Near infrared spectroscopy and process analytical technology to master the process of busulfan paediatric capsules in a university hospital

Identification, Isolation, and Characterization of a Novel Degradation Impurity of Busulfan Using Preparative Chromatography, NMR, and LC-MS

BACKGROUND

Busulfan is the most effective medication for treating chronic myelogenous or granulocytic leukemia because it has cytotoxic properties that harm or kill hematopoietic cells. It cannot absorb light in the Ultraviolet range due to its structure. Because of this, it is very challenging to quantify using traditional HPLC coupled with UV/Photodiode Array detectors. So, using sodium diethyldithiocarbamate, a derivatization method was developed to quantify related impurities. A significant unknown impurity was identified in derivatized samples of busulfan and a noticeably high percentage level was discovered during routine drug testing.

OBJECTIVE

We aimed to isolate, and characterize the unknown impurity observed in the samples and to identify its root cause.

METHODS

Preparative HPLC was used to isolate the unidentified, derivatized impurity, and 1H NMR, 13C NMR, and MS were used to decipher its structural components.

RESULTS

The spectral characterization data analysis showed that the unknown impurity was related to busulfan. Additionally, it was noted that the impurity developed as a result of the residual buffer used to prepare the derivatizing reagent.

CONCLUSION

The isolated impurity was found to be same as comparable to that found in busulfan drug substances, according to the results of the characterization tools. An alternative method of reagent preparation was optimized and deemed satisfactory because the buffer used in reagent preparation is the only factor contributing to the formation of impurities.

HIGHLIGHTS

Using cutting-edge analytical characterization tools, it was possible to explain the structural characteristics of an unknown impurity and discover that it was a novel impurity, which undoubtedly contributes to the comprehension of drug substance reaction properties.

Streamlining of the Powder Mixing Process based on a Segregation Test

In direct compression of tablets, it is crucial to maintain content uniformity within acceptable margins, especially in formulations with low drug loading. To assure it, complex and multistep mixing processes are utilized in the industry. In this study, we suggest the use of a simple segregation test to evaluate mixing process performance and mixture segregation to produce tablets having satisfying content uniformity while keeping the process as simple and low cost as possible. Eventually, the formulation propensity to segregation can be evaluated using process analytical technology (PAT) to adjust the mixing process parameters to changing source drug properties. In this study, that approach was examined on a model drug with a broad batch-to-batch variability in particle size and shape. Excipients were chosen so that the resulting blend composition mimicked some marketed formulations. For each drug batch, two formulation blends were prepared through different preparation processes (one simple and one complex) and subsequently subjected to segregation tests. From those, segregation coefficients were obtained to compare segregation tendencies and homogeneity robustness between the drug batches and the blend preparation methods. The inter-particulate interactions were substantially influenced by the drug particle morphology and size and resulted in different segregation behavior. Based on these findings, a simple segregation test proved to be a useful tool for determining the suitability of different batches of the model drug to be used in a certain formulation. Moreover, for a particular batch A, the test revealed a potential for mixing process simplification and therefore process intensification and cost reduction.

Process Analytical Technology Tools for Monitoring Pharmaceutical Unit Operations: A Control Strategy for Continuous Process Verification

Various frameworks and methods, such as quality by design (QbD), real time release test (RTRT), and continuous process verification (CPV), have been introduced to improve drug product quality in the pharmaceutical industry. The methods recognize that an appropriate combination of process controls and predefined material attributes and intermediate quality attributes (IQAs) during processing may provide greater assurance of product quality than end-product testing. The efficient analysis method to monitor the relationship between process and quality should be used. Process analytical technology (PAT) was introduced to analyze IQAs during the process of establishing regulatory specifications and facilitating continuous manufacturing improvement. Although PAT was introduced in the pharmaceutical industry in the early 21st century, new PAT tools have been introduced during the last 20 years. In this review, we present the recent pharmaceutical PAT tools and their application in pharmaceutical unit operations. Based on unit operations, the significant IQAs monitored by PAT are presented to establish a control strategy for CPV and real time release testing (RTRT). In addition, the equipment type used in unit operation, PAT tools, multivariate statistical tools, and mathematical preprocessing are introduced, along with relevant literature. This review suggests that various PAT tools are rapidly advancing, and various IQAs are efficiently and precisely monitored in the pharmaceutical industry. Therefore, PAT could be a fundamental tool for the present QbD and CPV to improve drug product quality.

