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Integrated capacity and production planning in the pharmaceutical supply chain: framework and models. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2023.108163] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
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Destro F, Barolo M, Nagy ZK. Quality-by-control of intensified continuous filtration-drying of active pharmaceutical ingredients. AIChE J 2023; 69:e17926. [PMID: 38633424 PMCID: PMC11022276 DOI: 10.1002/aic.17926] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/19/2022] [Accepted: 09/20/2022] [Indexed: 04/19/2024]
Abstract
Continuous manufacturing and closed-loop quality control are emerging technologies that are pivotal for next-generation pharmaceutical modernization. We develop a process control framework for a continuous carousel for integrated filtration-drying of crystallization slurries. The proposed control system includes model-based monitoring and control routines, such as state estimation and real-time optimization, implemented in a hierarchical, three-layer quality-by-control (QbC) framework. We implement the control system in ContCarSim, a publicly available carousel simulator. We benchmark the proposed control system against simpler methods, comprising a reduced subset of the elements of the overall control system, and against open-loop operation (the current standard in pharmaceutical manufacturing). The proposed control system demonstrates superior performance in terms of higher consistency in product quality and increased productivity, proving the benefits of closed-loop control and of model-based techniques in pharmaceutical manufacturing. This study represents a step forward toward end-to-end continuous pharmaceutical processing, and in the evolution of quality-by-design toward quality-by-control.
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Affiliation(s)
- Francesco Destro
- CAPE-Lab—Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, Padova, Italy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana, USA
| | - Massimiliano Barolo
- CAPE-Lab—Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, Padova, Italy
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, Indiana, USA
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Destro F, Nagy ZK, Barolo M. A benchmark simulator for quality-by-design and quality-by-control studies in continuous pharmaceutical manufacturing - Intensified filtration-drying of crystallization slurries. Comput Chem Eng 2022; 163:107809. [PMID: 38178942 PMCID: PMC10765423 DOI: 10.1016/j.compchemeng.2022.107809] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
Abstract
This article introduces ContCarSim, a benchmark simulator for the development and testing of quality-by-design and quality-by-control strategies in the continuous intensified filtration-drying of paracetamol/ethanol slurries on a novel carousel technology, developed by Alconbury Weston Ltd (United Kingdom). The simulator is based on a detailed mechanistic mathematical modeling framework, and has been validated with filtration and drying experiments on a prototype equipment. A set of design- and control-relevant challenges to be addressed through ContCarSim are proposed. A case study is developed, to demonstrate the features of the simulator and its suitability to design, test and optimize the unit operation. ContCarSim is expected to promote the transition to end-to-end continuous pharmaceutical manufacturing and the adoption of closed-loop quality control by the pharmaceutical industry. The simulator can also be employed as a benchmark for data analytics and process monitoring studies.
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Affiliation(s)
- Francesco Destro
- CAPE-Lab – Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD (Italy)
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Massimiliano Barolo
- CAPE-Lab – Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD (Italy)
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Destro F, Barolo M. A review on the modernization of pharmaceutical development and manufacturing - Trends, perspectives, and the role of mathematical modeling. Int J Pharm 2022; 620:121715. [PMID: 35367580 DOI: 10.1016/j.ijpharm.2022.121715] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2022] [Revised: 03/23/2022] [Accepted: 03/29/2022] [Indexed: 01/20/2023]
Abstract
Recently, the pharmaceutical industry has been facing several challenges associated to the use of outdated development and manufacturing technologies. The return on investment on research and development has been shrinking, and, at the same time, an alarming number of shortages and recalls for quality concerns has been registered. The pharmaceutical industry has been responding to these issues through a technological modernization of development and manufacturing, under the support of initiatives and activities such as quality-by-design (QbD), process analytical technology, and pharmaceutical emerging technology. In this review, we analyze this modernization trend, with emphasis on the role that mathematical modeling plays within it. We begin by outlining the main socio-economic trends of the pharmaceutical industry, and by highlighting the life-cycle stages of a pharmaceutical product in which technological modernization can help both achieve consistently high product quality and increase return on investment. Then, we review the historical evolution of the pharmaceutical regulatory framework, and we discuss the current state of implementation and future trends of QbD. The pharmaceutical emerging technology is reviewed afterwards, and a discussion on the evolution of QbD into the more effective quality-by-control (QbC) paradigm is presented. Further, we illustrate how mathematical modeling can support the implementation of QbD and QbC across all stages of the pharmaceutical life-cycle. In this respect, we review academic and industrial applications demonstrating the impact of mathematical modeling on three key activities within pharmaceutical development and manufacturing, namely design space description, process monitoring, and active process control. Finally, we discuss some future research opportunities on the use of mathematical modeling in industrial pharmaceutical environments.
