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Conway SL, Rosenberg KJ, Sotthivirat S, Goldfarb DJ. A Rational Hierarchy to Capture Raw Material Attribute Variability in the Pharmaceutical Drug Product Development and Manufacturing Lifecycle. J Pharm Sci 2024; 113:523-538. [PMID: 37838275 DOI: 10.1016/j.xphs.2023.10.014] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/14/2023] [Revised: 10/09/2023] [Accepted: 10/09/2023] [Indexed: 10/16/2023]
Abstract
Assessing the robustness of a drug product formulation and manufacturing process to variations in raw material (RM) properties is an essential aspect of pharmaceutical product development. Motivated by the need to demonstrate understanding of attribute-performance relationships at the time of new product registration and for subsequent process maintenance, we review practices to explore RM variations. We describe limitations that can arise when active ingredients and excipients invariably undergo changes during a drug product lifecycle. Historical approaches, such as Quality-by-Design (QbD) experiments, are useful for initial evaluations but can be inefficient and cumbersome to maintain once commercial manufacturing commences. The relatively miniscule data sets accessible in product development - used to predict response to a hypothetical risk of variation - become less relevant as real-world experience of actual variability in the commercial landscape grows. Based on our observations of development and manufacturing, we instead propose a holistic framework exploiting a hierarchy of RM variability, and challenge this with common failure modes. By explicitly incorporating higher ranking RM variations as perturbations, material-conserving experiments are shown to provide powerful and enduring robustness data. Case studies illustrate how correctly contextualizing such data in formulation and process development can avoid the traps of historical QbD approaches and become valuable for evaluating changes occurring later in the drug product lifecycle.
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Affiliation(s)
- Stephen L Conway
- Center for Materials Science and Engineering, MMD, Merck & Co., Inc., Rahway, NJ, USA; Current affiliation Packaging Commercialization, MMD Merck & Co., Inc., Rahway, NJ, USA.
| | - Kenneth J Rosenberg
- Center for Materials Science and Engineering, MMD, Merck & Co., Inc., Rahway, NJ, USA; Formerly of Merck & Co., Inc., Rahway, NJ, USA
| | - Sutthilug Sotthivirat
- Oral Formulation Sciences and Technology, MRL, Merck & Co., Inc., Rahway, NJ, USA; Formerly of Merck & Co., Inc., Rahway, NJ, USA
| | - David J Goldfarb
- Center for Materials Science and Engineering, MMD, Merck & Co., Inc., Rahway, NJ, USA
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2
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Kaewpradit S, Chingunpitak J, Samhadthai W, Suppawattana T, Jantarat C. Comparison of Properties of Acetaminophen Tablets Prepared by Wet Granulation Using Freeze-Dried Versus Phase-Inversion Bacterial Cellulose as Diluent. AAPS PharmSciTech 2024; 25:32. [PMID: 38332361 DOI: 10.1208/s12249-024-02752-7] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/22/2023] [Accepted: 01/23/2024] [Indexed: 02/10/2024] Open
Abstract
Bacterial cellulose (BC) is an interesting material for drug delivery applications due to its high purity. This study aimed to compare the properties of tablets prepared by the wet granulation method using bacterial cellulose prepared by different methods as a diluent, using acetaminophen as a model drug. BC used as diluents were prepared using two different methods: freeze-drying (BC-FD) and phase-inversion (BC-PI), and their characteristics were analyzed and compared with that of commercial microcrystalline cellulose PH 101 (Comprecel® M101). Acetaminophen tablets were prepared by wet granulation using BC-FD, BC-PI, or Comprecel® M101 as diluents, and their tablet properties were examined. The result showed that the morphology, polymorph, and crystallinity of BC-PI and Comprecel® M101 were similar but they were different compared with that of BC-FD. Tablets could be successfully formed using BC-PI and Comprecel® M101 as diluents without any physical defects but the tablet prepared using BC-FD as diluent appeared chipped edge. The characteristics (thickness, weight variation, hardness, friability, disintegration, drug content, and dissolution) of the tablets prepared using BC-PI diluent were also similar to those prepared using Comprecel® M101 diluent, but those of BC-FD diluent were inferior. This indicates that BC prepared in BC-PI can potentially be used as a diluent for tablets prepared by wet granulation.
