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Longobardi G, Moore TL, Conte C, Ungaro F, Satchi-Fainaro R, Quaglia F. Polyester nanoparticles delivering chemotherapeutics: Learning from the past and looking to the future to enhance their clinical impact in tumor therapy. WILEY INTERDISCIPLINARY REVIEWS. NANOMEDICINE AND NANOBIOTECHNOLOGY 2024; 16:e1990. [PMID: 39217459 DOI: 10.1002/wnan.1990] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/29/2024] [Revised: 07/20/2024] [Accepted: 07/23/2024] [Indexed: 09/04/2024]
Abstract
Polymeric nanoparticles (NPs), specifically those comprised of biodegradable and biocompatible polyesters, have been heralded as a game-changing drug delivery platform. In fact, poly(α-hydroxy acids) such as polylactide (PLA), poly(lactide-co-glycolide) (PLGA), and poly(ε-caprolactone) (PCL) have been heavily researched in the past three decades as the material basis of polymeric NPs for drug delivery applications. As materials, these polymers have found success in resorbable sutures, biodegradable implants, and even monolithic, biodegradable platforms for sustained release of therapeutics (e.g., proteins and small molecules) and diagnostics. Few fields have gained more attention in drug delivery through polymeric NPs than cancer therapy. However, the clinical translational of polymeric nanomedicines for treating solid tumors has not been congruent with the fervor or funding in this particular field of research. Here, we attempt to provide a comprehensive snapshot of polyester NPs in the context of chemotherapeutic delivery. This includes a preliminary exploration of the polymeric nanomedicine in the cancer research space. We examine the various processes for producing polyester NPs, including methods for surface-functionalization, and related challenges. After a detailed overview of the multiple factors involved with the delivery of NPs to solid tumors, the crosstalk between particle design and interactions with biological systems is discussed. Finally, we report state-of-the-art approaches toward effective delivery of NPs to tumors, aiming at identifying new research areas and re-evaluating the reasons why some research avenues have underdelivered. We hope our effort will contribute to a better understanding of the gap to fill and delineate the future research work needed to bring polyester-based NPs closer to clinical application. This article is categorized under: Therapeutic Approaches and Drug Discovery > Nanomedicine for Oncologic Disease Nanotechnology Approaches to Biology > Nanoscale Systems in Biology Therapeutic Approaches and Drug Discovery > Emerging Technologies.
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Affiliation(s)
| | - Thomas Lee Moore
- Department of Pharmacy, University of Naples Federico II, Naples, Italy
| | - Claudia Conte
- Department of Pharmacy, University of Naples Federico II, Naples, Italy
| | - Francesca Ungaro
- Department of Pharmacy, University of Naples Federico II, Naples, Italy
| | - Ronit Satchi-Fainaro
- Department of Physiology and Pharmacology, Faculty of Medicine, Tel Aviv University, Tel Aviv, Israel
- Sagol School of Neurosciences, Tel Aviv University, Tel Aviv, Israel
| | - Fabiana Quaglia
- Department of Pharmacy, University of Naples Federico II, Naples, Italy
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Laleman F, Mathot F, Bourlès E, Scutellà B, Hansen L, De Beer T. The influence of thermal radiation during microwave-assisted freeze-drying of pharmaceutical unit doses. Int J Pharm 2024; 664:124640. [PMID: 39191335 DOI: 10.1016/j.ijpharm.2024.124640] [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: 06/10/2024] [Revised: 08/22/2024] [Accepted: 08/23/2024] [Indexed: 08/29/2024]
Abstract
New drying technologies for biologicals have recently been developed to accelerate the time-consuming batch freeze-drying (BFD) process. Among others, microwave-assisted freeze-drying (MFD) has been suggested as a faster and more effective drying technology. In this study, MFD cycles with the microwave radiation switched on and off were performed to assess the contribution of the microwave radiation to drying acceleration. It was found that thermal radiation emitted by the drying chamber walls was predominantly accelerating the drying of monodose placebos rather than microwave radiation. The combination of ultra-low chamber pressure, high thermal heat transfer and a short primary-to-secondary phase transition reduces drying times by more than 80 % compared to conventional BFD. In a second step, a design of experiment approach was used to assess the effect of thermal radiation versus microwave radiation and their combination, together with dosage properties such as fill volume and excipient concentration upon drying rate. The outcome showed the importance of high fill volume and high excipient concentration for an effective microwave contribution to the drying rate. Nevertheless, the drying acceleration for small pharmaceutical dosages with restricted solutes was mainly driven by thermal radiation rather than 2.45 GHz microwave radiation. The inability of ice to convert microwave energy into heat hampers the potential use of microwave freeze-drying for single-dose vaccines.
