1
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Inoue K, Masuda Y, Torisu T, Nonaka K, Uchiyama S. Prediction models for the flux decay profile and initial flux of microfiltration for therapeutic proteins. Biotechnol Bioeng 2024; 121:1889-1901. [PMID: 38500437 DOI: 10.1002/bit.28692] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/04/2023] [Revised: 02/16/2024] [Accepted: 02/28/2024] [Indexed: 03/20/2024]
Abstract
Microfiltration (MF) is an essential step during biopharmaceutical manufacturing. However, unexpected flux decay can occur. Although the flux decay profile and initial flux are important factors determining MF filterability, predicting them accurately is challenging, as the root cause of unexpected flux decay remains elusive. In this study, the methodology for developing a prediction model of flux decay profiles was established. First, the filtration profiles of different monodisperse polystyrene latex and silica beads of various sizes were evaluated. These results revealed that the size and surface electrostatic properties of the beads affect the flux decay profile. Taking the size and surface electrostatic properties of protein aggregates into account, we constructed a predictive model using model bead filtration profiles. We showed that this methodology was applicable to two different MF filters to predict the flux decay profile of therapeutic proteins. Because our proposed prediction model is based on normalized flux, the initial flux is required to predict the overall filtration profile. Then, we applied the Hagen-Poiseuille equation using sample viscosity values to estimate the initial flux. The developed prediction models can be used for effective MF scale-up assessment during the early stages of process development.
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Affiliation(s)
- Kota Inoue
- Biotechnology Research Laboratories, Biologics Division, Daiichi Sankyo Co., Ltd, Chiyoda-machi, Japan
- Department of Biotechnology, Graduate School of Engineering, Osaka University, Suita, Japan
| | - Yumiko Masuda
- Biotechnology Research Laboratories, Biologics Division, Daiichi Sankyo Co., Ltd, Chiyoda-machi, Japan
| | - Tetsuo Torisu
- Department of Biotechnology, Graduate School of Engineering, Osaka University, Suita, Japan
| | - Koichi Nonaka
- Biotechnology Research Laboratories, Biologics Division, Daiichi Sankyo Co., Ltd, Chiyoda-machi, Japan
| | - Susumu Uchiyama
- Department of Biotechnology, Graduate School of Engineering, Osaka University, Suita, Japan
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2
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Griffin VP, Pace S, Ogunyankin MO, Holstein M, Hung J, Dhar P. Understanding the Impact of Combined Hydrodynamic Shear and Interfacial Dilatational Stress, on Interface-Mediated Particle Formation for Monoclonal Antibody Formulations. J Pharm Sci 2024:S0022-3549(24)00138-2. [PMID: 38615816 DOI: 10.1016/j.xphs.2024.04.009] [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: 12/11/2023] [Revised: 04/09/2024] [Accepted: 04/09/2024] [Indexed: 04/16/2024]
Abstract
During biomanufacturing, several unit operations expose solutions of biologics to multiple stresses, such as hydrodynamic shear forces due to fluid flow and interfacial dilatational stresses due to mechanical agitation or bubble collapse. When these stresses individually act on proteins adsorbed to interfaces, it results in an increase in protein particles in the bulk solution, a phenomenon referred to as interface-induced protein particle formation. However, an understanding of the dominant cause, when multiple stresses are acting simultaneously or sequentially, on interface-induced protein particle formation is limited. In this work, we established a unique set-up using a peristaltic pump and a Langmuir-Pockels trough to study the impact of hydrodynamic shear stress due to pumping and interfacial dilatational stress, on protein particle formation. Our experimental results together demonstrate that for protein solutions subjected to various combinations of stress (i.e., interfacial and hydrodynamic stress in different sequences), surface pressure values during adsorption and when subjected to compression/dilatational stresses, showed no change, suggesting that the interfacial properties of the protein film are not impacted by pumping. The concentration of protein particles is an order of magnitude higher when interfacial dilatational stress is applied at the air-liquid interface, compared to solutions that are only subjected to pumping. Furthermore, the order in which these stresses are applied, have a significant impact on the concentration of protein particles measured in the bulk solution. Together, these studies conclude that for biologics exposed to multiple stresses throughout bioprocessing and manufacturing, exposure to air-liquid interfacial dilatational stress is the predominant mechanism impacting protein particle formation at the interface and in the bulk solution.
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Affiliation(s)
- Valerie P Griffin
- Department of Chemical and Petroleum Engineering, The University of Kansas, 1530 W 15(th) Street, Lawrence, KS 66045, USA
| | - Samantha Pace
- Department of Drug Product, Department of Discovery Pharmaceutics, Bristol-Myers Squibb, Inc., 3551 Lawrenceville Road, Lawrence Township, NJ, 08648, USA
| | - Maria Olu Ogunyankin
- Development, Bristol-Myers Squibb, Inc., One Squibb Drive, New Brunswick, NJ, 08901, USA
| | - Melissa Holstein
- Biologics Development, Bristol-Myers Squibb, Inc., 38 Jackson Road, Devens, MA, 01434, USA
| | - Jessica Hung
- Biologics Development, Bristol-Myers Squibb, Inc., 38 Jackson Road, Devens, MA, 01434, USA
| | - Prajnaparamita Dhar
- Department of Chemical and Petroleum Engineering, The University of Kansas, 1530 W 15(th) Street, Lawrence, KS 66045, USA
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3
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Kennelly TR, Eshraghi J, Dabiri S, Vlachos PP. An experimentally validated cavitation inception model for spring-driven autoinjectors. Int J Pharm 2024; 652:123753. [PMID: 38159583 DOI: 10.1016/j.ijpharm.2023.123753] [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: 08/15/2023] [Revised: 12/24/2023] [Accepted: 12/27/2023] [Indexed: 01/03/2024]
Abstract
Cavitation, the formation and collapse of vapor-filled bubbles, poses a problem in spring-driven autoinjectors (AIs). It occurs when the syringe accelerates abruptly during activation, causing pressure fluctuations within the liquid. These bubbles expand and then collapse, generating shock waves that can harm both the device and the drug molecules. This issue stems from the syringe's sudden acceleration when the driving rod hits the plunger. To better understand cavitation in AIs, we explore how design factors like drive spring force, air gap size, and fluid viscosity affect its likelihood and severity. We use a dynamic model for spring-driven autoinjectors to predict and analyze the factors contributing to cavitation initiation and severity. This model predicts the motion of AI components, such as the displacement and velocity of the syringe barrel, and allows us to investigate pressure wave propagation and the subsequent dynamics of cavitation under various operating conditions. We investigated different air gap heights (from 1 to 4 mm), drive spring forces (from 8 to 30 N), and drug solution viscosities (from 1 to 18 cp) to assess cavitation inception based on operational parameters. Results reveal that AI dynamics and cavitation onset and severity strongly depend upon AI operating parameters, namely drive spring force and air gap height. The maximum syringe acceleration increases with spring stiffness and decreases with air gap height; increases in air gap height prolong the time interval of syringe acceleration but diminish the maximum syringe acceleration. From actuation to injection, air gap pressure peaks twice, first due to impact with the rod/plunger and secondly due to the deacceleration event upon injection. The maximum air gap pressure increases with spring stiffness and decreases with air gap height. Results show that maximum cavitation bubble radii and collapse-driven extension rates occur with higher driver spring forces, smaller air gap heights, and less viscous solutions. A cavitation criterion is developed for cavitation in autoinjectors that concludes that cavitation in autoinjectors depends on the peak syringe acceleration.
