1
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Park J, Liu R, Kim AS, Cyr NN, Boehlein SK, Resende MFR, Savin DA, Bailey LS, Sumerlin BS, Hudalla GA. Sweet corn phytoglycogen dendrimers as a lyoprotectant for dry-state protein storage. J Biomed Mater Res A 2024; 112:2026-2041. [PMID: 38856491 DOI: 10.1002/jbm.a.37761] [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: 10/15/2023] [Revised: 05/14/2024] [Accepted: 05/29/2024] [Indexed: 06/11/2024]
Abstract
Protein biotherapeutics typically require expensive cold-chain storage to maintain their fold and function. Packaging proteins in the dry state via lyophilization can reduce these cold-chain requirements. However, formulating proteins for lyophilization often requires extensive optimization of excipients that both maintain the protein folded state during freezing and drying (i.e., "cryoprotection" and "lyoprotection"), and form a cake to carry the dehydrated protein. Here we show that sweet corn phytoglycogens, which are glucose dendrimers, can act as both a protein lyoprotectant and a cake-forming agent. Phytoglycogen (PG) dendrimers from 16 different maize sources (PG1-16) were extracted via ethanol precipitation. PG size was generally consistent at ~70-100 nm for all variants, whereas the colloidal stability in water, protein contaminant level, and maximum density of cytocompatibility varied for PG1-16. 10 mg/mL PG1, 2, 9, 13, 15, and 16 maintained the activity of various proteins, including green fluorescent protein, lysozyme, β-galactosidase, and horseradish peroxidase, over a broad range of concentrations, through multiple rounds of lyophilization. PG13 was identified as the lead excipient candidate as it demonstrated narrow dispersity, colloidal stability in phosphate-buffered saline, low protein contaminants, and cytocompatibility up to 10 mg/mL in NIH3T3 cell cultures. All dry protein-PG13 mixtures had a cake-like appearance and all frozen protein-PG13 mixtures had a Tg' of ~ -26°C. The lyoprotection and cake-forming properties of PG13 were density-dependent, requiring a minimum density of 5 mg/mL for maximum activity. Collectively these data establish PG dendrimers as a new class of excipient to formulate proteins in the dry state.
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Affiliation(s)
- Junha Park
- J. Crayton Pruitt Family Department of Biomedical Engineering, Wertheim College of Engineering, University of Florida, Gainesville, Florida, USA
| | - Renjie Liu
- J. Crayton Pruitt Family Department of Biomedical Engineering, Wertheim College of Engineering, University of Florida, Gainesville, Florida, USA
| | - Alexander S Kim
- Department of Chemistry, University of Florida, Gainesville, Florida, USA
| | - Noah N Cyr
- Polymer Chemical Characterization Lab, Department of Chemistry, University of Florida, Gainesville, Florida, USA
| | - Susan K Boehlein
- Horticultural Sciences Department, University of Florida, Gainesville, Florida, USA
| | - Marcio F R Resende
- Horticultural Sciences Department, University of Florida, Gainesville, Florida, USA
| | - Daniel A Savin
- Department of Chemistry, University of Florida, Gainesville, Florida, USA
- Polymer Chemical Characterization Lab, Department of Chemistry, University of Florida, Gainesville, Florida, USA
| | - Laura S Bailey
- Polymer Chemical Characterization Lab, Department of Chemistry, University of Florida, Gainesville, Florida, USA
| | - Brent S Sumerlin
- Department of Chemistry, University of Florida, Gainesville, Florida, USA
- Polymer Chemical Characterization Lab, Department of Chemistry, University of Florida, Gainesville, Florida, USA
| | - Gregory A Hudalla
- J. Crayton Pruitt Family Department of Biomedical Engineering, Wertheim College of Engineering, University of Florida, Gainesville, Florida, USA
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2
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Laleman F, Mathot F, Bourlès E, Scutellà B, Hansen L, De Beer T. The influence of thermal radiation during microwave-assisted freeze-drying of pharmaceutical unit doses. Int J Pharm 2024; 664:124640. [PMID: 39191335 DOI: 10.1016/j.ijpharm.2024.124640] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/10/2024] [Revised: 08/22/2024] [Accepted: 08/23/2024] [Indexed: 08/29/2024]
Abstract
New drying technologies for biologicals have recently been developed to accelerate the time-consuming batch freeze-drying (BFD) process. Among others, microwave-assisted freeze-drying (MFD) has been suggested as a faster and more effective drying technology. In this study, MFD cycles with the microwave radiation switched on and off were performed to assess the contribution of the microwave radiation to drying acceleration. It was found that thermal radiation emitted by the drying chamber walls was predominantly accelerating the drying of monodose placebos rather than microwave radiation. The combination of ultra-low chamber pressure, high thermal heat transfer and a short primary-to-secondary phase transition reduces drying times by more than 80 % compared to conventional BFD. In a second step, a design of experiment approach was used to assess the effect of thermal radiation versus microwave radiation and their combination, together with dosage properties such as fill volume and excipient concentration upon drying rate. The outcome showed the importance of high fill volume and high excipient concentration for an effective microwave contribution to the drying rate. Nevertheless, the drying acceleration for small pharmaceutical dosages with restricted solutes was mainly driven by thermal radiation rather than 2.45 GHz microwave radiation. The inability of ice to convert microwave energy into heat hampers the potential use of microwave freeze-drying for single-dose vaccines.
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Affiliation(s)
- Frederik Laleman
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Belgium.
| | | | | | | | | | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, Ottergemsesteenweg 460, Ghent 9000, Belgium
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3
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Buckland B, Sanyal G, Ranheim T, Pollard D, Searles JA, Behrens S, Pluschkell S, Josefsberg J, Roberts CJ. Vaccine process technology-A decade of progress. Biotechnol Bioeng 2024; 121:2604-2635. [PMID: 38711222 DOI: 10.1002/bit.28703] [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: 12/22/2023] [Revised: 03/04/2024] [Accepted: 03/14/2024] [Indexed: 05/08/2024]
Abstract
In the past decade, new approaches to the discovery and development of vaccines have transformed the field. Advances during the COVID-19 pandemic allowed the production of billions of vaccine doses per year using novel platforms such as messenger RNA and viral vectors. Improvements in the analytical toolbox, equipment, and bioprocess technology have made it possible to achieve both unprecedented speed in vaccine development and scale of vaccine manufacturing. Macromolecular structure-function characterization technologies, combined with improved modeling and data analysis, enable quantitative evaluation of vaccine formulations at single-particle resolution and guided design of vaccine drug substances and drug products. These advances play a major role in precise assessment of critical quality attributes of vaccines delivered by newer platforms. Innovations in label-free and immunoassay technologies aid in the characterization of antigenic sites and the development of robust in vitro potency assays. These methods, along with molecular techniques such as next-generation sequencing, will accelerate characterization and release of vaccines delivered by all platforms. Process analytical technologies for real-time monitoring and optimization of process steps enable the implementation of quality-by-design principles and faster release of vaccine products. In the next decade, the field of vaccine discovery and development will continue to advance, bringing together new technologies, methods, and platforms to improve human health.
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Affiliation(s)
- Barry Buckland
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| | - Gautam Sanyal
- Vaccine Analytics, LLC, Kendall Park, New Jersey, USA
| | - Todd Ranheim
- Advanced Analytics Core, Resilience, Chapel Hill, North Carolina, USA
| | - David Pollard
- Sartorius, Corporate Research, Marlborough, Massachusetts, USA
| | | | - Sue Behrens
- Engineering and Biopharmaceutical Processing, Keck Graduate Institute, Claremont, California, USA
| | - Stefanie Pluschkell
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
| | - Jessica Josefsberg
- Merck & Co., Inc., Process Research & Development, Rahway, New Jersey, USA
| | - Christopher J Roberts
- National Institute for Innovation in Manufacturing Biopharmaceuticals, University of Delaware, Newark, Delaware, USA
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4
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Hanawa Y, Zhang J, Sasmito AP, Xu M, Akhtar S, Mohit M, Yoshida J, Sawada K, Sasaki Y, Sakuma A. New Formulas for Evaluation of Cyclohexanol Solidification on Substrates with Surface Nanostructures. ACS OMEGA 2024; 9:24299-24307. [PMID: 38882089 PMCID: PMC11170747 DOI: 10.1021/acsomega.3c09972] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/13/2023] [Revised: 04/22/2024] [Accepted: 05/16/2024] [Indexed: 06/18/2024]
Abstract
In semiconductor manufacturing, the sublimation drying process is crucial but poorly understood-particularly regarding the solidification of agents such as cyclohexanol on Si substrates. This knowledge gap results in inconsistent film properties and risks such as structural collapse. To address this critical gap in knowledge, the present study focused on an in-depth examination of the nucleation behavior exhibited by cyclohexanol during its cooling and solidification on Si substrates. Using a digital camera (GoPro10), the solidification process in experiments was recorded for a range of cooling rates and using substrates with distinct surface patterns. To evaluate temporal changes in crystal nucleation, video images were visually checked, and the temporal changes in the number of nuclei were examined. For a more quantitative analysis, the least-squares method was successfully employed to correlate mathematical equations to time-dependent nucleation data. Interestingly, the outcomes revealed significant correlations between the nucleation rate, cooling rate, and substrate pattern. In summary, this research offers a robust experimental framework for understanding the complex solidification behavior of cyclohexanol on Si substrates. The study contributes both qualitative and quantitative analyses, enriching our understanding of the variables that govern the solidification process, which has significant implications for enhancing the overall reliability and efficiency of semiconductor manufacturing.