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Affiliation(s)
- Frederik Laleman
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Belgium.
| | | | | | | | | | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Belgium
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Lammens J, Goudarzi NM, Leys L, Nuytten G, Van Bockstal PJ, Vervaet C, Boone MN, De Beer T. Spin Freezing and Its Impact on Pore Size, Tortuosity and Solid State. Pharmaceutics 2021; 13:pharmaceutics13122126. [PMID: 34959407 PMCID: PMC8704350 DOI: 10.3390/pharmaceutics13122126] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/25/2021] [Revised: 12/03/2021] [Accepted: 12/07/2021] [Indexed: 12/03/2022] Open
Abstract
Spin freeze-drying, as a part of a continuous freeze-drying technology, is associated with a much higher drying rate and a higher level of process control in comparison with batch freeze-drying. However, the impact of the spin freezing rate on the dried product layer characteristics is not well understood at present. This research focuses on the relation between spin-freezing and pore size, pore shape, dried product mass transfer resistance and solid state of the dried product layer. This was thoroughly investigated via high-resolution X-ray micro-computed tomography (µCT), scanning electron microscopy (SEM), thermal imaging and solid state X-ray diffraction (XRD). It was concluded that slow spin-freezing rates resulted in the formation of highly tortuous structures with a high dried-product mass-transfer resistance, while fast spin-freezing rates resulted in lamellar structures with a low tortuosity and low dried-product mass-transfer resistance.
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Affiliation(s)
- Joris Lammens
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (J.L.); (C.V.)
| | - Niloofar Moazami Goudarzi
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, B-9000 Gent, Belgium; (N.M.G.); (M.N.B.)
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, B-9000 Gent, Belgium
| | - Laurens Leys
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (L.L.); (G.N.); (P.-J.V.B.)
| | - Gust Nuytten
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (L.L.); (G.N.); (P.-J.V.B.)
| | - Pieter-Jan Van Bockstal
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (L.L.); (G.N.); (P.-J.V.B.)
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (J.L.); (C.V.)
| | - Matthieu N. Boone
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, B-9000 Gent, Belgium; (N.M.G.); (M.N.B.)
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, B-9000 Gent, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (L.L.); (G.N.); (P.-J.V.B.)
- Correspondence:
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4
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Yamada M, Badr S, Udugama IA, Fukuda S, Nakaya M, Yoshioka Y, Sugiyama H. A systematic techno-economic approach to decide between continuous and batch operation modes for injectable manufacturing. Int J Pharm 2021; 613:121353. [PMID: 34896214 DOI: 10.1016/j.ijpharm.2021.121353] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/08/2021] [Revised: 11/08/2021] [Accepted: 12/02/2021] [Indexed: 12/23/2022]
Abstract
A comprehensive approach is proposed to systematically determine the optimal mode of operation between continuous and batch injectable manufacturing considering product and market conditions. At the core of this approach are two integrated complete mathematical modules for discrete and continuous injectable manufacturing, which are supplemented with an economic evaluation module that can then be used to explore the impact of all relevant process parameters (e.g., lot-size, number of operators, solubility, product demand, raw material costs). When the developed approach was applied to two case studies, it was found that batch production was preferred at low to moderate solution (raw material) costs. In contrast, at higher solution costs, the preference for batch and continuous production processes changed back and forth as the annual product demand changed. The study also found that continuous production processes became increasingly preferred at medium to large final dosage volumes and a competitive alternative even at moderate solution costs. From a decision-making point of view, batch injectable manufacturing will be preferred over the novel continuous manufacturing technology unless there is a significant economic incentive to overcome the perceived technology risk. The proposed approach is intended as a decision-support tool for pharmaceutical process engineers.
