1
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Neugebauer P, Zettl M, Moser D, Poms J, Kuchler L, Sacher S. Process analytical technology in Downstream-Processing of Drug Substances- A review. Int J Pharm 2024; 661:124412. [PMID: 38960339 DOI: 10.1016/j.ijpharm.2024.124412] [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: 04/30/2024] [Revised: 06/11/2024] [Accepted: 06/29/2024] [Indexed: 07/05/2024]
Abstract
Process Analytical Technology (PAT) has revolutionized pharmaceutical manufacturing by providing real-time monitoring and control capabilities throughout the production process. This review paper comprehensively examines the application of PAT methodologies specifically in the production of solid active pharmaceutical ingredients (APIs). Beginning with an overview of PAT principles and objectives, the paper explores the integration of advanced analytical techniques such as spectroscopy, imaging modalities and others into solid API substance production processes. Novel developments in in-line monitoring at academic level are also discussed. Emphasis is placed on the role of PAT in ensuring product quality, consistency, and compliance with regulatory requirements. Examples from existing literature illustrate the practical implementation of PAT in solid API substance production, including work-up, crystallization, filtration, and drying processes. The review addresses the quality and reliability of the measurement technologies, aspects of process implementation and handling, the integration of data treatment algorithms and current challenges. Overall, this review provides valuable insights into the transformative impact of PAT on enhancing pharmaceutical manufacturing processes for solid API substances.
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Affiliation(s)
- Peter Neugebauer
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria; Institute of Process and Particle Engineering, Graz University of Technology, 8010 Graz, Austria
| | - Manuel Zettl
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Daniel Moser
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Johannes Poms
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Lisa Kuchler
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria
| | - Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, 8010 Graz, Austria.
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2
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Liu Q, Wu C, Liu H, Wang M, Zhao C, Zhang F. Real-Time Monitoring of Multistep Batch and Flow Synthesis Processes of a Key Intermediate of Lifitegrast by a Combined Spectrometer System with Both Near-Infrared and Raman Spectroscopies Coupled to Partial Least-Squares. ACS OMEGA 2024; 9:20214-20222. [PMID: 38737057 PMCID: PMC11079892 DOI: 10.1021/acsomega.4c00565] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 01/17/2024] [Revised: 04/10/2024] [Accepted: 04/16/2024] [Indexed: 05/14/2024]
Abstract
Process analytical technology (PAT) has been successfully applied in numerous chemical synthesis cases and is an important tool in pharmaceutical process research and development. PAT brings new methods and opportunities for the real-time monitoring of chemical processes. In multistep synthesis, real-time monitoring of the complex reaction mixtures is a significant challenge but provides an opportunity to enhance reaction understanding and control. In this study, a combined multichannel spectrometer system with both near-infrared and Raman spectroscopy was built, and calibration models were developed to quantify the desired products, intermediates, and impurities in real-time at multiple points along the synthetic pathway. The capabilities of the system have been demonstrated by operating dynamic experiments in both batch and continuous-flow processes. It represents a significant step forward in data-driven, multistep pharmaceutical ingredient synthesis.
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Affiliation(s)
- Quan Liu
- School
of Pharmaceutical Science, Shanghai Jiao
Tong University, Minhang District, 200240 Shanghai, China
| | - Chuanjun Wu
- Shanghai
Institute of Pharmaceutical Industry, China
State Institute of Pharmaceutical Industry, Pudong District, 201203 Shanghai, China
| | - Huiting Liu
- Shanghai
PROXS Chemical Technology Co. Ltd., Pudong District, 201203 Shanghai, China
| | - Mengfei Wang
- Shanghai
Institute of Pharmaceutical Industry, China
State Institute of Pharmaceutical Industry, Pudong District, 201203 Shanghai, China
| | - Chuanmeng Zhao
- Shanghai
Institute of Pharmaceutical Industry, China
State Institute of Pharmaceutical Industry, Pudong District, 201203 Shanghai, China
| | - Fuli Zhang
- Shanghai
Institute of Pharmaceutical Industry, China
State Institute of Pharmaceutical Industry, Pudong District, 201203 Shanghai, China
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3
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Wagner F, Sagmeister P, Jusner CE, Tampone TG, Manee V, Buono FG, Williams JD, Kappe CO. A Slug Flow Platform with Multiple Process Analytics Facilitates Flexible Reaction Optimization. ADVANCED SCIENCE (WEINHEIM, BADEN-WURTTEMBERG, GERMANY) 2024; 11:e2308034. [PMID: 38273711 PMCID: PMC10987115 DOI: 10.1002/advs.202308034] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/30/2023] [Revised: 12/21/2023] [Indexed: 01/27/2024]
Abstract
Flow processing offers many opportunities to optimize reactions in a rapid and automated manner, yet often requires relatively large quantities of input materials. To combat this, the use of a flexible slug flow reactor, equipped with two analytical instruments, for low-volume optimization experiments are reported. A Buchwald-Hartwig amination toward the drug olanzapine, with 6 independent optimizable variables, is optimized using three different automated approaches: self-optimization, design of experiments, and kinetic modeling. These approaches are complementary and provide differing information on the reaction: pareto optimal operating points, response surface models, and mechanistic models, respectively. The results are achieved using <10% of the material that would be required for standard flow operation. Finally, a chemometric model is built utilizing automated data handling and three subsequent validation experiments demonstrate good agreement between the slug flow reactor and a standard (larger scale) flow reactor.