Application of miniaturized near-infrared spectroscopy for quality control of extemporaneous orodispersible films

Extemporaneous oral preparations are routinely compounded in the pharmacy due to a lack of suitable formulations for special populations. Such small-scale pharmacy preparations also present an avenue for individualized pharmacotherapy. Orodispersible films (ODF) have increasingly been evaluated as a suitable dosage form for extemporaneous oral preparations. Nevertheless, as with all other extemporaneous preparations, safety and quality remain a concern. Although the United States Pharmacopeia (USP) recommends analytical testing of compounded preparations for quality assurance, pharmaceutical assays are typically not routinely performed for such non-sterile pharmacy preparations, due to the complexity and high cost of conventional assay methods such as high performance liquid chromatography (HPLC). Spectroscopic methods including Raman, infrared and near-infrared spectroscopy have been successfully applied as quality control tools in the industry. The state-of-art benchtop spectrometers used in those studies have the advantage of superior resolution and performance, but are not suitable for use in a small-scale pharmacy setting. In this study, we investigated the application of a miniaturized near infrared (NIR) spectrometer as a quality control tool for identification and quantification of drug content in extemporaneous ODFs. Miniaturized near infrared (NIR) spectroscopy is suitable for small-scale pharmacy applications in view of its small size, portability, simple user interface, rapid measurement and real-time prediction results. Nevertheless, the challenge with miniaturized NIR spectroscopy is its lower resolution compared to state-of-art benchtop equipment. We have successfully developed NIR spectroscopy calibration models for identification of ODFs containing five different drugs, and quantification of drug content in ODFs containing 2-10mg ondansetron (OND). The qualitative model for drug identification produced 100% prediction accuracy. The quantitative model to predict OND drug content in ODFs was divided into two calibrations for improved accuracy: Calibration I and II covered the 2-4mg and 4-10mg ranges respectively. Validation was performed for method accuracy, linearity and precision. In conclusion, this study demonstrates the feasibility of miniaturized NIR spectroscopy as a quality control tool for small-scale, pharmacy preparations. Due to its non-destructive nature, every dosage unit can be tested thus affording positive impact on patient safety.

On-line monitoring of extraction process of Flos Lonicerae Japonicae using near infrared spectroscopy combined with synergy interval PLS and genetic algorithm

There is a growing need for the effective on-line process monitoring during the manufacture of traditional Chinese medicine to ensure quality consistency. In this study, the potential of near infrared (NIR) spectroscopy technique to monitor the extraction process of Flos Lonicerae Japonicae was investigated. A new algorithm of synergy interval PLS with genetic algorithm (Si-GA-PLS) was proposed for modeling. Four different PLS models, namely Full-PLS, Si-PLS, GA-PLS, and Si-GA-PLS, were established, and their performances in predicting two quality parameters (viz. total acid and soluble solid contents) were compared. In conclusion, Si-GA-PLS model got the best results due to the combination of superiority of Si-PLS and GA. For Si-GA-PLS, the determination coefficient (R_p²) and root-mean-square error for the prediction set (RMSEP) were 0.9561 and 147.6544μg/ml for total acid, 0.9062 and 0.1078% for soluble solid contents, correspondingly. The overall results demonstrated that the NIR spectroscopy technique combined with Si-GA-PLS calibration is a reliable and non-destructive alternative method for on-line monitoring of the extraction process of TCM on the production scale.

Overall uncertainty measurement for near infrared analysis of cryptotanshinone in tanshinone extract

This study presented a new strategy of overall uncertainty measurement for near infrared (NIR) quantitative analysis of cryptotanshinone in tanshinone extract powders. The overall uncertainty of NIR analysis from validation data of precision, trueness and robustness study was fully investigated and discussed. Quality by design (QbD) elements, such as risk assessment and design of experiment (DOE) were utilized to organize the validation data. An "I×J×K" (series I, the number of repetitions J and level of concentrations K) full factorial design was used to calculate uncertainty from the precision and trueness data. And a 2(7-4) Plackett-Burmann matrix with four different influence factors resulted from the failure mode and effect analysis (FMEA) analysis was adapted for the robustness study. The overall uncertainty profile was introduced as a graphical decision making tool to evaluate the validity of NIR method over the predefined concentration range. In comparison with the T. Saffaj's method (Analyst, 2013, 138, 4677.) for overall uncertainty assessment, the proposed approach gave almost the same results, demonstrating that the proposed method was reasonable and valid. Moreover, the proposed method can help identify critical factors that influence the NIR prediction performance, which could be used for further optimization of the NIR analytical procedures in routine use.