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Affiliation(s)
- Masahiro Yamada
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Sara Badr
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Isuru A Udugama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan
| | - Shouko Fukuda
- Settsu Plant, Shionogi Pharma Co., Ltd., 2-5-1, Mishima, Settsu-Shi, 556-0022 Osaka, Japan
| | - Manabu Nakaya
- Settsu Plant, Shionogi Pharma Co., Ltd., 2-5-1, Mishima, Settsu-Shi, 556-0022 Osaka, Japan
| | - Yasuyuki Yoshioka
- Settsu Plant, Shionogi Pharma Co., Ltd., 2-5-1, Mishima, Settsu-Shi, 556-0022 Osaka, Japan
| | - Hirokazu Sugiyama
- Department of Chemical System Engineering, The University of Tokyo, 7-3-1, Hongo, Bunkyo-ku, 113-8656 Tokyo, Japan.
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Nguyen PTT, Do NHN, Goh XY, Goh CJ, Ong RH, Le PK, Phan-Thien N, Duong HM. Recent Progresses in Eco-Friendly Fabrication and Applications of Sustainable Aerogels from Various Waste Materials. WASTE AND BIOMASS VALORIZATION 2021; 13:1825-1847. [PMID: 34745389 PMCID: PMC8560886 DOI: 10.1007/s12649-021-01627-3] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 06/28/2021] [Accepted: 10/24/2021] [Indexed: 06/13/2023]
Abstract
Tons of waste from residential, commercial and manufacturing activities are generated due to the growing population, urbanization and economic development, prompting the need for sustainable measures. Numerous ways of converting waste to aerogels, a novel class of ultra-light and ultra-porous materials, have been researched to tackle the issues of waste. This review provides an overview of the status of aerogels made from agricultural waste, municipal solid, and industrial waste focusing on the fabrication, properties, and applications of such aerogels. The review first introduced common methods to synthesize the aerogels from waste, including dispersion and drying techniques. Following that, numerous works related to aerogels from waste are summarized and compared, mainly focusing on the sustainability aspect of the processes involved and their contributions for environmental applications such as thermal insulation and oil absorption. Next, advantages, and disadvantages of the current approaches are analyzed. Finally, some prospective waste aerogels and its applications are proposed.
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Affiliation(s)
- Phuc T. T. Nguyen
- Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore
| | - Nga H. N. Do
- Refinery and Petrochemical Technology Research Centre, Ho Chi Minh City University of Technology (HCMUT), 268 Ly Thuong Kiet Street, District 10, Ho Chi Minh City, Vietnam
- Vietnam National University Ho Chi Minh City, Linh Trung Ward, Thu Duc District, Ho Chi Minh City, Vietnam
| | - Xue Yang Goh
- Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore
| | - Chong Jin Goh
- Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore
| | - Ren Hong Ong
- Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore
| | - Phung K. Le
- Refinery and Petrochemical Technology Research Centre, Ho Chi Minh City University of Technology (HCMUT), 268 Ly Thuong Kiet Street, District 10, Ho Chi Minh City, Vietnam
- Vietnam National University Ho Chi Minh City, Linh Trung Ward, Thu Duc District, Ho Chi Minh City, Vietnam
| | - Nhan Phan-Thien
- Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore
| | - Hai M. Duong
- Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore
- University of Cuu Long (UCL), Vinh Long, Vinh Long Province Vietnam
- Department of Chemical Engineering, Stanford University, Stanford, USA
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6
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Baudhuin H, Van Bockstal PJ, De Beer T, Vaneycken I, Bridoux J, Raes G, Caveliers V, Keyaerts M, Devoogdt N, Lahoutte T, Xavier C. Lyophilization of NOTA-sdAbs: First step towards a cold diagnostic kit for 68Ga-labeling. Eur J Pharm Biopharm 2021; 166:194-204. [PMID: 34186190 DOI: 10.1016/j.ejpb.2021.06.012] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/30/2021] [Revised: 05/27/2021] [Accepted: 06/22/2021] [Indexed: 12/30/2022]