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Affiliation(s)
- Sirikanya Kaewpradit
- Drug and Cosmetics Excellence Center, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand
- School of Pharmacy, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand
| | - Jiraporn Chingunpitak
- Drug and Cosmetics Excellence Center, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand
- School of Pharmacy, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand
| | - Wannaphorn Samhadthai
- School of Pharmacy, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand
| | | | - Chutima Jantarat
- Drug and Cosmetics Excellence Center, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand.
- School of Pharmacy, Walailak University, Thasala, Nakhon Si Thammarat, 80160, Thailand.
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3
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Anuschek M, Skelbæk-Pedersen AL, Kvistgaard Vilhelmsen T, Skibsted E, Zeitler JA, Rantanen J. Terahertz time-domain spectroscopy for the investigation of tablets prepared from roller compacted granules. Int J Pharm 2023; 642:123165. [PMID: 37356510 DOI: 10.1016/j.ijpharm.2023.123165] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/28/2023] [Revised: 06/19/2023] [Accepted: 06/20/2023] [Indexed: 06/27/2023]
Abstract
Roller compaction before tableting is a common unit operation to increase the processability of powders. Terahertz time-domain spectroscopy (THz-TDS) has recently been introduced as a potential process analytical technology (PAT) for measuring tablet porosity based on the refractive index of the tablet. Tablet porosity is a governing parameter for tablet disintegration and dissolution. The first aim of this study was to investigate tablets prepared from roller-compacted materials with THz-TDS to explore its usefulness for particle size evaluation of granules in tablets. Secondly, the impact of roller compaction and granule size before tablet compression on the established THz-TDS based measurement of tablet porosity was investigated. Microcrystalline cellulose and α-lactose monohydrate were roller compacted separately at five specific compaction forces (2, 4, 8, 12, and 16 kN cm-1) and fractionated into three size fractions. Tablets were prepared from the fractionated and unfractionated granules at twelve tableting pressures and subjected to THz-TDS transmission measurements. It was possible to use the scattering behaviour of the tablets at terahertz frequencies to describe the granulated materials' particle size changes during tableting. At the same time, prediction of porosity was impaired due to the deviation of the refractive index in strongly scattering samples. A correction method was introduced in which the porosity error was corrected based on the tablet's scattering behaviour, resulting in an improved prediction of tablet porosity. In conclusion, THz-TDS is considered a promising technique for the process monitoring of tableting based on its sensitivity to porosity and particle size changes within the tablet non-destructively, with a possible application as part of an in-process control strategy of the tableting of granulated or non-granulated materials.
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Affiliation(s)
- Moritz Anuschek
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark; ET Oral Product Development, Novo Nordisk A/S, Måløv, Denmark.
| | | | | | - Erik Skibsted
- ET Oral Product Development, Novo Nordisk A/S, Måløv, Denmark
| | - J Axel Zeitler
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Cambridge, UK
| | - Jukka Rantanen
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark
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4
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Interpretable artificial neural networks for retrospective QbD of pharmaceutical tablet manufacturing based on a pilot-scale developmental dataset. Int J Pharm 2023; 633:122620. [PMID: 36669581 DOI: 10.1016/j.ijpharm.2023.122620] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/23/2022] [Revised: 01/12/2023] [Accepted: 01/13/2023] [Indexed: 01/19/2023]
Abstract
As the pharmaceutical industry increasingly adopts the Pharma 4.0. concept, there is a growing need to effectively predict the product quality based on manufacturing or in-process data. Although artificial neural networks (ANNs) have emerged as powerful tools in data-rich environments, their implementation in pharmaceutical manufacturing is hindered by their black-box nature. In this work, ANNs were developed and interpreted to demonstrate their applicability to increase process understanding by retrospective analysis of developmental or manufacturing data. The in vitro dissolution and hardness of extended-release, directly compressed tablets were predicted from manufacturing and spectroscopic data of pilot-scale development. The ANNs using material attributes and operational parameters provided better results than using NIR or Raman spectra as predictors. ANNs were interpreted by sensitivity analysis, helping to identify the root cause of the batch-to-batch variability, e.g., the variability in particle size, grade, or substitution of the hydroxypropyl methylcellulose excipient. An ANN-based control strategy was also successfully utilized to mitigate the batch-to-batch variability by flexibly operating the tableting process. The presented methodology can be adapted to arbitrary data-rich manufacturing steps from active substance synthesis to formulation to predict the quality from manufacturing or development data and gain process understanding and consistent product quality.