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Affiliation(s)
- Tyler R Kennelly
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States.
| | - Javad Eshraghi
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States; Eli Lilly and Company, Indianapolis, IN 46225, United States
| | - Sadegh Dabiri
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States
| | - Pavlos P Vlachos
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States
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4
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Moino C, Artusio F, Pisano R. Shear stress as a driver of degradation for protein-based therapeutics: More accomplice than culprit. Int J Pharm 2024; 650:123679. [PMID: 38065348 DOI: 10.1016/j.ijpharm.2023.123679] [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: 08/03/2023] [Revised: 11/27/2023] [Accepted: 12/04/2023] [Indexed: 01/08/2024]
Abstract
Protein degradation is a major concern for protein-based therapeutics. It may alter the biological activity of the product and raise the potential for undesirable effects on the patients. Among the numerous drivers of protein degradation, shear stress has been the focus around which much work has revolved since the 1970s. In the pharmaceutical realm, the product is often processed through several unit operations, which include mixing, pumping, filtration, filling, and atomization. Nonetheless, the drug might be exposed to significant shear stresses, which might cooperatively contribute to product degradation, together with interfacial stress. This review presents fundamentals of shear stress about protein structure, followed by an overview of the drivers of product degradation. The impact of shear stress on protein stability in different unit operations is then presented, and recommendations for limiting the adverse effects on the biopharmaceutical formulations are outlined. Finally, several devices used to explore the effects of shear stress are discussed.
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Affiliation(s)
- Camilla Moino
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, Torino 10129, Italy
| | - Fiora Artusio
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, Torino 10129, Italy
| | - Roberto Pisano
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, Torino 10129, Italy.
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5
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Fanthom TB, Wilson C, Gruber D, Bracewell DG. Solid-Solid Interfacial Contact of Tubing Walls Drives Therapeutic Protein Aggregation During Peristaltic Pumping. J Pharm Sci 2023; 112:3022-3034. [PMID: 37595747 DOI: 10.1016/j.xphs.2023.08.012] [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: 05/05/2023] [Revised: 08/13/2023] [Accepted: 08/13/2023] [Indexed: 08/20/2023]
Abstract
Peristaltic pumping during bioprocessing can cause therapeutic protein loss and aggregation during use. Due to the complexity of this apparatus, root-cause mechanisms behind protein loss have been long sought. We have developed new methodologies isolating various peristaltic pump mechanisms to determine their effect on monomer loss. Closed-loops of peristaltic tubing were used to investigate the effects of peristaltic pump parameters on temperature and monomer loss, whilst two mechanism isolation methodologies are used to isolate occlusion and lateral expansion-relaxation of peristaltic tubing. Heat generated during peristaltic pumping can cause heat-induced monomer loss and the extent of heat gain is dependent on pump speed and tubing type. Peristaltic pump speed was inversely related to the rate of monomer loss whereby reducing speed 2.0-fold increased loss rates by 2.0- to 5.0-fold. Occlusion is a parameter that describes the amount of tubing compression during pumping. Varying this to start the contacting of inner tubing walls is a threshold that caused an immediate 20-30% additional monomer loss and turbidity increase. During occlusion, expansion-relaxation of solid-liquid interfaces and solid-solid interface contact of tubing walls can occur simultaneously. Using two mechanisms isolation methods, the latter mechanism was found to be most destructive and a function of solid-solid contact area, where increasing the contact area 2.0-fold increased monomer loss by 1.6-fold. We establish that a form of solid-solid contact mechanism whereby the contact solid interfaces disrupt adsorbed protein films is the root-cause behind monomer loss and protein aggregation during peristaltic pumping.
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Affiliation(s)
- Thomas B Fanthom
- Department of Biochemical Engineering, Bernard Katz Building, University College London, Gower Street, London, WC1E 6BT, UK
| | - Christopher Wilson
- Ipsen Biopharm, 9 Ash Road North, Wrexham Industrial Estate, Wales, LL13 9UF, UK
| | - David Gruber
- Ipsen Biopharm, 9 Ash Road North, Wrexham Industrial Estate, Wales, LL13 9UF, UK
| | - Daniel G Bracewell
- Department of Biochemical Engineering, Bernard Katz Building, University College London, Gower Street, London, WC1E 6BT, UK.
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6
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Thite NG, Ghazvini S, Wallace N, Feldman N, Calderon CP, Randolph TW. Interfacial Adsorption Controls Particle Formation in Antibody Formulations Subjected to Extensional Flows and Hydrodynamic Shear. J Pharm Sci 2023; 112:2766-2777. [PMID: 37453529 DOI: 10.1016/j.xphs.2023.07.010] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/22/2023] [Revised: 07/10/2023] [Accepted: 07/10/2023] [Indexed: 07/18/2023]
Abstract
During their manufacturing and delivery to patients, therapeutic proteins are commonly exposed to various interfaces and to hydrodynamic shear forces. Although adsorption of proteins to solid-liquid interfaces is known to foster formation of protein aggregates and particles, the impact of shear remains controversial, in part because of experimental challenges in separating the effects of shear from those caused by simultaneous exposure to interfaces. Extensional flows (occurring when solutions flow through sudden contractions) exert localized elongational forces that have been suspected to be damaging to proteins. In this work, we measured aggregation and particle formation in formulations of polyclonal and monoclonal antibodies subjected to extensional flow, high shear (105 s-1) and exposure to stainless-steel/water interfaces. Modification of the surface charge at the stainless steel/water interface changed protein adsorption characteristics without altering shear profiles, enabling shear and interfacial interactions to be separated. Even under conditions where antibodies were subjected to high hydrodynamic shear and extensional flow, production of subvisible particles could be inhibited by modifying the stainless-steel surface charge to minimize antibody adsorption. Digital images of particles recorded by flow imaging microscopy (FIM) and analyzed with machine learning algorithms were consistent with a particle formation mechanism by which antibodies adsorb and aggregate at the stainless-steel/water interface and subsequently form particles when shear displaces the interfacial aggregates, transporting them into the bulk solution. Topographical differences measured using atomic force microscopy (AFM) supported the proposed mechanism by showing reduced levels of protein adsorption on surface-charge-modified stainless-steel.
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Affiliation(s)
- Nidhi G Thite
- Department of Chemical and Biological Engineering, University of Colorado Boulder, Boulder, CO 80309, United States
| | | | | | | | - Christopher P Calderon
- Department of Chemical and Biological Engineering, University of Colorado Boulder, Boulder, CO 80309, United States; Ursa Analytics, Denver, CO 80212, United States
| | - Theodore W Randolph
- Department of Chemical and Biological Engineering, University of Colorado Boulder, Boulder, CO 80309, United States.
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7
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Rodriguez Barroso LG, Lanzagorta Garcia E, Mojicevic M, Alkan Tas B, Huerta M, Pogue R, Devine DM, Brennan-Fournet M. Triangular Silver Nanoplates as a Bioanalytical Tool: Potential COVID-19 Detection. Int J Mol Sci 2023; 24:11974. [PMID: 37569350 PMCID: PMC10418913 DOI: 10.3390/ijms241511974] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/30/2023] [Revised: 07/21/2023] [Accepted: 07/24/2023] [Indexed: 08/13/2023] Open
Abstract
Nanotechnology offers new possibilities in molecular diagnostics, with nanoparticles gaining attention as biosensor upgrades. This study evaluates gold-coated silver nanoplates coated with PEG for enhanced protection, aiming to detect Spike protein with higher sensitivity, and emphasizes the importance of considering complex environments and appropriate controls for specific binding and accurate analysis. The sensitivity of antibody-coated PEGAuTSNPs as tools for immunoassays is demonstrated through fibronectin (Fn)- anti-fibronectin binding within an isolated extracellular matrix as a complex and native environment of Fn. Moreover, the optimal functionalization volume of Spike protein was determined (4 µg/mL of PEGAuTSNP). Anti-Spike was added to confirm binding, while the TJP1 protein was used as a negative control. The same experiment was used in the presence of horse serum to simulate a complex environment. According to Localized Surface Plasmon Resonance analysis and Dynamic Light Scattering size measurements, anti-Spike exhibited a stronger affinity for the nanoplates, causing TJP1 to be replaced by the antibody on the nanoplates' surface. Future research will involve exploring alternative complex environments, filtering larger molecules, and the optimization of immunoassay performance.
