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Xiao H, Feng Y, Goundry WRF, Karlsson S. Organic Solvent Nanofiltration in Pharmaceutical Applications. Org Process Res Dev 2024; 28:891-923. [PMID: 38660379 PMCID: PMC11036530 DOI: 10.1021/acs.oprd.3c00470] [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: 12/05/2023] [Revised: 02/22/2024] [Accepted: 02/28/2024] [Indexed: 04/26/2024]
Abstract
Separation and purification in organic solvents are indispensable procedures in pharmaceutical manufacturing. However, they still heavily rely on the conventional separation technologies of distillation and chromatography, resulting in high energy and massive solvent consumption. As an alternative, organic solvent nanofiltration (OSN) offers the benefits of low energy consumption, low solid waste generation, and easy scale-up and incorporation into continuous processes. Thus, there is a growing interest in employing membrane technology in the pharmaceutical area to improve process sustainability and energy efficiency. This Review comprehensively summarizes the recent progress (especially the last 10 years) of organic solvent nanofiltration and its applications in the pharmaceutical industry, including the concentration and purification of active pharmaceutical ingredients, homogeneous catalyst recovery, solvent exchange and recovery, and OSN-assisted peptide/oligonucleotide synthesis. Furthermore, the challenges and future perspectives of membrane technology in pharmaceutical applications are discussed in detail.
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Affiliation(s)
- Hui Xiao
- Early
Chemical Development, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Macclesfield SK10 2NA, United Kingdom
| | - Yanyue Feng
- Early
Chemical Development, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca Gothenburg, SE-431 83 Mölndal, Sweden
| | - William R. F. Goundry
- Early
Chemical Development, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca, Macclesfield SK10 2NA, United Kingdom
| | - Staffan Karlsson
- Early
Chemical Development, Pharmaceutical Sciences, Biopharmaceuticals R&D, AstraZeneca Gothenburg, SE-431 83 Mölndal, Sweden
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Martin V, Egelund PHG, Johansson H, Thordal Le Quement S, Wojcik F, Sejer Pedersen D. Greening the synthesis of peptide therapeutics: an industrial perspective. RSC Adv 2020; 10:42457-42492. [PMID: 35516773 PMCID: PMC9057961 DOI: 10.1039/d0ra07204d] [Citation(s) in RCA: 32] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/21/2020] [Accepted: 11/03/2020] [Indexed: 12/13/2022] Open
Abstract
Solid-phase peptide synthesis (SPPS) is generally the method of choice for the chemical synthesis of peptides, allowing routine synthesis of virtually any type of peptide sequence, including complex or cyclic peptide products. Importantly, SPPS can be automated and is scalable, which has led to its widespread adoption in the pharmaceutical industry, and a variety of marketed peptide-based drugs are now manufactured using this approach. However, SPPS-based synthetic strategies suffer from a negative environmental footprint mainly due to extensive solvent use. Moreover, most of the solvents used in peptide chemistry are classified as problematic by environmental agencies around the world and will soon need to be replaced, which in recent years has spurred a movement in academia and industry to make peptide synthesis greener. These efforts have been centred around solvent substitution, recycling and reduction, as well as exploring alternative synthetic methods. In this review, we focus on methods pertaining to solvent substitution and reduction with large-scale industrial production in mind, and further outline emerging technologies for peptide synthesis. Specifically, the technical requirements for large-scale manufacturing of peptide therapeutics are addressed.
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Affiliation(s)
- Vincent Martin
- Novo Nordisk A/S, CMC API Development Smørmosevej 17-19 DK-2880 Bagsværd Denmark +45 4444 8888
| | - Peter H G Egelund
- Novo Nordisk A/S, CMC API Development Smørmosevej 17-19 DK-2880 Bagsværd Denmark +45 4444 8888
| | - Henrik Johansson
- Novo Nordisk A/S, CMC API Development Smørmosevej 17-19 DK-2880 Bagsværd Denmark +45 4444 8888
| | | | - Felix Wojcik
- Novo Nordisk A/S, CMC API Development Smørmosevej 17-19 DK-2880 Bagsværd Denmark +45 4444 8888
| | - Daniel Sejer Pedersen
- Novo Nordisk A/S, CMC API Development Smørmosevej 17-19 DK-2880 Bagsværd Denmark +45 4444 8888
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Isidro-Llobet A, Kenworthy MN, Mukherjee S, Kopach ME, Wegner K, Gallou F, Smith AG, Roschangar F. Sustainability Challenges in Peptide Synthesis and Purification: From R&D to Production. J Org Chem 2019; 84:4615-4628. [PMID: 30900880 DOI: 10.1021/acs.joc.8b03001] [Citation(s) in RCA: 196] [Impact Index Per Article: 39.2] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Abstract
In recent years, there has been a growing interest in therapeutic peptides within the pharmaceutical industry with more than 50 peptide drugs on the market, approximately 170 in clinical trials, and >200 in preclinical development. However, the current state of the art in peptide synthesis involves primarily legacy technologies with use of large amounts of highly hazardous reagents and solvents and little focus on green chemistry and engineering. In 2016, the ACS Green Chemistry Institute Pharmaceutical Roundtable identified development of greener processes for peptide API as a critical unmet need, and as a result, a new Roundtable team formed to address this important area. The initial focus of this new team is to highlight best practices in peptide synthesis and encourage much needed innovations. In this Perspective, we aim to summarize the current challenges of peptide synthesis and purification in terms of sustainability, highlight possible solutions, and encourage synergies between academia, the pharmaceutical industry, and contract research organizations/contract manufacturing organizations.
