Optimization of Primary Drying in Lyophilization During Early-Phase Drug Development Using a Definitive Screening Design With Formulation and Process Factors

Establishing a Multi-Vial Design Space for the Freeze-Drying Process by Means of Mathematical Modeling of the Primary Drying Stage

Primary drying is the most critical stage of the freeze-drying process. This work aimed to establish a design space for this process by means of mathematical modeling of the primary drying stage, capable of addressing the thermal characteristics of distinct vial suppliers. Modeling of primary drying was implemented on Microsoft Excel using steady-state heat and mass transfer equations at two extreme conditions as assessed by risk analysis, to predict product temperature and primary-drying time. The heat transfer coefficients (Kv) of four different vial suppliers were experimentally determined, both, at the center and edge of the freeze-dryer's shelf. Statistically significant differences (ANOVA p<0.05) were observed between suppliers throughout the assessed pressure range. Overall, the average Kve/Kvc (edge/center) ratio was higher than 1.6 for all suppliers due to the radiation effect. A design space for the drying process was established using mathematical modeling taking into account the Kv of the worst-case supplier, in the shelf edge. A primary drying cycle was carried out at a shelf temperature of -25 °C and a chamber pressure of 45 mTorr for 8 % sucrose and at -10 °C and 75 mTorr for 5 % NaCl. Freeze-dried products with good cosmetic appearance were obtained for the four vial suppliers both, in the shelf center and edge. The results show that it is possible to predict and establish the critical parameters for the primary drying stage, under a design space concept, considering the differences in the Kv of vial suppliers without adverse consequences on the quality of the finished freeze-dried product.

Question-based review for pharmaceutical development: An enhanced quality approach

Over the last years, the pharmaceutical industry has faced real challenges regarding quality assurance. In this context, the establishment of more holistic approaches to the pharmaceutical development has been encouraged. The emergence of the Quality by Design (QbD) paradigm as systematic, scientific and risk-based methodology introduced a new concept of pharmaceutical quality. In essence, QbD can be interpreted as a strategy to maximize time and cost savings. An in-depth understanding of the formulation and manufacturing process is demanded to optimize the safety, efficacy and quality of a drug product at all stages of development. This innovative approach streamlines the pharmaceutical Research and Development (R&D) process, provides greater manufacturing flexibility and reduces regulatory burden. To assist in QbD implementation, International Conference on Harmonisation (ICH), U.S. Food and Drug Administration (FDA) and European Medicines Agency (EMA) organized and launched QbD principles in their guidance for industry, identifying key concepts and tools to design and develop a high-quality drug product. Despite the undeniable advantages of the QbD approach, and the widespread information on QbD regulatory expectations, its full implementation in the pharmaceutical field is still limited. The present review aims to establish a crosswise overview on the current application status of QbD within the framework of the ICH guidelines (ICH Q8(R2) - Q14 and ICH Q2(R2)). Moreover, it outlines the way information gathered from the QbD methodology is being harmonized in Marketing Authorization Applications (MAAs) for European market approval. This work also highlights the challenges that hinder the deployment of the QbD strategy as a standard practice.

Evaluation of long- and short-term storage conditions and efficiency of a novel microencapsulated Salmonella phage cocktail for controlling Salmonella in chicken meat

This study aims to assess the stability and activity of using a lyophilization, formulation design and to evaluate their efficiency for controlling Salmonella in chicken meat. The phage-loaded 0.3 M sucrose gelatin mixture at 4 and 25 °C displayed significantly less phage titer loss (p < 0.05) than the other excipients and liquid phage cocktail in 12 months. The results showed that there were significant reductions of Salmonella at the end of the storage in chicken meat for newly prepared phage powder (1.86 log CFU/cm2 and 2.18 log CFU/cm2), lyophilized phage powders stored at 4 °C (1.08 log CFU/cm2 and 1.26 log CFU/cm2) and stored at 25 °C (0.66 log CFU/cm2 and 1.00 log CFU/cm2) for 10 months at MOI 100 and 1000, respectively. The results demonstrated that lyophilized phages in a simple food grade formulation can be successfully stored and might be used in biocontrol of Salmonella in meat.