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Affiliation(s)
- Laura G. Rodriguez Barroso
- PRISM Research Institute, Technological University of the Shannon: Midlands Midwest, Dublin Rd, N37 HD68 Athlone, Ireland; (L.G.R.B.); (E.L.G.); (B.A.T.); (D.M.D.); (M.B.-F.)
| | - Eduardo Lanzagorta Garcia
- PRISM Research Institute, Technological University of the Shannon: Midlands Midwest, Dublin Rd, N37 HD68 Athlone, Ireland; (L.G.R.B.); (E.L.G.); (B.A.T.); (D.M.D.); (M.B.-F.)
| | - Marija Mojicevic
- PRISM Research Institute, Technological University of the Shannon: Midlands Midwest, Dublin Rd, N37 HD68 Athlone, Ireland; (L.G.R.B.); (E.L.G.); (B.A.T.); (D.M.D.); (M.B.-F.)
| | - Buket Alkan Tas
- PRISM Research Institute, Technological University of the Shannon: Midlands Midwest, Dublin Rd, N37 HD68 Athlone, Ireland; (L.G.R.B.); (E.L.G.); (B.A.T.); (D.M.D.); (M.B.-F.)
| | - Miriam Huerta
- Physics Institute, Universidad Autónoma de San Luis Potosí, Av. Parque Chapultepec 1570, San Luis Potosí 78295, Mexico;
| | - Robert Pogue
- Campus Asa Norte, Universidade Católica de Brasília, SGAN Módulo B 916 Avenida W5, Brasilia 70790-160, Brazil;
| | - Declan M. Devine
- PRISM Research Institute, Technological University of the Shannon: Midlands Midwest, Dublin Rd, N37 HD68 Athlone, Ireland; (L.G.R.B.); (E.L.G.); (B.A.T.); (D.M.D.); (M.B.-F.)
| | - Margaret Brennan-Fournet
- PRISM Research Institute, Technological University of the Shannon: Midlands Midwest, Dublin Rd, N37 HD68 Athlone, Ireland; (L.G.R.B.); (E.L.G.); (B.A.T.); (D.M.D.); (M.B.-F.)
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8
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Kizuki S, Wang Z, Torisu T, Yamauchi S, Uchiyama S. Relationship between aggregation of therapeutic proteins and agitation parameters: Acceleration and frequency. J Pharm Sci 2023; 112:492-505. [PMID: 36167196 DOI: 10.1016/j.xphs.2022.09.022] [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: 12/31/2021] [Revised: 09/20/2022] [Accepted: 09/20/2022] [Indexed: 01/18/2023]
Abstract
An increase in protein aggregates during transportation should be suppressed in therapeutic protein products because the aggregates have a potential risk of immunogenicity. In this study, three protein solutions in vials were exposed to tri-axial vibration with various combinations of frequency and acceleration using a transportation test system to investigate the relationship between low g-force stresses and protein aggregate generation. The number concentration of micron aggregates detected by flow imaging analysis increased markedly when the acceleration and frequency of agitation were within a specific range, in other words, above a threshold. This threshold was common among the three protein solutions. The suppression of micron aggregate formation by adding a surfactant suggested that agitation above the threshold increased micron aggregates mainly via interface-mediated routes. Notably, agitation, including agitation below the threshold, accelerated spontaneous oligomerization (nanometer aggregate generation) of proteins in bulk solution even in the presence of the surfactant. Studies of stability against mechanical stresses (e.g., a random vibration test to simulate actual shipment, with a time-compressed setting by increasing acceleration) need to be performed and discussed with careful consideration of the threshold for generating micron aggregates.
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Affiliation(s)
- Shinji Kizuki
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka, 565-0871, Japan; Formulation Research Lab., Taiho Pharmaceutical Co. Ltd., 224-2, Ebisuno, Hiraishi, Kawauchi-cho, Tokushima, 771-0194, Japan
| | - Zekun Wang
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka, 565-0871, Japan
| | - Tetsuo Torisu
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka, 565-0871, Japan.
| | - Satoru Yamauchi
- Business Development Headquarters, ESPEC CORP. 5-2-5, Minamimachi, Kanokodai, Kita-ku, Kobe, Hyogo, 651-1514, Japan
| | - Susumu Uchiyama
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka, 565-0871, Japan; Exploratory Research Center on Life and Living Systems, National Institutes of Natural Sciences, 5-1 Higashiyama, Myodaiji, Okazaki, Aichi, 444-8787, Japan.
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9
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Kopp MRG, Grigolato F, Zürcher D, Das TK, Chou D, Wuchner K, Arosio P. Surface-Induced Protein Aggregation and Particle Formation in Biologics: Current Understanding of Mechanisms, Detection and Mitigation Strategies. J Pharm Sci 2023; 112:377-385. [PMID: 36223809 DOI: 10.1016/j.xphs.2022.10.009] [Citation(s) in RCA: 16] [Impact Index Per Article: 16.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/30/2022] [Revised: 10/05/2022] [Accepted: 10/05/2022] [Indexed: 01/12/2023]
Abstract
Protein stability against aggregation is a major quality concern for the production of safe and effective biopharmaceuticals. Amongst the different drivers of protein aggregation, increasing evidence indicates that interactions between proteins and interfaces represent a major risk factor for the formation of protein aggregates in aqueous solutions. Potentially harmful surfaces relevant to biologics manufacturing and storage include air-water and silicone oil-water interfaces as well as materials from different processing units, storage containers, and delivery devices. The impact of some of these surfaces, for instance originating from impurities, can be difficult to predict and control. Moreover, aggregate formation may additionally be complicated by the simultaneous presence of interfacial, hydrodynamic and mechanical stresses, whose contributions may be difficult to deconvolute. As a consequence, it remains difficult to identify the key chemical and physical determinants and define appropriate analytical methods to monitor and predict protein instability at these interfaces. In this review, we first discuss the main mechanisms of surface-induced protein aggregation. We then review the types of contact materials identified as potentially harmful or detected as potential triggers of proteinaceous particle formation in formulations and discuss proposed mitigation strategies. Finally, we present current methods to probe surface-induced instabilities, which represent a starting point towards assays that can be implemented in early-stage screening and formulation development of biologics.
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Affiliation(s)
- Marie R G Kopp
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | - Fulvio Grigolato
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | - Dominik Zürcher
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland
| | | | | | | | - Paolo Arosio
- Department of Chemistry and Applied Biosciences, ETH Zurich, Zurich, Switzerland.