Abstract
Lyophilization is commonly used in the production of pharmaceutical compounds to increase the stability of the Active Pharmaceutical Ingredient (API) by removing solvents. This study investigates the possibility to lyophilize an anti-HER2 and an anti-MMR single-domain antibody fragment (sdAb)-based precursor as a first step in the development of a diagnostic kit for PET imaging. METHODS NOTA-sdAb precursors have been lyophilized with the following formulation: 100 µg NOTA-sdAb in 0.1 M NaOAc (NaOAc), 5% (w/v%) mannitol-sucrose mix at a 2:1 ratio and 0.1 mg/mL polysorbate 80. During development of the formulation and drying cycle, factors such as cake appearance, glass transition temperature and residual moisture were analyzed to ensure qualitative and stable lyophilized samples. Stability studies of lyophilized precursor were conducted up to 18 months after storage at 2-8 °C by evaluating the precursor integrity, aggregation, functionality and 68Ga-labeling efficiency. A comparative biodistribution study (lyophilized vs non-lyophilized precursor) was conducted in wild type mice (n = 3) and in tumor bearing mice (n = 6). RESULTS The lyophilized NOTA-anti-HER2 precursor shows consistent stability data in vitro for up to 12 months at 2-8 °C in three separate batches, with results indicating stability even for up to T18m. No aggregation, degradation or activity loss was observed. Radiochemical purity after 68Ga-labeling is consistent over a period of 12 months (RCP ≥ 95% at T12m). In vivo biodistribution analyses show a typical [68Ga]Ga-NOTA-anti-HER2 sdAb distribution profile and a comparable tumor uptake for the lyophilized compound vs non-lyophilized (5.5% vs 5.7 %IA/g, respectively). In vitro results of lyophilized NOTA-anti-MMR precursor indicates stability for up to 18 months, while in vivo data show a comparable tumor uptake (2.5% vs 2.8 %IA/g, respectively) and no significant difference in kidney retention (49.4% vs 47.5 %IA/g, respectively). CONCLUSION A formulation and specific freeze-drying cycle were successfully developed to lyophilize NOTA-sdAb precursors for long-term storage at 2-8 °C. In vivo data show no negative impact of the lyophilization process on the in vivo behavior or functionality of the lyophilized precursor. These results highlight the potential to develop a kit for the preparation of 68Ga-sdAb-based radiopharmaceuticals.
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Affiliation(s)
- Henri Baudhuin
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium.
| | - Pieter-Jan Van Bockstal
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Universiteit Gent, Ghent, Belgium.
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Universiteit Gent, Ghent, Belgium.
| | - Ilse Vaneycken
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium; Nuclear Medicine Department (NUCG), Universitair Ziekenhuis Brussel (UZ Brussel), Brussels, Belgium.
| | - Jessica Bridoux
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium.
| | - Geert Raes
- Laboratory of Cellular and Molecular Immunology, Vrije Universiteit Brussel, Brussels, Belgium; Myeloid Cell Immunology Laboratory, VIB Center for Inflammation Research, Brussels, Belgium.
| | - Vicky Caveliers
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium; Nuclear Medicine Department (NUCG), Universitair Ziekenhuis Brussel (UZ Brussel), Brussels, Belgium.
| | - Marleen Keyaerts
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium; Nuclear Medicine Department (NUCG), Universitair Ziekenhuis Brussel (UZ Brussel), Brussels, Belgium.
| | - Nick Devoogdt
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium.
| | - Tony Lahoutte
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium; Nuclear Medicine Department (NUCG), Universitair Ziekenhuis Brussel (UZ Brussel), Brussels, Belgium.
| | - Catarina Xavier
- Department of Medical Imaging (MIMA), Vrije Universiteit Brussel, Brussels, Belgium.