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5
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Lee WB, Widjaja E, Heng PWS, Chan LW. Effect of excipient particle size distribution variability on compact tensile strength; and its in-line prediction by force-displacement and force-time profiling. Eur J Pharm Sci 2021; 159:105703. [PMID: 33444745 DOI: 10.1016/j.ejps.2021.105703] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/06/2020] [Revised: 12/18/2020] [Accepted: 01/06/2021] [Indexed: 11/16/2022]
Abstract
BACKGROUND Direct compression is potentially sensitive to particle size distribution (PSD) variability in pharmaceutical grade excipients. Yet, the impact is insufficiently studied. Furthermore, the use of force sensor as a process analytical technology (PAT) platform, to monitor the effect of PSD variations on compact tensile strength, is a readily available but underutilized strategy. METHODS To address these shortfalls, the effect of PSD variability on compaction was investigated. Low (4% w/w drug) and high (15% w/w drug) dose blends comprising chlorpheniramine, microcrystalline cellulose and spray-agglomerated lactose were tableted. The PSD of spray-agglomerated lactose was varied by adding ungranulated fines to simulate commercially-relevant variability. Tensile strength and disintegration time were determined. The use of force sensor, to generate force-displacement and force-time profiles, for in-line tensile strength prediction was evaluated. RESULTS Increasing proportion of ungranulated fines (≥ 16%) reduced tensile strength by 10% and 4% in low and high dose formulations (p < 0.02). Increased friction during compaction hindered particle movement and reduced the energy available for bonding. Nevertheless, disintegration performances were equally acceptable for immediate drug release (≈ 30 s). Modelling of tensile strength with force-displacement and force-time profiles yielded ≥ 98% accuracy for in-line prediction (relative root mean square error of prediction = 3.7% and 4.8%). CONCLUSION A better understanding of the relationship between PSD variability and direct compression was attained; and force-displacement and force-time profiling are pragmatic and elegant PAT strategies. Significantly, with further refinements, the force sensor in the rotary tablet press can be repurposed for process monitoring and quality inspection. This unlocks opportunities for process understanding and control, without additional investments in PAT platforms.
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Affiliation(s)
- Wee Beng Lee
- GEA-NUS Pharmaceutical Processing Research Laboratory, Department of Pharmacy, National University of Singapore, 18 Science Drive 4, Singapore 117543, Singapore
| | - Effendi Widjaja
- MSD International GmbH, 50 Tuas West Drive, Singapore 638408, Singapore
| | - Paul Wan Sia Heng
- GEA-NUS Pharmaceutical Processing Research Laboratory, Department of Pharmacy, National University of Singapore, 18 Science Drive 4, Singapore 117543, Singapore
| | - Lai Wah Chan
- GEA-NUS Pharmaceutical Processing Research Laboratory, Department of Pharmacy, National University of Singapore, 18 Science Drive 4, Singapore 117543, Singapore.
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Zarmpi P, Flanagan T, Meehan E, Mann J, Østergaard J, Fotaki N. Biopharmaceutical implications of excipient variability on drug dissolution from immediate release products. Eur J Pharm Biopharm 2020; 154:195-209. [PMID: 32681966 DOI: 10.1016/j.ejpb.2020.07.014] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/09/2019] [Revised: 07/02/2020] [Accepted: 07/13/2020] [Indexed: 12/13/2022]
Abstract
Elucidating the impact of excipient variability on oral product performance in a biopharmaceutical perspective would be beneficial and allow excipient implementation on Quality by Design (QbD) approaches. The current study investigated the impact of varying viscosity of binders (hypromellose (HPMC)) and superdisintegrants (sodium starch glycolate (SSG)) and particle size distribution of lubricants (magnesium stearate (MgSt)) on the in vitro dissolution of a highly and a poorly soluble drug from immediate release formulations. Compendial (pharmacopoeia buffers) and biorelevant (media simulating the gastrointestinal fluids) media and the USP 2 and USP 4 apparatuses were used to assess the exerted excipient effects on drug dissolution. Real-time dissolution UV imaging provided mechanistic insights into disintegration and dissolution of the immediate release formulations. Varying the viscosity type of HPMC or SSG did not significantly affect drug dissolution irrespective of the compound used. Faster drug dissolution was observed when decreasing the particle size of MgSt for the highly soluble drug. The use of real-time dissolution UV Imaging revealed the influential role of excipient variability on tablet disintegration, as for the highly soluble drug, tablets containing high viscosity HPMC or low particle size MgSt disintegrated faster as compared to the control tablets while for the poorly soluble drug, slower tablet disintegration was observed when increasing the viscosity of the HPMC as compared to the control tablets. Changes in drug dissolution when varying excipients may be anticipated if the excipient change has previously affected drug solubility. The use of multivariate data analysis revealed the influential biopharmaceutical factors such as critical excipient types/properties, drug aqueous solubility, medium/hydrodynamic characteristics affecting the impact of excipient variability on in vitro drug dissolution.
