1
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Fontana L, Nakach M, Koumurian B, Urban C, Authelin JR, Vandenbroucke M. Importance of K v Distribution in Freeze Drying: Part II: Use in Lyo Simulation Modeling. J Pharm Sci 2024:S0022-3549(24)00251-X. [PMID: 39033976 DOI: 10.1016/j.xphs.2024.07.005] [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: 04/16/2024] [Revised: 07/08/2024] [Accepted: 07/08/2024] [Indexed: 07/23/2024]
Abstract
This article is the second of a series of two articles. In the first article of the series, a new Kv distribution model and an experimental methodology to measure the Kv distribution were introduced. In this second part, the Kv distribution is integrated into a lyo-simulation tool, to more accurately predict the variability of the product temperature, primary drying time, total sublimation mass flow and Pirani signal. The Kv distribution is also integrated into the graphical design space. The impact of incorporating the Rp distribution is briefly discussed. The comparison of the simulation tool with actual product temperature monitoring, Pirani signal or overall sublimation flow shows very good agreement in the case studies presented. Overall, the lyo-simulation incorporating the Kv distribution is a very useful tool to support industrial development, i.e. process optimization, scale assessment, technology transfer, and troubleshooting of the lyophilization process.
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Affiliation(s)
- Lauren Fontana
- Sanofi R&D, 68 New York Avenue Framingham, MA 01701, United States
| | - Mostafa Nakach
- Sanofi R&D, 1 Impasse des ateliers 94403 Vitry sur Seine, France
| | - Benoit Koumurian
- Sanofi R&D, 1 Impasse des ateliers 94403 Vitry sur Seine, France
| | - Christian Urban
- Sanofi R&D Industriepark Höchst 65926 Frankfurt am Main, Germany
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2
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Vanbillemont B, Greiner AL, Ehrl V, Menzen T, Friess W, Hawe A. A model-based optimization strategy to achieve fast and robust freeze-drying cycles. Int J Pharm X 2023; 5:100180. [PMID: 37125084 PMCID: PMC10133743 DOI: 10.1016/j.ijpx.2023.100180] [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: 12/05/2022] [Revised: 03/22/2023] [Accepted: 04/08/2023] [Indexed: 05/02/2023] Open
Abstract
Freeze-drying is a time and cost-intensive process. The primary drying phase is the main target in a process optimization exercise. Biopharmaceuticals require an amorphous matrix for stabilization, which may collapse during primary drying if the critical temperature of the formulation is exceeded. The risk of product collapse should be minimized during a process optimization to accomplish a robust process, while achieving an economical process time. Mechanistic models facilitate the search for an optimal primary drying protocol. We propose a novel two-stage shelf temperature optimization approach to maximize sublimation during the primary drying phase, without risking product collapse. The approach includes experiments to obtain high-resolution variability data of process parameters such as the heat transfer coefficient, vial dimensions and dried layer resistance. These process parameters variability data are incorporated into an uncertainty analysis to estimate the risk of failure of the protocol. This optimization approach enables to identify primary drying protocols that are faster and more robust than a classical approach. The methodology was experimentally verified using two formulations which allow for either aggressive or conservative freeze-drying of biopharmaceuticals.
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Affiliation(s)
- Brecht Vanbillemont
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
- Corresponding author.