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Affiliation(s)
| | - Jianliang Zhang
- Faculty of Fiber Science and Engineering, Kyoto Institute of Technology, Kyoto 606-8585, Japan
| | - Agus P Sasmito
- Department of Mining and Materials Engineering, McGill University, Montreal, Quebec H3A 0E8, Canada
| | - Minghan Xu
- Department of Mining and Materials Engineering, McGill University, Montreal, Quebec H3A 0E8, Canada
| | - Saad Akhtar
- GERAD and Department of Mathematics and Industrial Engineering, Polytechnique Montreal, Montreal, Quebec H3T 1N8, Canada
| | - Mohammaderfan Mohit
- Department of Mining and Materials Engineering, McGill University, Montreal, Quebec H3A 0E8, Canada
| | | | | | - Yuta Sasaki
- SCREEN Holdings Co., Ltd., Kyoto 612-8486, Japan
| | - Atsushi Sakuma
- Faculty of Fiber Science and Engineering, Kyoto Institute of Technology, Kyoto 606-8585, Japan
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5
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Härdter N, Geidobler R, Presser I, Winter G. Microwave-Assisted Freeze-Drying: Impact of Microwave Radiation on the Quality of High-Concentration Antibody Formulations. Pharmaceutics 2023; 15:2783. [PMID: 38140123 PMCID: PMC10747838 DOI: 10.3390/pharmaceutics15122783] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/02/2023] [Revised: 11/22/2023] [Accepted: 12/11/2023] [Indexed: 12/24/2023] Open
Abstract
Microwave-assisted freeze-drying (MFD) offers significant time savings compared to conventional freeze-drying (CFD). While a few studies have investigated the stability of biopharmaceuticals with low protein concentrations after MFD and storage, the impact of MFD on high-concentration monoclonal antibody (mAb) formulations remains unclear. In this study, we systematically examined the effect of protein concentration in MFD and assessed protein stability following MFD, CFD, and subsequent storage using seven protein formulations with various stabilizers and concentrations. We demonstrated that microwaves directly interact with the active pharmaceutical ingredient (API), leading to decreased physical stability, specifically aggregation, in high-concentration antibody formulations. Furthermore, typically used sugar:protein ratios from CFD were insufficient for stabilizing mAbs when applying microwaves. We identified the intermediate drying phase as the most critical for particle formation, and cooling the samples provided some protection for the mAb. Our findings suggest that MFD technology may not be universally applicable to formulations well tested in CFD and could be particularly beneficial for formulations with low API concentrations requiring substantial amounts of glass-forming excipients, such as vaccines and RNA-based products.
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Affiliation(s)
- Nicole Härdter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Raimund Geidobler
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Ingo Presser
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Gerhard Winter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
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6
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Artusio F, Adami M, Barresi AA, Fissore D, Frare MC, Udrescu CI, Pisano R. The Freeze-Drying of Pharmaceuticals in Vials Nested in a Rack System-Part II: Primary Drying Behaviour. Pharmaceutics 2023; 15:2570. [PMID: 38004549 PMCID: PMC10674193 DOI: 10.3390/pharmaceutics15112570] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/11/2023] [Revised: 10/25/2023] [Accepted: 10/27/2023] [Indexed: 11/26/2023] Open
Abstract
The freeze-drying of biopharmaceuticals is a common strategy to extend their shelf-life and facilitate the distribution of therapeutics. The drying phase is the most demanding one in terms of energy consumption and determines the overall process time. Our previous work showed how the loading configuration can impact freezing. This paper focuses on primary drying by comparing the thermal behaviour of vials loaded in direct contact with the shelf or nested in a rack system. The overall heat transfer coefficient from the apparatus to the product was evaluated at different chamber pressures (5-30 Pa) and shelf temperatures (from -10 °C to +30 °C), and in the case of various vial positions (central, semi-border, and border vials). Because of the suspended configuration, the heat transfer coefficient was less affected by chamber pressure in vials nested in a rack system. The two loading configurations displayed comparable heat transfer efficiency below 10 Pa. For higher chamber pressure, the heat transfer coefficients of nested vials were lower than those of vials in direct contact with the shelf. Nevertheless, the rack system was beneficial for reducing the inter-vial variability as it promoted higher uniformity in the heat transfer coefficients of central vials. Eventually, thermal image analyses highlighted limited temperature differences between the vials and the rack system.
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Affiliation(s)
- Fiora Artusio
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy; (F.A.); (D.F.)
| | | | - Antonello A. Barresi
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy; (F.A.); (D.F.)
| | - Davide Fissore
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy; (F.A.); (D.F.)
| | | | - Claudia I. Udrescu
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy; (F.A.); (D.F.)
| | - Roberto Pisano
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy; (F.A.); (D.F.)
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7
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Kopp KT, Saerens L, Voorspoels J, Van den Mooter G. Solidification and oral delivery of biologics to the colon- A review. Eur J Pharm Sci 2023; 190:106523. [PMID: 37429482 DOI: 10.1016/j.ejps.2023.106523] [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: 02/01/2023] [Revised: 06/16/2023] [Accepted: 07/08/2023] [Indexed: 07/12/2023]
Abstract
The oral delivery of biologics such as therapeutic proteins, peptides and oligonucleotides for the treatment of colon related diseases has been the focus of increasing attention over the last years. However, the major disadvantage of these macromolecules is their degradation propensity in liquid state which can lead to the undesirable and complete loss of function. Therefore, to increase the stability of the biologic and reduce their degradation propensity, formulation techniques such as solidification can be performed to obtain a stable solid dosage form for oral administration. Due to their fragility, stress exerted on the biologic during solidification has to be reduced with the incorporation of stabilizing excipients into the formulation. This review focuses on the state-of-the-art solidification techniques required to obtain a solid dosage form for the oral delivery of biologics to the colon and the use of suitable excipients for adequate stabilization upon solidification. The solidifying processes discussed within this review are spray drying, freeze drying, bead coating and also other techniques such as spray freeze drying, electro spraying, vacuum- and supercritical fluid drying. Further, the colon as site of absorption in both healthy and diseased state is critically reviewed and possible oral delivery systems for biologics are discussed.
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Affiliation(s)
- Katharina Tatjana Kopp
- Eurofins Amatsigroup, Industriepark-Zwijnaarde 7B, 9052 Gent, Belgium; Drug Delivery and Disposition, KU Leuven, Department of Pharmaceutical and Pharmacological Sciences, Campus Gasthuisberg ON2, Herestraat 49, 3000 Leuven, Belgium
| | - Lien Saerens
- Eurofins Amatsigroup, Industriepark-Zwijnaarde 7B, 9052 Gent, Belgium
| | - Jody Voorspoels
- Eurofins Amatsigroup, Industriepark-Zwijnaarde 7B, 9052 Gent, Belgium
| | - Guy Van den Mooter
- Drug Delivery and Disposition, KU Leuven, Department of Pharmaceutical and Pharmacological Sciences, Campus Gasthuisberg ON2, Herestraat 49, 3000 Leuven, Belgium.
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8
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Shirane D, Tanaka H, Sakurai Y, Taneichi S, Nakai Y, Tange K, Ishii I, Akita H. Development of an Alcohol Dilution-Lyophilization Method for the Preparation of mRNA-LNPs with Improved Storage Stability. Pharmaceutics 2023; 15:1819. [PMID: 37514007 PMCID: PMC10383539 DOI: 10.3390/pharmaceutics15071819] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/23/2023] [Revised: 06/22/2023] [Accepted: 06/23/2023] [Indexed: 07/30/2023] Open
Abstract
The lipid nanoparticle (LNP) is one of the promising nanotechnologies for the delivery of RNA molecules, such as small interfering RNA (siRNA) and messenger RNA (mRNA). A series of LNPs that contain an mRNA encoding the antigen protein of SARS-CoV-2 were already approved as RNA vaccines against this infectious disease. Since LNP formulations are generally metastable, their physicochemical properties are expected to shift toward a more stable state during the long-time storage of suspensions. The current mRNA vaccines are supplied in the form of frozen formulations with a cryoprotectant for preventing deterioration. They must be stored in a freezer at temperatures from -80 °C to -15 °C. It is thought that therapeutic applications of this mRNA-LNP technology could be accelerated if a new formulation that permits mRNA-LNPs to be stored under milder conditions were available. We previously reported on a one-pot method for producing siRNA-encapsulated LNPs by combining freeze-drying technology with the conventional alcohol dilution method (referred to herein as the "alcohol dilution-lyophilization method"). In this study, this method was applied to the preparation of mRNA-LNPs to provide a freeze-dried formulation of mRNA LNPs. The resulting formulation can be stored at 4 °C for at least 4 months.