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Affiliation(s)
- P Zarmpi
- Department of Pharmacy and Pharmacology, University of Bath, Bath, United Kingdom
| | - T Flanagan
- Pharmaceutical Technology & Development, AstraZeneca, Macclesfield, United Kingdom; Currently at UCB Pharma, Chemin du Foriest, B - 1420 Braine-l'Alleud, Belgium
| | - E Meehan
- Pharmaceutical Technology & Development, AstraZeneca, Macclesfield, United Kingdom
| | - J Mann
- Pharmaceutical Technology & Development, AstraZeneca, Macclesfield, United Kingdom
| | - J Østergaard
- Department of Pharmacy, Faculty of Health and Medicinal Sciences, University of Copenhagen, Denmark
| | - N Fotaki
- Department of Pharmacy and Pharmacology, University of Bath, Bath, United Kingdom.
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Xie H, He Q, Zhao Y, Li H, Zhao M, Chen X, Cai Z, Fang K, Song H. In situ analysis of oxytetracycline tablets based on matrix-assisted laser desorption/ionization mass spectrometry imaging. RAPID COMMUNICATIONS IN MASS SPECTROMETRY : RCM 2020; 34:e8592. [PMID: 31515848 DOI: 10.1002/rcm.8592] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/05/2019] [Revised: 08/24/2019] [Accepted: 09/09/2019] [Indexed: 06/10/2023]
Abstract
RATIONALE A thorough understanding of the content and distribution of active ingredients in pharmaceuticals is essential for drug efficacy and safety. Technological advancements in mass spectrometry imaging present an opportunity for methodological innovation by providing qualification and quantification analysis, as well as spatial information, in the same assay, which has great potential for applications in the rapid analysis and quality control of drugs. METHODS Matrix-assisted laser desorption/ionization mass spectrometry imaging (MALDI-MSI) was employed to directly analyze oxytetracycline tablets in order to map the distribution of the active constituent within the whole tablet. Quantitative analysis was capable of differentiating tablets containing various doses of the active pharmaceutical ingredient. RESULTS To establish the methodology, detailed factors that influence matrix spraying and spatial resolution during sample preparation and the data acquisition process were optimized systematically. Quantitative analysis could differentiate the tablets containing various doses of the active compound. The proposed method was successfully applied to analyze real commercial tablets. CONCLUSIONS The developed method could successfully achieve the spatial location of oxytetracycline in actual tablet samples. These results could contribute to pharmaceutical tracing technology, especially the formulation process of tablets, which is helpful for monitoring the quality of pharmaceutical products and guaranteeing drug security.