| | | | - Vanessa Ehrl
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
| | - Tim Menzen
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig Maximilian University, Munich 81377, Germany
| | - Andrea Hawe
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
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3
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Carfagna M, Rosa M, Hawe A, Frieß W. Lyophilization cycle design for highly concentrated protein formulations supported by micro freeze-dryer and heat flux sensor. Int J Pharm 2023; 643:123285. [PMID: 37532010 DOI: 10.1016/j.ijpharm.2023.123285] [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: 04/13/2023] [Revised: 07/11/2023] [Accepted: 07/30/2023] [Indexed: 08/04/2023]
Abstract
High-concentration protein formulations (HCPFs) represent a common strategy and freeze-drying can mitigate the stability challenges of HCPFs. In general, an in-depth characterization of the lyophilization process is essential to not impair the product quality by inappropriate process parameters. The aim of this study was to create a primary drying design space for lyophilized HCPFs by utilizing the heat flux sensor (HFS) integrated in a MicroFD with a minimum number of cycles and product vials. All the necessary data to obtain the design space were determined starting from only two lyophilization cycles, each holding 19 vials. The vial heat transfer coefficient (Kv) was determined by the HFS and compared to gravimetric values. The results indicate a consistant offset between the HFS and the gravimetry based values for annealed samples with higher protein content. This work highlights a possibility of integrating new technologies, the HFS and the MicroFD to generate a design space for lyophilization of HCPFs, which enables to implement a QbD approach at minimal material and time investment.
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Affiliation(s)
- Marco Carfagna
- Coriolis Pharma Research GmbH, Fraunhoferstrasse 18 b, 82152 Martinsried, Germany; Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Butenandtstrasse 5, Ludwig-Maximilians-Universitaet München, D-81377 Munich, Germany
| | - Monica Rosa
- Coriolis Pharma Research GmbH, Fraunhoferstrasse 18 b, 82152 Martinsried, Germany
| | - Andrea Hawe
- Coriolis Pharma Research GmbH, Fraunhoferstrasse 18 b, 82152 Martinsried, Germany.
| | - Wolfgang Frieß
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Butenandtstrasse 5, Ludwig-Maximilians-Universitaet München, D-81377 Munich, Germany
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4
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Chia A, Poulin É, Bouchard J, Lapointe-Garant PP, Van Meervenne B, Taveirne F. Experimental validation of multi-vial control for primary drying in a pilot-scale unit. Chem Eng Res Des 2023. [DOI: 10.1016/j.cherd.2023.03.033] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 04/05/2023]
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5
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Juckers A, Knerr P, Harms F, Strube J. Model-Based Product Temperature and Endpoint Determination in Primary Drying of Lyophilization Processes. Pharmaceutics 2022; 14:pharmaceutics14040809. [PMID: 35456643 PMCID: PMC9031979 DOI: 10.3390/pharmaceutics14040809] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2022] [Revised: 03/31/2022] [Accepted: 04/05/2022] [Indexed: 11/21/2022] Open
Abstract
Lyophilization process design still relies mainly on empirical studies with high experimental loads. In the regulatory demanded Quality by Design approach, process modeling is a key aspect. It allows process design, optimization and process control to ensure a safe process and product quality. A modeling approach is outlined that is able to predict the primary drying endpoint and temperature profile of distinct vials. Model parameters are determined by a reproducible determination concept. Simulated results are validated with a fractional factorial Design of Experiments (DoE) in pilot scale. The model shows higher accuracy and precision than the experiments and similar parameter interactions for both the endpoint and temperature determination. This approach can now be used to explore the primary design space in lyophilization process design. This paper proposes a distinct method for endpoint determination and product temperature prediction by a modeling approach based on Velardi et al. combined with a distinct model parameter determination according to Wegiel et al. and Tang et al.
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Affiliation(s)
- Alex Juckers
- Institute for Separation and Process Technology, Clausthal University of Technology, 38678 Clausthal-Zellerfeld, Germany;
- Martin Christ Gefriertrocknungsanlagen GmbH, 37520 Osterode am Harz, Germany; (P.K.); (F.H.)
| | - Petra Knerr
- Martin Christ Gefriertrocknungsanlagen GmbH, 37520 Osterode am Harz, Germany; (P.K.); (F.H.)
| | - Frank Harms
- Martin Christ Gefriertrocknungsanlagen GmbH, 37520 Osterode am Harz, Germany; (P.K.); (F.H.)