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10
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Morales AM, Sreedhara A, Buecheler J, Brosig S, Chou D, Christian T, Das T, de Jong I, Fast J, Jagannathan B, Moussa EM, Nejadnik MR, Prajapati I, Radwick A, Rahman Y, Singh S. End-to-End Approach to Surfactant Selection, Risk Mitigation, and Control Strategies for Protein-Based Therapeutics. AAPS J 2022; 25:6. [PMID: 36471030 DOI: 10.1208/s12248-022-00773-3] [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: 08/01/2022] [Accepted: 10/31/2022] [Indexed: 12/12/2022] Open
Abstract
A survey performed by the AAPS Drug Product Handling community revealed a general, mostly consensus, approach to the strategy for the selection of surfactant type and level for biopharmaceutical products. Discussing and building on the survey results, this article describes the common approach for surfactant selection and control strategy for protein-based therapeutics and focuses on key studies, common issues, mitigations, and rationale. Where relevant, each section is prefaced by survey responses from the 22 anonymized respondents. The article format consists of an overview of surfactant stabilization, followed by a strategy for the selection of surfactant level, and then discussions regarding risk identification, mitigation, and control strategy. Since surfactants that are commonly used in biologic formulations are known to undergo various forms of degradation, an effective control strategy for the chosen surfactant focuses on understanding and controlling the design space of the surfactant material attributes to ensure that the desired material quality is used consistently in DS/DP manufacturing. The material attributes of a surfactant added in the final DP formulation can influence DP performance (e.g., protein stability). Mitigation strategies are described that encompass risks from host cell proteins (HCP), DS/DP manufacturing processes, long-term storage, as well as during in-use conditions.
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Affiliation(s)
- Annette Medina Morales
- Dosage Form Design and Development, BioPharmaceuticals Development, R&D, AstraZeneca, 1 Medimmune Way, Gaithersburg, Maryland, 20878, USA.
| | - Alavattam Sreedhara
- Genentech, Pharmaceutical Development, South San Francisco, California, 94080, USA
| | - Jakob Buecheler
- Technical Research and Development, Novartis Pharma AG, 4002, Basel, Switzerland
| | - Sebastian Brosig
- Technical Research and Development, Novartis Pharma AG, 4002, Basel, Switzerland
| | - Danny Chou
- Compassion BioSolution, LLC, Lomita, California, 90717, USA
| | | | - Tapan Das
- Analytical Development and Attribute Sciences, Bristol Myers Squibb, New Brunswick, New Jersey, USA
| | - Isabella de Jong
- Genentech, Pharmaceutical Development, South San Francisco, California, 94080, USA
| | - Jonas Fast
- Pharmaceutical Development, F. Hoffmann-La Roche Ltd, CH-4070, Basel, Switzerland
| | | | - Ehab M Moussa
- Drug Product Development, AbbVie, North Chicago, Illinios, 60064, USA
| | - M Reza Nejadnik
- Department of Pharmaceutical Sciences & Experimental Therapeutics, College of Pharmacy, University of Iowa, Iowa City, Iowa, 52242, USA
| | - Indira Prajapati
- Dosage Form Design and Development, BioPharmaceuticals Development, R&D, AstraZeneca, 1 Medimmune Way, Gaithersburg, Maryland, 20878, USA
| | | | - Yusra Rahman
- Department of Pharmaceutical Sciences & Experimental Therapeutics, College of Pharmacy, University of Iowa, Iowa City, Iowa, 52242, USA
| | - Shubhadra Singh
- GlaxoSmithKline R&D, Biopharmaceutical Product Sciences, Collegeville, Philadelphia, Pennsylvania, 19426, USA
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11
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Thite NG, Ghazvini S, Wallace N, Feldman N, Calderon CP, Randolph TW. Machine Learning Analysis Provides Insight into Mechanisms of Protein Particle Formation Inside Containers During Mechanical Agitation. J Pharm Sci 2022; 111:2730-2744. [PMID: 35835184 PMCID: PMC9481670 DOI: 10.1016/j.xphs.2022.06.017] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/27/2022] [Revised: 06/20/2022] [Accepted: 06/20/2022] [Indexed: 11/26/2022]
Abstract
Container choice can influence particle generation within protein formulations. Incompatibility between proteins and containers can manifest as increased particle concentrations, shifts in particle size distributions and changes in particle morphology distributions. In this study, flow imaging microscopy (FIM) combined with machine learning-based goodness-of-fit hypothesis testing algorithms were used in accelerated stability studies to investigate the impact of containers on particle formation. Containers in four major container categories subdivided into eleven container types were filled with monoclonal antibody formulations and agitated with and without headspace, producing subvisible particles. Digital images of the particles were recorded using flow imaging microscopy and analyzed with machine learning algorithms. Particle morphology distributions depended on container category and type, revealing differences that would not have been obvious by analysis of particle concentrations or container surface characteristics alone. Additionally, the algorithm was used to compare morphologies of particles generated in containers against those generated using isolated stresses at air-liquid and container-air-liquid interfaces. These comparisons showed that the morphology distributions of particles formed during agitation most closely resemble distributions that result from exposure of proteins to moving triple interface lines at points where container-air-liquid interfaces intersect. The approach described here can be used to identify dominant causes of particle generation due to protein-container interactions.
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Affiliation(s)
- Nidhi G Thite
- Department of Chemical and Biological Engineering, University of Colorado Boulder, Boulder, CO 80309, United States
| | - Saba Ghazvini
- AstraZeneca Gaithersburg, Maryland 20878, United States
| | | | - Naomi Feldman
- AstraZeneca Gaithersburg, Maryland 20878, United States
| | - Christopher P Calderon
- Department of Chemical and Biological Engineering, University of Colorado Boulder, Boulder, CO 80309, United States; Ursa Analytics, Denver, CO 80212, United States
| | - Theodore W Randolph
- Department of Chemical and Biological Engineering, University of Colorado Boulder, Boulder, CO 80309, United States.
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12
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Insulin aggregation starts at dynamic triple interfaces, originating from solution agitation. Colloids Surf B Biointerfaces 2022; 214:112451. [PMID: 35290820 DOI: 10.1016/j.colsurfb.2022.112451] [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: 11/03/2021] [Revised: 02/24/2022] [Accepted: 03/07/2022] [Indexed: 12/30/2022]
Abstract
The consequences of agitation on protein stability are particularly relevant to therapeutic proteins. However, the precise contribution of the different effects induced by agitation in pathways leading to protein denaturation and aggregation at interfaces is not entirely understood. In particular, the contribution of a moving triple line, induced by the sweeping of a solution meniscus on a container wall upon agitation, has only been rarely assessed. In this article, we therefore designed experimental setups to analyze how mixing, shear stress, and dynamic triple interfaces influence insulin aggregation in physiological conditions. This has been achieved by controlling agitation speed, shear stress, and the extension of triple interfaces in order to shed light on the contribution of different agitation-induced effects on insulin aggregation in physiological conditions. We demonstrate that strong agitation is necessary for the onset of insulin aggregation, while the growth of the aggregates is sustained even under weak agitation. Kinetic insulin aggregation studies in conditions of intermittent wetting show that the aggregation rate correlates with the amount of dynamic triple interfaces that the proteins are exposed to. Finally, we demonstrate that the triple line, where the protein solution, the air, and a hydrophobic surface meet constitutes a preferential early aggregation site.