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Affiliation(s)
- Hanyi Xie
- Shandong Analysis and Test Centre, Qilu University of Technology (Shandong Academy of Sciences), Jinan, Shandong, P.R. China
| | - Qichuan He
- Shandong Analysis and Test Centre, Qilu University of Technology (Shandong Academy of Sciences), Jinan, Shandong, P.R. China
| | - Yanfang Zhao
- Shandong Analysis and Test Centre, Qilu University of Technology (Shandong Academy of Sciences), Jinan, Shandong, P.R. China
| | - Huijuan Li
- Shandong Analysis and Test Centre, Qilu University of Technology (Shandong Academy of Sciences), Jinan, Shandong, P.R. China
| | - Mei Zhao
- Shandong Analysis and Test Centre, Qilu University of Technology (Shandong Academy of Sciences), Jinan, Shandong, P.R. China
| | - Xiangfeng Chen
- Shandong Analysis and Test Centre, Qilu University of Technology (Shandong Academy of Sciences), Jinan, Shandong, P.R. China
| | - Zongwei Cai
- State Key Laboratory of Environmental and Biological Analysis, Department of Chemistry, Hong Kong Baptist University, Hong Kong, China
| | - Kezhong Fang
- Shandong New Time Pharmaceutical Co., Ltd, Lunan Pharmaceutical Group, Linyi, Shandong, P.R. China
| | - Hexing Song
- Intelligene Biosystems (QingDao) Co. Ltd., Qingdao, Shandong, P.R. China
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8
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Grangeia HB, Silva C, Simões SP, Reis MS. Quality by design in pharmaceutical manufacturing: A systematic review of current status, challenges and future perspectives. Eur J Pharm Biopharm 2020; 147:19-37. [DOI: 10.1016/j.ejpb.2019.12.007] [Citation(s) in RCA: 55] [Impact Index Per Article: 13.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2019] [Revised: 12/03/2019] [Accepted: 12/11/2019] [Indexed: 12/17/2022]
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9
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Muliadi AR, Banda A, Mao C. Recent Progress in Roll Compaction Process Development for Pharmaceutical Solid Dosage Form Manufacture. CONTINUOUS PHARMACEUTICAL PROCESSING 2020. [DOI: 10.1007/978-3-030-41524-2_7] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/13/2023]
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10
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Lapham DP, Lapham JL. BET surface area measurement of commercial magnesium stearate by krypton adsorption in preference to nitrogen adsorption. Int J Pharm 2019; 568:118522. [PMID: 31319149 DOI: 10.1016/j.ijpharm.2019.118522] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/05/2019] [Revised: 06/18/2019] [Accepted: 07/13/2019] [Indexed: 11/28/2022]
Affiliation(s)
- Darren P Lapham
- MCA Services, Unit 1A Long Barn, North End, Meldreth, Cambridgeshire, UK.
| | - Julie L Lapham
- MCA Services, Unit 1A Long Barn, North End, Meldreth, Cambridgeshire, UK
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11
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Integrated continuous manufacturing in pharmaceutical industry: current evolutionary steps toward revolutionary future. Pharm Pat Anal 2019; 8:139-161. [DOI: 10.4155/ppa-2019-0011] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
Abstract
Continuous manufacturing (CM) has the potential to provide pharmaceutical products with better quality, improved yield and with reduced cost and time. Moreover, ease of scale-up, small manufacturing footprint and on-line/in-line monitoring and control of the process are other merits for CM. Regulating authorities are supporting the adoption of CM by pharmaceutical manufacturers through issuing proper guidelines. However, implementation of this technology in pharmaceutical industry is encountered by a number of challenges regarding the process development and quality assurance. This article provides a background on the implementation of CM in pharmaceutical industry, literature survey of the most recent state-of-the-art technologies and critically discussing the encountered challenges and its future prospective in pharmaceutical industry.
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12
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Gavan A, Iurian S, Casian T, Porfire A, Porav S, Voina I, Oprea A, Tomuta I. Fluidised bed granulation of two APIs: QbD approach and development of a NIR in-line monitoring method. Asian J Pharm Sci 2019; 15:506-517. [PMID: 32952673 PMCID: PMC7486511 DOI: 10.1016/j.ajps.2019.03.003] [Citation(s) in RCA: 18] [Impact Index Per Article: 3.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/22/2018] [Revised: 01/28/2019] [Accepted: 03/18/2019] [Indexed: 11/18/2022] Open
Abstract
The study focused on the fluid-bed granulation process of a product with two active pharmaceutical ingredients, intended for coated tablets preparation and further transfer to industrial scale. The work aimed to prove that an accurate control of the critical granulation parameters can level the input material variability and offer a user-friendly process control strategy. Moreover, an in-line Near-Infrared monitoring method was developed, which offered a real time overview of the moisture level along the granulation process, thus a reliable supervision and control process analytical technology (PAT) tool. The experimental design's results showed that the use of apparently interchangeable active pharmaceutical ingredients (APIs) and filler sorts that comply with pharmacopoeial specifications, lead to different end-product critical attributes. By adapting critical granulation parameters (i.e. binder spray rate and atomising pressure) as a function of material characteristics, led to granules with average sizes comprised in a narrow range of 280–320 µm and low non-granulated fraction of under 5%. Therefore, the accurate control of process parameters according to the formulation particularities achieved the maintenance of product within the design space and removed material related variability. To complete the Quality by design (QbD) strategy, despite its limited spectral domain, the microNIR spectrometer was successfully used as a robust PAT monitoring tool that offered a real time overview of the moisture level and allowed the supervision and control of the granulation process.
