Background/Objectives: This study explores the integration of Design of Experiments (DoE) with Physiologically Based Biopharmaceutics Modeling (PBBM) to streamline the development of extended-release (XR) formulations. Using donepezil (DPZ) as a model drug, we developed an optimized XR formulation exhibiting a dissolution profile comparable to the reference product, Aricept® (Eisai GmbH, Frankfurt, Germany). Methods: A Box–Behnken experimental design was applied to systematically evaluate how formulation variables—HPMC 100, HPMC 4000, and NaCMC—affect drug release kinetics, tablet hydration, and erosion. This strategy enabled the identification of optimal excipient concentrations with minimal experimental effort. Results: The in vitro dissolution data were then integrated into a PBBM framework to simulate drug release and pharmacokinetics, enabling virtual bioequivalence (VBE) assessments. The combined approach provided robust predictive insights into formulation performance, substantially reducing reliance on resource-intensive in vivo studies. Beyond its successful application with DPZ, this integrated methodology offers a scalable and generalizable strategy for efficiently developing bioequivalent XR formulations for various clinically relevant drugs. Conclusions: Our findings highlight the importance of leveraging advanced statistical methods and in silico modeling to overcome contemporary pharmaceutical development challenges, paving the way for innovative, cost-effective solutions that significantly accelerate time-to-market.
Loading....