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Affiliation(s)
- Florian Wagner
- Center for Continuous Flow Synthesis and Processing (CC FLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 13Graz8010Austria
- Institute of ChemistryUniversity of GrazNAWI Graz, Heinrichstrasse 28Graz8010Austria
| | - Peter Sagmeister
- Center for Continuous Flow Synthesis and Processing (CC FLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 13Graz8010Austria
- Institute of ChemistryUniversity of GrazNAWI Graz, Heinrichstrasse 28Graz8010Austria
| | - Clemens E. Jusner
- Center for Continuous Flow Synthesis and Processing (CC FLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 13Graz8010Austria
- Institute of ChemistryUniversity of GrazNAWI Graz, Heinrichstrasse 28Graz8010Austria
| | - Thomas G. Tampone
- Boehringer Ingelheim Pharmaceuticals, Inc900 Ridgebury RoadRidgefieldCT06877USA
| | - Vidhyadhar Manee
- Boehringer Ingelheim Pharmaceuticals, Inc900 Ridgebury RoadRidgefieldCT06877USA
| | - Frederic G. Buono
- Boehringer Ingelheim Pharmaceuticals, Inc900 Ridgebury RoadRidgefieldCT06877USA
| | - Jason D. Williams
- Center for Continuous Flow Synthesis and Processing (CC FLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 13Graz8010Austria
- Institute of ChemistryUniversity of GrazNAWI Graz, Heinrichstrasse 28Graz8010Austria
| | - C. Oliver Kappe
- Center for Continuous Flow Synthesis and Processing (CC FLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 13Graz8010Austria
- Institute of ChemistryUniversity of GrazNAWI Graz, Heinrichstrasse 28Graz8010Austria
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4
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Liu J, Sato Y, Kulkarni VK, Sullivan AI, Zhang W, Crudden CM, Hein JE. Insights into the synthesis of NHC-stabilized Au nanoclusters through real-time reaction monitoring. Chem Sci 2023; 14:10500-10507. [PMID: 37800004 PMCID: PMC10548510 DOI: 10.1039/d3sc02077k] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2023] [Accepted: 08/20/2023] [Indexed: 10/07/2023] Open
Abstract
Atomically precise gold nanoclusters (AuNCs) are interesting nanomaterials with potential applications in catalysis, bioimaging and optoelectronics. Their compositions and properties are commonly evaluated by various analytical techniques, including UV-vis spectroscopy, NMR spectroscopy, ESI mass spectrometry, and single-crystal X-ray diffraction. While these techniques have provided detailed insights into the structure and properties of nanoclusters, synthetic methods still suffer from a lack of in situ and real-time reaction monitoring methodologies. This limits insight into the mechanism of formation of AuNCs and hinders attempts at optimization. We have demonstrated the utility of HPLC-MS as a monitoring methodology in the synthesis of two NHC-protected gold nanoclusters: [Au13(NHC)9Cl3]2+ and [Au24(NHC)14Cl2H3]3+. Herein we show that HPLC coupled with mass spectrometry and 13C NMR spectroscopy of labelled derivatives enables new insight into critical reaction dynamics of AuNCs synthesis and rapid reaction optimization.
