (FaSSIF);
USP Apparatus II (paddle); 50–75 rpm; 37°C; with acceptance criteria of >80%
release within 30 minutes.[44]
For BCS Class IV drugs (or borderline Class II/IV like apixaban), combined
dissolution-permeation apparatus (e.g., Transwell with Caco-2 monolayers) can
assess simultaneous dissolution and intestinal permeability, improving in
vitro-in vivo correlation (IVIVC).[44]
Stability Testing Under ICH Conditions
Stability
testing per ICH Q1A: Long-term at 25°C ± 2°C / 60% RH ± 5% for 24 months;
accelerated at 40°C ± 2°C / 75% RH ± 5% for 6 months; stress testing including
oxidative (H₂O₂), photostability (ICH Q1B), and hydrolysis (acidic, basic,
neutral aqueous media). Apixaban exhibits high degradability under acidic and
basic conditions,[8]
necessitating neutral pH excipients and moisture protection. Stability data
demonstrating ≤5% degradation under ICH conditions and maintained
disintegration time (<30 seconds at 24 months) are critical for regulatory
approval and patient safety.
Artificial Intelligence-Driven Quality by Design for
Apixaban ODT Development
Limitations of Traditional OFAT and DoE Approaches
Conventional
pharmaceutical development employs one-factor-at-a-time (OFAT) experimentation,
varying a single formulation or process variable while holding others constant.
Design of Experiments (DoE) methods – factorial designs, central composite
designs, Box-Behnken designs – address OFAT limitations by systematically
varying multiple factors simultaneously.[21][45][18]
However,
DoE has constraints: second-order polynomials cannot adequately represent
highly non-linear relationships between formulation variables and quality
attributes; DoE is typically constrained to 3–5 independent variables; and DoE
identifies a single optimal formulation rather than a robust design space with
multiple acceptable solutions.[21]
Quality Target Product Profile and Critical Quality
Attributes
The
Quality Target Product Profile (QTPP) for apixaban ODTs must specify:
Indication – stroke prevention in atrial fibrillation; VTE
treatment/prophylaxis.[46]
Dosage form: Orodispersible tablet; Strength: 2.5 mg, 5 mg; Disintegration
time: <30 seconds in simulated saliva or water at 37°C; Bioavailability:
equivalent to reference film-coated tablets (via bioequivalence study);
Stability: ≥24 months at 25°C/60% RH; Palatability: acceptable taste and
mouthfeel.[19]
Critical
Quality Attributes (CQAs) include: disintegration time (≤30 s; target ≤20 s for
optimal patient acceptance),[19]
dissolution profile (minimum 80% dissolved in 30 minutes; f2 similarity factor
≥50 compared to reference product),[47][48]
content uniformity (90.0–110.0%; USP <905>),[43]
mechanical properties (hardness 40–100 N; friability <1.0%),[49][50]
moisture content (2.0–4.0%),[51]
particle size distribution (API D50: 5–15 µm or nanocrystal 232 ± 23 nm),[48][52]
taste-masking performance, and stability (shelf life ≥24 months).[52]
Critical Material Attributes (CMAs)
Systematic
identification of CMAs was conducted using Failure Mode and Effects Analysis
(FMEA). The following CMAs are ranked by Risk Priority Number (RPN) based on severity,
occurrence, and detectability:[51][53]
Table 3.