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Affiliation(s)
- Alexandru Gavan
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | - Sonia Iurian
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
- Corresponding author. Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, 41 Victor Babes Street, Cluj-Napoca 400012, Romania. Tel.: +40 74 5629083.
| | - Tibor Casian
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | - Alina Porfire
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | - Sebastian Porav
- National Institute for Research and Development of Isotopic and Molecular Technologies, Cluj-Napoca 400293, Romania
| | - Ioana Voina
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
| | | | - Ioan Tomuta
- Faculty of Pharmacy, Iuliu Hatieganu University of Medicine and Pharmacy, Cluj-Napoca 400012, Romania
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13
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Burcham CL, Florence AJ, Johnson MD. Continuous Manufacturing in Pharmaceutical Process Development and Manufacturing. Annu Rev Chem Biomol Eng 2019; 9:253-281. [PMID: 29879381 DOI: 10.1146/annurev-chembioeng-060817-084355] [Citation(s) in RCA: 72] [Impact Index Per Article: 14.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
The pharmaceutical industry has found new applications for the use of continuous processing for the manufacture of new therapies currently in development. The transformation has been encouraged by regulatory bodies as well as driven by cost reduction, decreased development cycles, access to new chemistries not practical in batch, improved safety, flexible manufacturing platforms, and improved product quality assurance. The transformation from batch to continuous manufacturing processing is the focus of this review. The review is limited to small, chemically synthesized organic molecules and encompasses the manufacture of both active pharmaceutical ingredients (APIs) and the subsequent drug product. Continuous drug product is currently used in approved processes. A few examples of production of APIs under current good manufacturing practice conditions using continuous processing steps have been published in the past five years, but they are lagging behind continuous drug product with respect to regulatory filings.
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Affiliation(s)
- Christopher L Burcham
- Small Molecule Design and Development, Eli Lilly and Company, Lilly Research Laboratory, Indianapolis, Indiana 48525, USA; ,
| | - Alastair J Florence
- EPSRC Future CMAC Hub, Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow, G11XQ United Kingdom;
| | - Martin D Johnson
- Small Molecule Design and Development, Eli Lilly and Company, Lilly Research Laboratory, Indianapolis, Indiana 48525, USA; ,
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14
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Lapham DP, Lapham JL. Gas adsorption on commercial magnesium stearate: The origin of atypical isotherms and BET transform data. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2018.10.035] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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15
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Stauffer F, Vanhoorne V, Pilcer G, Chavez PF, Schubert MA, Vervaet C, De Beer T. Managing active pharmaceutical ingredient raw material variability during twin-screw blend feeding. Eur J Pharm Biopharm 2018; 135:49-60. [PMID: 30582959 DOI: 10.1016/j.ejpb.2018.12.012] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/30/2018] [Revised: 10/31/2018] [Accepted: 12/20/2018] [Indexed: 10/27/2022]
Abstract
Continuous powder feeding is a critical step in continuous manufacturing of solid dosage forms, as this unit operation should ensure the mass flow consistency at the desired powder feed rate to guarantee the process throughput and final product consistency. In this study, twin-screw feeding of a pharmaceutical formulation (i.e., blend) existing of a highly dosed very poorly flowing active pharmaceutical ingredient (API) leading to insufficient feeding capacity was investigated. Furthermore, the API showed very high batch-to-batch variability in raw material properties dominating the formulation blend properties. Formulation changes were evaluated to improve the flowability of the blends and to mitigate the impact of API batch-to-batch variability on the twin-screw feeding. Herewith, feeding evaluation tests and an extensive material characterization of the reformulated blends were performed to assess the impact of the formulation changes upon continuous twin-screw feeding. The transfer of the glidant from extra-granular to intra-granular phase allowed to improve the flowability of the blends. A sufficient feeding capacity for the downstream process and a mitigation of the impact of batch-to-batch variability of the API upon twin-screw feeding of the blends could be achieved. No effect of the formulation or of the API properties on the feeding stability was observed. The material characterization of the blends allowed identifying the material attributes which were critical for continuous twin-screw feeding (i.e., bulk density, mass charge and powder cohesiveness).