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Affiliation(s)
- Junliang Liu
- Department of Chemistry, The University of British Columbia Vancouver BC V6T 1Z1 Canada
| | - Yusuke Sato
- Department of Chemistry, The University of British Columbia Vancouver BC V6T 1Z1 Canada
| | - Viveka K Kulkarni
- Department of Chemistry, Queen's University Kingston ON K7L 3N6 Canada
- Carbon to Metal Coatings Institute, Queen's University Kingston ON Canada
| | - Angus I Sullivan
- Department of Chemistry, Queen's University Kingston ON K7L 3N6 Canada
- Carbon to Metal Coatings Institute, Queen's University Kingston ON Canada
| | - Wenyu Zhang
- Department of Chemistry, The University of British Columbia Vancouver BC V6T 1Z1 Canada
| | - Cathleen M Crudden
- Department of Chemistry, Queen's University Kingston ON K7L 3N6 Canada
- Carbon to Metal Coatings Institute, Queen's University Kingston ON Canada
- Institute of Transformative Bio-Molecules (WPI-ITbM), Nagoya University Nagoya 464-8602 Japan
| | - Jason E Hein
- Department of Chemistry, The University of British Columbia Vancouver BC V6T 1Z1 Canada
- Acceleration Consortium, University of Toronto ON Canada
- Department of Chemistry, University of Bergen N-5007 Bergen Norway
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5
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Dalligos D, Pilling MJ, Dimitrakis G, Ball LT. Coaxial Dielectric Spectroscopy as an In-Line Process Analytical Technique for Reaction Monitoring. Org Process Res Dev 2023; 27:1094-1103. [PMID: 37342802 PMCID: PMC10278184 DOI: 10.1021/acs.oprd.3c00081] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/14/2023] [Indexed: 06/23/2023]
Abstract
The suitability of broadband dielectric spectroscopy (DS) as a tool for in-line (in situ) reaction monitoring is demonstrated. Using the esterification of 4-nitrophenol as a test-case, we show that multivariate analysis of time-resolved DS data-collected across a wide frequency range with a coaxial dip-probe-allows reaction progress to be measured with both high precision and high accuracy. In addition to the workflows for data collection and analysis, we also establish a convenient method for rapidly assessing the applicability of DS to previously untested reactions or processes. We envisage that, given its orthogonality to other spectroscopic methods, its low cost, and its ease of implementation, DS will be a valuable addition to the process chemist's analytical toolbox.
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Affiliation(s)
- Desiree
M. Dalligos
- Department
of Chemical and Environmental Engineering, University of Nottingham, Coates Building, Nottingham NG7 2RD, U.K.
- School
of Chemistry, University of Nottingham, Nottingham NG7 2RD, U.K.
| | - Michael J. Pilling
- Chemical
Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield SK10 2NA, U.K.
| | - Georgios Dimitrakis
- Department
of Chemical and Environmental Engineering, University of Nottingham, Coates Building, Nottingham NG7 2RD, U.K.
| | - Liam T. Ball
- School
of Chemistry, University of Nottingham, Nottingham NG7 2RD, U.K.
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6
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Feng Báez JP, George De la Rosa MV, Alvarado-Hernández BB, Romañach RJ, Stelzer T. Evaluation of a compact composite sensor array for concentration monitoring of solutions and suspensions via multivariate analysis. J Pharm Biomed Anal 2023; 233:115451. [PMID: 37182364 DOI: 10.1016/j.jpba.2023.115451] [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: 01/25/2023] [Revised: 04/24/2023] [Accepted: 05/07/2023] [Indexed: 05/16/2023]
Abstract
Compact composite probes were identified as a priority to alleviate space constraints in miniaturized unit operations and pharmaceutical manufacturing platforms. Therefore, in this proof of principle study, a compact composite sensor array (CCSA) combining ultraviolet and near infrared features at four different wavelengths (280, 340, 600, 860 nm) in a 380 × 30 mm housing (length x diameter, 7 mm diameter at the probe head), was evaluated for its capabilities to monitor in situ concentration of solutions and suspensions via multivariate analysis using partial least squares (PLS) regression models. Four model active pharmaceutical ingredients (APIs): warfarin sodium isopropanol solvate (WS), lidocaine hydrochloride monohydrate (LID), 6-mercaptopurine monohydrate (6-MP), and acetaminophen (ACM) in their aqueous solution and suspension formulation were used for the assessment. The results demonstrate that PLS models can be applied for the CCSA prototype to measure the API concentrations with similar accuracy (validation samples within the United States Pharmacopeia (USP) limits), compared to univariate CCSA models and multivariate models for an established Raman spectrometer. Specifically, the multivariate CCSA models applied to the suspensions of 6-MP and ACM demonstrate improved accuracy of 63% and 31%, respectively, compared to the univariate CCSA models [1]. On the other hand, the PLS models for the solutions WS and LID showed a reduced accuracy compared to the univariate models [1].
