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Patil NB, Atapalkar RS, Chavan SP, Kulkarni AA. Multi-Step Synthesis of Miltefosine: Integration of Flow Chemistry with Continuous Mechanochemistry. Chemistry 2021; 27:17695-17699. [PMID: 34697844 DOI: 10.1002/chem.202103499] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2021] [Indexed: 11/09/2022]
Abstract
Herein we report for the first time, an advanced continuous flow synthesis of the blockbuster Leishmaniasis drug miltefosine from simple starting materials by a sequence involving four steps of chemical transformation including a continuous mechanochemical step. First three reaction steps were performed in simple tubular reactors in a telescopic mode, while in the last step the product precipitated from the 3rd step was used for a continuous mechanochemical synthesis of miltefosine. When compared to a typical batch protocol that takes 15 h, miltefosine was obtained in 58 % overall yield in flow synthesis mode at the laboratory scale in a total residence time 34 min at synthesis rate of 10 g/hr, which is sufficient to treat 4800 patients per day.
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Affiliation(s)
- Niteen B Patil
- Division of Organic Chemistry, CSIR-National Chemical Laboratory, Pune, 411008, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad, 201002, India
| | - Ranjit S Atapalkar
- Chemical Engineering & Process Development, CSIR-National Chemical Laboratory, Pune, 411008, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad, 201002, India
| | - Subhash P Chavan
- Division of Organic Chemistry, CSIR-National Chemical Laboratory, Pune, 411008, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad, 201002, India
| | - Amol A Kulkarni
- Chemical Engineering & Process Development, CSIR-National Chemical Laboratory, Pune, 411008, India.,Academy of Scientific and Innovative Research (AcSIR), Ghaziabad, 201002, India
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Hu C. Reactor design and selection for effective continuous manufacturing of pharmaceuticals. J Flow Chem 2021; 11:243-263. [PMID: 34026279 PMCID: PMC8130218 DOI: 10.1007/s41981-021-00164-3] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/21/2021] [Accepted: 04/14/2021] [Indexed: 11/23/2022]
Abstract
Pharmaceutical production remains one of the last industries that predominantly uses batch processes, which are inefficient and can cause drug shortages due to the long lead times or quality defects. Consequently, pharmaceutical companies are transitioning away from outdated batch lines, in large part motivated by the many advantages of continuous manufacturing (e.g., low cost, quality assurance, shortened lead time). As chemical reactions are fundamental to any drug production process, the selection of reactor and its design are critical to enhanced performance such as improved selectivity and yield. In this article, relevant theories, and models, as well as their required input data are summarized to assist the reader in these tasks, focusing on continuous reactions. Selected examples that describe the application of plug flow reactors (PFRs) and continuous-stirred tank reactors (CSTRs)-in-series within the pharmaceutical industry are provided. Process analytical technologies (PATs), which are important tools that provide real-time in-line continuous monitoring of reactions, are recommended to be considered during the reactor design process (e.g., port design for the PAT probe). Finally, other important points, such as density change caused by thermal expansion or solid precipitation, clogging/fouling, and scaling-up, are discussed.
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Affiliation(s)
- Chuntian Hu
- CONTINUUS Pharmaceuticals, Woburn, MA 01801 USA
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Testa CJ, Hu C, Shvedova K, Wu W, Sayin R, Casati F, Halkude BS, Hermant P, Shen DE, Ramnath A, Su Q, Born SC, Takizawa B, Chattopadhyay S, O’Connor TF, Yang X, Ramanujam S, Mascia S. Design and Commercialization of an End-to-End Continuous Pharmaceutical Production Process: A Pilot Plant Case Study. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00383] [Citation(s) in RCA: 20] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
Affiliation(s)
- Christopher J. Testa
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Chuntian Hu
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Khrystyna Shvedova
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Wei Wu
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Ridade Sayin
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Federica Casati
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
- IMA S.p.A., Via I Maggio 14-16, Ozzano dell’Emilia, Bologna 40064, Italy
| | - Bhakti S. Halkude
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Paul Hermant
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Dongying Erin Shen
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Anjana Ramnath
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Qinglin Su
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Stephen C. Born
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | - Bayan Takizawa
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
| | | | - Thomas F. O’Connor
- Food and Drug Administration, 10903 New Hampshire Ave, Silver Spring, Maryland 20993, United States
| | - Xiaochuan Yang
- Food and Drug Administration, 10903 New Hampshire Ave, Silver Spring, Maryland 20993, United States
| | - Sukumar Ramanujam
- USV Private Limited, Arvind Vithal Gandhi Chowk, BSD Marg, Station Road, Govandi East, Mumbai 400080, India
| | - Salvatore Mascia
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, Massachusetts 01801, United States
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Hu C, Shores BT, Derech RA, Testa CJ, Hermant P, Wu W, Shvedova K, Ramnath A, Al Ismaili LQ, Su Q, Sayin R, Born SC, Takizawa B, O'Connor TF, Yang X, Ramanujam S, Mascia S. Continuous reactive crystallization of an API in PFR-CSTR cascade with in-line PATs. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00216j] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Abstract
The influence of PFR on crystal size distribution, reaction and crystallization yields, and supersaturation level was investigated.
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Affiliation(s)
| | | | | | | | | | - Wei Wu
- CONTINUUS Pharmaceuticals
- Woburn
- USA
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