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Neugebauer P, Zettl M, Moser D, Poms J, Kuchler L, Sacher S. Process analytical technology in Downstream-Processing of Drug Substances- A review. Int J Pharm 2024; 661:124412. [PMID: 38960339 DOI: 10.1016/j.ijpharm.2024.124412] [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: 04/30/2024] [Revised: 06/11/2024] [Accepted: 06/29/2024] [Indexed: 07/05/2024]
Abstract
Process Analytical Technology (PAT) has revolutionized pharmaceutical manufacturing by providing real-time monitoring and control capabilities throughout the production process. This review paper comprehensively examines the application of PAT methodologies specifically in the production of solid active pharmaceutical ingredients (APIs). Beginning with an overview of PAT principles and objectives, the paper explores the integration of advanced analytical techniques such as spectroscopy, imaging modalities and others into solid API substance production processes. Novel developments in in-line monitoring at academic level are also discussed. Emphasis is placed on the role of PAT in ensuring product quality, consistency, and compliance with regulatory requirements. Examples from existing literature illustrate the practical implementation of PAT in solid API substance production, including work-up, crystallization, filtration, and drying processes. The review addresses the quality and reliability of the measurement technologies, aspects of process implementation and handling, the integration of data treatment algorithms and current challenges. Overall, this review provides valuable insights into the transformative impact of PAT on enhancing pharmaceutical manufacturing processes for solid API substances.
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Affiliation(s)
- Peter Neugebauer
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria; Institute of Process and Particle Engineering, Graz University of Technology, 8010 Graz, Austria
| | - Manuel Zettl
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Daniel Moser
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Lisa Kuchler
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria.
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2
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Hur I, Casas-Orozco D, Laky D, Destro F, Nagy ZK. Digital design of an integrated purification system for continuous pharmaceutical manufacturing. Chem Eng Sci 2024; 285:119534. [PMID: 38975615 PMCID: PMC11225065 DOI: 10.1016/j.ces.2023.119534] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 07/09/2024]
Abstract
In this work dynamic models of the continuous crystallization, filtration, deliquoring, washing, and drying steps are introduced, which are developed in the open-source pharmaceutical modeling tool PharmaPy. These models enable the simulation and digital design of an integrated continuous two-stage crystallization and filtration-drying carousel system. The carousel offers an intensified process that can manufacture products with tailored properties through optimal design and control. Results show that improved crystallization design enhances overall process efficiency by improving critical material attributes of the crystal slurry for downstream filtration and drying operations. The digital design of the integrated process achieves enhanced productivity while satisfying multiple design and product quality constraints. Additionally, the impact of model uncertainty on the optimal operating conditions is investigated. The findings demonstrate the systematic process development potential of PharmaPy, providing improved process understanding, design space identification, and optimized robust operation.
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Affiliation(s)
- Inyoung Hur
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
| | - Daniel Casas-Orozco
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
| | - Daniel Laky
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
| | - Francesco Destro
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 4797 USA
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3
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Nașcu I, Diangelakis NA, Muñoz SG, Pistikopoulos EN. Advanced Model Predictive Control Strategies for Evaporation Processes in the Pharmaceutical Industries. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2023.108212] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/08/2023]
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4
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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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Ottoboni S, Brown CJ, Mehta B, Jimeno G, Mitchell NA, Sefcik J, Price CJ. Digital Design of Filtration and Washing of Active Pharmaceutical Ingredients via Mechanistic Modeling. Org Process Res Dev 2022; 26:3236-3253. [PMID: 36569418 PMCID: PMC9764418 DOI: 10.1021/acs.oprd.2c00165] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2022] [Indexed: 12/12/2022]
Abstract
To facilitate integrated end-to-end pharmaceutical manufacturing using digital design, a model capable of transferring material property information between operations to predict product attributes in integrated purification processes has been developed. The focus of the work reported here combines filtration and washing operations used in active pharmaceutical ingredient (API) purification and isolation to predict isolation performance without the need of extensive experimental work. A fixed Carman-Kozeny filtration model is integrated with several washing mechanisms (displacement, dilution, and axial dispersion). Two limiting cases are considered: case 1 where there is no change in the solid phase during isolation (no particle dissolution and/or growth), and case 2 where the liquid and solid phases are equilibrated over the course of isolation. In reality, all actual manufacturing conditions would be bracketed by these two limiting cases, so consideration of these two scenarios provides rigorous theoretical bounds for assessing isolation performance. This modeling approach aims to facilitate the selection of most appropriate models suitable for different isolation scenarios, without the requirement to use overly complex models for straightforward isolation processes. Mefenamic acid and paracetamol were selected as representative model compounds to assess a range of isolation scenarios. In each case, the objective of the models was to identify the purity of the product reached with a fixed wash ratio and minimize the changes to the crystalline particle attributes that occur during the isolation process. This was undertaken with the aim of identifying suitable criteria for the selection of appropriate filtration and washing models corresponding to relevant processing conditions, and ultimately developing guidelines for the digital design of filtration and washing processes.
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Affiliation(s)
- Sara Ottoboni
- EPSRC
Future Manufacturing Hub in Continuous Manufacturing and Advanced
Crystallisation, University of Strathclyde, GlasgowG1 1RD, U.K.
- Department
of Chemical and Process Engineering, University
of Strathclyde, GlasgowG1 1XJ, U.K.
| | - Cameron J. Brown
- EPSRC
Future Manufacturing Hub in Continuous Manufacturing and Advanced
Crystallisation, University of Strathclyde, GlasgowG1 1RD, U.K.
- Strathclyde
Institute of Pharmacy & Biomedical Science (SIPBS), University of Strathclyde, GlasgowG4 0RE, U.K.
| | - Bhavik Mehta
- Siemens
Process Systems Engineering Ltd., LondonW6 7HA, U.K.
| | | | | | - Jan Sefcik
- EPSRC
Future Manufacturing Hub in Continuous Manufacturing and Advanced
Crystallisation, University of Strathclyde, GlasgowG1 1RD, U.K.
- Department
of Chemical and Process Engineering, University
of Strathclyde, GlasgowG1 1XJ, U.K.
| | - Chris J. Price
- EPSRC
Future Manufacturing Hub in Continuous Manufacturing and Advanced
Crystallisation, University of Strathclyde, GlasgowG1 1RD, U.K.
- Department
of Chemical and Process Engineering, University
of Strathclyde, GlasgowG1 1XJ, U.K.
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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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