Definitive Screening Designs to Optimize Library-Free DIA-MS Identification and Quantification of Neuropeptides

Method optimization is crucial for successful mass spectrometry (MS) analysis. However, extensive method assessments, altering various parameters individually, are rarely performed due to practical limitations regarding time and sample quantity. To maximize sample space for optimization while maintaining reasonable instrumentation requirements, a definitive screening design (DSD) is leveraged for systematic optimization of data-independent acquisition (DIA) parameters to maximize crustacean neuropeptide identifications. While DSDs require several injections, a library-free methodology enables surrogate sample usage for comprehensive optimization of MS parameters to assess biomolecules from limited samples. We identified several parameters contributing significant first- or second-order effects to method performance, and the DSD model predicted ideal values to implement. These increased reproducibility and detection capabilities enabled the identification of 461 peptides, compared to 375 and 262 peptides identified through data-dependent acquisition (DDA) and a published DIA method for crustacean neuropeptides, respectively. Herein, we demonstrate a DSD optimization workflow, using standard material, not reliant on spectral libraries for the analysis of any low abundance molecules from previous samples of limited availability. This extends the DIA method to low abundance isoforms dysregulated or only detectable in disease samples, thus improving characterization of previously inaccessible biomolecules, such as neuropeptides. Data are available via ProteomeXchange with identifier PXD038520.

Influence of lyophilization primary drying time and temperature on porous silk scaffold fabrication for biomedical applications

Lyophilization of protein solutions, such as silk fibroin (silk), produces porous scaffolds useful for tissue engineering (TE). The impact of modifying lyophilization primary drying parameters on scaffold properties has not yet been explored previously. In this work, changes to primary drying duration and temperature were investigated using 3%, 6%, 9%, and 12% (w/v) silk solutions, via protocols labeled as Long Hold, Slow Ramp, and Standard. The 9% and 12% scaffolds were not successfully fabricated using the Standard protocol, while the Long Hold and Slow Ramp protocols resulted in scaffolds from all silk solution concentrations. Scaffolds fabricated using the Long Hold protocol had higher Young's moduli, smaller pore Feret diameters, and faster degradation. To investigate the utility of the different lyophilized scaffolds for in vitro cell culturing, the HepaRG liver cell line was cultured in the 3% to 12% scaffolds fabricated using the Long Hold protocol. The HepaRG cells grown in 3% scaffolds initially had greater lipid accumulation and metabolic activity than the other groups, although these differences were no longer apparent by Day 28. The deoxyribonucleic acid content of the HepaRG cells grown in 3% scaffold group was also initially significantly higher than the other groups. Significant differences in gene expression by 9% scaffolded HepaRG cells (CK19, HNFα) were seen on Day 14 while significant differences by 12% scaffolded HepaRG cells (ALB, APOA4) were seen on Day 28. Overall, modifying the primary drying parameters and silk concentration resulted in lyophilized scaffolds with tunable properties useful for TE applications.

Targeted delivery of capecitabine to colon cancer cells using nano polymeric micelles based on beta cyclodextrin

Nano polymeric micelles (nano PMs) help to increase accessibility to tumor sites, decrease side effects and allow controlled drug dissemination over a long period of time. The aim of this study was to optimize the delivery of the anticancer drug capecitabine (CAP) using nano PMs and cyclodextrin (CD) to allow the treatment of colon cancer. A pH-responsive copolymer was prepared and the variables of loading time, loading temperature, the amount of copolymer and also the ratio of acrylic/maleic copolymer to beta CD and the effect that these variables have on drug loading were investigated, with variable optimization studies carried out following a definitive screening design (DSD). The morphology and structure of the particles were determined by scanning electron microscopy (SEM) and Fourier-transform infrared (FTIR) spectroscopy. In vitro drug release exemplified that the micelles were pH-sensitive, this action was shown that firstly the drug release was done perfectly targeted and under control and secondly the drug has been released above 80% inside the colon.

Nano polymeric micelles (nano PMs) help to increase accessibility to tumor sites, decrease side effects and allow controlled drug dissemination over a long period of time.

Effects of Manufacturing Process Variables on the Tablet Weight Variation of Mini-tablets Clarified by a Definitive Screening Design

This study investigated the effect of manufacturing process variables of mini-tablets, in particular, the effect of process variables concerning fluidized bed granulation on tablet weight variation. Test granules were produced with different granulation conditions according to a definitive screening design (DSD). The five evaluated factors assigned to DSD were: the grinding speed of the sample mill at the grinding process of the active pharmaceutical ingredient (X1), microcrystalline cellulose content in granules (X2), inlet air temperature (X3), binder concentration (X4) and the spray speed of the binder solution (X5) at the granulation process. First, the relationships between the evaluated factors and the granule properties were investigated. As a result of the DSD analysis, the mode of action of granulation parameters on the granule properties was fully characterized. Subsequently, the variation in tablet weight was examined. In addition to mini-tablets (3 mm diameter), this experiment assessed regular tablets (8 mm diameter). From the results for regular tablets, the variation in tablet weight was affected by the flowability of granules. By contrast, regarding the mini-tablets, no significant effect on the variation of tablet weight was found from the evaluated factors. From this result, this study further focused on other important factors besides the granulation process, and then the effect of the die-hole position of the multiple-tip tooling on tablet weight variation was proven to be significant. Our findings provide a better understanding of manufacturing mini-tablets.

