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Chandrababu KB, Kannan A, Savage JR, Stadmiller S, Ryle AE, Cheung C, Kelley RF, Maa YF, Saggu M, Bitterfield DL. Stability Comparison Between Microglassification and Lyophilization Using a Monoclonal Antibody. J Pharm Sci 2024; 113:1054-1060. [PMID: 37863428 DOI: 10.1016/j.xphs.2023.10.021] [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: 06/15/2023] [Revised: 10/13/2023] [Accepted: 10/13/2023] [Indexed: 10/22/2023]
Abstract
Producing solid-state formulations of biologics remains a daunting task despite the prevalent use of lyophilization and spray drying technologies in the biopharmaceutical industry. The challenges include protein stability (temperature stresses), high capital costs, particle design/controllability, shortened processing times and manufacturing considerations (scalability, yield improvements, aseptic operation, etc.). Thus, scientists/engineers are constantly working to improve existing methodologies and exploring novel dehydration/powder-forming technologies. Microglassification™ is a dehydration technology that uses solvent extraction to rapidly dehydrate protein formulations at ambient temperatures, eliminating the temperature stress experienced by biologics in traditional lyophilization and spray drying methods. The process results in microparticles that are spherical, dense, and chemically stable. In this study, we compared the molecular stability of a monoclonal antibody formulation processed by lyophilization to the same formulation processed using Microglassification™. Both powders were placed on stability for 3 months at 40 °C and 6 months at 25 °C. Both dehydration methods showed similar chemical stability, including percent monomer, charge variants, and antigen binding. These results show that Microglassification™ is viable for the production of stable solid-state monoclonal antibody formulations.
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Affiliation(s)
| | - Aadithya Kannan
- Pharmaceutical Development, Genentech Inc., South San Francisco, CA 94080, United States
| | - John R Savage
- Lindy Biosciences, 627 Davis Dr. #400 Morrisville, North Carolina 27560, United States
| | - Samantha Stadmiller
- Lindy Biosciences, 627 Davis Dr. #400 Morrisville, North Carolina 27560, United States
| | - Adam E Ryle
- Lindy Biosciences, 627 Davis Dr. #400 Morrisville, North Carolina 27560, United States
| | - Chloe Cheung
- Pharmaceutical Development, Genentech Inc., South San Francisco, CA 94080, United States
| | - Robert F Kelley
- Pharmaceutical Development, Genentech Inc., South San Francisco, CA 94080, United States
| | - Yuh-Fun Maa
- Pharmaceutical Development, Genentech Inc., South San Francisco, CA 94080, United States
| | - Miguel Saggu
- Pharmaceutical Development, Genentech Inc., South San Francisco, CA 94080, United States.
| | - Deborah L Bitterfield
- Lindy Biosciences, 627 Davis Dr. #400 Morrisville, North Carolina 27560, United States.
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Sharma A, Khamar D, Cullen S, Hayden A, Hughes H. Innovative Drying Technologies for Biopharmaceuticals. Int J Pharm 2021; 609:121115. [PMID: 34547393 DOI: 10.1016/j.ijpharm.2021.121115] [Citation(s) in RCA: 22] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 08/24/2021] [Accepted: 09/15/2021] [Indexed: 01/30/2023]
Abstract
In the past two decades, biopharmaceuticals have been a breakthrough in improving the quality of lives of patients with various cancers, autoimmune, genetic disorders etc. With the growing demand of biopharmaceuticals, the need for reducing manufacturing costs is essential without compromising on the safety, quality, and efficacy of products. Batch Freeze-drying is the primary commercial means of manufacturing solid biopharmaceuticals. However, Freeze-drying is an economically unfriendly means of production with long production cycles, high energy consumption and heavy capital investment, resulting in high overall costs. This review compiles some potential, innovative drying technologies that have not gained popularity for manufacturing parenteral biopharmaceuticals. Some of these technologies such as Spin-freeze-drying, Spray-drying, Lynfinity® Technology etc. offer a paradigm shift towards continuous manufacturing, whereas PRINT® Technology and MicroglassificationTM allow controlled dry particle characteristics. Also, some of these drying technologies can be easily scaled-up with reduced requirement for different validation processes. The inclusion of Process Analytical Technology (PAT) and offline characterization techniques in tandem can provide additional information on the Critical Process Parameters (CPPs) and Critical Quality Attributes (CQAs) during biopharmaceutical processing. These processing technologies can be envisaged to increase the manufacturing capacity for biopharmaceutical products at reduced costs.