Critical Material Attributes for Apixaban ODT
|
Critical Material Attribute
|
Specification Range
|
Impact on CQAs
|
RPN
|
Analytical Method
|
|
API Particle Size Distribution
|
D50: 5–15 µm (micronised); or 200–250 nm (nanocrystals)
|
Dissolution, content uniformity, blend uniformity
|
60
|
Laser diffraction (ISO 13320) or Dynamic light scattering
|
|
API Polymorphic Form
|
Form I (anhydrous, thermodynamically stable)
|
Chemical stability, dissolution kinetics, moisture sorption
|
60
|
XRPD, DSC, Raman spectroscopy
|
|
Super disintegrant Type and Concentration
|
Crospovidone 5–15% w/w; or Croscarmellose sodium 2–10% w/w
|
Disintegration time, dissolution, wetting time
|
60
|
HPLC assay (concentration); USP <701> disintegration
|
|
MCC Grade and PSD
|
PH-101, PH-102, or PH-200; D50: 50–180 µm
|
Compressibility, hardness, friability, disintegration
|
48
|
Laser diffraction, bulk/tapped density
|
|
Taste-Masking Agent Properties
|
β-cyclodextrin or HPβCD inclusion complex; or Eudragit® E PO
coating (5–10% w/w)
|
Palatability, drug release kinetics in saliva vs. GI fluids
|
48
|
HPLC dissolution in pH 6.8 (saliva) and pH 1.2/6.8 (GI)
|
|
Lubricant Type and Concentration
|
Magnesium stearate 0.5–1.5% w/w; or Sodium stearyl fumarate
0.5–1.0% w/w
|
Disintegration time, dissolution (over-lubrication risk)
|
36
|
HPLC assay; disintegration time monitoring
|
Critical Process Parameters (CPPs)
Process
parameters were identified through systematic risk assessment and DoE
approaches. The following CPPs are defined for direct compression
manufacturing.[51][54][55]
Table 4. Critical Process Parameters for
Apixaban ODT Direct Compression Manufacturing
|
Critical Process Parameter
|
Acceptable Range
|
Target Setpoint
|
Impact on CQAs
|
Control Strategy
|
|
Blending Time
|
10–20 minutes
|
15 minutes
|
Content uniformity, blend homogeneity
|
NIR in-line monitoring; sampling at
5-min intervals
|
|
Compression Force (Main)
|
8–15 kN
|
10.6 kN [55]
|
Hardness, friability, disintegration time, dissolution
|
Force-displacement monitoring; feedback control
|
|
Turret Speed
|
20–40 tablets/min
|
30 tablets/min
|
Dwell time, tablet weight variation,
hardness uniformity
|
Speed control with tablet weight
in-process checks
|
|
Dwell Time
|
80–150 ms
|
100 ms
|
Tablet consolidation, elastic recovery, hardness
|
Calculated from turret speed and punch geometry
|
|
Environmental Relative
Humidity
|
35–50% RH
|
40 ± 5% RH
|
Moisture uptake during compression,
electrostatic effects
|
HVAC control; RH monitoring in
compression room
|
|
Sublimation Temperature/Time
(if sublimation)
|
50–70°C / 2–4 hours
|
50°C / 6 hours
|
Residual moisture, chemical stability, porosity
|
Thermocouples + GC validation for complete subliming agent
removal
|
Artificial Neural Network Modelling for Formulation
Optimisation
Artificial
neural networks (ANNs) have emerged as the predominant machine learning tool
for pharmaceutical formulation optimisation due to superior capability in
modelling nonlinear relationships between formulation composition, processing
conditions, and product performance.[56]
For
apixaban ODT development, ANN implementation follows a structured workflow
aligned with FDA's 7-step risk-based credibility assessment framework.[13]
Network Architecture: single hidden layer with 5–10 nodes using hyperbolic
tangent activation functions, as demonstrated in clinically validated
pharmaceutical ANN applications achieving R² >0.94 for dissolution and
bioavailability predictions.[57]
Data
Splitting Strategy: training set 67% of data for model fitting; validation set
33% for independent performance assessment (random holdback);[57]
external test set 10% from confirmatory runs or pilot-scale batches.