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Affiliation(s)
- Daiki Shirane
- Laboratory of DDS Design and Drug Disposition, Graduate School of Pharmaceutical Sciences, Chiba University, 1-8-1 Inohana, Chuo-ku, Chiba 260-0856, Japan
| | - Hiroki Tanaka
- Laboratory of DDS Design and Drug Disposition, Graduate School of Pharmaceutical Sciences, Tohoku University, 6-3 Aoba, Aramaki, Aoba-ku, Sendai 980-8578, Japan
| | - Yu Sakurai
- Laboratory of DDS Design and Drug Disposition, Graduate School of Pharmaceutical Sciences, Tohoku University, 6-3 Aoba, Aramaki, Aoba-ku, Sendai 980-8578, Japan
| | - Sakura Taneichi
- DDS Research Laboratory, NOF CORPORATION, 3-3 Chidori-cho, Kawasaki-ku, Kawasaki 210-0865, Japan
| | - Yuta Nakai
- DDS Research Laboratory, NOF CORPORATION, 3-3 Chidori-cho, Kawasaki-ku, Kawasaki 210-0865, Japan
| | - Kota Tange
- DDS Research Laboratory, NOF CORPORATION, 3-3 Chidori-cho, Kawasaki-ku, Kawasaki 210-0865, Japan
| | - Itsuko Ishii
- Department of Clinical Pharmacy, Graduate School of Pharmaceutical Sciences, Chiba University, 1-8-1 Inohana, Chuo-ku, Chiba 260-0856, Japan
| | - Hidetaka Akita
- Laboratory of DDS Design and Drug Disposition, Graduate School of Pharmaceutical Sciences, Tohoku University, 6-3 Aoba, Aramaki, Aoba-ku, Sendai 980-8578, Japan
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9
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Härdter N, Geidobler R, Presser I, Winter G. Accelerated Production of Biopharmaceuticals via Microwave-Assisted Freeze-Drying (MFD). Pharmaceutics 2023; 15:pharmaceutics15051342. [PMID: 37242584 DOI: 10.3390/pharmaceutics15051342] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2023] [Revised: 04/23/2023] [Accepted: 04/24/2023] [Indexed: 05/28/2023] Open
Abstract
Recently, attention has been drawn to microwave-assisted freeze-drying (MFD), as it drastically reduces the typically long drying times of biopharmaceuticals in conventional freeze-drying (CFD). Nevertheless, previously described prototype machines lack important attributes such as in-chamber freezing and stoppering, not allowing for the performance of representative vial freeze-drying processes. In this study, we present a new technical MFD setup, designed with GMP processes in mind. It is based on a standard lyophilizer equipped with flat semiconductor microwave modules. The idea was to enable the retrofitting of standard freeze-dryers with a microwave option, which would reduce the hurdles of implementation. We aimed to collect process data with respect to the speed, settings, and controllability of the MFD processes. Moreover, we studied the performance of six monoclonal antibody (mAb) formulations in terms of quality after drying and stability after storage for 6 months. We found drying processes to be drastically shortened and well controllable and observed no signs of plasma discharge. The characterization of the lyophilizates revealed an elegant cake appearance and remarkably good stability in the mAb after MFD. Furthermore, overall storage stability was good, even when residual moisture was increased due to high concentrations of glass-forming excipients. A direct comparison of stability data following MFD and CFD demonstrated similar stability profiles. We conclude that the new machine design is highly advantageous, enabling the fast-drying of excipient-dominated, low-concentrated mAb formulations in compliance with modern manufacturing technology.
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Affiliation(s)
- Nicole Härdter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Raimund Geidobler
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Ingo Presser
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Gerhard Winter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
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10
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Tchessalov S, Shalaev E, Bhatnagar B, Nail S, Alexeenko A, Jameel F, Srinivasan J, Dekner M, Sahni E, Schneid S, Kazarin P, McGarvey O, Van Meervenne B, Kshirsagar V, Pande P, Philipp J, Sacha G, Wu K, Azzarella J, Shivkumar G, Bhatt S, Mehta SB. Best Practices and Guidelines (2022) for Scale-up and Technology Transfer in Freeze Drying Based on Case Studies. Part 2: Past Practices, Current Best Practices, and Recommendations. AAPS PharmSciTech 2023; 24:96. [PMID: 37012545 DOI: 10.1208/s12249-023-02553-4] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/13/2023] [Accepted: 03/06/2023] [Indexed: 04/05/2023] Open
Abstract
Scale-up and transfer of lyophilization processes remain very challenging tasks considering the technical challenges and the high cost of the process itself. The challenges in scale-up and transfer were discussed in the first part of this paper and include vial breakage during freezing at commercial scale, cake resistance differences between scales, impact of differences in refrigeration capacities, and geometry on the performance of dryers. The second part of this work discusses successful and unsuccessful practices in scale-up and transfer based on the experience of the authors. Regulatory aspects of scale-up and transfer of lyophilization processes were also outlined including a topic on the equivalency of dryers. Based on an analysis of challenges and a summary of best practices, recommendations on scale-up and transfer of lyophilization processes are given including projections on future directions in this area of the freeze drying field. Recommendations on the choice of residual vacuum in the vials were also provided for a wide range of vial capacities.
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Affiliation(s)
| | | | | | | | - Alina Alexeenko
- Birck Nanotechnology Center, Purdue University, 1205 W State St., West Lafayette, Indiana, 47907, USA
| | | | | | | | | | | | - Petr Kazarin
- Birck Nanotechnology Center, Purdue University, 1205 W State St., West Lafayette, Indiana, 47907, USA.
| | | | | | | | | | | | | | - Ke Wu
- AbbVie, Irvine, California, USA
| | | | | | | | - Shyam B Mehta
- Teva Pharmaceuticals, West Chester, Pennsylvania, USA
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11
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Yoon K, Narsimhan V. Comparison of vial heat transfer coefficients during the primary and secondary drying stages of freeze-drying. Int J Pharm 2023; 635:122746. [PMID: 36812952 DOI: 10.1016/j.ijpharm.2023.122746] [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: 11/07/2022] [Revised: 01/25/2023] [Accepted: 02/14/2023] [Indexed: 02/22/2023]
Abstract
This study uses a heat flux sensor and temperature probes to directly measure vial heat transfer coefficients (Kv) during primary and secondary drying stages of lyophilization. It is observed that Kv is 40-80% smaller during secondary drying than primary drying, and this value exhibits a weaker dependence on chamber pressure than in primary drying. These observations arise because water vapor in the chamber significantly decreases between primary and secondary drying, which alters the gas conductivity between the shelf and vial. This study tabulates Kv values for secondary drying for different vials and different chamber pressures, and demarcates the contributions from gas conduction. Lastly, the study performs an energy budget analysis on two different vials (10R glass vial and 10 mL plastic vial) to determine the major factors that contribute to vial energy consumption. During primary drying, the majority of energy supplied goes towards sublimation, while for secondary drying, the majority of energy goes towards heating the vial wall rather than desorbing bound water. We discuss the consequences of this behavior for heat transfer modeling. During secondary drying, the heat of desorption can be neglected in thermal modeling for some materials (e.g., glass) but not others (e.g., plastic vials).
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Affiliation(s)
- Kyu Yoon
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA
| | - Vivek Narsimhan
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, USA.
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12
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Pisano R, Artusio F, Adami M, Barresi AA, Fissore D, Frare MC, Zanetti F, Zunino G. Freeze-Drying of Pharmaceuticals in Vials Nested in a Rack System-Part I: Freezing Behaviour. Pharmaceutics 2023; 15:pharmaceutics15020635. [PMID: 36839958 PMCID: PMC9960346 DOI: 10.3390/pharmaceutics15020635] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/18/2022] [Revised: 02/06/2023] [Accepted: 02/11/2023] [Indexed: 02/16/2023] Open
Abstract
The distribution of biopharmaceuticals often requires either ultra-cold conditions or lyophilisation. In both cases, the drug product is frozen and, thus, exposed to similar stress conditions, which can be detrimental to its quality. However, these stresses can be inhibited or mitigated by a suitable formulation and/or an appropriate freezing design. This paper addresses how the key freezing parameters, i.e., ice nucleation temperature and cooling rate, impact the freezing behaviour of a sucrose-based formulation. The analysis included two loading configurations, vials directly resting on the shelf and nested in a rack system. The loading configuration affected the product freezing rate and the ice nucleation temperature distribution, resulting in larger ice crystals in the case of vials nested in a rack system. SEM micrographs and specific surface area measurements confirmed the different product morphology. Eventually, the different product morphology impacted the bioactivity recovery of lactate dehydrogenase.