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13
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Nakach M, Amine C, Pellet C, Bensaid F, Authelin JR, Wils P. Mixing of Monoclonal Antibody Formulated Drug Substance Solutions in Square Disposable Vessels. J Pharm Sci 2022; 111:2799-2813. [DOI: 10.1016/j.xphs.2022.05.004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/23/2021] [Revised: 05/06/2022] [Accepted: 05/06/2022] [Indexed: 11/25/2022]
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14
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Cavicchi RE, Philips LA, Cheong FC, Ruffner DB, Kasimbeg P, Vreeland W. Distribution of Average Aggregate Density from Stir-stressed NISTmAb Protein. J Pharm Sci 2022; 111:1614-1624. [DOI: 10.1016/j.xphs.2022.03.011] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2021] [Revised: 03/17/2022] [Accepted: 03/17/2022] [Indexed: 11/26/2022]
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15
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Catching Speedy Gonzales: Driving forces for protein film formation on silicone rubber tubing during pumping. J Pharm Sci 2022; 111:1577-1586. [DOI: 10.1016/j.xphs.2022.02.013] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/23/2021] [Revised: 02/23/2022] [Accepted: 02/23/2022] [Indexed: 11/19/2022]
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16
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Linkuvienė V, Ross EL, Crawford L, Weiser SE, Man D, Kay S, Kolhe P, Carpenter JF. Effects of transportation of IV bags containing protein formulations via hospital pneumatic tube system: Particle characterization by multiple methods. J Pharm Sci 2022; 111:1024-1039. [DOI: 10.1016/j.xphs.2022.01.016] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/30/2021] [Revised: 01/12/2022] [Accepted: 01/12/2022] [Indexed: 01/01/2023]
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17
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Zhang Y, Dou Z, Veilleux JC, Shi GH, Collins DS, Vlachos PP, Dabiri S, Ardekani AM. Modeling cavitation bubble dynamics in an autoinjector and its implications on drug molecules. Int J Pharm 2021; 608:121062. [PMID: 34506926 DOI: 10.1016/j.ijpharm.2021.121062] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/15/2021] [Revised: 08/20/2021] [Accepted: 08/29/2021] [Indexed: 12/26/2022]
Abstract
The collapse of cavitation bubbles induced by abrupt acceleration of the syringe in an autoinjector device can lead to protein aggregation. The details of bubble dynamics are investigated using an axisymmetric, three-dimensional simulation with passive tracers to illustrate the transport of protein molecules. When a bubble near the syringe wall collapses, protein molecules are concentrated in the re-entrant jet, pushed towards the syringe wall, and then spread across the wall, potentially leading to protein adsorption on the syringe wall and aggregation. This phenomenon is more prominent for bubbles positioned closer to the bottom wall, growing to a larger maximum radius. The bubble's maximum radius decreases with the bubble's distance from the syringe wall and air gap pressure, and increases with an increase in liquid column height and nucleus size. The strain rate induced by the bubble collapse is not large enough to unfold the proteins. When the re-entrant jet impacts the bubble surface or syringe wall, the bubble breaks up, generating smaller bubbles with high surface concentration of protein molecules, potentially inducing aggregation in the bulk. The bubble dynamics are influenced by dimensionless distance of the nucleus from the wall, normalized by maximum bubble radius (γ). The re-entrant jet velocity increases with γ, while the maximum liquid pressure, typically 100∼1000 bar, first decreases and then increases with γ. For a cloud of cavitation bubbles, i.e., closely clustered bubbles, coalescence of bubbles can occur, leading to a higher peak pressure at collapse.
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Affiliation(s)
- Yuchen Zhang
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States
| | - Zhongwang Dou
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States
| | | | - Galen H Shi
- Eli Lilly and Company, Indianapolis, IN 46225, United States
| | - David S Collins
- Eli Lilly and Company, Indianapolis, IN 46225, United States
| | - Pavlos P Vlachos
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States
| | - Sadegh Dabiri
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States
| | - Arezoo M Ardekani
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47906, United States.
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18
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Das TK, Sreedhara A, Colandene JD, Chou DK, Filipe V, Grapentin C, Searles J, Christian TR, Narhi LO, Jiskoot W. Stress Factors in Protein Drug Product Manufacturing and Their Impact on Product Quality. J Pharm Sci 2021; 111:868-886. [PMID: 34563537 DOI: 10.1016/j.xphs.2021.09.030] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/24/2021] [Revised: 09/21/2021] [Accepted: 09/21/2021] [Indexed: 01/22/2023]
Abstract
Injectable protein-based medicinal products (drug products, or DPs) must be produced by using sterile manufacturing processes to ensure product safety. In DP manufacturing the protein drug substance, in a suitable final formulation, is combined with the desired primary packaging (e.g., syringe, cartridge, or vial) that guarantees product integrity and enables transportation, storage, handling and clinical administration. The protein DP is exposed to several stress conditions during each of the unit operations in DP manufacturing, some of which can be detrimental to product quality. For example, particles, aggregates and chemically-modified proteins can form during manufacturing, and excessive amounts of these undesired variants might cause an impact on potency or immunogenicity. Therefore, DP manufacturing process development should include identification of critical quality attributes (CQAs) and comprehensive risk assessment of potential protein modifications in process steps, and the relevant steps must be characterized and controlled. In this commentary article we focus on the major unit operations in protein DP manufacturing, and critically evaluate each process step for stress factors involved and their potential effects on DP CQAs. Moreover, we discuss the current industry trends for risk mitigation, process control including analytical monitoring, and recommendations for formulation and process development studies, including scaled-down runs.
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Affiliation(s)
- Tapan K Das
- Bristol Myers Squibb, Biologics Development, New Brunswick, New Jersey 08903, USA.
| | | | - James D Colandene
- GlaxoSmithKline, Biopharmaceutical Product Sciences, 1250 S Collegeville Road, Collegeville, PA 19425, USA
| | - Danny K Chou
- Compassion BioSolution, LLC, Lomita, CA 90717, USA
| | | | - Christoph Grapentin
- Lonza AG, Drug Product Services, Hochbergerstrasse 60G, 4057 Basel, Switzerland
| | - Jim Searles
- Pfizer Inc., Biotherapeutics Pharmaceutical Sciences Research and Development, 875 Chesterfield Pkwy W, Chesterfield, MO 63017 USA
| | | | | | - Wim Jiskoot
- Leiden University, Division of BioTherapeutics, Leiden Academic Centre for Drug Research, Leiden, the Netherlands; Coriolis Pharma, Martinsried, Germany
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19
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A Review on Mixing-Induced Protein Particle Formation: The Puzzle of Bottom-Mounted Mixers. J Pharm Sci 2020; 109:2363-2374. [DOI: 10.1016/j.xphs.2020.03.024] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/03/2020] [Revised: 03/24/2020] [Accepted: 03/25/2020] [Indexed: 12/18/2022]
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20
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Maruno T, Ohkubo T, Uchiyama S. Stirring rate affects thermodynamics and unfolding kinetics in isothermal titration calorimetry. J Biochem 2020; 168:53-62. [PMID: 32134445 DOI: 10.1093/jb/mvaa028] [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: 11/12/2019] [Accepted: 02/10/2020] [Indexed: 11/13/2022] Open
Abstract
Isothermal titration calorimetry (ITC) directly provides thermodynamic parameters depicting the energetics of intermolecular interactions in solution. During ITC experiments, a titration syringe with a paddle is continuously rotating to promote a homogeneous mixing. Here, we clarified that the shape of the paddles (flat, corkscrew and small-pitched corkscrew) and the stirring rates influence on the thermodynamic parameters of protein-ligand interaction. Stirring with the flat paddle at lower and higher rate both yielded a lower exothermic heat due to different reasons. The complete reaction with no incompetent fractions was achieved only when the stirring was performed at 500 or 750 rpm using the small-pitched corkscrew paddle. The evaluation of the protein solution after 1,500 rpm stirring indicated that proteins in the soluble fraction decreased to 94% of the initial amount, among which 6% was at an unfolded state. In addition, a significant increase of micron aggregates was confirmed. Furthermore, a new approach for the determination of the unfolding kinetics based on the time dependence of the total reaction heat was developed. This study demonstrates that a proper stirring rate and paddle shape are essential for the reliable estimation of thermodynamic parameters in ITC experiments.