Non-invasive quantification of 5 fluorouracil and gemcitabine in aqueous matrix by direct measurement through glass vials using near-infrared spectroscopy

Fourier transform near infrared spectroscopy (NIRS) was used for quantitative analysis of two cytotoxic drugs used in pharmaceutical infusion, 5-fluorouracil (5FU) and gemcitabine (GEM), at therapeutic concentrations in aqueous matrix. Spectra were collected from 4000 cm(-1) to 13,000 cm(-1) by direct measurement through standard glass vials and calibration models were developed for 5FU and GEM using partial least-squares regression. NIR determination coefficient (R(2)) greater than 0.9992, root-mean-square-error of cross-validation (RMESCV) of 0.483 mg/ml for 5FU and 0.139 mg/ml for GEM and the root mean square error of prediction (RMSEP) of 0.519 for 5FU and 0.108 mg/ml for GEM show a good prediction ability of NIR spectroscopy to predict 5FU and GEM concentrations directly through a glass packaging. According to accuracy profile, the linearity was validated from 7 to 50mg/ml and 2 to 40 mg/ml for 5-fluorouracil and gemcitabine respectively. This new approach for cytotoxic drugs control at hospital has shown the feasibility of near infrared spectroscopy to quantify antineoplastic drugs in aqueous matrix by a direct measurement through glass vial in less than 1 min and by non-invasive measurement perfect to limit exposure of operator to cytotoxic drugs.

Application of near-infrared spectroscopy combined with multivariate analysis in monitoring of crude heparin purification process

Ion-exchange chromatography is a widely used purification technology in the heparin manufacturing process. To improve the efficiency and understand the process directly, a rapid and equally precise method needs to be developed to measure heparin concentration in chromatography process. Here, two robust partial least squares regression (PLS-R) models were established for quantification of heparin based on the near-infrared (NIR) spectroscopy with 80 samples of adsorption process and 76 samples of elution process. Several variables selection algorithms, including correlation coefficient method, successive projection algorithm (SPA) and interval partial least squares (iPLSs), were performed to remove non-informative variables. The results showed that the correlation coefficient of validation (Rp) and the residual predictive deviation (RPD) corresponded to 0.957 and 3.4472 for adsorption process, 0.968 and 3.9849 for elution process, respectively. The approach was found considerable potential for real-time monitoring the heparin concentration of chromatography process.

Strategies for multivariate modeling of moisture content in freeze-dried mannitol-containing products by near-infrared spectroscopy

Accurate determination of residual moisture content of a freeze-dried (FD) pharmaceutical product is critical for prediction of its quality. Near-infrared (NIR) spectroscopy is a fast and non-invasive method routinely used for quantification of moisture. However, several physicochemical properties of the FD product may interfere with absorption bands related to the water content. A commonly used stabilizer and bulking agent in FD known for variation in physicochemical properties, is mannitol. To minimize this physicochemical interference, different approaches for multivariate correlation between NIR spectra of a FD product containing mannitol and the corresponding moisture content measured by Karl Fischer (KF) titration have been investigated. A novel method, MIPCR (Main and Interactions of Individual Principal Components Regression), was found to have significantly increased predictive ability of moisture content compared to a traditional PLS approach. The philosophy behind the MIPCR is that the interference from a variety of particle and morphology attributes has interactive effects on the water related absorption bands. The transformation of original wavelength variables to orthogonal scores gives a new set of variables (scores) without covariance structure, and the possibility of inclusion of interaction terms in the further modeling. The residual moisture content of the FD product investigated is in the range from 0.7% to 2.6%. The mean errors of cross validated prediction of models developed in the investigated NIR regions were reduced from a range of 24.1-27.6% for traditional PLS method to 15.7-20.5% for the MIPCR method. Improved model quality by application of MIPCR, without the need for inclusion of a large number of calibration samples, might increase the use of NIR in early phase product development, where availability of calibration samples is often limited.

Rapid evaluation for heterogeneities in monoclonal antibodies by liquid chromatography/mass spectrometry with a column-switching system

The development of therapeutic antibodies has grown over the last several years. Most of the recombinant monoclonal antibodies (mAbs) produced by mammalian cells are glycoproteins. Glycosylation of the mAbs can be associated with effector functions, such as antibody-dependent cellular cytotoxicity and complement-dependent cytotoxicity, as well as immunogenicity and clearance. Thus, mAb glycan heterogeneity is a significant characteristic associated with the safety and efficacy of the products. Therefore, glycan heterogeneity should be evaluated during research and development (R&D) and during development of mAbs manufacturing processes to identify the process parameters that affect glycan heterogeneity and to enhance understanding of the manufacturing process. There is an increasing need for a rapid, easy, and automated evaluation method for glycan heterogeneity. Liquid chromatography/mass spectrometry (LC/MS) is a method that can be used to analyze glycoforms. LC/MS is marked by the ability to measure the oligosaccharide composition of each glycoform, whereas other general methods, such as capillary electrophoresis, sodium dodecyl sulfate-polyacrylamide gel electrophoresis, and ion-exchange chromatography, cannot. However, a laborious off-line purification of mAbs is required to evaluate glycan heterogeneities. In this study, we demonstrate the use of a rapid, easy, and automated evaluation system for mAb glycoforms by LC/MS. This LC/MS system uses a column-switching system equipped with 2 columns, a protein A affinity column and a reversed-phase column (desalting column). We devised 2 column-switching systems: one that targeted intact mAbs (system 1) and one that targeted the light and heavy chains of the mAbs (system 2). Our results show that the proposed systems are applicable as a tool to evaluate the glycoforms in several situations, including the research, development, and production processes of mAbs. Additionally, we hope that our systems are useful as process analytical technology (PAT) for molecular heterogeneities containing glycoforms of mAbs in implementation of quality by design (QbD).