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Affiliation(s)
- Roberto Pisano
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
- Correspondence:
| | - Fiora Artusio
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
| | | | - Antonello A. Barresi
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
| | - Davide Fissore
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
| | | | | | - Gabriele Zunino
- Department of Applied Science and Technology, Politecnico di Torino, 24 Corso Duca degli Abruzzi, 10129 Torino, Italy
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13
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Accelerated water removal from frozen thin films containing bacteria. Int J Pharm 2022; 630:122408. [PMID: 36400132 DOI: 10.1016/j.ijpharm.2022.122408] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/18/2022] [Revised: 10/31/2022] [Accepted: 11/10/2022] [Indexed: 11/16/2022]
Abstract
Freeze-drying, or lyophilization, is widely used to produce pharmaceutical solids that contain temperature-sensitive materials. Herein, using Escherichia coli as a model live organism, whose viability in dry powders is highly sensitive to the water content in the powders, we demonstrated that the drying rate from the frozen thin films generated by thin-film freezing (TFF) is significantly faster than from the bulk frozen solids in conventional shelf freeze-drying. This is likely because the loosely stacked frozen thin films provided a larger solid-air interface and the low thickness of the thin films provided a low mass transfer resistance. The highly porous microstructure and high specific surface area of the thin-film freeze-dried powders may also be related to the faster drying observed. Moreover, we demonstrated that TFF can be applied to produce dry powders of E. coli, a Gram-negative bacterium, or Lactobacillus acidophilus, a Gram-positive bacterium, with minimum bacterial viability loss (i.e., within one log reduction). It is concluded that the TFF technology is promising in accelerating water removal from frozen samples.
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14
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Kommineni N, Butreddy A, Sainaga Jyothi VG, Angsantikul P. Freeze-drying for the preservation of immunoengineering products. iScience 2022; 25:105127. [PMID: 36267916 PMCID: PMC9576584 DOI: 10.1016/j.isci.2022.105127] [Citation(s) in RCA: 7] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022] Open
Abstract
Immunoengineering technologies harness the power of immune system modulators such as monoclonal antibodies, cytokines, and vaccines to treat myriad diseases. Immunoengineering innovations have showed great promise in various practices including oncology, infectious disease, autoimmune diseases, and transplantation. Despite the countless successes, the majority of immunoengineering products contain active moieties that are prone to instability. The current review aims to feature freeze-drying as a robust and scalable solution to the inherent stability challenges in immunoengineering products by preventing the active moiety from degradation. Furthermore, this review describes the stability issues related to immunoengineering products and the utility of the lyophilization process to preserve the integrity and efficacy of immunoengineering tools ranging from biologics to nanoparticle-based vaccines. The concept of the freeze-drying process is described highlighting the quality by design (QbD) for robust process optimization. Case studies of lyophilized immunoengineering technologies and relevant clinical studies using immunoengineering products are discussed.
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Affiliation(s)
| | - Arun Butreddy
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, Oxford, MS 38677, USA
| | - Vaskuri G.S. Sainaga Jyothi
- Department of Pharmaceutics, National Institute of Pharmaceutical Education and Research, Hyderabad, Telangana 500037, India
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15
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Mehanna MM, Abla KK. Recent Advances in Freeze-Drying: Variables, Cycle Optimization, and Innovative Techniques. Pharm Dev Technol 2022; 27:904-923. [PMID: 36174214 DOI: 10.1080/10837450.2022.2129385] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
Abstract
Freeze-drying (FD) is the most substantial drying technique utilized in the pharmaceutical and biopharmaceutical industries. It is a drying process where the solvent is crystallized at low temperatures and then sublimed from the solid-state directly into the vapor phase. Although FD possesses several merits as its suitability for thermolabile materials and its ability to produce dry products with high-quality attributes, it is a complex and prolonged process that requires optimization of both; process and formulation variables. This review attains to disassemble freeze-drying complications through a detailed explanation of the lyophilization concept, stages, the factors influencing the process including controlled ice nucleation, and the modified and innovative freeze-drying technologies proposed in recent years to overcome the shortage of traditional freeze-drying. In addition, this work points out the quality by design (QbD), critical quality of attributes (CQAs), limitations, and drawbacks of lyophilization.HighlightsLyophilization is a propitious drying technique for thermolabile materials.Optimizing the lyophilization cycle requires controlling the process parameters.The formulation excipients and the dispersion medium play crucial roles in designing a successful process.Numerous approaches were developed to ameliorate the lyophilization performance.
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Affiliation(s)
- Mohammed M Mehanna
- Department of Industrial Pharmacy, Faculty of Pharmacy, Alexandria University, Alexandria, Egypt
| | - Kawthar K Abla
- Pharmaceutical Nanotechnology Research Lab, Faculty of Pharmacy, Beirut Arab University, Beirut, Lebanon
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16
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Freeze-drying: A Flourishing Strategy to Fabricate Stable Pharmaceutical and Biological Products. Int J Pharm 2022; 628:122233. [DOI: 10.1016/j.ijpharm.2022.122233] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/18/2022] [Revised: 09/07/2022] [Accepted: 09/20/2022] [Indexed: 11/21/2022]
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17
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Ghaemmaghamian Z, Zarghami R, Walker G, O'Reilly E, Ziaee A. Stabilizing vaccines via drying: Quality by design considerations. Adv Drug Deliv Rev 2022; 187:114313. [PMID: 35597307 DOI: 10.1016/j.addr.2022.114313] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/03/2022] [Revised: 02/26/2022] [Accepted: 04/26/2022] [Indexed: 12/12/2022]
Abstract
Pandemics and epidemics are continually challenging human beings' health and imposing major stresses on the societies particularly over the last few decades, when their frequency has increased significantly. Protecting humans from multiple diseases is best achieved through vaccination. However, vaccines thermal instability has always been a hurdle in their widespread application, especially in less developed countries. Furthermore, insufficient vaccine processing capacity is also a major challenge for global vaccination programs. Continuous drying of vaccine formulations is one of the potential solutions to these challenges. This review highlights the challenges on implementing the continuous drying techniques for drying vaccines. The conventional drying methods, emerging technologies and their adaptation by biopharmaceutical industry are investigated considering the patented technologies for drying of vaccines. Moreover, the current progress in applying Quality by Design (QbD) in each of the drying techniques considering the critical quality attributes (CQAs), critical process parameters (CPPs) are comprehensively reviewed. An expert advice is presented on the required actions to be taken within the biopharmaceutical industry to move towards continuous stabilization of vaccines in the realm of QbD.
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Affiliation(s)
- Zahra Ghaemmaghamian
- Pharmaceutical Engineering Research Laboratory, Pharmaceutical Process Centers of Excellence, School of Chemical Engineering, University of Tehran, Tehran, Iran
| | - Reza Zarghami
- Pharmaceutical Engineering Research Laboratory, Pharmaceutical Process Centers of Excellence, School of Chemical Engineering, University of Tehran, Tehran, Iran
| | - Gavin Walker
- SSPC, The SFI Research Centre of Pharmaceuticals, Bernal Institute, Department of Chemical Sciences, University of Limerick, Limerick, Ireland
| | - Emmet O'Reilly
- SSPC, The SFI Research Centre of Pharmaceuticals, Bernal Institute, Department of Chemical Sciences, University of Limerick, Limerick, Ireland
| | - Ahmad Ziaee
- SSPC, The SFI Research Centre of Pharmaceuticals, Bernal Institute, Department of Chemical Sciences, University of Limerick, Limerick, Ireland.