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Affiliation(s)
- Jean P Feng Báez
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Puerto Rico, Medical Sciences Campus, San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA
| | - Mery Vet George De la Rosa
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Puerto Rico, Medical Sciences Campus, San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA
| | | | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico, Mayagüez Campus, Mayagüez, PR 00681, USA
| | - Torsten Stelzer
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Puerto Rico, Medical Sciences Campus, San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA.
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7
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Malig TC, Kumar A, Kurita KL. Online and In Situ Monitoring of the Exchange, Transmetalation, and Cross-Coupling of a Negishi Reaction. Org Process Res Dev 2022. [DOI: 10.1021/acs.oprd.2c00081] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Thomas C. Malig
- Department of Small Molecule Analytical Chemistry, Genentech, Inc., South San Francisco, California 94080, United States
| | - Archana Kumar
- Department of Analytical Chemistry, ORIC Pharmaceuticals, Inc., South San Francisco, California 94080, United States
| | - Kenji L. Kurita
- Department of Small Molecule Analytical Chemistry, Genentech, Inc., South San Francisco, California 94080, United States
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8
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Ke J, Gao C, Folgueiras-Amador AA, Jolley KE, de Frutos O, Mateos C, Rincón JA, Brown RCD, Poliakoff M, George MW. Self-Optimization of Continuous Flow Electrochemical Synthesis Using Fourier Transform Infrared Spectroscopy and Gas Chromatography. APPLIED SPECTROSCOPY 2022; 76:38-50. [PMID: 34911387 DOI: 10.1177/00037028211059848] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/14/2023]
Abstract
A continuous-flow electrochemical synthesis platform has been developed to enable self-optimization of reaction conditions of organic electrochemical reactions using attenuated total reflection Fourier transform infrared spectroscopy (ATR FT-IR) and gas chromatography (GC) as online real-time monitoring techniques. We have overcome the challenges in using ATR FT-IR as the downstream analytical methods imposed when a large amount of hydrogen gas is produced from the counter electrode by designing two types of gas-liquid separators (GLS) for analysis of the product mixture flowing from the electrochemical reactor. In particular, we report an integrated GLS with an ATR FT-IR probe at the reactor outlet to give a facile and low-cost solution to determining the concentrations of products in gas-liquid two-phase flow. This approach provides a reliable method for quantifying low-volatile analytes, which can be problematic to be monitored by GC. Two electrochemical reactions the methoxylation of 1-formylpyrrolidine and the oxidation of 3-bromobenzyl alcohol were investigated to demonstrate that the optimal conditions can be located within the pre-defined multi-dimensional reaction parameter spaces without intervention of the operator by using the stable noisy optimization by branch and FIT (SNOBFIT) algorithm.
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Affiliation(s)
- Jie Ke
- School of Chemistry, 6123University of Nottingham, Nottingham, UK
| | - Chuang Gao
- School of Chemistry, 6123University of Nottingham, Nottingham, UK
- Department of Chemical and Environmental Engineering, The University of Nottingham Ningbo China, Ningbo, China
| | | | - Katherine E Jolley
- School of Chemistry, 6123University of Nottingham, Nottingham, UK
- School of Chemistry, University of Southampton, Southampton, UK
| | - Oscar de Frutos
- Centro de Investigación Lilly S.A., Alcobendas-Madrid, Spain
| | - Carlos Mateos
- Centro de Investigación Lilly S.A., Alcobendas-Madrid, Spain
| | - Juan A Rincón
- Centro de Investigación Lilly S.A., Alcobendas-Madrid, Spain
| | | | - Martyn Poliakoff
- School of Chemistry, 6123University of Nottingham, Nottingham, UK
| | - Michael W George
- School of Chemistry, 6123University of Nottingham, Nottingham, UK
- Department of Chemical and Environmental Engineering, The University of Nottingham Ningbo China, Ningbo, China
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9
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Li B, Guo W, Chi H, Zhang Z, Ramsey ED. Key measurements performed using on-line supercritical fluid chromatography to support process design and development. Trends Analyt Chem 2022. [DOI: 10.1016/j.trac.2021.116479] [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]
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10
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Reactions of two primary aromatic amines in modified supercritical carbon dioxide to synthesize sulfonamides: On-line SFC to perform solubility measurements and method to monitor reaction progress. J Supercrit Fluids 2022. [DOI: 10.1016/j.supflu.2021.105419] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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11
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Sagandira CR, Nqeketo S, Mhlana K, Sonti T, Gaqa S, Watts P. Towards 4th industrial revolution efficient and sustainable continuous flow manufacturing of active pharmaceutical ingredients. REACT CHEM ENG 2022. [DOI: 10.1039/d1re00483b] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Abstract
The convergence of end-to-end continuous flow synthesis with downstream processing, process analytical technology (PAT), artificial intelligence (AI), machine learning and automation in ensuring improved accessibility of quality medicines on demand.
