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Menzel R, Budde D, Maier T, Pahl I, Raddatz L, Lausch R, Zumbrum M, Hauk A. Parylene C Coating Efficacy Studies: Enhancing Biocompatibility of 3D Printed Polyurethane Parts for Biopharmaceutical and CGT Applications. ACS APPLIED BIO MATERIALS 2024; 7:5369-5381. [PMID: 39041651 PMCID: PMC11337162 DOI: 10.1021/acsabm.4c00561] [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: 04/25/2024] [Revised: 06/25/2024] [Accepted: 06/25/2024] [Indexed: 07/24/2024]
Abstract
Additive manufacturing, particularly Vat photopolymerization, presents a promising technique for producing complex, tailor-made structures, making it an attractive option for generating single-use components used in biopharmaceutical manufacturing equipment or cell culture devices. However, the potential leaching of cytotoxic compounds from Vat photopolymer resins poses a significant concern, especially regarding cell growth and viability in cell culture applications. This study explores the potential of parylene C coating to enhance the inertness of a polyurethane-based photopolymer resin, aiming to prevent cytotoxicity and improve biocompatibility. The study includes an analysis of extractables from the resin and photoinitiator to evaluate the resin's composition and to define selected marker compounds for investigating the coating efficiency. The time-dependent accumulation of relevant extractable compounds over a 70-day period are assessed to address the long-term use of the coated components. The impact of irradiation on the material and the coating was evaluated, along with an accelerated aging study to address the long-term performance of the coating. Biocompatibility in terms of in vitro cell growth studies is evaluated using Chinese hamster ovary cells, a standard cell line in biopharmaceutical manufacturing. Results demonstrate that parylene C coating significantly reduces the release of cytotoxic compounds, such as the photoinitiator diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide (TPO). Although accelerated aging indicates a reduction in the barrier properties of the coating over time, the parylene C coating still effectively slows the release of extractables and significantly improves cell compatibility of the 3D printed parts. The findings suggest that parylene C-coated components can be safely integrated into biopharmaceutical manufacturing processes, with recommendations to minimize storage times between coating application and use to ensure optimal performance.
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Affiliation(s)
- Roberto Menzel
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Dana Budde
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Tanja Maier
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Ina Pahl
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Lukas Raddatz
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Ralf Lausch
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Michael Zumbrum
- Sartorius
Stedim North America, Inc., 565 Johnson Avenue, Bohemia, New York 11716, United States
| | - Armin Hauk
- Sartorius
Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
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2
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Li J. A comprehensive study of the effect of elevated temperature on the extractability and rate of exaggerated and exhaustive extractions of medical devices. J Pharm Biomed Anal 2023; 235:115587. [PMID: 37516062 DOI: 10.1016/j.jpba.2023.115587] [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: 06/16/2023] [Revised: 07/11/2023] [Accepted: 07/14/2023] [Indexed: 07/31/2023]
Abstract
The effectiveness of an elevated temperature on the thermodynamic and kinetic properties of the solvent extraction of medical devices is evaluated in this study. The main objective of the current work is to specifically address the question of how effective a temperature of 50 °C, relative to 37 °C, is in improving the extractability and rate of the exaggerated and exhaustive extractions of medical devices. The extractability at equilibrium is related to the extraction partition coefficient, while the extraction rate is related to the corresponding diffusion coefficient. The partition and diffusion coefficients (or the enthalpies of extraction and diffusional activation energies) of solid-liquid extractions for different polymeric materials, solvents, and types of extractables entities at different temperatures are compiled comprehensively from extensive publications in the literature. The collected partition and diffusion coefficients at different temperatures are used to derive the partition enthalpies and diffusional activation energies in this study. The combined 209 partition enthalpies and 262 diffusional activation energies are then used to calculate the ratios of the partition and diffusion coefficients, when the extraction temperature increases from 37 °C to 50 °C. It is concluded from the study that the maximum improvement in extracted chemical amount with this specific temperature increase is about 3-fold, but the median improvement is only 16%. The most probable improvement is 25%. The maximum improvement (or decrease) in extraction time is 3.2-fold by the change in the diffusional coefficient, but the median value is 1.9-fold. The most probable decrease in extraction time is 2.4-fold. The collected data also allow the calculation of the ratio of the diffusion coefficient for a 10 °C increase, and the results are compared with the "factor 10 rule" in the literature on the relationship between the diffusion coefficient and temperature. The explicit conclusions of the study certainly provide evidences (not assumptions) in designing practical and cost-effective exaggerated and exhaustive extractions in the chemical characterization of medical devices, taking into considerations of extraction cycle time, temperature-dependent chemical stability, and the number of repeated extractions.