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18
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Harguindeguy M, Stratta L, Fissore D, Pisano R. Combining Mathematical Modeling and Thermal Infrared Data in the Freezing of Pharmaceutical Liquid Formulations. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.1c04595] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Maitê Harguindeguy
- Department of Applied Science and Technology, Politecnico di Torino, 24 corso Duca degli Abruzzi, IT-10129 Torino, Italy
| | - Lorenzo Stratta
- Molecular Engineering Laboratory, Department of Applied Science and Technology, Politecnico di Torino, 24 corso Duca degli Abruzzi, IT-10129 Torino, Italy
| | - Davide Fissore
- Department of Applied Science and Technology, Politecnico di Torino, 24 corso Duca degli Abruzzi, IT-10129 Torino, Italy
| | - Roberto Pisano
- Molecular Engineering Laboratory, Department of Applied Science and Technology, Politecnico di Torino, 24 corso Duca degli Abruzzi, IT-10129 Torino, Italy
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19
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Szabó E, Záhonyi P, Galata DL, Madarász L, Vass P, Farkas A, Dhondt J, Andersen SK, Vígh T, Verreck G, Csontos I, Marosi G, Nagy ZK. Powder filling of electrospun material in vials: A proof-of-concept study. Int J Pharm 2021; 613:121413. [PMID: 34954004 DOI: 10.1016/j.ijpharm.2021.121413] [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: 08/09/2021] [Revised: 12/13/2021] [Accepted: 12/18/2021] [Indexed: 11/30/2022]
Abstract
The present paper reports the powder filling of milled electrospun materials in vials, which contained voriconazole and sulfobutylether-β-cyclodextrin. High-speed electrospinning was used for the production of the fibrous sample, which was divided into 6 parts. Each portion was milled using different milling methods and sizes of sieves to investigate whether the milling influences the powder and filling properties. Bulk and tapped density tests, laser diffraction and angle of repose measurements were applied to characterize the milled powders, while a vibratory feeder was used for the feeding experiments. The correlation between the material property descriptors and the feeding responses was investigated by multivariate data analysis. Based on the results, three samples were chosen for the vial filling, which was accomplished with 3400 mg electrospun material containing 200 mg voriconazole, representative of the commercial product. The feed rate was set to fit the 240 g/h production rate of the electrospinning and the relative standard deviation of three repeated vial filling was determined to see the accuracy of the process. This research shows that by applying a suitable milling method it is possible to process electrospun fibers to a powder, which can be filled into vials and used as reconstitution dosage forms.
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Affiliation(s)
- Edina Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Petra Záhonyi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Dorián L Galata
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Panna Vass
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Jens Dhondt
- Oral Solid Dosage, Drug Product Development, Pharmaceutical Development and Manufacturing Sciences, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Sune K Andersen
- Oral Solid Dosage, Drug Product Development, Pharmaceutical Development and Manufacturing Sciences, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Tamás Vígh
- Oral Solid Dosage, Drug Product Development, Pharmaceutical Development and Manufacturing Sciences, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - Geert Verreck
- Oral Solid Dosage, Drug Product Development, Pharmaceutical Development and Manufacturing Sciences, Pharmaceutical Research and Development, Division of Janssen Pharmaceutica, Johnson & Johnson, Turnhoutseweg 30, B-2340 Beerse, Belgium
| | - István Csontos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary
| | - Zsombor K Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111 Budapest, Műegyetem rakpart 3, Hungary.
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20
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Sharma A, Khamar D, Cullen S, Hayden A, Hughes H. Innovative Drying Technologies for Biopharmaceuticals. Int J Pharm 2021; 609:121115. [PMID: 34547393 DOI: 10.1016/j.ijpharm.2021.121115] [Citation(s) in RCA: 22] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/13/2021] [Revised: 08/24/2021] [Accepted: 09/15/2021] [Indexed: 01/30/2023]
Abstract
In the past two decades, biopharmaceuticals have been a breakthrough in improving the quality of lives of patients with various cancers, autoimmune, genetic disorders etc. With the growing demand of biopharmaceuticals, the need for reducing manufacturing costs is essential without compromising on the safety, quality, and efficacy of products. Batch Freeze-drying is the primary commercial means of manufacturing solid biopharmaceuticals. However, Freeze-drying is an economically unfriendly means of production with long production cycles, high energy consumption and heavy capital investment, resulting in high overall costs. This review compiles some potential, innovative drying technologies that have not gained popularity for manufacturing parenteral biopharmaceuticals. Some of these technologies such as Spin-freeze-drying, Spray-drying, Lynfinity® Technology etc. offer a paradigm shift towards continuous manufacturing, whereas PRINT® Technology and MicroglassificationTM allow controlled dry particle characteristics. Also, some of these drying technologies can be easily scaled-up with reduced requirement for different validation processes. The inclusion of Process Analytical Technology (PAT) and offline characterization techniques in tandem can provide additional information on the Critical Process Parameters (CPPs) and Critical Quality Attributes (CQAs) during biopharmaceutical processing. These processing technologies can be envisaged to increase the manufacturing capacity for biopharmaceutical products at reduced costs.
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Affiliation(s)
- Ashutosh Sharma
- Pharmaceutical and Molecular Biotechnology Research Centre (PMBRC), Waterford Institute of Technology, Main Campus, Cork Road, Waterford X91K0EK, Ireland.
| | - Dikshitkumar Khamar
- Sanofi, Manufacturing Science, Analytics and Technology (MSAT), IDA Industrial Park, Waterford X91TP27, Ireland
| | - Sean Cullen
- Gilead Sciences, Commercial Manufacturing, IDA Business & Technology Park, Carrigtwohill, Co. Cork T45DP77, Ireland
| | - Ambrose Hayden
- Pharmaceutical and Molecular Biotechnology Research Centre (PMBRC), Waterford Institute of Technology, Main Campus, Cork Road, Waterford X91K0EK, Ireland
| | - Helen Hughes
- Pharmaceutical and Molecular Biotechnology Research Centre (PMBRC), Waterford Institute of Technology, Main Campus, Cork Road, Waterford X91K0EK, Ireland
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21
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Investigation of the Freezing Phenomenon in Vials Using an Infrared Camera. Pharmaceutics 2021; 13:pharmaceutics13101664. [PMID: 34683957 PMCID: PMC8539506 DOI: 10.3390/pharmaceutics13101664] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/07/2021] [Revised: 09/30/2021] [Accepted: 10/05/2021] [Indexed: 01/19/2023] Open
Abstract
The freezing phenomenon has a dramatic impact on the quality of freeze-dried products. Several freezing models applied to solutions in vials have been proposed to predict the resulting product morphology and describe heat transfer mechanisms. However, there is a lack of detailed experimental observations of the freezing phenomenon in vials in the literature. Thus, the present work offers new experimental observations of the freezing phenomenon in vials by infrared (IR) thermography. IR imaging allowed each vial’s whole axial temperature profile to be collected during freezing, providing significant insights into the process. Spontaneous nucleation and vacuum-induced surface freezing (VISF), as a controlled nucleation technique, are investigated. Batches having vials in direct contact with the shelf (exchanging heat mainly through conduction) as well as suspended (exchanging heat mainly through natural convection and radiation) were tested. The study used three solutions: sucrose 5%, mannitol 5%, and dextran 10%. SEM images coupled with an automated image segmentation technique were also performed to examine possible correlations between the freezing observations and the resulting pore size distributions. IR thermography was found to be a promising tool for experimentally predicting the resulting product morphology in-line.
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22
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Park J, Cho JH, Braatz RD. Mathematical modeling and analysis of microwave-assisted freeze-drying in biopharmaceutical applications. Comput Chem Eng 2021. [DOI: 10.1016/j.compchemeng.2021.107412] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
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23
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Lyophilization of Nanocapsules: Instability Sources, Formulation and Process Parameters. Pharmaceutics 2021; 13:pharmaceutics13081112. [PMID: 34452072 PMCID: PMC8400524 DOI: 10.3390/pharmaceutics13081112] [Citation(s) in RCA: 30] [Impact Index Per Article: 10.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/20/2021] [Revised: 07/09/2021] [Accepted: 07/15/2021] [Indexed: 01/20/2023] Open
Abstract
Polymeric nanocapsules have gained more and more interest in the medical sciences. Their core-shell structure offers numerous advantages, especially regarding their use as drug delivery systems. This review begins by presenting the different intrinsic sources of the instability of nanocapsules. The physical and chemical potential instabilities of nanocapsules reduce their shelf-life and constitute a barrier to their clinical use and to their commercialization. To overcome these issues, lyophilization is often used as a process of choice in the pharmaceutical industry especially when labile compounds are used. The state of the art of lyophilization nanocapsules is reviewed. The formulation properties and the process parameters are discussed for a complete understanding of their impact on the stability and storage of the final dried product. To assess the quality of the dried product, various characterization methods are also discussed.
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24
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Chen Y, Mutukuri TT, Wilson NE, Zhou QT. Pharmaceutical protein solids: Drying technology, solid-state characterization and stability. Adv Drug Deliv Rev 2021; 172:211-233. [PMID: 33705880 PMCID: PMC8107147 DOI: 10.1016/j.addr.2021.02.016] [Citation(s) in RCA: 26] [Impact Index Per Article: 8.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2020] [Revised: 01/18/2021] [Accepted: 02/22/2021] [Indexed: 01/30/2023]
Abstract
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.