Overfitting Control Mechanisms include: early stopping when validation error
increases for consecutive epochs;[56]
optimal hidden layer selection through systematic evaluation of 3–15 hidden
nodes.[56]
Performance
Metrics: R² >0.90 for training, >0.85 for validation;[57][56]
Q² (cross-validated R²) >0.80 for predictive validity;[51]
RMSE <5% of response range.[58][59][60]
SHAP
(SHapley Additive exPlanations) analysis for model interpretability enables
identification of most influential formulation variables, detection of
interaction effects, and transparent communication of model predictions to
regulatory reviewers.[61]
Real-Time
Release Testing (RTRT): ANN-based prediction of disintegration time from
in-process CMAs enables release decisions without destructive testing. Final
prediction equation DT = 34.09 + 2×D_c + 3.59×%H − 5.29×%H×D_c achieved R² =
0.9017 with average relative prediction error of 3.69%.[58]
Genetic Algorithm Optimisation for Multi-Objective
Formulation Design
Genetic
algorithms (GAs) are population-based evolutionary optimisation techniques employed
for exploring high-dimensional formulation design spaces and resolving
competing CQA objectives.[56][62]
For
apixaban ODTs, GA optimisation addresses inherent trade-offs between rapid
disintegration, mechanical robustness, dissolution enhancement, and moisture
stability. The Pareto Dominance principle states that a solution x₁ dominates
x₂ if x₁ is no worse than x₂ in all objectives and strictly better in at least
one. Multi-objective evolutionary algorithms (MOEAs) generate a set of
non-dominated solutions representing optimal trade-offs.[62][63]
The
Desirability Function approach transforms multi-objective problems into a
single composite score: D = (∏ dᵢwᵢ)^(1/Σwᵢ), where dᵢ = individual
desirability for objective i (0 = unacceptable, 1 = ideal) and wᵢ = weight
reflecting relative importance. For apixaban ODTs, regulatory-critical
objectives (disintegration ≤30s, friability ≤1%) receive higher weights
(w=3–5), while cost optimisation receives lower weight (w=1).[62][54]
GA
Implementation includes: population size 50–100 candidate formulations;
single-point or uniform crossover with probability Pc=0.7–0.9; Gaussian or
polynomial mutation with probability Pm=0.01–0.05; termination at maximum
100–500 generations or convergence (Pareto front hypervolume change <1% over
20 generations). Surrogate-Based Acceleration: ANNs serve as computationally
efficient surrogates, with initial DoE (40 experiments) → ANN training → GA
optimisation (200 generations × 100 population = 20,000 evaluations) →
validation of top 10 Pareto-optimal formulations.[56]
Artificial Intelligence-Assisted Regulatory
Documentation for Apixaban Orodispersible Tablets
Electronic Common Technical Document Structure and AI
Content Integration
The
eCTD format, harmonised under ICH M4, organises regulatory submissions into
five modules: Module 1 (regional administrative information), Module 2 (CTD
summaries), Module 3 (Quality–CMC), Module 4 (Nonclinical study reports),
Module 5 (Clinical study reports).[64][65]
For
apixaban ODT submissions, Modules 2, 3, and 5 contain AI-optimised formulation
data and require specific documentation of AI credibility assessment. The
integration of AI into pharmaceutical development necessitates transparent
documentation of AI model development, validation, and deployment within
regulatory submissions to ensure credibility and compliance with data integrity
requirements.[66][13]
eCTD Module 2: Quality Overall Summary and Integration
of AI-Derived Data
Module
2.3.S documents drug substance general information (nomenclature,
physicochemical properties including polymorphic screening via XRPD and DSC,
solubility studies, particle size distribution), manufacture, characterisation,
and control of drug substance. AI-assisted drug–excipient compatibility
screening via DE-INTERACT tool (3,500+ instance ANN model with training
accuracy 0.9930, validation accuracy 0.9161) should be documented with model
architecture, validation results, and regulatory justification.[67]
Module
2.3.P documents the drug product, with the pharmaceutical development section
(2.3.P.2) being the core of QbD documentation. This section must
comprehensively describe: Quality Target Product Profile (QTPP) and Critical
Quality Attributes (CQAs); risk assessment (FMEA and Ishikawa diagram) and
CMA/CPP identification;[53]
Design of Experiments and design space establishment with ANN model achieving
R² >0.86, Q² >0.64 for all CQA responses;[51]
AI model credibility assessment per FDA 7-step framework[13]
with demonstrated R² = 0.94 for disintegration prediction and average relative
error 4.1% on pilot batches;[68]
and genetic algorithm multi-objective optimisation with Pareto front analysis
identifying non-dominated formulations and final formulation selected with
desirability function D = 0.82.[62][54]
eCTD Module 3: Quality Documentation (CMC)
Module
3.2.S contains extended characterisation data, complete spectroscopic data
(¹H-NMR, ¹³C-NMR, IR, UV, MS), and forced degradation studies per ICH Q1B.[8]
Module
3.2.P.2 (Pharmaceutical Development) must include: the complete DoE design
matrix and raw data; ANN model documentation specifying architecture (single
hidden layer, 7 nodes, hyperbolic tangent activation),[57]
training data characterisation, model training and validation performance
statistics (training R² = 0.946 for disintegration, 0.921 for dissolution;
RMSE: disintegration 2.1 s, dissolution 3.8%), external validation on 5
pilot-scale batches (average relative error 4.1%);[68]
variable importance ranking via connection weight analysis;[56]
and GA optimisation record with Pareto frontier analysis and validated
GA-optimised formulation (disintegration 18.5 ± 1.2 s, dissolution 86.3 ± 2.1%
at 30 min, hardness 68.4 ± 3.5 N, friability 0.73 ± 0.08%).[54]
Stage
3 (Continued Process Verification): AI-powered CPV framework with Isolation
Forest anomaly detection model and random forest predictive control model
applied to batch data to identify deviations from normal operating conditions.[69]
Table 5.