[Research progress on lyophilization for pretreatment of emerging organic contaminants in environmental samples]

有机新污染物是一类在先进分析技术帮助下新鉴定的、现有法规未管制的、人为源的有机污染物。有机新污染物主要包括药品与个人护理、农药、全氟化合物、内分泌干扰物等,其会产生内分泌干扰效应、诱发抗性基因传播,还对人类和野生生物的生存与发展构成潜在威胁,因此检测环境样品中的有机新污染物浓度对生态环境和人体健康具有重大意义。由于环境样品中的有机新污染物浓度较低,为了达到检测仪器的检测要求,通常需要对环境样品进行前处理,包括样品的净化和浓缩。冷冻干燥技术是一种在真空干燥条件下通过升华方式去除水分的前处理技术,主要包括样品冷冻、初级干燥和再干燥3个阶段,常用于食品和药品行业。在药品行业中,冷冻干燥技术能维持药品的生物活性和化学活性,保持药品的物理化学特性。近年来,冷冻干燥技术逐步用于环境水样中有机新污染物的前处理。其主要的操作步骤包括水样预处理、冷冻干燥、洗脱、吹干、过滤、定容和上机检测。冷冻干燥技术具有操作简单、低成本、样品处理体积少、样品易保存和处理过程中样品损失少等优点,具有广泛应用于环境样品中有机新污染物监测的潜力。该文综述了环境样品中有机新污染物常见的种类,并重点介绍冷冻干燥技术的原理及其在环境样品前处理过程中的应用,提出了冷冻干燥技术在环境分析中的应用前景,为环境样品中有机新污染物的监测提供了参考。

Pharmaceutical protein solids: Drying technology, solid-state characterization and stability

Despite the boom in biologics over the past decade, the intrinsic instability of these large molecules poses significant challenges to formulation development. Almost half of all pharmaceutical protein products are formulated in the solid form to preserve protein native structure and extend product shelf-life. In this review, both traditional and emerging drying techniques for producing protein solids will be discussed. During the drying process, various stresses can impact the stability of protein solids. However, understanding the impact of stress on protein product quality can be challenging due to the lack of reliable characterization techniques for biological solids. Both conventional and advanced characterization techniques are discussed including differential scanning calorimetry (DSC), solid-state Fourier transform infrared spectrometry (ssFTIR), solid-state fluorescence spectrometry, solid-state hydrogen deuterium exchange (ssHDX), solid-state nuclear magnetic resonance (ssNMR) and solid-state photolytic labeling (ssPL). Advanced characterization tools may offer mechanistic investigations into local structural changes and interactions at higher resolutions. The continuous exploration of new drying techniques, as well as a better understanding of the effects caused by different drying techniques in solid state, would advance the formulation development of biological products with superior quality.

Rapid serum-free/suspension adaptation: Medium development using a definitive screening design for Chinese hamster ovary cells

The biopharmaceutical industry prefers to culture the mammalian cells in suspension with a serum-free media (SFM) due to improved productivity and process consistency. However, mammalian cells preferentially grow as adherent cells in a complete medium (CM) containing serum. Therefore, cells require adaptation from adherence in CM to suspension culture in SFM. This work proposes an adaptation method that includes media supplementation during the adaption of Chinese hamster ovary cells. As a result, the adaptation was accelerated compared to the traditional repetitive subculturing. Ca²⁺ /Mg²⁺ supplementation significantly reduced the doubling time compared to the adaptation without supplementation during the adaptation of adherent cells from 100% CM to 75% CM (p < 0.05). Furthermore, a definitive screening design (DSD) was applied to select essential nutrients during the adaptation from 10% CM to 0% CM. The main effects of Ca²⁺ and Dulbecco's modified essential medium (DMEM) were found significant to both viable cell density and viability at harvest. Additionally, the interaction term between Ca²⁺ and DMEM was found significant, which highlights the ability of DSD to capture interaction terms. Eventually, the media supplementation method resulted in adaptation SFM in 27 days, compared to the previously reported 66 days. Additionally, the membrane surface integrin expression was found significantly decreased when adherent cells were adapted to suspension. Moreover, the Ca²⁺ /Mg²⁺ supplementation correlated with faster integrin recovery after trypsinization. However, faster integrin recovery did not contribute to the accelerated cell growth when subculturing from 100% CM to 75% CM.