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Affiliation(s)
| | - Sinazo Nqeketo
- Nelson Mandela University, University Way, Port Elizabeth, 6031, South Africa
| | - Kanyisile Mhlana
- Nelson Mandela University, University Way, Port Elizabeth, 6031, South Africa
| | - Thembela Sonti
- Nelson Mandela University, University Way, Port Elizabeth, 6031, South Africa
| | - Sibongiseni Gaqa
- Nelson Mandela University, University Way, Port Elizabeth, 6031, South Africa
| | - Paul Watts
- Nelson Mandela University, University Way, Port Elizabeth, 6031, South Africa
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12
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Knoll S, Jusner CE, Sagmeister P, Williams JD, Hone CA, Horn M, Kappe CO. Autonomous model-based experimental design for rapid reaction development. REACT CHEM ENG 2022. [DOI: 10.1039/d2re00208f] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/19/2022]
Abstract
To automate and democratize model-based experimental design for flow chemistry applications, we report the development of open-source software, Optipus. Reaction models are built in an iterative and automated fashion, for rapid reaction development.
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Affiliation(s)
- Sebastian Knoll
- Institute of Automation and Control, Graz University of Technology, Inffeldgasse 21b, 8010 Graz, Austria
| | - Clemens E. Jusner
- Center for Continuous Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010 Graz, Austria
- Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010 Graz, Austria
| | - Peter Sagmeister
- Center for Continuous Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010 Graz, Austria
- Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010 Graz, Austria
| | - Jason D. Williams
- Center for Continuous Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010 Graz, Austria
- Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010 Graz, Austria
| | - Christopher A. Hone
- Center for Continuous Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010 Graz, Austria
- Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010 Graz, Austria
| | - Martin Horn
- Institute of Automation and Control, Graz University of Technology, Inffeldgasse 21b, 8010 Graz, Austria
| | - C. Oliver Kappe
- Center for Continuous Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Inffeldgasse 13, 8010 Graz, Austria
- Institute of Chemistry, University of Graz, NAWI Graz, Heinrichstrasse 28, 8010 Graz, Austria
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13
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Bringley DA, Roberts BJ, Calimsiz S, Brown BH, Davy JA, Kwong B, Gao D, Martins A, Sarma K, Shao E, Shen J, Smith MV, Sujino K, Triman AS, Wright N. Synthesis of Rovafovir Etalafenamide (Part II): Dynamic Control for Successful Scale-Up of an Oxygen-Releasing Elimination Reaction Mediated by Oxone. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00439] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Dustin A. Bringley
- Gilead Sciences Inc., Department of Process Chemistry, 333 Lakeside Drive, Foster City, California 94404, United States
| | - Benjamin J. Roberts
- Gilead Sciences Inc., Department of Process Chemistry, 333 Lakeside Drive, Foster City, California 94404, United States
| | - Selcuk Calimsiz
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Brandon H. Brown
- Gilead Sciences Inc., Department of Process Chemistry, 333 Lakeside Drive, Foster City, California 94404, United States
| | - Jason A. Davy
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Bernard Kwong
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Detian Gao
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Andrew Martins
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Keshab Sarma
- Gilead Sciences Inc., Department of Process Chemistry, 333 Lakeside Drive, Foster City, California 94404, United States
| | - Elan Shao
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Jinyu Shen
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Mark V. Smith
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Keiko Sujino
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
| | - Alan S. Triman