Drug Product Specification – Apixaban Orodispersible Tablets
|
Test
|
Specification
|
Method
|
|
Appearance
|
White to off-white,
round, biconvex tablet
|
Visual
|
|
Identification
|
Retention time corresponds to apixaban
standard
|
HPLC
|
|
Assay
|
90.0–110.0% of labelled
amount
|
HPLC
|
|
Content Uniformity
|
Meets USP <905> (AV ≤15.0)
|
HPLC
|
|
Dissolution
|
≥80% (Q) at 30 min in
pH 6.8 phosphate buffer with 0.5% SLS
|
USP <711>
|
|
Disintegration Time
|
≤30 seconds
|
USP <701>
|
|
Hardness
|
40–100 N
|
Tablet hardness tester
|
|
Friability
|
≤1.0%
|
USP <1216>
|
|
Moisture
Content
|
2.0–4.0%
|
Karl Fischer titration
|
|
Impurities (Total)
|
≤2.0%
|
HPLC
|
|
Microbiological
Quality
|
Total aerobic count
≤10³ CFU/g; Total yeast/Mould ≤10² CFU/g; Absence of specified pathogens
|
USP <61>,
<62>
|
eCTD Module 5: Bioequivalence Strategy
For
apixaban ODTs, bioequivalence (BE) to the reference film-coated tablet
formulation (Eliquis®) is the regulatory pathway for approval. The BE study
design follows FDA and EMA guidance on orally disintegrating dosage forms:
randomised, open-label, single-dose, two-period, two-sequence crossover study
under fasting conditions; healthy adult volunteers (n=24–36); 90% confidence
intervals for geometric mean ratios (Test/Reference) of AUC₀₋ₜ, AUC₀₋∞, and
Cmax must fall within 80.00–125.00%.[70][71]
BCS-based
biowaiver: apixaban is BCS Class II (low solubility, high permeability);
biowaivers are not applicable per FDA M9 guidance. AI-assisted PBPK models
integrated with AI predict bioavailability based on dissolution profile,
particle size, and formulation composition; models inform go/no-go decisions
before expensive clinical trials.[72][52]
Data Integrity, ALCOA+ Compliance, and AI Model
Governance
ALCOA+
defines the data integrity framework required for GMP compliance and regulatory
inspection readiness.[73][74]
All AI model training data, predictions, and decisions must be linked to
specific user IDs, timestamps, and batch records via electronic laboratory
notebooks (ELN) with audit trails per 21 CFR Part 11.[75]
AI
Model Lifecycle Management per ICH Q12: Established Conditions (ECs) for the
ANN model include model architecture, training dataset composition, and
validation acceptance criteria. Product Lifecycle Management (PLM) specifies
change categories: (1) model retraining with expanded dataset (low risk,
company discretion); (2) architecture modification (moderate risk, Prior
Approval Supplement); (3) change in context of use (high risk, Prior Approval
Supplement with clinical data if applicable).[76]
Table 6. Regulatory
Compliance Checklist for AI-Generated Dossiers
|
Category
|
Requirement
|
Compliance Evidence
|
Reference
|
|
Governance
|
AI use disclosed in Module 2.3.R
Regional Information
|
AI tools (ANN, GA) explicitly described
in QOS pharmaceutical development section
|
FDA 7-step framework [13]
|
|
Governance
|
AI model context of use clearly defined
|
COU statement: "ANN predicts CQAs from CMAs/CPPs; serves as
formulation screening tool supplemented by confirmatory experiments"
|
FDA 7-step framework Step 2 [13]
|
|
Data Integrity
|
Audit trail for AI-generated data per 21
CFR Part 11
|
Electronic laboratory notebooks with
immutable timestamps; all training data traceable to source experiments
|
21 CFR Part 11 [75]
|
|
Validation
|
External validation on independent batches
|
R² >0.85 on validation set; average relative error 4.1% on 5
pilot batches [68]
|
FDA 7-step framework Steps 4-6 [13]
|
|
Lifecycle
|
Post-approval change control for AI