| | - Jochen Strube
- Institute for Separation and Process Technology, Clausthal University of Technology, 38678 Clausthal-Zellerfeld, Germany;
- Correspondence:
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6
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Deck LT, Ochsenbein DR, Mazzotti M. A Stochastic Shelf-Scale Modeling Framework for the Freezing Stage in Freeze-Drying Processes. Int J Pharm 2021; 613:121276. [PMID: 34767908 DOI: 10.1016/j.ijpharm.2021.121276] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/26/2021] [Revised: 11/01/2021] [Accepted: 11/02/2021] [Indexed: 11/16/2022]
Abstract
Freezing and freeze-drying processes are commonly used to improve the stability and thus shelf life of pharmaceutical formulations. Despite strict product quality requirements, batch heterogeneity is widely observed in frozen products, thus potentially causing process failure. Such heterogeneity is the result of the stochasticity of ice nucleation and the variability in heat transfer among vials, which lead to unique freezing histories of individual vials. We present for the first time a modeling framework for large-scale freezing processes of vials on a shelf. The model is based on first principles and couples heat transfer with ice nucleation kinetics, thus enabling studies on batch heterogeneity. Ice nucleation is assumed to be an inhomogeneous Poisson process and it is simulated using a Monte Carlo approach. We applied the model to understand the individual pathways leading to batch heterogeneity. Our simulations revealed a novel mechanism how ice nucleation leads to heterogeneity based on thermal interaction among vials. We investigated the effect of various cooling protocols, namely shelf-ramped cooling, holding steps and controlled nucleation, on the nucleation and solidification behavior across the shelf. We found that under rather general conditions holding schemes lead to similar solidification times, as in the case of controlled nucleation, thus identifying a potential pathway for freezing process optimization.
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Affiliation(s)
- Leif-Thore Deck
- Institute of Energy and Process Engineering, ETH Zurich, 8092 Zurich, Switzerland
| | - David R Ochsenbein
- The Janssen Pharmaceutical Companies of Johnson & Johnson, Hochstrasse 201, 8200 Schaffhausen, Switzerland
| | - Marco Mazzotti
- Institute of Energy and Process Engineering, ETH Zurich, 8092 Zurich, Switzerland.
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7
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Moino C, Bourlés E, Pisano R, Scutellà B. In-Line Monitoring of the Freeze-Drying Process by Means of Heat Flux Sensors. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c00536] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Camilla Moino
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
| | - Erwan Bourlés
- GSK Vaccines, 89 Rue de l’Institut, 1330 Rixensart, Belgium
| | - Roberto Pisano
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
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8
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Harguindeguy M, Fissore D. Micro Freeze-Dryer and Infrared-Based PAT: Novel Tools for Primary Drying Design Space Determination of Freeze-Drying Processes. Pharm Res 2021; 38:707-719. [PMID: 33686561 PMCID: PMC8057969 DOI: 10.1007/s11095-021-03023-x] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/17/2020] [Accepted: 02/23/2021] [Indexed: 11/30/2022]
Abstract
PURPOSE Present (i) an infrared (IR)-based Process Analytical Technology (PAT) installed in a lab-scale freeze-dryer and (ii) a micro freeze-dryer (MicroFD®) as effective tools for freeze-drying design space calculation of the primary drying stage. METHODS The case studies investigated are the freeze-drying of a crystalline (5% mannitol) and of an amorphous (5% sucrose) solution processed in 6R vials. The heat (Kv) and the mass (Rp) transfer coefficients were estimated: tests at 8, 13 and 26 Pa were carried out to assess the chamber pressure effect on Kv. The design space of the primary drying stage was calculated using these parameters and a well-established model-based approach. The results obtained using the proposed tools were compared to the ones in case Kv and Rp were estimated in a lab-scale unit through gravimetric tests and a thermocouple-based method, respectively. RESULTS The IR-based method allows a non-gravimetric estimation of the Kv values while with the micro freeze-dryer gravimetric tests require a very small number of vials. In both cases, the obtained values of Kv and Rp, as well as the resulting design spaces, were all in very good agreement with those obtained in a lab-scale unit through the gravimetric tests (Kv) and the thermocouple-based method (Rp). CONCLUSIONS The proposed tools can be effectively used for design space calculation in substitution of other well-spread methods. Their advantages are mainly the less laborious Kv estimation process and, as far as the MicroFD® is concerned, the possibility of saving time and formulation material when evaluating Rp.