- Gilead Sciences Inc., Department of Process Chemistry, 333 Lakeside Drive, Foster City, California 94404, United States
| | - Nande Wright
- Gilead Alberta ULC, Department of Process Chemistry, 1021 Hayter Road NW, Edmonton, Alberta T6S 1A1, Canada
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14
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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: 15] [Impact Index Per Article: 5.0] [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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15
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Sagmeister P, Lebl R, Castillo I, Rehrl J, Kruisz J, Sipek M, Horn M, Sacher S, Cantillo D, Williams JD, Kappe CO. Advanced Real-Time Process Analytics for Multistep Synthesis in Continuous Flow*. Angew Chem Int Ed Engl 2021; 60:8139-8148. [PMID: 33433918 PMCID: PMC8048486 DOI: 10.1002/anie.202016007] [Citation(s) in RCA: 55] [Impact Index Per Article: 18.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/01/2020] [Indexed: 12/28/2022]
Abstract
In multistep continuous flow chemistry, studying complex reaction mixtures in real time is a significant challenge, but provides an opportunity to enhance reaction understanding and control. We report the integration of four complementary process analytical technology tools (NMR, UV/Vis, IR and UHPLC) in the multistep synthesis of an active pharmaceutical ingredient, mesalazine. This synthetic route exploits flow processing for nitration, high temperature hydrolysis and hydrogenation reactions, as well as three inline separations. Advanced data analysis models were developed (indirect hard modeling, deep learning and partial least squares regression), to quantify the desired products, intermediates and impurities in real time, at multiple points along the synthetic pathway. The capabilities of the system have been demonstrated by operating both steady state and dynamic experiments and represents a significant step forward in data-driven continuous flow synthesis.
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Affiliation(s)
- Peter Sagmeister
- Center for Continuous Flow Synthesis and Processing (CCFLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 138010GrazAustria
- Institute of ChemistryUniversity of Graz, NAWI GrazHeinrichstrasse 288010GrazAustria
| | - René Lebl
- Center for Continuous Flow Synthesis and Processing (CCFLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 138010GrazAustria
- Institute of ChemistryUniversity of Graz, NAWI GrazHeinrichstrasse 288010GrazAustria
| | - Ismael Castillo
- Institute of Automation and ControlGraz University of TechnologyInffeldgasse 21b8010GrazAustria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering (RCPE)Inffeldgasse 138010GrazAustria
| | - Julia Kruisz
- Research Center Pharmaceutical Engineering (RCPE)Inffeldgasse 138010GrazAustria
| | - Martin Sipek
- Evon GmbHWollsdorf 1548181St. Ruprecht a. d. RaabAustria
| | - Martin Horn
- Institute of Automation and ControlGraz University of TechnologyInffeldgasse 21b8010GrazAustria
| | - Stephan Sacher
- Research Center Pharmaceutical Engineering (RCPE)Inffeldgasse 138010GrazAustria
| | - David Cantillo
- Center for Continuous Flow Synthesis and Processing (CCFLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 138010GrazAustria
- Institute of ChemistryUniversity of Graz, NAWI GrazHeinrichstrasse 288010GrazAustria
| | - Jason D. Williams
- Center for Continuous Flow Synthesis and Processing (CCFLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 138010GrazAustria
- Institute of ChemistryUniversity of Graz, NAWI GrazHeinrichstrasse 288010GrazAustria
| | - C. Oliver Kappe
- Center for Continuous Flow Synthesis and Processing (CCFLOW)Research Center Pharmaceutical Engineering GmbH (RCPE)Inffeldgasse 138010GrazAustria
- Institute of ChemistryUniversity of Graz, NAWI GrazHeinrichstrasse 288010GrazAustria
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16
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Park J, Choi YS, Kim J, Lee J, Kim TJ, Youn YS, Lim SH, Kim JY. Calibration-free real-time organic film thickness monitoring technique by reflected X-Ray fluorescence and compton scattering measurement. NUCLEAR ENGINEERING AND TECHNOLOGY 2021. [DOI: 10.1016/j.net.2020.09.018] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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17