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Affiliation(s)
- Takahiro Maruno
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Tadayasu Ohkubo
- Graduate School of Pharmaceutical Sciences, Osaka University, 1-6 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Susumu Uchiyama
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan.,Exploratory Research Center on Life and Living Systems, National Institutes of Natural Sciences, 5-1 Higashiyama, Myodaiji, Okazaki, Aichi 444-8787, Japan
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21
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Thorat AA, Munjal B, Geders TW, Suryanarayanan R. Freezing-induced protein aggregation - Role of pH shift and potential mitigation strategies. J Control Release 2020; 323:591-599. [DOI: 10.1016/j.jconrel.2020.04.033] [Citation(s) in RCA: 28] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/11/2020] [Revised: 04/15/2020] [Accepted: 04/22/2020] [Indexed: 12/25/2022]
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22
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Aggregation and Particle Formation During Pumping of an Antibody Formulation Are Controlled by Electrostatic Interactions Between Pump Surfaces and Protein Molecules. J Pharm Sci 2020; 109:1473-1482. [DOI: 10.1016/j.xphs.2020.01.023] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/12/2019] [Revised: 01/15/2020] [Accepted: 01/23/2020] [Indexed: 11/24/2022]
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23
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Surfaces Affect Screening Reliability in Formulation Development of Biologics. Pharm Res 2020; 37:27. [PMID: 31907628 DOI: 10.1007/s11095-019-2733-1] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2019] [Accepted: 11/08/2019] [Indexed: 12/13/2022]
Abstract
PURPOSE The ability to predict an antibody's propensity for aggregation is particularly important during product development to ensure the quality and safety of therapeutic antibodies. We demonstrate the role of container surfaces on the aggregation process of three mAbs under elevated temperature and long-term storage conditions in the absence of mechanical stress. METHODS A systematic study of aggregation is performed for different proteins, vial material, storage temperature, and presence of surfactant. We use size exclusion chromatography and micro-flow imaging to determine the bulk concentration of aggregates, which we combine with optical and atomic force microscopy of vial surfaces to determine the effect of solid-liquid interfaces on the bulk aggregate concentration under different conditions. RESULTS We show that protein particles under elevated temperature conditions adhere to the vial surfaces, causing a substantial underestimation of aggregation propensity as determined by common methods used in development of biologics. Under actual long-term storage conditions at 5°C, aggregate particles do not adhere to the surface, causing an increase in bulk concentration of particles, which cannot be predicted from elevated temperature screening tests by common methods alone. We also identify specific protein - surface interactions which promote oligomer formation in the nanometre range. CONCLUSIONS Special care should be taken when interpreting size exclusion and particle count data from stability studies if different temperatures and vial types are involved. We propose a novel combination of methods to characterise vial surfaces and bulk solution for a full understanding of protein aggregation processes in a sample.
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24
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Her C, Carpenter JF. Effects of Tubing Type, Formulation, and Postpumping Agitation on Nanoparticle and Microparticle Formation in Intravenous Immunoglobulin Solutions Processed With a Peristaltic Filling Pump. J Pharm Sci 2020; 109:739-749. [DOI: 10.1016/j.xphs.2019.05.013] [Citation(s) in RCA: 24] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/31/2019] [Revised: 05/10/2019] [Accepted: 05/14/2019] [Indexed: 11/29/2022]
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25
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Grigolato F, Arosio P. Synergistic effects of flow and interfaces on antibody aggregation. Biotechnol Bioeng 2019; 117:417-428. [DOI: 10.1002/bit.27212] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/24/2019] [Revised: 08/27/2019] [Accepted: 10/21/2019] [Indexed: 12/14/2022]
Affiliation(s)
- Fulvio Grigolato
- Department of Chemistry and Applied BiosciencesInstitute for Chemical and Bioengineering, ETH Zurich Zurich Switzerland
| | - Paolo Arosio
- Department of Chemistry and Applied BiosciencesInstitute for Chemical and Bioengineering, ETH Zurich Zurich Switzerland
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26
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Hoover BM, Murphy RM. Evaluation of Nanoparticle Tracking Analysis for the Detection of Rod-Shaped Particles and Protein Aggregates. J Pharm Sci 2019; 109:452-463. [PMID: 31604086 DOI: 10.1016/j.xphs.2019.10.006] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/18/2019] [Revised: 09/30/2019] [Accepted: 10/03/2019] [Indexed: 10/25/2022]
Abstract
Nanoparticle tracking analysis (NTA) is an important technique for measuring hydrodynamic size of globular biological particles including liposomes and viruses. Less attention has been paid to NTA of rod-like particles, despite their considerable interest. For example, amyloid fibrils and protofibrils are protein aggregates with rod-like morphology, diameters of 2-15 nm, and lengths from 50 nm to 1 μm, and linked to diseases including Alzheimer's and Parkinson's. We used NTA to measure the concentration and hydrodynamic size of gold nanorods (10 nm diameter, 35-250 nm length) and myosin (2 nm diameter, 160 nm length), as models of rod-like particles. Measured hydrodynamic diameters of gold nanorods were consistent with theoretical calculations, as long as particle concentration and solution conditions were controlled. Myosin monomers were invisible by NTA, but a small population of aggregates was detected. We combined NTA results with other light scattering data to gain insight into number and size distribution of protein solutions containing both monomer and aggregates. Finally, we demonstrated the utility of NTA and its limitations by characterizing aggregates of alpha-synuclein. Of note is the use of NTA to detect a change in morphology from compact to elongated by analyzing the ratio of hydrodynamic size to intensity.
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Affiliation(s)
- Brandon M Hoover
- Biophysics Program, University of Wisconsin, Madison, Wisconsin 53706
| | - Regina M Murphy
- Department of Chemical and Biological Engineering, University of Wisconsin, Madison, Wisconsin 53706.
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27
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Wang W, Ohtake S. Science and art of protein formulation development. Int J Pharm 2019; 568:118505. [PMID: 31306712 DOI: 10.1016/j.ijpharm.2019.118505] [Citation(s) in RCA: 55] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/27/2019] [Revised: 07/08/2019] [Accepted: 07/08/2019] [Indexed: 02/07/2023]
Abstract
Protein pharmaceuticals have become a significant class of marketed drug products and are expected to grow steadily over the next decade. Development of a commercial protein product is, however, a rather complex process. A critical step in this process is formulation development, enabling the final product configuration. A number of challenges still exist in the formulation development process. This review is intended to discuss these challenges, to illustrate the basic formulation development processes, and to compare the options and strategies in practical formulation development.