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Affiliation(s)
- Maitê Harguindeguy
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy.
| | - Davide Fissore
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
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9
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Strategies and formulations of freeze-dried tablets for controlled drug delivery. Int J Pharm 2021; 597:120373. [PMID: 33577912 DOI: 10.1016/j.ijpharm.2021.120373] [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: 12/07/2020] [Revised: 01/24/2021] [Accepted: 02/05/2021] [Indexed: 11/21/2022]
Abstract
The freeze-drying process has been particularly attractive for preparing tablets for controlled drug release. Although traditional methods, such as granulation or direct compression methods, have been used in various studies to produce tablets with controlled release, freeze-drying processes have been utilized in certain circumstances due to their distinct advantages. However, overall, further development of these strategies, which started with early studies on orally disintegrating tablets, is still necessary. In this review, the incorporation of different formulations into freeze-dried tablets will be discussed. Moreover, the use of excipients, freeze-drying conditions, formulation reconstitution and tablet structure for optimizing the performance of freeze-dried tablets will be reported, including strategies with nanoformulations and natural materials. Generally, this discussion with potential approaches will benefit further development of freeze-dried tablets containing drugs in the pharmaceutical industry.
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10
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Harguindeguy M, Fissore D. Temperature/end point monitoring and modelling of a batch freeze-drying process using an infrared camera. Eur J Pharm Biopharm 2020; 158:113-122. [PMID: 33171203 DOI: 10.1016/j.ejpb.2020.10.023] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/06/2020] [Revised: 10/11/2020] [Accepted: 10/30/2020] [Indexed: 11/15/2022]
Abstract
Temperature monitoring and accurate drying end time determination are crucial for final product quality in vacuum freeze-drying of pharmaceuticals. Whether crystalline or amorphous solutes are used in the formulation, product temperature during ice sublimation should be kept below a threshold limit to avoid damage to the product structure. Hence, there is a need to continuously monitor product temperature throughout this process. Current monitoring tools, such as thermocouples and Pirani gauge pressure sensors, have several limitations such as affecting product dynamics or imprecise end point determination. In this work, a monitoring tool based on infrared (IR) thermography is used for batch freeze-drying processes. Batches using three different vial sizes, with up to 157 vials, were studied, allowing to extend and better describe the representativeness of IR thermography for this application. The detailed axial temperature profiles obtained through IR imaging allowed not only a comprehensive non-invasive temperature monitoring of the product, but also tracking of the sublimation interface. IR temperature measurements and primary drying end point determination were compared to standard methods and thus verified. Parameters important for freeze drying design space calculation, namely the global heat coefficient (Kv) and cake resistance to vapor flow (Rp), were also accurately estimated with the proposed method.
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Affiliation(s)
- Maitê Harguindeguy
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Turin, Italy.