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Affiliation(s)
- Jianwei Li
- Chemical Characterization Solutions, LLC, PO Box 113, Newport, MN 55055, USA.
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3
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Saylor DM, Young JA. Modeling extraction of medical device polymers for biocompatibility evaluation. Regul Toxicol Pharmacol 2023; 141:105405. [PMID: 37182690 DOI: 10.1016/j.yrtph.2023.105405] [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: 02/01/2023] [Revised: 03/21/2023] [Accepted: 05/01/2023] [Indexed: 05/16/2023]
Abstract
Extraction testing is critical for biocompatibility evaluation of medical devices, whether to generate samples for biological testing or form the basis for toxicological risk assessment. However, it is not always clear how to compare extraction testing between different extraction conditions and sample geometries. We employ a physics-based model to elucidate the theoretical impact of extraction conditions, sample geometry and material properties on extraction efficiency (M/M0) and extract concentration (C/C0) for single-step and iterative/exhaustive extraction test methods. The model is specified by three parameters: thermodynamic contributions (Ψ), kinetic contributions (τ), and number of extraction iterations (N). We find that over the range of typical parameters for single-step extractions, M/M0 only approaches one (complete exhaustion) for relatively large values of Ψ (≥10) and τ(≥1). Further, the model suggests that test article geometry and solvent volume can have a dramatic and sometimes opposing effect on M/M0 and C/C0. Our results imply that iterative extractions can be approximated as a single-step extraction with scaled parameters Ψ' = ΨN and τ' = τN. The model provides a framework to reduce the biocompatibility evaluation test burden by optimizing test article and extraction condition selection and guiding development of new test protocols.
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Affiliation(s)
- David M Saylor
- Center for Devices and Radiological Health, FDA, Silver Spring, MD, 20993, USA.
| | - Joshua A Young
- Center for Devices and Radiological Health, FDA, Silver Spring, MD, 20993, USA
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4
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Bossong M, Budde D, Hauk A, Pahl I, Menzel R, Langguth P. Biosorption of process-equipment-related leachables (PERLs) in biomanufacturing: A quantitative approach to study partitioning of PERLs in a cell culture system. Int J Pharm 2023; 635:122742. [PMID: 36804518 DOI: 10.1016/j.ijpharm.2023.122742] [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: 11/11/2022] [Revised: 02/11/2023] [Accepted: 02/14/2023] [Indexed: 02/19/2023]
Abstract
The assessment and potential risk of process equipment-related leachables (PERLs) in the production of biopharmaceuticals and cell therapeutics using single-use (SU) equipment has been discussed previously. However, potential interactions of cells with PERLs have not yet been considered. Here, we present a quantitative adsorption study of neutral, organic small-molecule leachable compounds - known for extractables & leachables (E&L) analysis of SU equipment - in aqueous suspensions of CHO and T cells. The solid-water partition coefficient Kd was obtained for all compounds that showed adsorption. The findings implied that hydrophobic interactions are dominant; however, there was no unambiguous correlation between the derived adsorption coefficient Kd and the octanol-water partition coefficient Kow. Interestingly, a maximum affinity of both cell types to the leachable bis(2,4-di-tert-butylphenyl)phosphate, which is known to be detrimental to cell development, was observed. A comparison of both cell types revealed that they generally interact with the same compounds in most cases but to different extents. Using partition coefficients enables estimation of the concentrations of leachable compounds associated with the biomass phase and in the aqueous suspensions and could be used for risk assessment of SU systems in biopharmaceutical and cell therapy (CT) manufacturing processes.