Experimental and stochastic analysis of lyophilisation

The development of the freeze-drying processes through the use of a combination of targeted experiments and the application of multidimensional computational models is applied increasingly in pharmaceutical practice, especially for scale-up purposes. This study deals with the analysis of uncertainties in the data on material properties and model parameters, and their influence on the results delivered by advanced computational models of lyophilisation. As a means of uncertainty analysis, the Stochastic Collocation Method is applied, allowing the use of existing reliable deterministic models as black boxes in the stochastic computations. As a deterministic model, the lyophilisation model is used, based on the axisymmetric approximation of a vial, and the Boundary Element Method as a solver. Five parameters, covering material properties, process conditions and model constants, are selected for the sensitivity analysis simulation of the lyophilisation of an aqueous mannitol solution. The results show that during the initial stage of the primary drying heat transfer from the shelf is crucial, and that the uncertainties in the contact surface area and material properties of the vial play a more important role than the thermal properties of the drying material. When the temperature of the material reaches its distinct primary drying stage level the mass transfer through the porous cake becomes the most important, with great sensitivity to the Knudsen diffusivity in the porous cake. We observed uncertainties in the results for the primary drying time in the order of ±6%, and uncertainties in the results for temperatures of ±0.6°C in the frozen material and ±3°C in the porous cake. The uncertainty analysis proved to be a great help in determining the critical parameters in the heat and mass transfer during the important primary drying step, which led to a better definition of the numerical model for use in the context of design space determination.

Application of First Principles Primary Drying Model to Lyophilization Process Design and Transfer: Case Studies From the Industry

Lyophilization modeling is well documented in academic circles but has not yet been widely adopted by pharmaceutical manufacturing companies. To facilitate wider adoption and implementation, an accessible ExcelTM-based tool is provided, presenting several fresh examples as a practical introduction to the process of modeling the primary drying phase. Case studies are presented of the tool's application during process development and scale up which highlight business benefits that have been realized by using the model. The authors and contributors are members of the BioPhorum's Lyophilization Workstream and represent several pharmaceutical companies. The current manuscript is intended to serve as a pathway to not only share the collective knowledge on the topic but also accelerate its adoption in the industry.

Robust freeze-drying process re-design of a legacy product based on risk analysis and design of experiments

In this study, a QbD freeze-drying process re-design applied to a lyophilized injectable drug product is presented. The main objective was to assess the freeze-drying process robustness using risk analysis and a proper experimental design. First, the product's thermal fingerprint was characterized by thermal analysis and freeze-drying microscopy. Then, according to the output of the risk analysis, primary drying temperature and pressure were studied by a Doehlert DoE design with four responses; primary drying time, appearance, residual moisture content, and reconstitution time. Statistically significant MLR models were obtained for residual moisture content and primary drying time. In the latter, the temperature factor was the predominant factor to predict the duration of the primary drying stage. Two additional lab-scale batches were run to confirm the mathematical model predictions. Finally, optimal primary drying conditions (30 °C, 0.400 mbar) were selected to minimize the duration of the primary drying stage, while preserving the quality of the product. It was possible to set high temperature and pressure values because no collapse temperature was found during the thermal characterization of the product. Secondary drying temperature and time were defined based on the residual moisture content results. It was shown that secondary drying is robust between 30 °C and 50 °C and from 3 to 16 h. In conclusion, we were able to define a robust freeze-drying process which was further validated at an industrial scale with satisfactory results and approved by the health authorities in different countries around Europe.

Sensitivity Study to Assess the Robustness of Primary Drying Process in Pharmaceutical Lyophilization

The objective of this work is to apply a sensitivity study to assess the robustness of the primary drying step of pharmaceutical lyophilization with respect to deviations in process parameters. The sensitivity study can provide valuable information regarding the effect of process input parameters on the product quality that can aid in designing robust lyophilization processes. In this study, the output response is related to its inputs using Smolyak sparse grid generalized polynomial chaos method, and the sensitivity was calculated using elementary effects method. Sensitivity of chamber pressure and shelf temperature on product temperature of 2 sucrose-based and one mannitol-based formulation was studied, and the results were analyzed in terms of risk of adverse effects due to process deviations on the product quality. The study revealed that the sensitivity varies among formulations, and preliminary information regarding the possible impact of process deviations can be obtained from the process cycle diagram. The product temperature showed greater sensitivity toward the change in the shelf temperature than toward change in the chamber pressure for the greater part of the primary drying stage. An aggressive process-deviation scenario at the late stage of primary drying was also studied for different formulations, and the results were consistent with the sensitivity study.