| | - Davide Fissore
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Turin, Italy
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11
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De-Luca R, Bano G, Tomba E, Bezzo F, Barolo M. Accelerating the Development and Transfer of Freeze-Drying Operations for the Manufacturing of Biopharmaceuticals by Model-Based Design of Experiments. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c03115] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/25/2023]
Affiliation(s)
- Riccardo De-Luca
- CAPE-Lab—Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, Padova 35131, Italy
| | | | | | - Fabrizio Bezzo
- CAPE-Lab—Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, Padova 35131, Italy
| | - Massimiliano Barolo
- CAPE-Lab—Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, Padova 35131, Italy
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12
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Scutellà B, Bourlès E. Development of freeze-drying cycle via design space approach: a case study on vaccines. Pharm Dev Technol 2020; 25:1302-1313. [PMID: 32752908 DOI: 10.1080/10837450.2020.1806298] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
Abstract
Freeze-drying is a dehydration process that provides improved stability of vaccine formulations for shipment and storage. During the primary drying steps of the process, product temperature has to be maintained below a critical value to avoid visual defects of the product, leading to an increase of the sublimation time and thus of the operational costs. In this work, we used the design space approach together with experimental analysis for the development of the primary drying step of a vaccine model formulation. First, the formulation was characterized by determining the glass transition and the collapse temperatures. Successively, the dynamic design space of primary drying was calculated via mathematical modelling, and a proven acceptable range (PAR) was defined around the selected operating values. Finally, the cycle and the PAR were validated by performing a freeze-drying cycle at pilot scale and by evaluating the values of the product critical quality attributes (e.g. moisture content, visual aspect, reconstitution time).
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13
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Carfagna M, Rosa M, Lucke M, Hawe A, Frieß W. Heat flux sensor to create a design space for freeze-drying development. Eur J Pharm Biopharm 2020; 153:84-94. [PMID: 32497769 DOI: 10.1016/j.ejpb.2020.05.028] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/09/2020] [Revised: 05/11/2020] [Accepted: 05/27/2020] [Indexed: 11/27/2022]
Abstract
Freeze-drying methodology requires an in-depth understanding and characterization for optimal processing of biopharmaceuticals. Particularly the primary drying phase, the longest and most expensive stage of the process, is of interest for optimization. The currently used process analytical technology (PAT) tools give highly valuable insights but come with limitations. Our study describes, for the first time, the application of a heat flux sensor (HFS) to build a primary drying design space and predict the process evolution. First, the heat transfer coefficient (Kv) generated by HFS and by the most accurate, but time-consuming and invasive, gravimetric method were compared. Second, the applicability to generate a design space was tested and verified. Obtained results revealed a good agreement of the values generated from this new and fast HFS compared to the gravimetric determination. Additionally, residual moisture assessed by Karl-Fischer titration and frequency modulated spectroscopy (FMS) support the quality of the obtained predictions. Thus, the HFS approach can substantially accelerate evaluation, development and transfer of a freeze-drying cycle.
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Affiliation(s)
- Marco Carfagna
- Coriolis Pharma Research GmbH, D-82152 Planegg, Germany; Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig Maximilian University, D-81377 Munich, Germany
| | - Monica Rosa
- Coriolis Pharma Research GmbH, D-82152 Planegg, Germany
| | | | - Andrea Hawe
- Coriolis Pharma Research GmbH, D-82152 Planegg, Germany.
| | - Wolfgang Frieß
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig Maximilian University, D-81377 Munich, Germany
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14
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Assegehegn G, Brito-de la Fuente E, Franco JM, Gallegos C. Freeze-drying: A relevant unit operation in the manufacture of foods, nutritional products, and pharmaceuticals. ADVANCES IN FOOD AND NUTRITION RESEARCH 2020; 93:1-58. [PMID: 32711860 DOI: 10.1016/bs.afnr.2020.04.001] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/26/2022]
Abstract
Freeze-drying, a drying unit operation frequently used in food, pharmaceutical, and biopharmaceutical industries to prolong the shelf life of labile products, is an energy-intensive, time-consuming, and expensive process. Although all three steps (freezing, primary drying, and secondary drying) of freeze-drying are important, primary drying is the longest and most critical one. As sublimation during primary drying is mainly described in terms of heat and mass transfer, the present work provides extensive theoretical and experimental analyses of these processes. First, a detailed review of the current state-of-the art of freeze-drying, focusing on the drying stage, is given, which contributes to a fundamental understanding of the drying process. Second, a detailed experimental study of the drying section of the freeze-drying process is discussed, furnishing information on the relationship between input and output process parameters during the primary drying stage and thus aiding freeze-drying process design and optimization. In this regard, the influence of primary drying input parameters (i.e., shelf temperature and chamber pressure) and vial position on output parameters such as product temperature, sublimation rate, overall vial heat transfer coefficient, and resistance to mass transfer of the dried product are extensively discussed. For all combinations of shelf temperature and chamber pressure studied herein, the highest product temperature, sublimation rate, and overall vial heat transfer coefficient are observed in front edge vials, whereas the lowest values are observed in center vials. In general, the highest sublimation rate, at a given product temperature, is observed for low chamber pressure-high shelf temperature combinations.