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Affiliation(s)
- Francesco Destro
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy
| | - Massimiliano Barolo
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy.
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Lee BW, Yin K, Splaine K, Roesch B. Thin-Film Evaporator Model for Continuous Active Pharmaceutical Ingredient Manufacturing. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.9b03974] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Boung Wook Lee
- Product Development and Supply, GlaxoSmithKline, 1250 S. Collegeville Road, Collegeville, Pennsylvania, 19426, United States
| | - Kehua Yin
- Product Development and Supply, GlaxoSmithKline, 1250 S. Collegeville Road, Collegeville, Pennsylvania, 19426, United States
| | - Kevin Splaine
- Product Development and Supply, GlaxoSmithKline, 1250 S. Collegeville Road, Collegeville, Pennsylvania, 19426, United States
| | - Brian Roesch
- Product Development and Supply, GlaxoSmithKline, 1250 S. Collegeville Road, Collegeville, Pennsylvania, 19426, United States
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Lambert E, Gorantla VS, Janjic JM. Pharmaceutical design and development of perfluorocarbon nanocolloids for oxygen delivery in regenerative medicine. Nanomedicine (Lond) 2019; 14:2697-2712. [PMID: 31657273 DOI: 10.2217/nnm-2019-0260] [Citation(s) in RCA: 22] [Impact Index Per Article: 4.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/10/2023] Open
Abstract
Perfluorocarbons (PFCs) have been investigated as oxygen carriers for several decades in varied biomedical applications. PFCs are chemically and biologically inert, temperature and storage stable, pose low to no infectious risk, can be commercially manufactured, and have well established gas transport properties. In this review, we highlight design and development strategies for their successful application in regenerative medicine, transplantation and organ preservation. Effective tissue preservation strategies are key to improving outcomes of extremity salvage and organ transplantation. Maintaining tissue integrity requires adequate oxygenation to support aerobic metabolism. The use of whole blood for oxygen delivery is fraught with limitations of poor shelf stability, infectious risk, religious exclusions and product shortages. Other agents also face clinical challenges in their implementation. As a solution, we discuss new ways of designing and developing PFC-based artificial oxygen carriers by implementing modern pharmaceutical quality by design and scale up manufacturing methodologies.
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Affiliation(s)
- Eric Lambert
- Graduate School of Pharmaceutical Sciences, School of Pharmacy, Duquesne University, Pittsburgh, PA 15282, USA.,Chronic Pain Research Consortium, Duquesne University, Pittsburgh, PA 15282, USA
| | - Vijay S Gorantla
- Department of Surgery, Wake Forest Institute for Regenerative Medicine, Winston-Salem, NC 27101, USA.,AIRMED Program, 59th Medical Wing, United States Air Force, United States Army Institute of Surgical Research, San Antonio, TX 78234, USA
| | - Jelena M Janjic
- Graduate School of Pharmaceutical Sciences, School of Pharmacy, Duquesne University, Pittsburgh, PA 15282, USA.,Chronic Pain Research Consortium, Duquesne University, Pittsburgh, PA 15282, USA.,AIRMED Program, 59th Medical Wing, United States Air Force, United States Army Institute of Surgical Research, San Antonio, TX 78234, USA
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Tabora JE, Lora Gonzalez F, Tom JW. Bayesian probabilistic modeling in pharmaceutical process development. AIChE J 2019. [DOI: 10.1002/aic.16744] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/20/2023]
Affiliation(s)
- Jose E. Tabora
- Chemical & Synthetic Development, Product Development Bristol‐Myers Squibb Company New Brunswick NJ USA
| | - Federico Lora Gonzalez
- Chemical & Synthetic Development, Product Development Bristol‐Myers Squibb Company New Brunswick NJ USA
| | - Jean W. Tom
- Chemical & Synthetic Development, Product Development Bristol‐Myers Squibb Company New Brunswick NJ USA
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