Mesoporous Silica Microparticle Tablets for Optimised Formulation and Overcoming Compressibility Challenges

Tablets are the most commonly used dosage form due to their low manufacturing cost and ease of administration. Incorporating mesoporous silica microparticles offers enhanced control over drug release and bioavailability; however, formulation remains challenging due to poor compressibility and disintegration characteristics. This study explores dynamic formulation strategies to enable successful incorporation of SYLOID XDP 3150 (SYLOID) into oral tablet formulations. Tablets were prepared via direct compression using varying ratios of Avicel PH 102 (MCC: microcrystalline cellulose) and lactose monohydrate (25:75, 50:50, and 75:25) with SYLOID incorporated at 0%, 20%, and 40% (w/w). A 500 mg tablet mass was maintained throughout, and SYLOID alone was also compressed to assess baseline behaviour. Key tablet properties including porosity, tensile strength, friability, and disintegration time were evaluated. Direct compression of SYLOID alone failed due to poor compactability and particle fragmentation at 221.72 MPa. Increased Avicel content led to reduced porosity and enhanced tensile strength, while higher SYLOID levels increased porosity but compromised mechanical strength and friability. Disintegration was faster in lactose-rich formulations but delayed with increased SYLOID due to its hydrophobicity. Incorporating a superdisintegrant and binder enabled the final formulations to meet USP requirements for disintegration and friability. Overall, SYLOID was shown to significantly affect tablet architecture and performance, necessitating excipient support to overcome its inherent limitations. These findings support further evaluation of drug-loaded SYLOID tablets to assess their impact on drug release profiles and oral bioavailability.