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Affiliation(s)
- M Bossong
- Department of Biopharmaceutics and Pharmaceutical Technology, Institute of Pharmaceutical and Biomedical Sciences, Johannes Gutenberg University, Mainz, Germany; Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany.
| | - D Budde
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - A Hauk
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - I Pahl
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - R Menzel
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - P Langguth
- Department of Biopharmaceutics and Pharmaceutical Technology, Institute of Pharmaceutical and Biomedical Sciences, Johannes Gutenberg University, Mainz, Germany
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5
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Menzel R, Pahl I, Dorey S, Maier T, Hauk A. Equivalence study of extractables from single-use biopharmaceutical manufacturing equipment after X-ray or gamma irradiation. Int J Pharm 2023; 634:122677. [PMID: 36740079 DOI: 10.1016/j.ijpharm.2023.122677] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/01/2022] [Revised: 01/30/2023] [Accepted: 01/31/2023] [Indexed: 02/05/2023]
Abstract
Single-use (SU) devices and assemblies used as manufacturing equipment in the biopharmaceutical industry require comprehensive qualifications. These qualifications include the assessment of compounds released from SU devices in contact with the process fluids, and how these leachable compounds potentially influence process performance, drug product quality, and patient safety. SU suppliers need to provide comprehensive qualification data for several parameters, for both new products and product changes, such as changes in the sterilization process applied to the SU device. The introduction of X-ray irradiation as an alternative to the currently used and established gamma irradiation of SU devices represents a situation where robust data is required to demonstrate equivalency between these two radiation technologies. Here, we present the results of a comprehensive extractables study for three SU components, bags, tubing, and sterilizing grade filters, evaluated after X-ray and gamma-ray irradiation. The selected study conditions were set up to allow a direct comparison of the results from the two sterilization methods, and to allow conclusions to be made on the impact of irradiation type on the polymers and their additives. Orthogonal analytical methods are applied to identify and quantify all organic compounds present. The data package provided here supports risk assessments for application of irradiated SU equipment in biopharmaceutical manufacturing. The formation of reaction products and the fundamental chemical pathways are discussed and found to be independent of the irradiation type. The results demonstrate the equivalency of both irradiation methods for extractables from plastic components used in pharmaceutical and biopharmaceutical manufacturing.
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Affiliation(s)
- Roberto Menzel
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Ina Pahl
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany.
| | - Samuel Dorey
- Sartorius Stedim FMT S.A.S, Z.I., Les Paluds, Aubagne Cedex, France
| | - Tanja Maier
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
| | - Armin Hauk
- Sartorius Stedim Biotech GmbH, August-Spindler-Straße 11, 37079 Göttingen, Germany
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6
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Sun X, Zhuang J, Ma X, Tang Y, Ali MM, Lu Z, Zheng X, Du Z. Structure elucidation and risk assessment of degradation products in gamma irradiated rubber closures. Polym Degrad Stab 2022. [DOI: 10.1016/j.polymdegradstab.2022.110126] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/14/2022]
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7
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Samaras JJ, Micheletti M, Ding W. Transformation of Biopharmaceutical Manufacturing Through Single-Use Technologies: Current State, Remaining Challenges, and Future Development. Annu Rev Chem Biomol Eng 2022; 13:73-97. [PMID: 35700527 DOI: 10.1146/annurev-chembioeng-092220-030223] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
Single-use technologies have transformed conventional biopharmaceutical manufacturing, and their adoption is increasing rapidly for emerging applications like antibody-drug conjugates and cell and gene therapy products. These disruptive technologies have also had a significant impact during the coronavirus disease 2019 pandemic, helping to advance process development to enable the manufacturing of new monoclonal antibody therapies and vaccines. Single-use systems provide closed plug-and-play solutions and enable process intensification and continuous processing. Several challenges remain, providing opportunities to advance single-use sensors and their integration with single-use systems, to develop novel plastic materials, and to standardize design for interchangeability. Because the industry is changing rapidly, a holistic analysis of the current single-use technologies is required, with a summary of the latest advancements in materials science and the implementation of these technologies in end-to-end bioprocesses.