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Sagmeister P, Lebl R, Castillo I, Rehrl J, Kruisz J, Sipek M, Horn M, Sacher S, Cantillo D, Williams JD, Kappe CO. Advanced Real‐Time Process Analytics for Multistep Synthesis in Continuous Flow**. Angew Chem Int Ed Engl 2021. [DOI: 10.1002/ange.202016007] [Citation(s) in RCA: 13] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
Affiliation(s)
- Peter Sagmeister
- Center for Continuous Flow Synthesis and Processing (CCFLOW) Research Center Pharmaceutical Engineering GmbH (RCPE) Inffeldgasse 13 8010 Graz Austria
- Institute of Chemistry University of Graz, NAWI Graz Heinrichstrasse 28 8010 Graz Austria
| | - René Lebl
- Center for Continuous Flow Synthesis and Processing (CCFLOW) Research Center Pharmaceutical Engineering GmbH (RCPE) Inffeldgasse 13 8010 Graz Austria
- Institute of Chemistry University of Graz, NAWI Graz Heinrichstrasse 28 8010 Graz Austria
| | - Ismael Castillo
- Institute of Automation and Control Graz University of Technology Inffeldgasse 21b 8010 Graz Austria
| | - Jakob Rehrl
- Research Center Pharmaceutical Engineering (RCPE) Inffeldgasse 13 8010 Graz Austria
| | - Julia Kruisz
- Research Center Pharmaceutical Engineering (RCPE) Inffeldgasse 13 8010 Graz Austria
| | - Martin Sipek
- Evon GmbH Wollsdorf 154 8181 St. Ruprecht a. d. Raab Austria
| | - Martin Horn
- Institute of Automation and Control Graz University of Technology Inffeldgasse 21b 8010 Graz Austria
| | - Stephan Sacher
- Research Center Pharmaceutical Engineering (RCPE) Inffeldgasse 13 8010 Graz Austria
| | - David Cantillo
- Center for Continuous Flow Synthesis and Processing (CCFLOW) Research Center Pharmaceutical Engineering GmbH (RCPE) Inffeldgasse 13 8010 Graz Austria
- Institute of Chemistry University of Graz, NAWI Graz Heinrichstrasse 28 8010 Graz Austria
| | - Jason D. Williams
- Center for Continuous Flow Synthesis and Processing (CCFLOW) Research Center Pharmaceutical Engineering GmbH (RCPE) Inffeldgasse 13 8010 Graz Austria
- Institute of Chemistry University of Graz, NAWI Graz Heinrichstrasse 28 8010 Graz Austria
| | - C. Oliver Kappe
- Center for Continuous Flow Synthesis and Processing (CCFLOW) Research Center Pharmaceutical Engineering GmbH (RCPE) Inffeldgasse 13 8010 Graz Austria
- Institute of Chemistry University of Graz, NAWI Graz Heinrichstrasse 28 8010 Graz Austria
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18
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Chae Y, Min S, Park E, Lim C, Cheon CH, Jeong K, Kwak K, Cho M. Real-Time Reaction Monitoring with In Operando Flow NMR and FTIR Spectroscopy: Reaction Mechanism of Benzoxazole Synthesis. Anal Chem 2021; 93:2106-2113. [PMID: 33389991 DOI: 10.1021/acs.analchem.0c03852] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/21/2023]
Abstract
In operando observation of reaction intermediates is crucial for unraveling reaction mechanisms. To address the sensitivity limitations of commercial ReactIR, a flow cell was integrated with a Fourier transform infrared (FTIR) spectrometer yielding a "flow FTIR" device coupled with an NMR spectrometer for the elucidation of reaction mechanisms. The former device detects the low-intensity IR peaks of reaction intermediates by adjusting the path length of the FTIR sample cell, whereas the flow NMR allows the quantitative analysis of reaction species, thus offsetting the limitations of IR spectroscopy resulting from different absorption coefficients of the normal modes. Using the flow NMR and FTIR device, the controversial mechanism of benzoxazole synthesis was conclusively determined by spectroscopic evaluation of the reaction intermediates. This system enabled the accurate acquisition of previously elusive kinetic data, such as the reaction time and rate-determining step. The implementation of reaction flow cells into NMR and FTIR systems could be widely applied to study various reaction mechanisms, including dangerous and harsh reactions, thus avoiding contact with potentially harmful reaction intermediates.