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Affiliation(s)
- Yuan Chen
- Department of Industrial and Physical Pharmacy, College of Pharmacy, Purdue University, 575 Stadium Mall Drive, West Lafayette, IN 47907, USA
| | - Tarun Tejasvi Mutukuri
- Department of Industrial and Physical Pharmacy, College of Pharmacy, Purdue University, 575 Stadium Mall Drive, West Lafayette, IN 47907, USA
| | - Nathan E Wilson
- Department of Industrial and Physical Pharmacy, College of Pharmacy, Purdue University, 575 Stadium Mall Drive, West Lafayette, IN 47907, USA
| | - Qi Tony Zhou
- Department of Industrial and Physical Pharmacy, College of Pharmacy, Purdue University, 575 Stadium Mall Drive, West Lafayette, IN 47907, USA.
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25
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Searles J, Ohtake S. Strategies for Implementing New Drying & Packaging Technology for Sterile Injectable Drug Products. J Pharm Sci 2021; 110:1931-1934. [PMID: 33493478 DOI: 10.1016/j.xphs.2021.01.019] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/16/2020] [Revised: 01/19/2021] [Accepted: 01/19/2021] [Indexed: 11/18/2022]
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26
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Vanbillemont B, De Beer T. Model-based optimization of the primary drying phase of oral lyophilizates. Int J Pharm X 2020; 2:100057. [PMID: 33235992 PMCID: PMC7670193 DOI: 10.1016/j.ijpx.2020.100057] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/10/2020] [Revised: 10/26/2020] [Accepted: 10/27/2020] [Indexed: 11/28/2022] Open
Abstract
Oral lyophilizates also called orally disintegrating tablets (ODTs) are a patient friendly and convenient dosage form. They are manufactured by dosing a suspension in blister cups and subsequently freeze-drying these blisters to achieve porous tablets that disintegrate quickly (< 10 s) when placed upon the tongue. This paper proposes a mechanistic model of the primary drying phase of these oral lyophilizates processed in cold-form blisters. A heat transfer coefficient (Kv) and dried layer resistance (Rp) are regressed and applied in a dynamic optimization of the primary drying phase. The optimization exercise showed the possibility of ultra-short sublimation times for polyvinyl acetate (PVA) based formulations with a primary drying time of 3.68 h for a 500 mg acetaminophen tablet.
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27
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Wang W, Zhang S, Pan Y, Yang J, Tang Y, Chen G. Multiphysics Modeling for Microwave Freeze-Drying of Initially Porous Frozen Material Assisted by Wave-Absorptive Medium. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c03852] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Wei Wang
- Department of Chemical Machinery and Safety Engineering, Dalian University of Technology, Dalian 116024, China
| | - Shuo Zhang
- Department of Chemical Machinery and Safety Engineering, Dalian University of Technology, Dalian 116024, China
| | - Yanqiu Pan
- Department of Chemical Engineering, Dalian University of Technology, Dalian 116024, China
| | - Jing Yang
- Department of Chemical Machinery and Safety Engineering, Dalian University of Technology, Dalian 116024, China
| | - Yujia Tang
- Department of Chemical Machinery and Safety Engineering, Dalian University of Technology, Dalian 116024, China
| | - Guohua Chen
- Department of Mechanical Engineering, Hong Kong Polytechnic University, Hung Hom, Kowloon 999077, Hong Kong, China
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28
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Domján J, Vass P, Hirsch E, Szabó E, Pantea E, Andersen SK, Vigh T, Verreck G, Marosi G, Nagy ZK. Monoclonal antibody formulation manufactured by high-speed electrospinning. Int J Pharm 2020; 591:120042. [PMID: 33157211 DOI: 10.1016/j.ijpharm.2020.120042] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/12/2020] [Revised: 10/28/2020] [Accepted: 10/29/2020] [Indexed: 12/11/2022]
Abstract
Solid formulations of monoclonal antibodies present several advantages, such as improved stability and increased shelf-life as well as simpler storage and transportation. In this study, we present a gentle drying technology for monoclonal antibodies, applying the water soluble 2-hydroxypropyl-β-cyclodextrin (HP-β-CD) as matrix, to prepare a solid reconstitution dosage form. High-speed electrospinning of an aqueous infliximab-containing HP-β-CD solution was carried out at 25 °C resulting in fibers with an average diameter of 2.5 μm. The mAb-loaded electrospun fibers were successful to preserve the stability of infliximab in solid form. The results of size exclusion chromatography and gel electrophoresis indicated no significant increase in aggregate formation during the electrospinning process compared to the initial matrix solution. The binding activity of infliximab was preserved during electrospinning compared to the reference liquid formulation. Due to the enhanced surface area, excellent reconstitution capability, i.e. clear solution within 2 min without any vigorous mixing, could be achieved in a small-scale reconstitution test. The results of this work demonstrate that high-speed electrospinning is a very promising technique to manufacture the solid formulation of monoclonal antibodies for applications such as fast reconstitutable powders.
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Affiliation(s)
- Júlia Domján
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Panna Vass
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary.
| | - Edit Hirsch
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Edina Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Eszter Pantea
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Sune K Andersen
- Janssen R&D, Oral Solids Development, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - Tamás Vigh
- Janssen R&D, Oral Solids Development, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - Geert Verreck
- Janssen R&D, Oral Solids Development, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Zsombor K Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
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Leys L, Vanbillemont B, Van Bockstal PJ, Lammens J, Nuytten G, Corver J, Vervaet C, De Beer T. A primary drying model-based comparison of conventional batch freeze-drying to continuous spin-freeze-drying for unit doses. Eur J Pharm Biopharm 2020; 157:97-107. [PMID: 33053425 DOI: 10.1016/j.ejpb.2020.09.009] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/12/2020] [Revised: 09/04/2020] [Accepted: 09/07/2020] [Indexed: 10/23/2022]
Abstract
An innovative continuous spin-freeze-drying technology for unit doses was recently developed. For this technology, a mechanistic primary drying model was developed allowing the calculation of the optimal dynamic drying trajectory for spin-frozen formulations. In this work, a model-based and experimentally verified comparison was made between conventional batch freeze-drying and spin-freeze-drying by analyzing the outputs (i.e., primary drying endpoint, optimal shelf temperature/power heater and product temperature profile) of both primary drying models. Input parameters such as dried product layer resistance (Rp) and heat input parameters (Kv,Ptot) were experimentally determined for both freeze-drying methods and compared. In addition, optimal dynamic process parameters were calculated for 3 model formulations by using both mechanistic models. Finally, model predictions were validated by measuring the product temperature and primary drying endpoint. It was observed that, when considering the same layer thickness, Rp was generally lower for continuous spin-frozen formulations compared to vials frozen in a conventional batch freeze-dryer. This observation contributes to the short primary drying times of spin-frozen formulations. In addition, as spin-freezing drastically increases the surface area of the product and lowers the dried layer thickness, drying times can be reduced even further while an excellent cake structure and appearance can still be obtained. The primary drying model for spin-frozen formulations proved to be equally accurate for the prediction of the primary drying endpoint and product temperature compared to the batch freeze-drying model.
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Affiliation(s)
- L Leys
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium.
| | - B Vanbillemont
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - P J Van Bockstal
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - J Lammens
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ghent, Belgium
| | - G Nuytten
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - J Corver
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ghent, Belgium
| | - T De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Department of Pharmaceutical Analysis, Ghent University, Ghent, Belgium.
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30
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Merckx P, Lammens J, Nuytten G, Bogaert B, Guagliardo R, Maes T, Vervaet C, De Beer T, De Smedt SC, Raemdonck K. Lyophilization and nebulization of pulmonary surfactant-coated nanogels for siRNA inhalation therapy. Eur J Pharm Biopharm 2020; 157:191-199. [PMID: 33022391 DOI: 10.1016/j.ejpb.2020.09.011] [Citation(s) in RCA: 23] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/06/2019] [Revised: 09/05/2020] [Accepted: 09/21/2020] [Indexed: 12/12/2022]
Abstract
RNA interference (RNAi) enables highly specific silencing of potential target genes for treatment of pulmonary pathologies. The intracellular RNAi pathway can be activated by cytosolic delivery of small interfering RNA (siRNA), inducing sequence-specific gene knockdown on the post-transcriptional level. Although siRNA drugs hold many advantages over currently applied therapies, their clinical translation is hampered by inefficient delivery across cellular membranes. We previously developed hybrid nanoparticles consisting of an siRNA-loaded nanosized hydrogel core (nanogel) coated with Curosurf®, a clinically used pulmonary surfactant (PS). The latter enhances both particle stability as well as intracellular siRNA delivery, which was shown to be governed by the PS-associated surfactant protein B (SP-B). Despite having a proven in vitro and in vivo siRNA delivery potential when prepared ex novo, clinical translation of this liquid nanoparticle suspension requires the identification of a long-term preservation strategy that maintains nanoparticle stability and potency. In addition, to achieve optimal pulmonary deposition of the nanocomposite, its compatibility with state-of-the-art pulmonary administration techniques should be evaluated. Here, we demonstrate that PS-coated nanogels can be lyophilized, reconstituted and subsequently nebulized via a vibrating mesh nebulizer. The particles retain their physicochemical integrity and their ability to deliver siRNA in a human lung epithelial cell line. The latter result suggests that the functional integrity of SP-B in the PS coat towards siRNA delivery might be preserved as well. Of note, successful lyophilization was achieved without the need for stabilizing lyo- or cryoprotectants. Our results demonstrate that PS-coated siRNA-loaded nanogels can be lyophilized, which offers the prospect of long-term storage. In addition, the formulation was demonstrated to be suitable for local administration with a state-of-the-art nebulizer for human use upon reconstitution. Hence, the data presented in this study represent an important step towards clinical application of such nanocomposites for treatment of pulmonary disease.