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Affiliation(s)
- Ashutosh Sharma
- Pharmaceutical and Molecular Biotechnology Research Centre (PMBRC), Waterford Institute of Technology, Main Campus, Cork Road, Waterford X91K0EK, Ireland.
| | - Dikshitkumar Khamar
- Sanofi, Manufacturing Science, Analytics and Technology (MSAT), IDA Industrial Park, Waterford X91TP27, Ireland
| | - Sean Cullen
- Gilead Sciences, Commercial Manufacturing, IDA Business & Technology Park, Carrigtwohill, Co. Cork T45DP77, Ireland
| | - Ambrose Hayden
- Pharmaceutical and Molecular Biotechnology Research Centre (PMBRC), Waterford Institute of Technology, Main Campus, Cork Road, Waterford X91K0EK, Ireland
| | - Helen Hughes
- Pharmaceutical and Molecular Biotechnology Research Centre (PMBRC), Waterford Institute of Technology, Main Campus, Cork Road, Waterford X91K0EK, Ireland
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Park SK, Noh GY, Yu HW, Lee EC, Jeong J, Park YM, Han HK, Jeong SH, Kim NA. Lessons Learned in Protein Precipitation Using a Membrane Emulsification Technique to Produce Reversible and Uniform Microbeads. Pharmaceutics 2021; 13:pharmaceutics13101738. [PMID: 34684031 PMCID: PMC8540039 DOI: 10.3390/pharmaceutics13101738] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/03/2021] [Revised: 10/08/2021] [Accepted: 10/16/2021] [Indexed: 11/16/2022] Open
Abstract
The effects of the manufacturing process and the regeneration of Shirasu porous glass (SPG) membranes were investigated on the reproducibility of protein precipitants, termed protein microbeads. Intravenous immunoglobulin (IVIG) was selected as a model protein to produce its microbeads in seven different cases. The results showed that the hydrophobically modified SPG membrane produced finer microbeads than the hydrophilic SPG membrane, but this was inconsistent when using the general regeneration method. Its reproducibility was determined to be mostly dependent on rinsing the SPG membrane prior to the modification and on the protein concentration used for emulsification. The higher concentration could foul and plug the membrane during protein release and thus the membrane must be washed thoroughly before hydrophobic modification. Moreover, the membrane regenerated by silicone resin dissolved in ethanol had better reproducibility than silicone resin dissolved in water. On the other hand, rinsing the protein precipitant with cold ethanol after the emulsification was not favorable and induced protein aggregation. With the addition of trehalose, the purity of the IVIG microbeads was almost the same as before microbeadification. Therefore, the regeneration method, protein concentration, and its stabilizer are key to the success of protein emulsification and precipitation using the SPG membrane.
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Affiliation(s)
- Sang-Koo Park
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
| | - Ga Yeon Noh
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
| | - Hyun Woo Yu
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
| | - Eun Chae Lee
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
| | - Junoh Jeong
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
| | - Young-Min Park
- Division of Health and Kinesiology, Incheon National University, Incheon 22012, Korea;
| | - Hyo-Kyung Han
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
| | - Seong Hoon Jeong
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
- Correspondence: (S.H.J.); (N.A.K.); Tel.: +82-10-5679-0621 (S.H.J.); +82-10-5590-1018 (N.A.K.)
| | - Nam Ah Kim
- BK21 FOUR Team and Integrated Research Institute for Drug Development, College of Pharmacy, Dongguk University, Seoul 10326, Korea; (S.-K.P.); (G.Y.N.); (H.W.Y.); (E.C.L.); (J.J.); (H.-K.H.)
- Correspondence: (S.H.J.); (N.A.K.); Tel.: +82-10-5679-0621 (S.H.J.); +82-10-5590-1018 (N.A.K.)