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Affiliation(s)
- Jasmin J Samaras
- Advanced Centre for Biochemical Engineering, University College London, London, United Kingdom
| | - Martina Micheletti
- Advanced Centre for Biochemical Engineering, University College London, London, United Kingdom
| | - Weibing Ding
- Manufacturing Science & Technology, GSK, King of Prussia, Pennsylvania, USA;
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8
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Egert T, Langowski HC. Linear Solvation Energy Relationships (LSERs) for Robust Prediction of Partition Coefficients between Low Density Polyethylene and Water Part I: Experimental Partition Coefficients and Model Calibration. Eur J Pharm Sci 2022; 172:106137. [PMID: 35150822 DOI: 10.1016/j.ejps.2022.106137] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/01/2021] [Revised: 01/10/2022] [Accepted: 02/01/2022] [Indexed: 11/17/2022]
Abstract
When equilibrium of leaching is reached within a product's duty cycle, partition coefficients polymer/solution dictate the maximum accumulation of a leachable and thus, patient exposure by leachables. Yet, in the pharmaceutical and food industry, exposure estimates based on predictive modeling typically rely on coarse estimations of the partition coefficient, with accurate and robust models lacking. This first part of the study aimed to explore linear solvation energy relationships (LSERs) as high performing models for the prediction of partition coefficients polymer/water. For this, partition coefficients between low density polyethylene (LDPE) and aqueous buffers for 159 compounds spanning a wide range of chemical diversity, molecular weight, vapor pressure, aqueous solubility and polarity (hydrophobicity) were determined and complimentary data collected from the literature (n=159, MW: 32 to 722, logKi,O/W: -0.72 to 8.61 and logKi,LDPE/W: -3.35 up to 8.36). The chemical space represented by this compounds set is considered indicative for the universe of compounds potentially leaching from plastics. Based on the dataset for the LDPE material purified by solvent extraction, a LSER model for partitioning between LDPE and water was calibrated to give:logKi,LDPE/W=-0.529+1.098Ei-1.557Si-2.991Ai-4.617Bi+3.886Vi. The model was proven accurate and precise (n = 156, R2 = 0.991, RMSE = 0.264). Further, it was demonstrated superior over a log-linear model fitted to the same data. Nonetheless, it could be shown that log-linear correlations against logKi,O/W can be of value for the estimation of partition coefficients for nonpolar compounds exhibiting low hydrogen-bonding donor and/or acceptor propensity. For these nonpolar compounds, the log - linear model was found to be: logKi,LDPE/W=1.18logKi,O/W-1.33 (n = 115, R2=0.985, RMSE = 0.313). In contrast, with mono-/bipolar compounds included into the regression data set, an only weak correlation was observed (n = 156, R2 = 0.930, RMSE = 0.742) rendering the log-linear model of more limited value for polar compounds. Notably, sorption of polar compounds into native (non-purified) LDPE was found to be up to 0.3 log units lower than into purified LDPE. To identify maximum (i. e. worst-case) levels of leaching in support of chemical safety risk assessments on systems attaining equilibrium before end of shelf-life, it appears adequate to utilize LSER - calculated partition coefficients (in combination with solubility data) by ignoring any kinetical information.