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Affiliation(s)
- Getachew Assegehegn
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany
| | - Edmundo Brito-de la Fuente
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany
| | - José M Franco
- Departamento de Ingeniería Química, Pro2TecS-Chemical Product and Process Technology Research Centre, Complex Fluid Engineering Laboratory, Universidad de Huelva, Huelva, Spain
| | - Críspulo Gallegos
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany.
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15
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Jeeraruangrattana Y, Smith G, Polygalov E, Ermolina I. Determination of ice interface temperature, sublimation rate and the dried product resistance, and its application in the assessment of microcollapse using through-vial impedance spectroscopy. Eur J Pharm Biopharm 2020; 152:144-163. [PMID: 32353532 DOI: 10.1016/j.ejpb.2020.04.015] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/27/2020] [Revised: 04/15/2020] [Accepted: 04/22/2020] [Indexed: 10/24/2022]
Abstract
Through-vial impedance spectroscopy (TVIS) is a new approach for characterizing product attributes during freeze-drying process development. In this study, a pair of copper foil electrodes was attached to the external surface of a Type I glass tubing vial, of nominal capacity 10 mL and containing 3.5 g of an aqueous solution of 5%w/v lactose, and the impedance spectrum of the vial and contents recorded during a lyophilization cycle. The cycle included a temperature ramp in the primary drying stage in order to induce a collapse event in the dry layer. Using the peak in the dielectric loss spectrum, associated with the dielectric relaxation of ice, methods were developed to predict the sublimation rate and the ice interface temperature at the sublimation front, from which the dry layer resistance was then calculated. A four-fold increase in sublimation rate and a reduction in the dry layer resistance wereobserved once the ice interface temperature reached -33 °C, which coincides with the onset of the glass transition (as determined by DSC) and the time point at which micro-collapse occurred (as evidenced by SEM images at the end of the cycle). This work suggests a prospective application of impedance measurements in driving process efficiencies by operating the dryer at the highest achievable temperature (i.e. the collapse temperature) whilst avoiding macro-collapse.
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Affiliation(s)
| | - Geoff Smith
- Leicester School of Pharmacy, De Montfort University, The Gateway, Leicester LE1 9BH, United Kingdom.
| | - Evgeny Polygalov
- Leicester School of Pharmacy, De Montfort University, The Gateway, Leicester LE1 9BH, United Kingdom
| | - Irina Ermolina
- Leicester School of Pharmacy, De Montfort University, The Gateway, Leicester LE1 9BH, United Kingdom
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16
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Assegehegn G, Brito-de la Fuente E, Franco JM, Gallegos C. Use of a temperature ramp approach (TRA) to design an optimum and robust freeze-drying process for pharmaceutical formulations. Int J Pharm 2020; 578:119116. [PMID: 32027958 DOI: 10.1016/j.ijpharm.2020.119116] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/02/2019] [Revised: 01/29/2020] [Accepted: 02/02/2020] [Indexed: 10/25/2022]
Abstract
Freeze-drying, until now, has been a process that was designed using a trial and error experimental approach. This approach is often material and time consuming, and the resulting freeze-drying processes are neither optimum nor robust. Accordingly, the objective of this study was to develop a simple-to-use and experimental-based approach to design an optimum and robust freeze-drying process for any given formulation. The temperature ramp approach (TRA) detailed in this study involves the implementation of a customized design of experiments (DoE) to perform few (three or four) experiments using a given drug formulation. The DoE results are analyzed to define optimum processing conditions (i.e., shelf temperature and chamber pressure) based on a predefined range of target product temperature for primary drying, which could be defined from formulation characterization at its frozen state. In this study, a successful freeze-drying process of two model formulations using the TRA was designed. Verification experiments at the optimum processing conditions showed excellent agreement in both product temperature and sublimation rate with the values obtained using the TRA. Thus, the TRA detailed in this study offers a significant advantage to reduce development time and material, and enhance the efficiency and robustness of the resulting freeze-drying process.