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7
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Operti MC, Bernhardt A, Grimm S, Engel A, Figdor CG, Tagit O. PLGA-based nanomedicines manufacturing: Technologies overview and challenges in industrial scale-up. Int J Pharm 2021; 605:120807. [PMID: 34144133 DOI: 10.1016/j.ijpharm.2021.120807] [Citation(s) in RCA: 86] [Impact Index Per Article: 28.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/14/2021] [Revised: 06/02/2021] [Accepted: 06/13/2021] [Indexed: 12/12/2022]
Abstract
Nanomedicines based on poly(lactic-co-glycolic acid) (PLGA) carriers offer tremendous opportunities for biomedical research. Although several PLGA-based systems have already been approved by both the Food and Drug Administration (FDA) and the European Medicine Agency (EMA), and are widely used in the clinics for the treatment or diagnosis of diseases, no PLGA nanomedicine formulation is currently available on the global market. One of the most impeding barriers is the development of a manufacturing technique that allows for the transfer of nanomedicine production from the laboratory to an industrial scale with proper characterization and quality control methods. This review provides a comprehensive overview of the technologies currently available for the manufacturing and analysis of polymeric nanomedicines based on PLGA nanoparticles, the scale-up challenges that hinder their industrial applicability, and the issues associated with their successful translation into clinical practice.
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Affiliation(s)
- Maria Camilla Operti
- Department of Tumor Immunology, Radboud Institute for Molecular Life Sciences, Radboud University Medical Center, 6500 HB Nijmegen, the Netherlands; Evonik Operations GmbH, Research Development & Innovation, 64293 Darmstadt, Germany.
| | - Alexander Bernhardt
- Evonik Operations GmbH, Research Development & Innovation, 64293 Darmstadt, Germany.
| | - Silko Grimm
- Evonik Operations GmbH, Research Development & Innovation, 64293 Darmstadt, Germany.
| | - Andrea Engel
- Evonik Corporation, Birmingham Laboratories, Birmingham, AL 35211, United States.
| | - Carl Gustav Figdor
- Department of Tumor Immunology, Radboud Institute for Molecular Life Sciences, Radboud University Medical Center, 6500 HB Nijmegen, the Netherlands.
| | - Oya Tagit
- Department of Tumor Immunology, Radboud Institute for Molecular Life Sciences, Radboud University Medical Center, 6500 HB Nijmegen, the Netherlands.
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8
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Ingle RG, Fang WJ. Prefilled dual chamber devices (DCDs) - Promising high-quality and convenient drug delivery system. Int J Pharm 2021; 597:120314. [PMID: 33540011 DOI: 10.1016/j.ijpharm.2021.120314] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2020] [Revised: 01/14/2021] [Accepted: 01/23/2021] [Indexed: 12/22/2022]
Abstract
Prefilled dual chamber devices (DCDs) are combination products containing freeze-dried drug and diluent in two separate chambers of the device. DCDs provide high stability and convenience to patients and doctors, thus significantly improving product quality, patient compliance and market competitiveness. DCDs should also provide seal integrity, sterility and compatibility with biopharmaceuticals and avoid leachability and needle stick injuries. DCDs are promising alternatives to traditional containers or devices for biopharmaceuticals. The regulatory and medical practice to choose plastic DCDs as better alternatives over well-established glass syringes will be addressed here. The impact and major issues during processing, manufacturing, and storage of DCDs are also highlighted. Further discussion clears its business potential, composition, stability testing, and quality standard requirements to deal with market competition. It also covers major role of extractables and leachables in storage stability of the product.
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Affiliation(s)
- Rahul G Ingle
- Institute of Drug Metabolism and Pharmaceutical Analysis, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China; Hangzhou Institute of Innovative Medicine, Zhejiang University, Hangzhou 310016, China
| | - Wei-Jie Fang
- Institute of Drug Metabolism and Pharmaceutical Analysis, College of Pharmaceutical Sciences, Zhejiang University, Hangzhou 310058, China; Hangzhou Institute of Innovative Medicine, Zhejiang University, Hangzhou 310016, China.