model updates
|
ICH Q12 PLM document specifying change
categories, risk assessment, and regulatory notification pathways
|
ICH Q12 [76]
|
|
EMA Alignment
|
GMP compliance for AI in manufacturing
|
Annex 22 (draft) compliance roadmap; human oversight
documentation; model validation per proposed GMP guidelines
|
EMA Annex 22 [12]
|
CONCLUSIONS
The
development of apixaban orodispersible tablets (ODTs) represents a critical
advancement in addressing unmet therapeutic needs across three vulnerable patient
populations: dysphagic patients (post-stroke, neurological disorders,
head-and-neck cancer), geriatric patients with polypharmacy-related swallowing
difficulties, and paediatric patients requiring weight-based anticoagulation.[77][78]
Current
apixaban film-coated tablets present significant adherence barriers in these
populations, contributing to suboptimal stroke prevention outcomes despite
robust clinical efficacy demonstrated in large-scale trials.[79]
The ODT formulation strategy addresses multiple patient-centric challenges
simultaneously: elimination of water requirement for administration, rapid oral
disintegration (target <30 seconds), pleasant organoleptic properties
through effective taste masking, and maintenance of immediate-release
bioequivalence to reference tablets to preserve established pharmacokinetic and
safety profiles.
From
a formulation science perspective, apixaban's classification as a BCS Class II
drug – characterised by low aqueous solubility (0.04 mg/mL) – necessitates
sophisticated approaches.[80][81]
The integration of QbD principles provides the systematic framework to define
QTPP parameters, identify CQAs including disintegration time, dissolution
efficiency, content uniformity, and palatability, and map these to CMAs and
CPPs through comprehensive risk assessment tools.[82][83][84]
The
integration of AI and machine learning (AI/ML) into QbD workflows – termed
AI-enabled Quality by Design (AI-QbD) – represents a transformative paradigm
shift in pharmaceutical development efficiency and precision.[85][86][87]
The joint FDA-EMA principles on AI in medicine development emphasise
human-centric design, transparency, risk-based approaches to AI model
validation, and lifecycle management incorporating post-market model updating.[89]
For
apixaban ODT development specifically, future AI-QbD innovations may include:
(1) in silico prediction of patient acceptability through virtual taste panel
modelling; (2) digital twin manufacturing platforms that simulate entire
production campaigns before physical scale-up; (3) continuous learning systems
where post-market stability and dissolution data automatically refine
formulation models under ICH Q12 lifecycle management frameworks; and (4)
AI-assisted regulatory submission preparation that auto-generates CTD sections
from experimental databases with full traceability.[88][94]
The
convergence of AI-enabled formulation development, precision medicine
approaches to stroke prevention, and patient-centric drug delivery platforms
positions apixaban ODT as an exemplar of next-generation pharmaceutical
innovation – where computational intelligence accelerates translation of
therapeutic efficacy into real-world clinical benefit across the full spectrum
of patients requiring anticoagulation.
ACKNOWLEDGEMENTS
The
authors acknowledge the Department of Pharmaceutics, The Oxford College of
Pharmacy, Bengaluru, for institutional support. No external funding was
received for this work.
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