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Affiliation(s)
- Getachew Assegehegn
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany.
| | - Edmundo Brito-de la Fuente
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany
| | - José M Franco
- Pro2TecS-Chemical Product and Process Technology Research Centre, Complex Fluid Engineering Laboratory, Departamento de Ingeniería Química, Universidad de Huelva, Huelva, Spain
| | - Críspulo Gallegos
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany
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Bano G, De-Luca R, Tomba E, Marcelli A, Bezzo F, Barolo M. Primary Drying Optimization in Pharmaceutical Freeze-Drying: A Multivial Stochastic Modeling Framework. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.9b06402] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Gabriele Bano
- CAPE-Lab − Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy
| | - Riccardo De-Luca
- CAPE-Lab − Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy
| | | | | | - Fabrizio Bezzo
- 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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Assegehegn G, Brito-de la Fuente E, Franco JM, Gallegos C. An Experimental-Based Approach to Construct the Process Design Space of a Freeze-Drying Process: An Effective Tool to Design an Optimum and Robust Freeze-Drying Process for Pharmaceuticals. J Pharm Sci 2019; 109:785-796. [PMID: 31288035 DOI: 10.1016/j.xphs.2019.07.001] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/28/2019] [Revised: 07/02/2019] [Accepted: 07/02/2019] [Indexed: 11/18/2022]
Abstract
The application of quality by design (QbD) is becoming an integral part of the formulation and process development for pharmaceutical products. An essential feature of the QbD philosophy is the design space. In this sense, a new approach to construct a process design space (PDS) for the primary drying section of a freeze-drying process is addressed in this paper. An effective customized design of experiments (DoE) is developed for freeze-drying experiments. The results obtained from the DoE are then used to construct the product-based PDS. The proposed product-based PDS construction approach has several advantages, including (1) eliminating assumptions on the heat transfer coefficient and dried product resistance, as it is constructed from experimental results specifically obtained from a given formulation, yielding more realistic and reliable results and (2) PDS construction based on a narrow range of product temperatures and considering the variations in product temperature and sublimation rate of vials across a shelf. This guarantees the effectiveness and robustness of the process and facilitates the process scale-up and transfer. The PDS developed herein was experimentally verified. The PDS predicted parameters were in excellent agreement with the experimentally obtained parameters.
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Affiliation(s)
- Getachew Assegehegn
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany.
| | - Edmundo Brito-de la Fuente
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany
| | - José M Franco
- Departamento de Ingeniería Química, Pro2TecS-Chemical Product and Process Technology Research Centre, Complex Fluid Engineering Laboratory, Universidad de Huelva, Huelva, Spain
| | - Críspulo Gallegos
- Fresenius-Kabi Deutschland GmbH, Product and Process Engineering Center, Global Manufacturing Pharmaceuticals, Bad Homburg, Germany
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Scale-Up of Freeze-Drying Cycles, the Use of Process Analytical Technology (PAT), and Statistical Analysis. METHODS IN PHARMACOLOGY AND TOXICOLOGY 2019. [DOI: 10.1007/978-1-4939-8928-7_10] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/05/2023]
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