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9
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Leys L, Vanbillemont B, Van Bockstal PJ, Lammens J, Nuytten G, Corver J, Vervaet C, De Beer T. A primary drying model-based comparison of conventional batch freeze-drying to continuous spin-freeze-drying for unit doses. Eur J Pharm Biopharm 2020; 157:97-107. [PMID: 33053425 DOI: 10.1016/j.ejpb.2020.09.009] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2020] [Revised: 09/04/2020] [Accepted: 09/07/2020] [Indexed: 10/23/2022]
Abstract
An innovative continuous spin-freeze-drying technology for unit doses was recently developed. For this technology, a mechanistic primary drying model was developed allowing the calculation of the optimal dynamic drying trajectory for spin-frozen formulations. In this work, a model-based and experimentally verified comparison was made between conventional batch freeze-drying and spin-freeze-drying by analyzing the outputs (i.e., primary drying endpoint, optimal shelf temperature/power heater and product temperature profile) of both primary drying models. Input parameters such as dried product layer resistance (Rp) and heat input parameters (Kv,Ptot) were experimentally determined for both freeze-drying methods and compared. In addition, optimal dynamic process parameters were calculated for 3 model formulations by using both mechanistic models. Finally, model predictions were validated by measuring the product temperature and primary drying endpoint. It was observed that, when considering the same layer thickness, Rp was generally lower for continuous spin-frozen formulations compared to vials frozen in a conventional batch freeze-dryer. This observation contributes to the short primary drying times of spin-frozen formulations. In addition, as spin-freezing drastically increases the surface area of the product and lowers the dried layer thickness, drying times can be reduced even further while an excellent cake structure and appearance can still be obtained. The primary drying model for spin-frozen formulations proved to be equally accurate for the prediction of the primary drying endpoint and product temperature compared to the batch freeze-drying model.
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Affiliation(s)
- L Leys
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium.
| | - B Vanbillemont
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - P J Van Bockstal
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - J Lammens
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ghent, Belgium
| | - G Nuytten
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - J Corver
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ghent, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium.
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10
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Vanbillemont B, Carpenter JF, Probst C, De Beer T. The Impact of Formulation Composition and Process Settings of Traditional Batch Versus Continuous Freeze-Drying On Protein Aggregation. J Pharm Sci 2020; 109:3308-3318. [PMID: 32739274 DOI: 10.1016/j.xphs.2020.07.023] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/26/2020] [Revised: 07/08/2020] [Accepted: 07/24/2020] [Indexed: 11/30/2022]
Abstract
The long-term stability of therapeutic protein products can be extended by freeze-drying. However, the freeze-drying process itself has several harmful stresses. A rationalized formulation design can significantly mitigate protein damage caused by freezing, dehydration and interfacial stresses of lyophilization and reconstitution. Recently, a continuous spin-freeze-drying concept was proposed as a more economical, controllable, flexible and qualitative alternative to batch freeze-drying. The purpose of this work is to compare spin-freeze-drying to traditional batch freeze-drying with regard to protein physical stability. The impacts of spinning, freezing and drying were investigated for both processing methods. Herewith, the interaction between these process phases and two common rational formulation strategies, (i.e. adding a disaccharide and a surfactant) was examined. Protein aggregates formed due to the process phase stresses were characterized with particle counting techniques and size exclusion chromatography. It was found that spin-freeze-drying exhibited essentially identical stresses causing comparable aggregation in all the process phases as compared to batch freeze-drying. Moreover, there were also analogous impacts of the formulation excipients. These observations led to the conclusion that similar freeze-drying formulation excipients and strategies tested for decades in batch freeze-drying of proteins can be utilized for spin-freeze-drying; in order to maintain protein stability during processing.
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Affiliation(s)
- Brecht Vanbillemont
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, 9000 Ghent, Belgium; Department of Pharmaceutical Sciences, Skaggs School of Pharmacy and Pharmaceutical Sciences, University of Colorado Anschutz Medical Campus, Aurora, CO 80045, USA
| | - John F Carpenter
- Department of Pharmaceutical Sciences, Skaggs School of Pharmacy and Pharmaceutical Sciences, University of Colorado Anschutz Medical Campus, Aurora, CO 80045, USA
| | | | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, 9000 Ghent, Belgium.
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11
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Show Me the Money! Process Modeling in Pharma from the Investor’s Point of View. Processes (Basel) 2019. [DOI: 10.3390/pr7090596] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/14/2022] Open
Abstract
Process modeling in pharma is gradually gaining momentum in process development but budget restrictions are growing. We first examine whether and how current practices rationalize within a decision process framework with a fictitious investor facing a decision problem subject to incomplete information. We then develop an algorithmic procedure for investment evaluation on both monetary and diffusion-of-innovation fronts. Our methodology builds upon discounted cash flow analysis and Bayesian inference and utilizes the Rogers diffusion of innovation paradigm for computing lower expected returns. We also introduce a set of intangible metrics for quantifying the level of diffusion of process modeling within an organization.