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Kim NA, Yu HW, Noh GY, Park SK, Kang W, Jeong SH. Protein microbeadification to achieve highly concentrated protein formulation with reversible properties and in vivo pharmacokinetics after reconstitution. Int J Biol Macromol 2021; 185:935-948. [PMID: 34237365 DOI: 10.1016/j.ijbiomac.2021.07.012] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/08/2021] [Revised: 07/01/2021] [Accepted: 07/02/2021] [Indexed: 10/20/2022]
Abstract
A protein precipitation technique was optimized to produce biophysically stable 'protein microbeads', applicable to highly concentrated protein formulation. Initially, production of BSA microbeads was performed using rapid dehydration by vortexing in organic solvents followed by cold ethanol treatment and a vacuum drying. Out of four solvents, n-octanol produced the most reversible microbeads upon reconstitution. A Shirasu porous glass (SPG) membrane emulsification technique was utilized to enhance the size distribution and manufacturing process of the protein microbeads with a marketized human IgG solution. Process variants such as dehydration time, temperature, excipients, drying conditions, and initial protein concentration were evaluated in terms of the quality of IgG microbeads and their reversibility. The hydrophobized SPG membrane produced a narrow size distribution of the microbeads, which were further enhanced by shorter dehydration time, low temperature, minimized the residual solvents, lower initial protein concentration, and addition of trehalose to the IgG solution. Final reversibility of the IgG microbeads with trehalose was over 99% at both low and high protein concentrations. Moreover, the formulation was highly stable under repeated mechanical shocks and at an elevated temperature compared to its liquid state. Its in vivo pharmacokinetic profiles in rats were consistent before and after the 'microbeadification'.
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Affiliation(s)
- Nam Ah Kim
- College of Pharmacy, Dongguk University-Seoul, Gyeonggi 13026, Republic of Korea.
| | - Hyun Woo Yu
- College of Pharmacy, Dongguk University-Seoul, Gyeonggi 13026, Republic of Korea
| | - Ga Yeon Noh
- College of Pharmacy, Dongguk University-Seoul, Gyeonggi 13026, Republic of Korea
| | - Sang-Koo Park
- College of Pharmacy, Dongguk University-Seoul, Gyeonggi 13026, Republic of Korea
| | - Wonku Kang
- College of Pharmacy, Chung-Ang University, Seoul 06974, Republic of Korea
| | - Seong Hoon Jeong
- College of Pharmacy, Dongguk University-Seoul, Gyeonggi 13026, Republic of Korea.
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Lim DG, Lee JC, Kim DJ, Kim SJ, Yu HW, Jeong SH. Effects of precipitation process on the biophysical properties of highly concentrated proteins. JOURNAL OF PHARMACEUTICAL INVESTIGATION 2020. [DOI: 10.1007/s40005-020-00471-2] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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Utoft A, Kinoshita K, Bitterfield DL, Needham D. Manipulating Single Microdroplets of NaCl Solutions: Solvent Dissolution, Microcrystallization, and Crystal Morphology. LANGMUIR : THE ACS JOURNAL OF SURFACES AND COLLOIDS 2018; 34:3626-3641. [PMID: 29510057 DOI: 10.1021/acs.langmuir.7b03977] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/08/2023]
Abstract
A new "three-micropipette manipulation technique" for forming, dehydrating, crystallizing, and resolvating nanograms of salt material has been developed to study supersaturated single microdroplets and microcrystals. This is the first report of studies that have measured in situ both supersaturation (as homogeneous nucleation) and saturation (as microcrystal redissolution) for single microdroplets of NaCl solution using the micropipette technique. This work reports a measure of the critical supersaturation concentration for homogeneous nucleation of NaCl (10.3 ± 0.3 M) at a supersaturation fraction of S = 1.9, the saturation concentration of NaCl in aqueous solution as measured with nanograms of material (5.5 ± 0.1 M), the diffusion coefficient for water in octanol, D = (1.96 ± 0.10) × 10-6 cm2/s, and the effect of the solvent's activity on dissolution kinetics. It is further shown that the same Epstein-Plesset (EP) model, which was originally developed for diffusion-controlled dissolution and uptake of gas, and successfully applied to liquid-in-liquid dissolution, can now also be applied to describe the diffusion-controlled uptake of water from a water-saturated environment using the extended activity-based model of Bitterfield et al. This aspect of the EP model has not previously been tested using single microdroplets. Finally, it is also reported how the water dissolution rate, rate of NaCl concentration change, resulting crystal structure, and the time frame of initial crystal growth are affected by changing the bathing medium from octanol to decane. A much slower loss of water-solvent and concomitant slower up-concentration of the NaCl solute resulted in a lower tendency to nucleate and slower crystal growth because much less excess material was available at the onset of nucleation in the decane system as compared to the octanol system. Thus, the crystal structure is reported to be dendritic for NaCl solution microdroplets dissolving rapidly and nucleating violently in octanol, while they are formed as single cubic crystals in a gentler way for solution-dissolution in decane. These new techniques and analyses can now also be used for any other system where all relevant parameters are known. An example of this is control of drug/hydrogel/emulsion particle size change due to solvent uptake.