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Affiliation(s)
- Thomas Egert
- Boehringer Ingelheim Pharma GmbH & Co.KG, Ingelheim/Rhein, Germany; Technical University of Munich, TUM School of Life Sciences Weihenstephan, Chair of Food Packaging Technology, Weihenstephaner Steig 22, Freising, 85354, Germany.
| | - Horst-Christian Langowski
- Technical University of Munich, TUM School of Life Sciences Weihenstephan, Chair of Food Packaging Technology, Weihenstephaner Steig 22, Freising, 85354, Germany; Fraunhofer Institute for Process Engineering and Packaging IVV, Giggenhauser Str. 35, Freising, 85354, Germany
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9
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Egert T, Langowski HC. Linear Solvation Energy Relationships (LSERs) for Robust Prediction of Partition Coefficients between Low Desity Polyethylene and Water Part II: Model Evaluation and Benchmarking. Eur J Pharm Sci 2022; 172:106138. [PMID: 35122951 DOI: 10.1016/j.ejps.2022.106138] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/14/2021] [Revised: 01/10/2022] [Accepted: 02/01/2022] [Indexed: 11/03/2022]
Abstract
By neglecting the kinetics of leaching, the accumulation of leachables in a clinically relevant medium in contact with plastics is principally driven by the equilibrium partition coefficient between the polymer and the medium phase. Based on experimental partition coefficients for a wide set of chemically diverse compounds between low density polyethylene (LDPE) and water, a linear solvation energy relationship (LSER) model was obtained in part I of this study, reading: logKi,LDPE/W=-0.529+1.098Ei-1.557Si-2.991Ai-4.617Bi+3.886Vi. The model was proven accurate and precise (n = 156, R2 = 0.991, RMSE = 0.264).) In this part II of the study, for further evaluation and benchmarking of the LSER model ∼ 33% (n = 52) of the total observations were ascribed to an independent validation set. Calculation of partition coefficients logKi,LDPE/W for this validation set was based on experimental LSER solute descriptors. Linear regression against the corresponding experimental values yielded R2 = 0.985 and RMSE = 0.352. When using LSER solute descriptors predicted from the compound's chemical structure by means of a QSPR prediction tool, instead, R2 = 0.984 and RMSE = 0.511 were obtained. These statistics are considered indicative for extractables with no experimental LSER solute descriptors available. By comparison to LSER models from the literature, a strong correlation between the quality of experimental partition coefficients and the chemical diversity of the training set to the model's predictability was observed, the latter of particular relevance for the application domain of the model. Further, to tentatively match partitioning into LDPE to partitioning into a liquid phase, partition coefficients logKi,LDPE/W were converted into logKi,LDPEamorph/W by considering the amorphous fraction of the polymer as effective phase volume only. A LSER model now recalibrated based on the observations for logKi,LDPEamorph/W exhibited the constant in the equation above to now read -0.079 instead of -0.529 which rendered the model more similar to a corresponding LSER-model for n-hexadencane/water. Based on LSER system parameters available, the sorption behavior of LDPE could be efficiently compared to the one of polydimethylsiloxane (PDMS), polyacrylate (PA) and polyoxymethylene (POM). The latter, by offering capabilities for polar interactions due to their heteroatomic building blocks, exhibit stronger sorption than LDPE to the more polar, non-hydrophobic domain of sorbates up to an logKi,LDPE/W range of 3 to 4. Above that range, all four polymers exhibited a roughly similar sorption behavior. Overall, LSERs were found to represent an accurate and user-friendly approach for the estimation of equilibrium partition coefficients involving a polymeric phase. All intrinsic input parameters can be retrieved from a free, web-based and curated database along with the outright calculation of the partition coefficient for any given neutral compound with a known structure for a given two-phased system.
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Affiliation(s)
- Thomas Egert
- Boehringer Ingelheim Pharma GmbH & Co.KG, Ingelheim/Rhein, Germany; Technical University of Munich, TUM School of Life Sciences, Weihenstephaner Steig 22, Freising, 85354, Germany.