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Affiliation(s)
- F Stauffer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium
| | - V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - G Pilcer
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | | | - M A Schubert
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium
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16
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Stauffer F, Vanhoorne V, Pilcer G, Chavez PF, Rome S, Schubert MA, Aerts L, De Beer T. Raw material variability of an active pharmaceutical ingredient and its relevance for processability in secondary continuous pharmaceutical manufacturing. Eur J Pharm Biopharm 2018; 127:92-103. [PMID: 29452241 DOI: 10.1016/j.ejpb.2018.02.017] [Citation(s) in RCA: 28] [Impact Index Per Article: 4.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/09/2017] [Revised: 02/12/2018] [Accepted: 02/12/2018] [Indexed: 10/18/2022]
Abstract
Active Pharmaceutical Ingredients (API) raw material variability is not always thoroughly considered during pharmaceutical process development, mainly due to low quantities of drug substance available. However, synthesis, crystallization routes and production sites evolve during product development and product life cycle leading to changes in physical material attributes which can potentially affect their processability. Recent literature highlights the need for a global approach to understand the link between material synthesis, material variability, process and product quality. The study described in this article aims at explaining the raw material variability of an API using extensive material characterization on a restricted number of representative batches using multivariate data analysis. It is part of a larger investigation trying to link the API drug substance manufacturing process, the resulting physical API raw material attributes and the drug product continuous manufacturing process. Eight API batches produced using different synthetic routes, crystallization, drying, delumping processes and processing equipment were characterized, extensively. Seventeen properties from seven characterization techniques were retained for further analysis using Principal Component Analysis (PCA). Three principal components (PCs) were sufficient to explain 92.9% of the API raw material variability. The first PC was related to crystal length, agglomerate size and fraction, flowability and electrostatic charging. The second PC was driven by the span of the particle size distribution and the agglomerates strength. The third PC was related to surface energy. Additionally, the PCA allowed to summarize the API batch-to-batch variability in only three PCs which can be used in future drug product development studies to quantitatively evaluate the impact of the API raw material variability upon the drug product process. The approach described in this article could be applied to any other compound which is prone to batch-to-batch variability.
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Affiliation(s)
- F Stauffer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium
| | - V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - G Pilcer
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | - P-F Chavez
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | - S Rome
- Analytical Sciences for Pharmaceuticals, UCB, Braine l'Alleud, Belgium
| | - M A Schubert
- Drug Delivery Design and Development, UCB, Braine l'Alleud, Belgium
| | - L Aerts
- Analytical Sciences for Pharmaceuticals, UCB, Braine l'Alleud, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium.