The Usefulness of Definitive Screening Design for a Quality by Design Approach as Demonstrated by a Pharmaceutical Study of Orally Disintegrating Tablet

Definitive screening design (DSD) is a new class of small three-level experimental design that is attracting much attention as a technical tool of a quality by design (QbD) approach. The purpose of this study is to examine the usefulness of DSD for QbD through a pharmaceutical study on the preparation of ethenzamide-containing orally disintegrating tablet. Model tablets were prepared by directly compressing the mixture of the active pharmaceutical ingredient (API) and excipients. The five evaluated factors assigned to DSD were: the contents of API (X1) and lubricant (X2), and the compression force (X3) of the tableting process, the mixing time (X4), and the filling ratio of powder in the V-type mixer (X5). After tablet preparation, hardness and disintegration time were measured. The same experiments were performed by using the conventional design of experiments [i.e., L8 and L16 orthogonal array designs and central composite design (CCD)]. Results showed that DSD successfully clarified how various factors contribute to tablet properties. Moreover, the analysis result from DSD agreed well with those from the L8 and L16 experiments. In additional experiments, response surfaces for tablet properties were created by DSD. Compared with the response surfaces created by CCD, DSD could produce reliable response surfaces for its smaller number of experiments. We conclude that DSD is a powerful tool for implementing pharmaceutical studies including the QbD approach.

Science and art of protein formulation development

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.

An Experimental-Based Approach to Construct the Process Design Space of a Freeze-Drying Process: An Effective Tool to Design an Optimum and Robust Freeze-Drying Process for Pharmaceuticals

The application of quality by design (QbD) is becoming an integral part of the formulation and process development for pharmaceutical products. An essential feature of the QbD philosophy is the design space. In this sense, a new approach to construct a process design space (PDS) for the primary drying section of a freeze-drying process is addressed in this paper. An effective customized design of experiments (DoE) is developed for freeze-drying experiments. The results obtained from the DoE are then used to construct the product-based PDS. The proposed product-based PDS construction approach has several advantages, including (1) eliminating assumptions on the heat transfer coefficient and dried product resistance, as it is constructed from experimental results specifically obtained from a given formulation, yielding more realistic and reliable results and (2) PDS construction based on a narrow range of product temperatures and considering the variations in product temperature and sublimation rate of vials across a shelf. This guarantees the effectiveness and robustness of the process and facilitates the process scale-up and transfer. The PDS developed herein was experimentally verified. The PDS predicted parameters were in excellent agreement with the experimentally obtained parameters.

Recent Development of Optimization of Lyophilization Process

The objective of this review is to survey the development of the optimization of lyophilization. The optimization study of the lyophilizer has been roughly developing by the order of (i) trial-and-error approach, (ii) process modeling using mathematical models, (iii) scalability, and (iv) quality-by-design. From the conventional lyophilization studies based on the trial-and-error, the key parameters to optimize the operation of lyophilization were found out, i.e., critical material attributes (CMAs), critical process parameters (CPPs), and critical quality attributes (CQAs). The mathematical models using the key parameters mentioned above have been constructed from the viewpoints of the heat and mass transfer natures. In many cases, it is revealed that the control of the primary drying stage determines the outcome of the lyophilization of products, as compared with the freezing stage and the secondary drying stage. Thus, the understanding of the lyophilization process has proceeded. For the further improvement of the time and economical cost, the design space is a promising method to give the possible operation range for optimizing the lyophilization operation. This method is to search the optimized condition by reducing the number of key parameters of CMAs, CPPs, and CQAs. Alternatively, the transfer of lyophilization recipe among the lab-, pilot-, and production-scale lyophilizers (scale-up) has been examined. Notably, the scale-up of lyophilization requires the preservation of lyophilization dynamics between the two scales, i.e., the operation of lab- or pilot-scale lyophilizer under HEPA-filtrated airflow condition. The design space determined by focusing on the primary drying stage is large and involves the undesired variations in the quality of final products due to the heterogeneous size distribution of ice crystals. Accordingly, the control of the formation of the ice crystal with large size gave impact on the product quality and the productivity although the large water content in the final product should be improved. Therefore, the lyophilization should take into account the quality by design (QbD). The monitoring method of the quality of the product in lyophilization process is termed the “process analytical technology (PAT).” Recent PAT tools can reveal the lyophilization dynamics to some extent. A combination of PAT tools with a model/scale-up theory is expected to result in the QbD, i.e., a quality/risk management and an in situ optimization of lyophilization operation.