| | - Horst-Christian Langowski
- Technical University of Munich, TUM School of Life Sciences, Weihenstephaner Steig 22, Freising, 85354, Germany; Fraunhofer Institute for Process Engineering and Packaging, Giggenhauser Str. 35, Freising, 85354, Germany
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10
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Reddy RE, Hu W, Lowry BR, Fogle JL, Malick RE, Erexson G, Westerberg JM, Carragher AL, Robinson EE, Orihuela CA, Hillier MC, Davis SR, Kruk PE, Ide ND, Mlinar L, Mulhern MM, Engstrom KM, Chaaya E, McKee LA, Manning PE, Tirino P, Joudioux R, Cornelio L. Risk Assessment of the Leachables’ Profile for Small-Molecule Pharmaceutical Drug Substances. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00296] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Rajarathnam E. Reddy
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Wenbin Hu
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Brian R. Lowry
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Jace L. Fogle
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Robert E. Malick
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Greg Erexson
- Preclinical Safety, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - John M. Westerberg
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Adelia L. Carragher
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Emily E. Robinson
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Carlos A. Orihuela
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Michael C. Hillier
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Steven R. Davis
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Paul E. Kruk
- Operations Science and Technology, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Nathan D. Ide
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Laurie Mlinar
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Mathew M. Mulhern
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Kenneth M. Engstrom
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Elie Chaaya
- Operations Manufacturing and Engineering, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Laura A. McKee
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Patrick E. Manning
- Process Research and Development, AbbVie Inc., 1 North Waukegan Road, North Chicago, Illinois 60064, United States
| | - Pasquale Tirino
- Manufacturing Science and Technology, AbbVie s.r.l., S.R. 148 Pontina Km 52 snc, Campoverde di Aprilia, Latino 04011, Italy
| | - Roberta Joudioux
- Manufacturing Science and Technology, AbbVie s.r.l., S.R. 148 Pontina Km 52 snc, Campoverde di Aprilia, Latino 04011, Italy
| | - Lisa Cornelio
- Manufacturing Science and Technology, AbbVie s.r.l., S.R. 148 Pontina Km 52 snc, Campoverde di Aprilia, Latino 04011, Italy
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11
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Qi L, Liu J, Ronk M, Gallegos A, Fujimori K, Luo Y, Li K, Lee H, Nashed-Samuel Y. A Holistic Approach of Extractables and Leachables Assessment of Rubber Stoppered Glass Vial Systems for Biotechnology Products. J Pharm Sci 2021; 110:3580-3593. [PMID: 34324943 DOI: 10.1016/j.xphs.2021.07.015] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/16/2021] [Revised: 07/22/2021] [Accepted: 07/22/2021] [Indexed: 11/17/2022]
Abstract
Rubber stoppered glass vial systems are widely used as primary containers for storing and delivering therapeutic protein products to patients. Addressing concerns and regulatory expectations related to the risk to biologic drug product quality and patient safety from rubber stoppered glass vial systems requires implementation of an extractable and leachable evaluation program based on material understanding, risk assessment, literature review, and a comprehensive scientifically sound analytical testing methodology. The extractable and leachable study design consisted of twelve drug products filled in twelve different size glass vials capped with laminated and nonlaminated rubber stoppers made from three different rubber formulations. Design of the model solvents was successful as they had little to no analytical interference and mimicked the formulation conditions and generated representative extractables capable of predicting leachables. The extraction conditions of time and temperature were appropriate as not to degrade the test materials or the extractable compounds, and yet generated significant quantities for identification of the extractable compounds with confidence. The extractables testing results were capable of predicting the leachable profiles of the twelve drug products. In each case, the leachable profile was a subset of the extractable profile. The organic and elemental impurities of the leachable profiles of drug products were the end-to-end verification of the quality of the glass vials, rubber stoppers and drug product lifecycles. Overall, the holistic approach was fully successful in the qualification of different vial systems as primary containers and delivery systems for different biotherapeutic products to ensure product quality and patient safety.
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Affiliation(s)
- Li Qi
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320.
| | - Jian Liu
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320
| | - Michael Ronk
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320
| | - Alejandra Gallegos
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320
| | - Kiyoshi Fujimori
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320
| | - Yanxin Luo
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320
| | - Kim Li
- Environment, Health, Safety and Sustainability, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320
| | - Hans Lee
- Los Angeles Trade-Technical College, 400 West Washington Blvd, Los Angeles, CA 90015
| | - Yasser Nashed-Samuel
- Attribute Sciences, Amgen Inc., One Amgen Center Drive, Thousand Oaks, CA 91320.
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