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Affiliation(s)
- Pieterjan Merckx
- Ghent Research Group on Nanomedicines, Laboratory of General Biochemistry and Physical Pharmacy, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Joris Lammens
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Gust Nuytten
- Laboratory of Pharmaceutical Process Analytical Technology, Faculty of Pharmaceutical Sciences, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Bram Bogaert
- Ghent Research Group on Nanomedicines, Laboratory of General Biochemistry and Physical Pharmacy, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Roberta Guagliardo
- Ghent Research Group on Nanomedicines, Laboratory of General Biochemistry and Physical Pharmacy, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Tania Maes
- Laboratory for Translational Research in Obstructive Pulmonary Diseases, Faculty of Medicine and Health Sciences, Department of Respiratory Medicine, Ghent University Hospital, Medical Research Building 2, Corneel Heymanslaan 10, 9000 Ghent, Belgium.
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Faculty of Pharmaceutical Sciences, Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Stefaan C De Smedt
- Ghent Research Group on Nanomedicines, Laboratory of General Biochemistry and Physical Pharmacy, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
| | - Koen Raemdonck
- Ghent Research Group on Nanomedicines, Laboratory of General Biochemistry and Physical Pharmacy, Faculty of Pharmaceutical Sciences, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium.
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31
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Vanbillemont B, Carpenter JF, Probst C, De Beer T. The Impact of Formulation Composition and Process Settings of Traditional Batch Versus Continuous Freeze-Drying On Protein Aggregation. J Pharm Sci 2020; 109:3308-3318. [PMID: 32739274 DOI: 10.1016/j.xphs.2020.07.023] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/26/2020] [Revised: 07/08/2020] [Accepted: 07/24/2020] [Indexed: 11/30/2022]
Abstract
The long-term stability of therapeutic protein products can be extended by freeze-drying. However, the freeze-drying process itself has several harmful stresses. A rationalized formulation design can significantly mitigate protein damage caused by freezing, dehydration and interfacial stresses of lyophilization and reconstitution. Recently, a continuous spin-freeze-drying concept was proposed as a more economical, controllable, flexible and qualitative alternative to batch freeze-drying. The purpose of this work is to compare spin-freeze-drying to traditional batch freeze-drying with regard to protein physical stability. The impacts of spinning, freezing and drying were investigated for both processing methods. Herewith, the interaction between these process phases and two common rational formulation strategies, (i.e. adding a disaccharide and a surfactant) was examined. Protein aggregates formed due to the process phase stresses were characterized with particle counting techniques and size exclusion chromatography. It was found that spin-freeze-drying exhibited essentially identical stresses causing comparable aggregation in all the process phases as compared to batch freeze-drying. Moreover, there were also analogous impacts of the formulation excipients. These observations led to the conclusion that similar freeze-drying formulation excipients and strategies tested for decades in batch freeze-drying of proteins can be utilized for spin-freeze-drying; in order to maintain protein stability during processing.
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Affiliation(s)
- Brecht Vanbillemont
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, 9000 Ghent, Belgium; Department of Pharmaceutical Sciences, Skaggs School of Pharmacy and Pharmaceutical Sciences, University of Colorado Anschutz Medical Campus, Aurora, CO 80045, USA
| | - John F Carpenter
- Department of Pharmaceutical Sciences, Skaggs School of Pharmacy and Pharmaceutical Sciences, University of Colorado Anschutz Medical Campus, Aurora, CO 80045, USA
| | | | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Faculty of Pharmaceutical Sciences, Ghent University, 9000 Ghent, Belgium.
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32
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Vetráková Ľ, Neděla V, Runštuk J, Tihlaříková E, Heger D, Shalaev E. Dynamical in-situ observation of the lyophilization and vacuum-drying processes of a model biopharmaceutical system by an environmental scanning electron microscope. Int J Pharm 2020; 585:119448. [PMID: 32461002 DOI: 10.1016/j.ijpharm.2020.119448] [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: 12/16/2019] [Revised: 04/23/2020] [Accepted: 05/18/2020] [Indexed: 01/22/2023]
Abstract
The paper discusses the real-time monitoring of the changing sample morphology during the entire lyophilization (freeze-drying) and vacuum-drying processes of model biopharmaceutical solutions by using an environmental scanning electron microscope (ESEM); the device's micromanipulators were used to study the interior of the samples in-situ without exposing the samples to atmospheric water vapor. The individual collapse temperatures (Tc) of the formulations, pure bovine serum albumin (BSA) and BSA/sucrose mixtures, ranged from -5 to -29 °C. We evaluated the impact of the freezing method (spontaneous freezing, controlled ice nucleation, and spray freezing) on the morphologies of the lyophiles at the constant drying temperature of -20 °C. The formulations with Tc above -20 °C resulted in the lyophiles' morphologies significantly dependent on the freezing method. We interpret the observations as an interplay of the freezing rates and directionalities, both of which markedly influence the morphologies of the frozen formulations, and, subsequently, the drying process and the mechanical stability of the freeze-dried cake. The formulation with Tc below -20 °C yielded a collapsed cake with features independent of the freezing method. The vacuum-drying produced a material with a smooth and pore-free surface, where deep cracks developed at the end of the process.
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Affiliation(s)
- Ľubica Vetráková
- Environmental Electron Microscopy Group, Institute of Scientific Instruments of the Czech Academy of Sciences, Brno, Czech Republic.
| | - Vilém Neděla
- Environmental Electron Microscopy Group, Institute of Scientific Instruments of the Czech Academy of Sciences, Brno, Czech Republic
| | - Jiří Runštuk
- Environmental Electron Microscopy Group, Institute of Scientific Instruments of the Czech Academy of Sciences, Brno, Czech Republic
| | - Eva Tihlaříková
- Environmental Electron Microscopy Group, Institute of Scientific Instruments of the Czech Academy of Sciences, Brno, Czech Republic
| | - Dominik Heger
- Department of Chemistry, Faculty of Science, Masaryk University, Brno, Czech Republic.
| | - Evgenyi Shalaev
- Pharmaceutical Development, Allergan plc, Irvine, CA, United States.
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33
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Spray Freeze-Drying as a Solution to Continuous Manufacturing of Pharmaceutical Products in Bulk. Processes (Basel) 2020. [DOI: 10.3390/pr8060709] [Citation(s) in RCA: 48] [Impact Index Per Article: 12.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/07/2023] Open
Abstract
Pharmaceutical manufacturing is evolving from traditional batch processes to continuous ones. The new global competition focused on throughput and quality of drug products is certainly the driving force behind this transition which, thus, represents the new challenge of pharmaceutical manufacturing and hence of lyophilization as a downstream operation. In this direction, the present review deals with the most recent technologies, based on spray freeze-drying, that can achieve this objective. It provides a comprehensive overview of the physics behind this process and of the most recent equipment design.
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34
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Review of Evidence Available on Hesperidin-Rich Products as Potential Tools against COVID-19 and Hydrodynamic Cavitation-Based Extraction as a Method of Increasing Their Production. Processes (Basel) 2020. [DOI: 10.3390/pr8050549] [Citation(s) in RCA: 66] [Impact Index Per Article: 16.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/06/2023] Open
Abstract
Based on recent computational and experimental studies, hesperidin, a bioactive flavonoid abundant in citrus peel, stands out for its high binding affinity to the main cellular receptors of SARS-CoV-2, outperforming drugs already recommended for clinical trials. Thus, it is very promising for prophylaxis and treatment of COVID-19, along with other coexistent flavonoids such as naringin, which could help restraining the proinflammatory overreaction of the immune system. Controlled hydrodynamic cavitation processes showed the highest speed, effectiveness and efficiency in the integral and green aqueous extraction of flavonoids, essential oils and pectin from citrus peel waste. After freeze-drying, the extracted pectin showed high quality and excellent antioxidant and antibacterial activities, attributed to flavonoids and essential oils adsorbed and concentrated on its surface. This study reviews the recent evidence about hesperidin as a promising molecule, and proposes a feasible and affordable process based on hydrodynamic cavitation for the integral aqueous extraction of citrus peel waste resulting in hesperidin-rich products, either aqueous extracts or pectin tablets. The uptake of this process on a relevant scale is urged, in order to achieve large-scale production and distribution of hesperidin-rich products. Meanwhile, experimental and clinical studies could determine the effective doses either for therapeutic and preventive purposes.