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Affiliation(s)
- Yeongseok Chae
- Center of Molecular Spectroscopy and Dynamics, Institute of Basic Science (IBS), Seoul 02841, South Korea.,Department of Chemistry, Korea University, Seoul 02841, South Korea
| | - Sein Min
- Department of Chemistry, Seoul Women's University, Seoul 01797, South Korea
| | - Eunjoon Park
- Department of Chemistry, Korea University, Seoul 02841, South Korea
| | - Chaiho Lim
- Center of Molecular Spectroscopy and Dynamics, Institute of Basic Science (IBS), Seoul 02841, South Korea.,Department of Chemistry, Korea University, Seoul 02841, South Korea
| | - Cheol-Hong Cheon
- Department of Chemistry, Korea University, Seoul 02841, South Korea
| | - Keunhong Jeong
- Department of Chemistry, Korea Military Academy, Seoul 01805, South Korea
| | - Kyungwon Kwak
- Center of Molecular Spectroscopy and Dynamics, Institute of Basic Science (IBS), Seoul 02841, South Korea.,Department of Chemistry, Korea University, Seoul 02841, South Korea
| | - Minhaeng Cho
- Center of Molecular Spectroscopy and Dynamics, Institute of Basic Science (IBS), Seoul 02841, South Korea.,Department of Chemistry, Korea University, Seoul 02841, South Korea
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19
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Sagmeister P, Poms J, Williams JD, Kappe CO. Multivariate analysis of inline benchtop NMR data enables rapid optimization of a complex nitration in flow. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00048e] [Citation(s) in RCA: 25] [Impact Index Per Article: 6.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/05/2023]
Abstract
Multivariate analysis is applied to inline benchtop NMR data for a complex nitration in flow. This rapid quantification enables reaction optimization using advanced techniques in flow, such as design of experiments and dynamic experimentation.
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Affiliation(s)
- Peter Sagmeister
- Center for Continuous Flow Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
| | - Johannes Poms
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
| | - Jason D. Williams
- Center for Continuous Flow Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
| | - C. Oliver Kappe
- Center for Continuous Flow Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
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20
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Sagmeister P, Williams JD, Hone CA, Kappe CO. Laboratory of the future: a modular flow platform with multiple integrated PAT tools for multistep reactions. REACT CHEM ENG 2019. [DOI: 10.1039/c9re00087a] [Citation(s) in RCA: 71] [Impact Index Per Article: 14.2] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/28/2022]
Abstract
The coupling of a modular microreactor platform, real-time inline analysis by IR and NMR, and online UPLC, leads to efficient optimization of a multistep organolithium transformation to a given product without the need for human intervention.
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Affiliation(s)
- Peter Sagmeister
- Center for Continuous Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
| | - Jason D. Williams
- Center for Continuous Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
| | - Christopher A. Hone
- Center for Continuous Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
| | - C. Oliver Kappe
- Center for Continuous Synthesis and Processing (CCFLOW)
- Research Center Pharmaceutical Engineering (RCPE)
- 8010 Graz
- Austria
- Institute of Chemistry
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21
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22
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Shi Z, Hermiller J, Muñoz SG. Estimation of mass-based composition in powder mixtures using Extended Iterative Optimization Technology (EIOT). AIChE J 2018. [DOI: 10.1002/aic.16417] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
Affiliation(s)
- Zhenqi Shi
- Small Molecule Design & Development; Lilly Research Laboratories; Indianapolis IN, 46285
| | - James Hermiller
- Small Molecule Design & Development; Lilly Research Laboratories; Indianapolis IN, 46285
| | - Salvador García Muñoz
- Small Molecule Design & Development; Lilly Research Laboratories; Indianapolis IN, 46285
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23
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Li B, Guo W, Ramsey ED. Monitoring the progress of the acetylation reactions of 4-aminophenol and 2-aminophenol in acetonitrile modified supercritical fluid carbon dioxide and pure acetonitrile using on-line supercritical fluid chromatography and on-line liquid chromatography. J Supercrit Fluids 2018. [DOI: 10.1016/j.supflu.2017.11.002] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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24
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Hirsch E, Pataki H, Farkas A, Bata H, Vass P, Fehér C, Barta Z, Párta L, Csontos I, Ballagi A, Nagy ZK, Marosi GJ. Raman-Based Feedback Control of the Enzymatic Hydrolysis of Lactose. Org Process Res Dev 2016. [DOI: 10.1021/acs.oprd.6b00212] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Edit Hirsch
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Hajnalka Pataki
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Attila Farkas
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Henrik Bata
- 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
| | - Csaba Fehér
- Department
of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - Zsolt Barta
- Department
of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - László Párta
- Gedeon Richter Plc., Gyömröi
út 19-21, H-1103 Budapest, Hungary
| | - István Csontos
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - András Ballagi
- Department
of Applied Biotechnology and Food Science, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
- Gedeon Richter Plc., Gyömröi
út 19-21, H-1103 Budapest, Hungary
| | - Zsombor K. Nagy
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
| | - György J. Marosi
- Department
of Organic Chemistry and Technology, Budapest University of Technology and Economics, Müegyetem rkp. 3, H-1111 Budapest, Hungary
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