Orbital DPI: High-Payload, Patient-Centric Pulmonary Drug Delivery

Orbital DPI: Transforming High-Dose Pulmonary Drug Delivery 

Aptar Pharma’s Orbital Dry Powder Inhaler (DPI) platform represents a significant breakthrough in the field of pulmonary drug delivery, addressing the growing need for high-dose therapies in respiratory medicine. Diseases such as cystic fibrosis, non-CF bronchiectasis, and severe pulmonary infections often require the administration of large quantities of active pharmaceutical ingredient (API) directly to the lungs to achieve therapeutic efficacy. Traditional dry powder inhalers (DPIs) frequently struggle to deliver these high payloads efficiently, often requiring multiple device reloads and demanding high inspiratory flow rates from patients—many of whom have compromised lung function. 

The Orbital DPI platform was engineered to overcome these limitations. Capable of administering between 100 and 400 mg of API over several gentle breaths, Orbital offers a patient-friendly alternative to conventional DPIs. This multi-breath dosing approach not only improves comfort but also enhances adherence, as patients are no longer required to inhale a large bolus of powder in a single breath. The system’s design ensures that each inhalation delivers a consistent and optimal particle size, maximizing therapeutic benefit while minimizing variability due to patient technique or lung capacity. 

Innovative Aerosolization Engine 

At the core of the Orbital platform is a unique, high-energy de-agglomeration mechanism that sets it apart from other inhalers. The Orbital engine utilizes a combination of orbital and spinning motions to fluidize and disperse cohesive powders, which are typically challenging to aerosolize due to strong interparticle forces. When the patient inhales, air is drawn through peripheral inlets, propelling the powder-containing reservoir into a rapid orbital motion around the chamber. This movement, combined with simultaneous spinning, creates a high-energy environment that breaks up agglomerates and disperses the powder into fine, respirable particles. 

This multistage process is carefully engineered to separate dose emission from particle dispersion. In many conventional DPIs, both functions are driven by a single patient inhalation, meaning a weaker breath results in both a lower emitted dose and poorer aerosolization. Orbital’s design decouples these processes: the epicyclical motion ensures efficient de-agglomeration, while the rate of dose emission is precisely controlled by the container’s engineered orifices. As a result, the aerodynamic particle size distribution remains consistent across breaths, regardless of the patient’s lung function or inspiratory effort. 

Patient-Centric and Digital Design 

Aptar Pharma’s commitment to patient-centric innovation is evident throughout the development of the Orbital DPI. Human factors engineering played a pivotal role, with user feedback guiding improvements in ergonomics, usability, and device handling. Early prototypes were refined to address issues such as grip comfort and loading orientation, resulting in a system that is intuitive and easy to use. The inclusion of digital inhalation counters and sensor integration further supports patient adherence and technique monitoring, paving the way for future “smart inhaler” capabilities. These features enable real-time feedback, dose tracking, and data transmission to clinicians, aligning Orbital with the evolving landscape of connected health devices. 

Formulation Versatility 

One of Orbital’s defining strengths is its versatility in handling a wide range of powder formulations. The platform efficiently aerosolizes both conventional blended powders and highly challenging biologic formulations, including proteins, peptides, and nucleic acids. The sealed container design protects sensitive formulations from moisture, ensuring reliable delivery of fragile biologics. This capability is particularly valuable as the industry moves toward more complex therapies, where maintaining the integrity and efficacy of biologic drugs is paramount. 

Clinical Impact: Validated Itraconazole Use Case 

Orbital’s clinical potential has been demonstrated through its validation with itraconazole, a broad-spectrum antifungal agent used in the treatment of pulmonary aspergillosis. Delivering fine particle doses exceeding 20 mg in a single administration, Orbital achieves lung concentrations that are orders of magnitude above the minimum inhibitory concentration for target pathogens. This represents a significant improvement over existing DPI technologies, enabling more effective treatment regimens, improved fungal clearance, and reduced systemic toxicity. The ability to deliver high doses with gentle breaths is especially advantageous for patients with compromised respiratory function. 

Conclusion 

In summary, Aptar Pharma’s Orbital DPI platform marks a major advancement in pulmonary drug delivery. By combining high-dose capability, innovative aerosolization technology, patient-centric design, and digital health integration, Orbital addresses the most pressing challenges in respiratory therapy. Its versatility and clinical validation position it as a robust solution for partners seeking to overcome the limitations of traditional inhalation devices and deliver transformative outcomes for patients.