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35
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Vanbillemont B, Lammens J, Goethals W, Vervaet C, Boone MN, De Beer T. 4D Micro-Computed X-ray Tomography as a Tool to Determine Critical Process and Product Information of Spin Freeze-Dried Unit Doses. Pharmaceutics 2020; 12:E430. [PMID: 32392705 PMCID: PMC7284464 DOI: 10.3390/pharmaceutics12050430] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/15/2020] [Revised: 05/02/2020] [Accepted: 05/04/2020] [Indexed: 11/17/2022] Open
Abstract
Maintaining chemical and physical stability of the product during freeze-drying is important but challenging. In addition, freeze-drying is typically associated with long process times. Therefore, mechanistic models have been developed to maximize drying efficiency without altering the chemical or physical stability of the product. Dried product mass transfer resistance ( R p ) is a critical input for these mechanistic models. Currently available techniques to determine R p only provide an estimation of the mean R p and do not allow measuring and determining essential local (i.e., intra-vial) R p differences. In this study, we present an analytical method, based on four-dimensional micro-computed tomography (4D- μ CT), which enables the possibility to determine intra-vial R p differences. Subsequently, these obtained R p values are used in a mechanistic model to predict the drying time distribution of a spin-frozen vial. Finally, this predicted primary drying time distribution is experimentally verified via thermal imaging during drying. It was further found during this study that 4D- μ CT uniquely allows measuring and determining other essential freeze-drying process parameters such as the moving direction(s) of the sublimation front and frozen product layer thickness, which allows gaining accurate process knowledge. To conclude, the study reveals that the variation in the end of primary drying time of a single vial could be predicted accurately using 4D- μ CT as similar results were found during the verification using thermal imaging.
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Affiliation(s)
- Brecht Vanbillemont
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium;
| | - Joris Lammens
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (J.L.); (C.V.)
| | - Wannes Goethals
- Radiation Physics Research Group, Department of Physics and Astronomy, Ghent University, Proeftuinstraat 86, 9000 Ghent, Belgium; (W.G.); (M.N.B.)
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, 9000 Ghent, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (J.L.); (C.V.)
| | - Matthieu N. Boone
- Radiation Physics Research Group, Department of Physics and Astronomy, Ghent University, Proeftuinstraat 86, 9000 Ghent, Belgium; (W.G.); (M.N.B.)
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, 9000 Ghent, Belgium
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium;
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36
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Vafaei S, Splingaire L, Schnupf U, Hisae K, Hasegawa D, Sugiura T, Manseki K. Low temperature synthesis of anatase TiO2 nanocrystals using an organic-inorganic gel precursor. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.04.060] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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37
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Tripathi NK, Shrivastava A. Recent Developments in Bioprocessing of Recombinant Proteins: Expression Hosts and Process Development. Front Bioeng Biotechnol 2019; 7:420. [PMID: 31921823 PMCID: PMC6932962 DOI: 10.3389/fbioe.2019.00420] [Citation(s) in RCA: 251] [Impact Index Per Article: 50.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/07/2019] [Accepted: 11/29/2019] [Indexed: 12/22/2022] Open
Abstract
Infectious diseases, along with cancers, are among the main causes of death among humans worldwide. The production of therapeutic proteins for treating diseases at large scale for millions of individuals is one of the essential needs of mankind. Recent progress in the area of recombinant DNA technologies has paved the way to producing recombinant proteins that can be used as therapeutics, vaccines, and diagnostic reagents. Recombinant proteins for these applications are mainly produced using prokaryotic and eukaryotic expression host systems such as mammalian cells, bacteria, yeast, insect cells, and transgenic plants at laboratory scale as well as in large-scale settings. The development of efficient bioprocessing strategies is crucial for industrial production of recombinant proteins of therapeutic and prophylactic importance. Recently, advances have been made in the various areas of bioprocessing and are being utilized to develop effective processes for producing recombinant proteins. These include the use of high-throughput devices for effective bioprocess optimization and of disposable systems, continuous upstream processing, continuous chromatography, integrated continuous bioprocessing, Quality by Design, and process analytical technologies to achieve quality product with higher yield. This review summarizes recent developments in the bioprocessing of recombinant proteins, including in various expression systems, bioprocess development, and the upstream and downstream processing of recombinant proteins.
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Affiliation(s)
- Nagesh K. Tripathi
- Bioprocess Scale Up Facility, Defence Research and Development Establishment, Gwalior, India
| | - Ambuj Shrivastava
- Division of Virology, Defence Research and Development Establishment, Gwalior, India
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38
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Pisano R, Arsiccio A, Capozzi LC, Trout BL. Achieving continuous manufacturing in lyophilization: Technologies and approaches. Eur J Pharm Biopharm 2019; 142:265-279. [PMID: 31252071 DOI: 10.1016/j.ejpb.2019.06.027] [Citation(s) in RCA: 29] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/19/2019] [Revised: 06/20/2019] [Accepted: 06/21/2019] [Indexed: 11/15/2022]
Abstract
This paper provides an organic overview of the most interesting continuous freeze-drying concepts that have been proposed over the years. Attention has mainly been focused on the field of pharmaceuticals, but some background has also been given on the food industry. This work aims at providing a solid starting point for future research on continuous manufacturing for the freeze-drying of pharmaceuticals.
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Affiliation(s)
- Roberto Pisano
- Department of Applied Science and Technology, Politecnico di Torino, Torino 10129, Italy.
| | - Andrea Arsiccio
- Department of Applied Science and Technology, Politecnico di Torino, Torino 10129, Italy
| | - Luigi C Capozzi
- Department of Applied Science and Technology, Politecnico di Torino, Torino 10129, Italy
| | - Bernhardt L Trout
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139, United States
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39
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Vass P, Démuth B, Farkas A, Hirsch E, Szabó E, Nagy B, Andersen SK, Vigh T, Verreck G, Csontos I, Marosi G, Nagy ZK. Continuous alternative to freeze drying: Manufacturing of cyclodextrin-based reconstitution powder from aqueous solution using scaled-up electrospinning. J Control Release 2019; 298:120-127. [PMID: 30779951 DOI: 10.1016/j.jconrel.2019.02.019] [Citation(s) in RCA: 36] [Impact Index Per Article: 7.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/14/2018] [Revised: 02/13/2019] [Accepted: 02/15/2019] [Indexed: 01/27/2023]
Abstract
The aims of this study were to evaluate electrospinning as a continuous alternative to freeze drying in the production of a reconstitution injection dosage form, and to prove that aqueous electrospinning can be realized with a high production rate at room temperature. High-speed electrospinning with a novel continuous cyclone collection was used to manufacture a formulation of the poorly water-soluble antifungal voriconazole (VOR) with sulfobutylether-β-cyclodextrin (SBE-β-CD). The freeze-dried, marketed product of this drug substance, Vfend® also contains SBE-β-CD as excipient. SBE-β-CD acted as a 'quasi-polymer', and it could be electrospun despite its low molecular mass (2163 Da). According to X-ray diffraction and differential scanning calorimetry, no traces of crystalline VOR were detectable in the fibers. Furthermore, Raman mapping and energy dispersive spectroscopy measurements showed a uniform distribution of amorphous VOR in the fibers. Reconstitution tests carried out with ground fibrous powder showed complete dissolution resulting in a clear solution after 30 s (similarly to Vfend®). The high productivity rate (~240 g/h) achieved using high-speed electrospinning makes this scaled-up, continuous and flexible manufacturing process capable of fulfilling the technological and capacity requirements of the pharmaceutical industry. This work shows that aqueous high-speed electrospinning, being a continuous and high-throughput process, is an economically viable production alternative to freeze drying.
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Affiliation(s)
- Panna Vass
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - Balázs Démuth
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary.
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - Edit Hirsch
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - Edina Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - Sune K Andersen
- Oral Solids Development, Janssen R&D, Turnhoutseweg 30, Beerse B-2340, Belgium
| | - Tamás Vigh
- Oral Solids Development, Janssen R&D, Turnhoutseweg 30, Beerse B-2340, Belgium
| | - Geert Verreck
- Oral Solids Development, Janssen R&D, Turnhoutseweg 30, Beerse B-2340, Belgium
| | - István Csontos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
| | - Zsombor K Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), Műegyetem rakpart 3, Budapest H-1111, Hungary
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