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Affiliation(s)
- Wei Wang
- Biological Development, Bayer USA, LLC, 800 Dwight Way, Berkeley, CA 94710, United States.
| | - Satoshi Ohtake
- Pharmaceutical Research and Development, Pfizer Biotherapeutics Pharmaceutical Sciences, Chesterfield, MO 63017, United States
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28
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Wang W, Roberts CJ. Protein aggregation – Mechanisms, detection, and control. Int J Pharm 2018; 550:251-268. [DOI: 10.1016/j.ijpharm.2018.08.043] [Citation(s) in RCA: 100] [Impact Index Per Article: 16.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/09/2018] [Revised: 08/18/2018] [Accepted: 08/20/2018] [Indexed: 12/19/2022]
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29
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Protein affinity for TiO2 and CeO2 manufactured nanoparticles. From ultra-pure water to biological media. Colloids Surf A Physicochem Eng Asp 2018. [DOI: 10.1016/j.colsurfa.2018.05.091] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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30
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Nejadnik MR, Randolph TW, Volkin DB, Schöneich C, Carpenter JF, Crommelin DJ, Jiskoot W. Postproduction Handling and Administration of Protein Pharmaceuticals and Potential Instability Issues. J Pharm Sci 2018; 107:2013-2019. [DOI: 10.1016/j.xphs.2018.04.005] [Citation(s) in RCA: 55] [Impact Index Per Article: 9.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/02/2018] [Revised: 03/18/2018] [Accepted: 04/06/2018] [Indexed: 11/25/2022]
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31
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Kalonia CK, Heinrich F, Curtis JE, Raman S, Miller MA, Hudson SD. Protein Adsorption and Layer Formation at the Stainless Steel-Solution Interface Mediates Shear-Induced Particle Formation for an IgG1 Monoclonal Antibody. Mol Pharm 2018; 15:1319-1331. [PMID: 29425047 PMCID: PMC5997281 DOI: 10.1021/acs.molpharmaceut.7b01127] [Citation(s) in RCA: 43] [Impact Index Per Article: 7.2] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/16/2023]
Abstract
Passage of specific protein solutions through certain pumps, tubing, and/or filling nozzles can result in the production of unwanted subvisible protein particles (SVPs). In this work, surface-mediated SVP formation was investigated. Specifically, the effects of different solid interface materials, interfacial shear rates, and protein concentrations on SVP formation were measured for the National Institute of Standards and Technology monoclonal antibody (NISTmAb), a reference IgG1 monoclonal antibody (mAb). A stainless steel rotary piston pump was used to identify formulation and process parameters that affect aggregation, and a flow cell (alumina or stainless steel interface) was used to further investigate the effect of different interface materials and/or interfacial shear rates. SVP particles produced were monitored using flow microscopy or flow cytometry. Neutron reflectometry and a quartz crystal microbalance with dissipation monitoring were used to characterize adsorption and properties of NISTmAb at the stainless steel interface. Pump/shear cell experiments showed that the NISTmAb concentration and interface material had a significant effect on SVP formation, while the effects of interfacial shear rate and passage number were less important. At the higher NISTmAb concentrations, the adsorbed protein became structurally altered at the stainless steel interface. The primary adsorbed layer remained largely undisturbed during flow, suggesting that SVP formation at high NISTmAb concentration was caused by the disruption of patches and/or secondary interactions.
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Affiliation(s)
- Cavan K. Kalonia
- Material Measurement Laboratory, National Institute of Standards and Technology (NIST), Gaithersburg, Maryland 20899, United States
- Formulation Sciences Department, MedImmune Inc., Gaithersburg, Maryland 20878, United States
| | - Frank Heinrich
- NIST Center for Neutron Research, National Institute of Standards and Technology, Gaithersburg, Maryland 20899, United States
- Department of Physics, Carnegie Mellon University, Pittsburgh, Pennsylvania 15213, United States
| | - Joseph E. Curtis
- NIST Center for Neutron Research, National Institute of Standards and Technology, Gaithersburg, Maryland 20899, United States
| | - Sid Raman
- Formulation Sciences Department, MedImmune Inc., Gaithersburg, Maryland 20878, United States
| | - Maria A. Miller
- Formulation Sciences Department, MedImmune Inc., Gaithersburg, Maryland 20878, United States
| | - Steven D. Hudson
- Material Measurement Laboratory, National Institute of Standards and Technology (NIST), Gaithersburg, Maryland 20899, United States
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32
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Maruno T, Watanabe H, Yoneda S, Uchihashi T, Adachi S, Arai K, Sawaguchi T, Uchiyama S. Sweeping of Adsorbed Therapeutic Protein on Prefillable Syringes Promotes Micron Aggregate Generation. J Pharm Sci 2018; 107:1521-1529. [PMID: 29421215 DOI: 10.1016/j.xphs.2018.01.021] [Citation(s) in RCA: 25] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/05/2017] [Revised: 01/19/2018] [Accepted: 01/24/2018] [Indexed: 11/17/2022]
Abstract
This study evaluated how differences in the surface properties of prefillable syringe barrels and in-solution sampling methods affect micron aggregates and protein adsorption levels. Three syringe types (glass barrel with silicone oil coating [GLS/SO+], glass barrel without silicone oil coating [GLS/SO-], and cyclo-olefin polymer [COP] barrel syringes) were tested with 3 therapeutic proteins (adalimumab, etanercept, and infliximab) using 2 sampling methods (aspiration or ejection). After quiescent incubation, solutions sampled by aspiration exhibited no significant change in micron aggregate concentration in any syringes, whereas those sampled by ejection exhibited increased micron aggregates in both GLS syringe types. Micron aggregate concentration in ejected solutions generally increased with increasing density of adsorbed proteins. Notably, COP syringes contained the lowest micron aggregate concentrations, which were independent of the sampling method. Correspondingly, the adsorbed protein density on COP syringes was the lowest at 1-2 mg/m2, which was much less compared with that on GLS syringes and was calculated to be equivalent to only 1-2 protein layers, as visually confirmed by high-speed atomic force microscopy. These data indicate that low-adsorption prefillable syringes should be used for therapeutic proteins because protein aggregate concentration in the ejected solution is elevated by increased protein adsorption to the syringe surface.
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Affiliation(s)
- Takahiro Maruno
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan; U-Medico Inc., 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Hiroki Watanabe
- Department of Physics, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8602, Japan
| | - Saki Yoneda
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Takayuki Uchihashi
- Department of Physics, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8602, Japan
| | - Satoru Adachi
- Zeon Corporation, Specialty Plastics Lab, R&D Center, 1-2-1 Yako, Kawasaki-ku, Kawasaki, Kanagawa 210-9507, Japan
| | - Kunihito Arai
- Zeon Corporation, Specialty Plastics Lab, R&D Center, 1-2-1 Yako, Kawasaki-ku, Kawasaki, Kanagawa 210-9507, Japan
| | - Taichi Sawaguchi
- Zeon Corporation, Specialty Plastics Lab, R&D Center, 1-2-1 Yako, Kawasaki-ku, Kawasaki, Kanagawa 210-9507, Japan
| | - Susumu Uchiyama
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan; Okazaki Institute for Integrative Bioscience, National Institutes of Natural Sciences, 5-1 Higashiyama, Myodaiji, Okazaki, Aichi 444-8787, Japan.
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33
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Willis LF, Kumar A, Dobson J, Bond NJ, Lowe D, Turner R, Radford SE, Kapur N, Brockwell DJ. Using extensional flow to reveal diverse aggregation landscapes for three IgG1 molecules. Biotechnol Bioeng 2018; 115:1216-1225. [PMID: 29315487 PMCID: PMC5900942 DOI: 10.1002/bit.26543] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2017] [Revised: 11/27/2017] [Accepted: 01/03/2018] [Indexed: 12/28/2022]
Abstract
Monoclonal antibodies (mAbs) currently dominate the biopharmaceutical sector due to their potency and efficacy against a range of disease targets. These proteinaceous therapeutics are, however, susceptible to unfolding, mis‐folding, and aggregation by environmental perturbations. Aggregation thus poses an enormous challenge to biopharmaceutical development, production, formulation, and storage. Hydrodynamic forces have also been linked to aggregation, but the ability of different flow fields (e.g., shear and extensional flow) to trigger aggregation has remained unclear. To address this question, we previously developed a device that allows the degree of extensional flow to be controlled. Using this device we demonstrated that mAbs are particularly sensitive to the force exerted as a result of this flow‐field. Here, to investigate the utility of this device to bio‐process/biopharmaceutical development, we quantify the effects of the flow field and protein concentration on the aggregation of three mAbs. We show that the response surface of mAbs is distinct from that of bovine serum albumin (BSA) and also that mAbs of similar sequence display diverse sensitivity to hydrodynamic flow. Finally, we show that flow‐induced aggregation of each mAb is ameliorated by different buffers, opening up the possibility of using the device as a formulation tool. Perturbation of the native state by extensional flow may thus allow identification of aggregation‐resistant mAb candidates, their bio‐process parameters and formulation to be optimized earlier in the drug‐discovery pipeline using sub‐milligram quantities of material.