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Affiliation(s)
- Anders Utoft
- Center for Single Particle Science and Engineering (SPSE), Health Sciences , University of Southern Denmark , Odense 5230 , Denmark
| | - Koji Kinoshita
- Center for Single Particle Science and Engineering (SPSE), Health Sciences , University of Southern Denmark , Odense 5230 , Denmark
| | | | - David Needham
- Center for Single Particle Science and Engineering (SPSE), Health Sciences , University of Southern Denmark , Odense 5230 , Denmark
- Department of Mechanical Engineering and Materials Science , Duke University , Durham , North Carolina 27708 , United States
- School of Pharmacy , University of Nottingham , Nottingham NG7 2RD , United Kingdom
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Yoneda JS, Miles AJ, Araujo APU, Wallace BA. Differential dehydration effects on globular proteins and intrinsically disordered proteins during film formation. Protein Sci 2017; 26:718-726. [PMID: 28097742 PMCID: PMC5368061 DOI: 10.1002/pro.3118] [Citation(s) in RCA: 19] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/14/2016] [Revised: 01/06/2017] [Accepted: 01/09/2017] [Indexed: 12/22/2022]
Abstract
Globular proteins composed of different secondary structures and fold types were examined by synchrotron radiation circular dichroism spectroscopy to determine the effects of dehydration on their secondary structures. They exhibited only minor changes upon removal of bulk water during film formation, contrary to previously reported studies of proteins dehydrated by lyophilization (where substantial loss of helical structure and gain in sheet structure was detected). This near lack of conformational change observed for globular proteins contrasts with intrinsically disordered proteins (IDPs) dried in the same manner: the IDPs, which have almost completely unordered structures in solution, exhibited increased amounts of regular (mostly helical) secondary structures when dehydrated, suggesting formation of new intra-protein hydrogen bonds replacing solvent-protein hydrogen bonds, in a process which may mimic interactions that occur when IDPs bind to partner molecules. This study has thus shown that the secondary structures of globular and intrinsically disordered proteins behave very differently upon dehydration, and that films are a potentially useful format for examining dehydrated soluble proteins and assessing IDPs structures.
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Affiliation(s)
- Juliana Sakamoto Yoneda
- Institute of Structural and Molecular Biology, Birkbeck College, University of London, London, UK.,Instituto de Física de São Carlos, Universidade de São Paulo, São Carlos, Brazil
| | - Andew J Miles
- Institute of Structural and Molecular Biology, Birkbeck College, University of London, London, UK
| | | | - B A Wallace
- Institute of Structural and Molecular Biology, Birkbeck College, University of London, London, UK
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Bitterfield DL, Utoft A, Needham D. An Activity-Based Dissolution Model for Solute-Containing Microdroplets. LANGMUIR : THE ACS JOURNAL OF SURFACES AND COLLOIDS 2016; 32:12749-12759. [PMID: 27802055 DOI: 10.1021/acs.langmuir.6b03126] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/06/2023]
Abstract
When a solute is present in an aqueous droplet, the water activity in the droplet and the rate of droplet dissolution are both decreased (as compared to a pure water droplet). One of the main parameters that controls this effect is the dynamically changing solute concentration, and therefore water activity and chemical potential, at the droplet interface. This work addresses the importance of understanding how water activity changes during solution droplet dissolution. A model for dissolution rate is presented that accounts for the kinetic effects of changing water activity at the droplet interface during the dissolution of an aqueous salt solution microdroplet into a second immiscible liquid phase. The important underlying question in this model is whether the dissolving component can be considered in local equilibrium on both sides of the droplet interface and whether this assumption is sufficient to account for the kinetics of dissolution. The dissolution model is based on the Epstein-Plesset equation, which has previously been applied to pure gas (bubble) and liquid (droplet) dissolution into liquid phases, but not to salt solutions. The model is tested by using the micropipet technique to form and observe the dehydration of single NaCl solution microdroplets in octanol or butyl acetate. The model successfully predicts the droplet diameter as a function of time in both organic solvents. The NaCl concentration in water is measured well into the supersaturated area >5.4 M, and the supersaturation limit at which NaCl nucleation happens is reported to be 10.24 ± 0.31 M.
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Affiliation(s)
- Deborah L Bitterfield
- Department of Mechanical Engineering and Materials Science, Duke University , Durham, North Carolina 27708, United States
| | - Anders Utoft
- Center for Single Particle Science and Engineering (SPSE), University of Southern Denmark , Odense, Denmark
| | - David Needham
- Department of Mechanical Engineering and Materials Science, Duke University , Durham, North Carolina 27708, United States
- Center for Single Particle Science and Engineering (SPSE), University of Southern Denmark , Odense, Denmark
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