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Lapham DP, Lapham JL. Gas adsorption on commercial magnesium stearate: Effects of degassing conditions on nitrogen BET surface area and isotherm characteristics. Int J Pharm 2017; 530:364-376. [DOI: 10.1016/j.ijpharm.2017.08.003] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/16/2017] [Revised: 07/25/2017] [Accepted: 08/01/2017] [Indexed: 10/19/2022]
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18
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Zarmpi P, Flanagan T, Meehan E, Mann J, Fotaki N. Biopharmaceutical aspects and implications of excipient variability in drug product performance. Eur J Pharm Biopharm 2017; 111:1-15. [DOI: 10.1016/j.ejpb.2016.11.004] [Citation(s) in RCA: 48] [Impact Index Per Article: 6.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/13/2016] [Revised: 11/02/2016] [Accepted: 11/07/2016] [Indexed: 12/29/2022]
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19
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Understanding the impact of microcrystalline cellulose physicochemical properties on tabletability. Int J Pharm 2015; 490:47-54. [DOI: 10.1016/j.ijpharm.2015.05.026] [Citation(s) in RCA: 46] [Impact Index Per Article: 5.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/03/2015] [Revised: 05/07/2015] [Accepted: 05/09/2015] [Indexed: 11/22/2022]
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20
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Dave VS, Saoji SD, Raut NA, Haware RV. Excipient Variability and Its Impact on Dosage Form Functionality. J Pharm Sci 2015; 104:906-15. [DOI: 10.1002/jps.24299] [Citation(s) in RCA: 64] [Impact Index Per Article: 7.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/15/2014] [Revised: 10/30/2014] [Accepted: 11/14/2014] [Indexed: 11/08/2022]
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21
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Thoorens G, Krier F, Leclercq B, Carlin B, Evrard B. Microcrystalline cellulose, a direct compression binder in a quality by design environment—A review. Int J Pharm 2014; 473:64-72. [DOI: 10.1016/j.ijpharm.2014.06.055] [Citation(s) in RCA: 231] [Impact Index Per Article: 23.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/26/2014] [Revised: 06/22/2014] [Accepted: 06/27/2014] [Indexed: 10/25/2022]
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22
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Fonteyne M, Wickström H, Peeters E, Vercruysse J, Ehlers H, Peters BH, Remon JP, Vervaet C, Ketolainen J, Sandler N, Rantanen J, Naelapää K, De Beer T. Influence of raw material properties upon critical quality attributes of continuously produced granules and tablets. Eur J Pharm Biopharm 2014; 87:252-63. [PMID: 24589422 DOI: 10.1016/j.ejpb.2014.02.011] [Citation(s) in RCA: 61] [Impact Index Per Article: 6.1] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2013] [Revised: 02/20/2014] [Accepted: 02/21/2014] [Indexed: 11/28/2022]
Abstract
Continuous manufacturing gains more and more interest within the pharmaceutical industry. The International Conference of Harmonisation (ICH) states in its Q8 'Pharmaceutical Development' guideline that the manufacturer of pharmaceuticals should have an enhanced knowledge of the product performance over a range of raw material attributes, manufacturing process options and process parameters. This fits further into the Process Analytical Technology (PAT) and Quality by Design (QbD) framework. The present study evaluates the effect of variation in critical raw material properties on the critical quality attributes of granules and tablets, produced by a continuous from-powder-to-tablet wet granulation line. The granulation process parameters were kept constant to examine the differences in the end product quality caused by the variability of the raw materials properties only. Theophylline-Lactose-PVP (30-67.5-2.5%) was used as model formulation. Seven different grades of theophylline were granulated. Afterward, the obtained granules were tableted. Both the characteristics of granules and tablets were determined. The results show that differences in raw material properties both affect their processability and several critical quality attributes of the resulting granules and tablets.
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Affiliation(s)
- Margot Fonteyne
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium.
| | - Henrika Wickström
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium; Pharmaceutical Sciences Laboratory, Department of Biosciences, Åbo Akademi University, Turku, Finland
| | - Elisabeth Peeters
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - Jurgen Vercruysse
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - Henrik Ehlers
- Pharmaceutical Sciences Laboratory, Department of Biosciences, Åbo Akademi University, Turku, Finland
| | | | - Jean Paul Remon
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Ghent, Belgium
| | | | - Niklas Sandler
- Pharmaceutical Sciences Laboratory, Department of Biosciences, Åbo Akademi University, Turku, Finland
| | - Jukka Rantanen
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark
| | - Kaisa Naelapää
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ghent, Belgium.
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Kushner J, Langdon BA, Hicks I, Song D, Li F, Kathiria L, Kane A, Ranade G, Agarwal K. A Quality-by-Design Study for an Immediate-Release Tablet Platform: Examining the Relative Impact of Active Pharmaceutical Ingredient Properties, Processing Methods, and Excipient Variability on Drug Product Quality Attributes. J Pharm Sci 2014; 103:527-38. [DOI: 10.1002/jps.23810] [Citation(s) in RCA: 28] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2013] [Revised: 10/22/2013] [Accepted: 10/29/2013] [Indexed: 11/10/2022]
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25
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26
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Kushner J. Utilizing quantitative certificate of analysis data to assess the amount of excipient lot-to-lot variability sampled during drug product development. Pharm Dev Technol 2011; 18:333-42. [DOI: 10.3109/10837450.2011.604784] [Citation(s) in RCA: 20] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022]
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