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Affiliation(s)
- Leon F Willis
- Astbury Centre for Structural Molecular Biology, University of Leeds, Leeds, West Yorkshire, UK.,School of Molecular and Cellular Biology, Faculty of Biological Sciences, University of Leeds, Leeds, West Yorkshire, UK
| | - Amit Kumar
- Astbury Centre for Structural Molecular Biology, University of Leeds, Leeds, West Yorkshire, UK.,School of Molecular and Cellular Biology, Faculty of Biological Sciences, University of Leeds, Leeds, West Yorkshire, UK
| | - John Dobson
- School of Mechanical Engineering, Faculty of Engineering, University of Leeds, Leeds, West Yorkshire, UK
| | | | - David Lowe
- MedImmune Ltd, Granta Park, Cambridge, UK
| | | | - Sheena E Radford
- Astbury Centre for Structural Molecular Biology, University of Leeds, Leeds, West Yorkshire, UK.,School of Molecular and Cellular Biology, Faculty of Biological Sciences, University of Leeds, Leeds, West Yorkshire, UK
| | - Nikil Kapur
- School of Mechanical Engineering, Faculty of Engineering, University of Leeds, Leeds, West Yorkshire, UK
| | - David J Brockwell
- Astbury Centre for Structural Molecular Biology, University of Leeds, Leeds, West Yorkshire, UK.,School of Molecular and Cellular Biology, Faculty of Biological Sciences, University of Leeds, Leeds, West Yorkshire, UK
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34
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Friability Testing as a New Stress-Stability Assay for Biopharmaceuticals. J Pharm Sci 2017; 106:2966-2978. [DOI: 10.1016/j.xphs.2017.05.035] [Citation(s) in RCA: 21] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/17/2017] [Revised: 05/08/2017] [Accepted: 05/22/2017] [Indexed: 12/21/2022]
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35
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Formulation, Delivery and Stability of Bone Morphogenetic Proteins for Effective Bone Regeneration. Pharm Res 2017; 34:1152-1170. [PMID: 28342056 PMCID: PMC5418324 DOI: 10.1007/s11095-017-2147-x] [Citation(s) in RCA: 159] [Impact Index Per Article: 22.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/27/2017] [Accepted: 03/17/2017] [Indexed: 12/22/2022]
Abstract
Bone morphogenetic proteins (BMPs) are responsible for bone formation during embryogenesis and bone regeneration and remodeling. The osteoinductive action of BMPs, especially BMP-2 and BMP-7, has led to their use in a range of insurmountable treatments where intervention is required for effective bone regeneration. Introduction of BMP products to the market, however, was not without reports of multiple complications and side effects. Aiming for optimization of the therapeutic efficacy and safety, efforts have been focused on improving the delivery of BMPs to lower the administered dose, localize the protein, and prolong its retention time at the site of action. A major challenge with these efforts is that the protein stability should be maintained. With this review we attempt to shed light on how the stability of BMPs can be affected in the formulation and delivery processes. We first provide a short overview of the current standing of the complications experienced with BMP products. We then discuss the different delivery parameters studied in association with BMPs, and their influence on the efficacy and safety of BMP treatments. In particular, the literature addressing the stability of BMPs and their possible interactions with components of the delivery system as well as their sensitivity to conditions of the formulation process is reviewed. In summary, recent developments in the fields of bioengineering and biopharmaceuticals suggest that a good understanding of the relationship between the formulation/delivery conditions and the stability of growth factors such as BMPs is a prerequisite for a safe and effective treatment.
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36
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Torisu T, Maruno T, Hamaji Y, Ohkubo T, Uchiyama S. Synergistic Effect of Cavitation and Agitation on Protein Aggregation. J Pharm Sci 2017; 106:521-529. [DOI: 10.1016/j.xphs.2016.10.015] [Citation(s) in RCA: 36] [Impact Index Per Article: 5.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/27/2016] [Revised: 09/27/2016] [Accepted: 10/13/2016] [Indexed: 12/19/2022]
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37
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Tian X, Nejadnik MR, Baunsgaard D, Henriksen A, Rischel C, Jiskoot W. A Comprehensive Evaluation of Nanoparticle Tracking Analysis (NanoSight) for Characterization of Proteinaceous Submicron Particles. J Pharm Sci 2016; 105:3366-3375. [PMID: 27663383 DOI: 10.1016/j.xphs.2016.08.009] [Citation(s) in RCA: 32] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/25/2016] [Revised: 08/13/2016] [Accepted: 08/15/2016] [Indexed: 10/21/2022]
Abstract
Nanoparticle tracking analysis (NTA) has attracted great interest for application in the field of submicron particle characterization for biopharmaceuticals. It has the virtue of direct sample visualization and particle-by-particle tracking, but the complexity of method development has limited its routine applicability. We systematically evaluated data collection and processing parameters as well as sample handling methods using shake-stressed protein samples. The camera shutter and gain were identified as the key factors influencing NTA results. We also demonstrated that sample filtration was necessary for NTA analysis if there were high numbers of micron particles, whereas the choice of filter membrane was critical for data quality. Sample dilution into corresponding formulation buffer did not affect particle size distributions in our study. Finally, NTA analysis exhibited excellent repeatability in intraday comparison of multiple measurements on the same sample and interday comparison on different batches of samples. Shaking-induced protein aggregation could also be sensitively monitored by NTA. In conclusion, NTA analysis can be used as a robust stability-indicating method for the characterization of proteinaceous submicron particles and thereby complement other analytical methods, provided that consistent sample handling and parametric settings are established for the specific case study.
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Affiliation(s)
- Xinsheng Tian
- Large Protein Biophysics and Formulation, Novo Nordisk A/S, Måløv, Denmark; Division of Drug Delivery Technology, Cluster BioTherapeutics, Leiden Academic Centre for Drug Research, Leiden University, Leiden, The Netherlands
| | - M Reza Nejadnik
- Division of Drug Delivery Technology, Cluster BioTherapeutics, Leiden Academic Centre for Drug Research, Leiden University, Leiden, The Netherlands
| | - Dorrit Baunsgaard
- Large Protein Biophysics and Formulation, Novo Nordisk A/S, Måløv, Denmark
| | - Anette Henriksen
- Large Protein Biophysics and Formulation, Novo Nordisk A/S, Måløv, Denmark
| | - Christian Rischel
- Large Protein Biophysics and Formulation, Novo Nordisk A/S, Måløv, Denmark
| | - Wim Jiskoot
- Division of Drug Delivery Technology, Cluster BioTherapeutics, Leiden Academic Centre for Drug Research, Leiden University, Leiden, The Netherlands.
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38
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Brückl L, Hahn R, Sergi M, Scheler S. A systematic evaluation of mechanisms, material effects, and protein-dependent differences on friction-related protein particle formation in formulation and filling steps. Int J Pharm 2016; 511:931-45. [DOI: 10.1016/j.ijpharm.2016.08.006] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/20/2016] [Revised: 08/02/2016] [Accepted: 08/03/2016] [Indexed: 10/21/2022]
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