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Srinivasan G, Raja B. Evaluation of immersion‐contact type heat transfer for continuous pharmaceutical spin freeze‐drying process. J FOOD PROCESS ENG 2019. [DOI: 10.1111/jfpe.13153] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
Affiliation(s)
- Ganeshmurthy Srinivasan
- Department of Mechanical Engineering, Indian Institute of Information TechnologyDesign and Manufacturing (IIITD&M) Chennai Tamil Nadu India
| | - Balakrishnan Raja
- Department of Mechanical Engineering, Indian Institute of Information TechnologyDesign and Manufacturing (IIITD&M) Chennai Tamil Nadu India
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Pansare SK, Patel SM. Lyophilization Process Design and Development: A Single-Step Drying Approach. J Pharm Sci 2018; 108:1423-1433. [PMID: 30468830 DOI: 10.1016/j.xphs.2018.11.021] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/05/2018] [Revised: 11/06/2018] [Accepted: 11/14/2018] [Indexed: 11/17/2022]
Abstract
High-throughput lyophilization process was designed and developed for protein formulations using a single-step drying approach at a shelf temperature (Ts) of ≥40°C. Model proteins were evaluated at different protein concentrations in amorphous-only and amorphous-crystalline formulations. Single-step drying resulted in product temperature (Tp) above the collapse temperature (Tc) and a significant reduction (of at least 40%) in process time compared to the control cycle (wherein Tp <Tc). For the amorphous-only formulation at a protein concentration of ≤25 mg/mL, single-step drying resulted in product shrinkage and partial collapse, whereas a 50 mg/mL concentration showed minor product shrinkage. The presence of a crystallizing bulking agent improved product appearance at ≤25 mg/mL protein concentration for single-step drying. No impact to other product quality attributes was observed for single-step drying. Vial type, fill height, and scale-up considerations (i.e., choked flow, condenser capacity, lyophilizer design and geometry) were the important factors identified for successful implementation of single-step drying. Although single-step drying showed significant reduction in the edge vial effect, the scale-up considerations need to be addressed critically. Finally, the single-step drying approach can indeed make the lyophilization process high throughput compared to traditional freeze-drying process (i.e., 2-step drying).
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Affiliation(s)
- Swapnil K Pansare
- MedImmune, LLC, Dosage Form Design and Development Gaithersburg, Maryland 20878
| | - Sajal M Patel
- MedImmune, LLC, Dosage Form Design and Development Gaithersburg, Maryland 20878.
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Van Bockstal PJ, Corver J, De Meyer L, Vervaet C, De Beer T. Thermal Imaging as a Noncontact Inline Process Analytical Tool for Product Temperature Monitoring during Continuous Freeze-Drying of Unit Doses. Anal Chem 2018; 90:13591-13599. [DOI: 10.1021/acs.analchem.8b03788] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Pieter-Jan Van Bockstal
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium
| | - Jos Corver
- RheaVita, IIC UGent, Technologiepark Zwijnaarde-3,
PO-box 17, 9052 Ghent, Belgium
| | - Laurens De Meyer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium
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Van Bockstal PJ, Corver J, Mortier STF, De Meyer L, Nopens I, Gernaey KV, De Beer T. Developing a framework to model the primary drying step of a continuous freeze-drying process based on infrared radiation. Eur J Pharm Biopharm 2018; 127:159-170. [DOI: 10.1016/j.ejpb.2018.02.025] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2017] [Revised: 02/09/2018] [Accepted: 02/19/2018] [Indexed: 11/29/2022]
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De Meyer L, Lammens J, Mortier STF, Vanbillemont B, Van Bockstal PJ, Corver J, Nopens I, Vervaet C, De Beer T. Modelling the primary drying step for the determination of the optimal dynamic heating pad temperature in a continuous pharmaceutical freeze-drying process for unit doses. Int J Pharm 2017; 532:185-193. [DOI: 10.1016/j.ijpharm.2017.09.004] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/13/2017] [Revised: 09/01/2017] [Accepted: 09/02/2017] [Indexed: 11/28/2022]
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