Critical review of near-infrared spectroscopic methods validations in pharmaceutical applications

Based on the large number of publications reported over the past five years, near-infrared spectroscopy (NIRS) is more and more considered an attractive and promising analytical tool regarding Process Analytical Technology and Green Chemistry. From the reviewed literature, few of these publications present a thoroughly validated NIRS method even if some guidelines have been published by different groups and regulatory authorities. However, as any analytical method, the validation of NIRS method is a mandatory step at the end of the development in order to give enough guarantees that each of the future results during routine use will be close enough to the true value. Besides the introduction of PAT concepts in the revised document of the European Pharmacopoeia (2.2.40) dealing with near-infrared spectroscopy recently published in Pharmeuropa, it agrees very well with this mandatory step. Indeed, the latter suggests to use similar analytical performance characteristics than those required for any analytical procedure based on acceptance criteria consistent with the intended use of the method. In this context, this review gives a comprehensive and critical overview of the methodologies applied to assess the validity of quantitative NIRS methods used in pharmaceutical applications.

Analysis of anticancer drugs: a review

In the last decades, the number of patients receiving chemotherapy has considerably increased. Given the toxicity of cytotoxic agents to humans (not only for patients but also for healthcare professionals), the development of reliable analytical methods to analyse these compounds became necessary. From the discovery of new substances to patient administration, all pharmaceutical fields are concerned with the analysis of cytotoxic drugs. In this review, the use of methods to analyse cytotoxic agents in various matrices, such as pharmaceutical formulations and biological and environmental samples, is discussed. Thus, an overview of reported analytical methods for the determination of the most commonly used anticancer drugs is given.

Preparing calibration sets for use in pharmaceutical analysis by NIR spectroscopy

A new methodology for constructing calibration sets based on the use of laboratory samples encompassing the same variability sources as production samples was developed. The proposed methodology requires the use of no reference method in order to obtain reference values for the analyte; also, it provides more simple and robust calibration models than does the conventional methodology while retaining its predictive capacity. The procedure involves subjecting a set of laboratory samples spanning the desired API concentration range to a granulation treatment similar to that of the industrial process in order to obtain samples with the same physical variability as the production samples. The laboratory samples thus obtained are used to develop partial least squares (PLS1) calibration models in order to quantify the API in a pharmaceutical granulate. Based on the results obtained in this work, NIR spectroscopy is an effective alternative to the reference methods currently used for calibration. The proposed methodology requires no reference values to construct models; therefore, it can be regarded as an absolute analytical method. Also, it confirms the advantages of NIR spectroscopy as part of the process analytical technology (PAT) used by the pharmaceutical industry. A second aim has been the use of the multiplicative curve resolution-alternating least squares (MCR-ALS) algorithm to examine potential polymorphic transformations of the API during granulation.

Rapid method to study the sedimentation of a pigment suspension prepared for coating fluids

Film coating fluids commonly contain a pigment suspension. The sedimentation of insoluble particles in the coating suspension is one of the main problems during the formulation of the coating fluid. The aims of this work were to investigate the suitability of an energy-dispersive X-ray fluorescence analyser for rapid measurement of the sedimentation of titanium dioxide in aqueous suspensions. The suspensions were produced with a high-speed Ultra-Turrax. The process factors evaluated were the stirring rate, time and volume, and the process of sedimentation of the pigment. The enrichment of the pigment at the bottom of the sample holder was followed by means of the very rapid method of energy-dispersive X-ray fluorescence analysis. It can be concluded that the sedimentation of the particles is described by the Weibull equation. With an appropriate combination of the factors, a threefold increase in the sedimentation time was achieved. The mathematically based information (sedimentation time, kinetics of sedimentation, etc.) is essential for an exact evaluation of the preparation of the coating fluid. The understanding of the process through use of this test method leads to the ability to identify the critical control points of film coating.