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Affiliation(s)
- Albert Isidro-Llobet
- Medicines Research Centre , GlaxoSmithKline , Gunnels Wood Road , Stevenage SG1 2NY , U.K
| | - Martin N Kenworthy
- Pharmaceutical Technology and Development , AstraZeneca , Silk Road Business Park, Charter Way , Macclesfield SK10 2NA , U.K
| | - Subha Mukherjee
- Chemical and Synthetic Development , Bristol-Myers Squibb Company , One Squibb Drive , New Brunswick , New Jersey 08903 , United States
| | - Michael E Kopach
- Small Molecule Design and Development , Eli Lilly and Company , 1400 West Raymond Street , Indianapolis , Indiana , United States
| | - Katarzyna Wegner
- Active Pharmaceutical Ingredient Development , IPSEN Manufacturing Ireland, Ltd. , Blanchardstown Industrial Park , Dublin 15 , Ireland
| | - Fabrice Gallou
- Chemical & Analytical Development , Novartis , 4056 Basel , Switzerland
| | - Austin G Smith
- Drug Substance Process Development , Amgen, Inc. , 1 Amgen Center Drive , Thousand Oaks , California 91320 , United States
| | - Frank Roschangar
- Chemical Development , Boehringer Ingelheim Pharmaceuticals , Ridgefield , Connecticut 06877 , United States
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Fodi T, Didaskalou C, Kupai J, Balogh GT, Huszthy P, Szekely G. Nanofiltration-Enabled In Situ Solvent and Reagent Recycle for Sustainable Continuous-Flow Synthesis. CHEMSUSCHEM 2017; 10:3435-3444. [PMID: 28737002 PMCID: PMC6032941 DOI: 10.1002/cssc.201701120] [Citation(s) in RCA: 42] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/25/2017] [Revised: 07/20/2017] [Indexed: 05/16/2023]
Abstract
Solvent usage in the pharmaceutical sector accounts for as much as 90 % of the overall mass during manufacturing processes. Consequently, solvent consumption poses significant costs and environmental burdens. Continuous processing, in particular continuous-flow reactors, have great potential for the sustainable production of pharmaceuticals but subsequent downstream processing remains challenging. Separation processes for concentrating and purifying chemicals can account for as much as 80 % of the total manufacturing costs. In this work, a nanofiltration unit was coupled to a continuous-flow rector for in situ solvent and reagent recycling. The nanofiltration unit is straightforward to implement and simple to control during continuous operation. The hybrid process operated continuously over six weeks, recycling about 90 % of the solvent and reagent. Consequently, the E-factor and the carbon footprint were reduced by 91 % and 19 %, respectively. Moreover, the nanofiltration unit led to a solution of the product eleven times more concentrated than the reaction mixture and increased the purity from 52.4 % to 91.5 %. The boundaries for process conditions were investigated to facilitate implementation of the methodology by the pharmaceutical sector.
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Affiliation(s)
- Tamas Fodi
- School of Chemical EngineeringThe University of ManchesterThe Mill, Sackville StreetManchesterM13 9PLUnited Kingdom
- Department of Organic Chemistry and TechnologyBudapest University of Technology and EconomicsSzent Gellert ter 4Budapest1117Hungary
- Compound Profiling Laboratory, Gedeon Richter Plc.PO Box 27Budapest1475Hungary
| | - Christos Didaskalou
- School of Chemical EngineeringThe University of ManchesterThe Mill, Sackville StreetManchesterM13 9PLUnited Kingdom
| | - Jozsef Kupai
- Department of Organic Chemistry and TechnologyBudapest University of Technology and EconomicsSzent Gellert ter 4Budapest1117Hungary
| | - Gyorgy T. Balogh
- Compound Profiling Laboratory, Gedeon Richter Plc.PO Box 27Budapest1475Hungary
| | - Peter Huszthy
- Department of Organic Chemistry and TechnologyBudapest University of Technology and EconomicsSzent Gellert ter 4Budapest1117Hungary
| | - Gyorgy Szekely
- School of Chemical EngineeringThe University of ManchesterThe Mill, Sackville StreetManchesterM13 9PLUnited Kingdom
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Marchetti P, Peeva L, Livingston A. The Selectivity Challenge in Organic Solvent Nanofiltration: Membrane and Process Solutions. Annu Rev Chem Biomol Eng 2017; 8:473-497. [PMID: 28511021 DOI: 10.1146/annurev-chembioeng-060816-101325] [Citation(s) in RCA: 62] [Impact Index Per Article: 8.9] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Abstract
Recent development of organic solvent nanofiltration (OSN) materials has been overwhelmingly directed toward tight membranes with ultrahigh permeance. However, emerging research into OSN applications is suggesting that improved separation selectivity is at least as important as further increases in membrane permeance. Membrane solutions are being proposed to improve selectivity, mostly by exploiting solute/solvent/membrane interactions and by fabricating tailored membranes. Because achieving a perfect separation with a single membrane stage is difficult, process engineering solutions, such as membrane cascades, are also being advocated. Here we review these approaches to the selectivity challenge, and to clarify our analysis, we propose a selectivity figure of merit that is based on the permselectivity between the two solutes undergoing separation as well as the ratio of their molecular weights.
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Affiliation(s)
- Patrizia Marchetti
- Department of Chemical Engineering, Imperial College London, SW7 2AZ London, United Kingdom; , ,
| | - Ludmila Peeva
- Department of Chemical Engineering, Imperial College London, SW7 2AZ London, United Kingdom; , ,
| | - Andrew Livingston
- Department of Chemical Engineering, Imperial College London, SW7 2AZ London, United Kingdom; , ,
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Schaepertoens M, Didaskalou C, Kim JF, Livingston AG, Szekely G. Solvent recycle with imperfect membranes: A semi-continuous workaround for diafiltration. J Memb Sci 2016. [DOI: 10.1016/j.memsci.2016.04.056] [Citation(s) in RCA: 22] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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