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Fisher AC, Liu W, Schick A, Ramanadham M, Chatterjee S, Brykman R, Lee SL, Kozlowski S, Boam AB, Tsinontides S, Kopcha M. An Audit of Pharmaceutical Continuous Manufacturing Regulatory Submissions and Outcomes in the US. Int J Pharm 2022; 622:121778. [DOI: 10.1016/j.ijpharm.2022.121778] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/14/2022] [Revised: 04/20/2022] [Accepted: 04/24/2022] [Indexed: 10/18/2022]
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2
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Zhang F, Du K, Guo L, Xu Q, Shan B. Comparative Study of Preprocessing on an ATR‐FTIR Calibration Model for In Situ Monitoring of Solution Concentration in Cooling Crystallization. Chem Eng Technol 2021. [DOI: 10.1002/ceat.202100104] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Fangkun Zhang
- Qingdao University of Science & Technology College of Automation and Electronic Engineering 266061 Qingdao China
| | - Kang Du
- Qingdao University of Science & Technology College of Automation and Electronic Engineering 266061 Qingdao China
| | - Luyu Guo
- Qingdao University of Science & Technology College of Automation and Electronic Engineering 266061 Qingdao China
| | - Qilei Xu
- Qingdao University of Science & Technology College of Automation and Electronic Engineering 266061 Qingdao China
| | - Baoming Shan
- Qingdao University of Science & Technology College of Automation and Electronic Engineering 266061 Qingdao China
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3
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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, Shvedova K, Hu C, Wu W, Born SC, Takizawa B, Mascia S. Heterogeneous Crystallization as a Process Intensification Technology in an Integrated Continuous Manufacturing Process for Pharmaceuticals. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00468] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Affiliation(s)
- Christopher J. Testa
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Khrystyna Shvedova
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Chuntian Hu
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Wei Wu
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Stephen C. Born
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Bayan Takizawa
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Salvatore Mascia
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
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5
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McDonald MA, Salami H, Harris PR, Lagerman CE, Yang X, Bommarius AS, Grover MA, Rousseau RW. Reactive crystallization: a review. REACT CHEM ENG 2021. [DOI: 10.1039/d0re00272k] [Citation(s) in RCA: 19] [Impact Index Per Article: 6.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Abstract
Reactive crystallization is not new, but there has been recent growth in its use as a means of improving performance and sustainability of industrial processes.
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Affiliation(s)
- Matthew A. McDonald
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- USA
| | - Hossein Salami
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- USA
| | - Patrick R. Harris
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- USA
| | - Colton E. Lagerman
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- USA
| | - Xiaochuan Yang
- Office of Pharmaceutical Quality
- Center for Drug Evaluation and Research
- U.S. Food and Drug Administration
- Silver Spring
- USA
| | - Andreas S. Bommarius
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- USA
| | - Martha A. Grover
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- USA
| | - Ronald W. Rousseau
- School of Chemical and Biomolecular Engineering
- Georgia Institute of Technology
- Atlanta
- 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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Wichrowski NJ, Fisher AC, Arden NS, Yang X. An Overview of Drug Substance Manufacturing Processes. AAPS PharmSciTech 2020; 21:271. [PMID: 33033946 DOI: 10.1208/s12249-020-01806-w] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/08/2020] [Accepted: 08/27/2020] [Indexed: 11/30/2022] Open
Abstract
To develop a comprehensive understanding of pharmaceutical drug substance manufacturing (DSM) processes, we conducted a data mining study to examine 50 new drug applications (NDAs) approved in 2010-2016. We analyzed the prevalence of several frequently deployed in-process control (IPC) techniques and postreaction workup procedures, as well as the operational conditions specified for reactions and workups. Our findings show that crystallization and high-performance liquid chromatography (HPLC) were the most commonly used workup steps and in-process controls, respectively, in drug substance manufacturing. On average, each NDA implemented 12.6 in-process controls and 11.3 workups. Operation time for reactions and workup procedures varied from a few minutes to multiple days, though 61% of these were between 1 and 10 h.
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Shores BT, Sieg PE, Nicosia AT, Hu C, Born SC, Shvedova K, Sayin R, Testa CJ, Wu W, Takizawa B, Ramanujam S, Mascia S. Design of a Continuous Solvent Recovery System for End-to-End Integrated Continuous Manufacturing of Pharmaceuticals. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00092] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
Affiliation(s)
- Brianna T. Shores
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Peter E. Sieg
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Ana T. Nicosia
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Chuntian Hu
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Stephen C. Born
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Khrystyna Shvedova
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Ridade Sayin
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Christopher J. Testa
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Wei Wu
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Bayan Takizawa
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
| | - Sukumar Ramanujam
- USV Private Limited, Arvind Vithal Gandhi Chowk, BSD Marg, Station Road, Govandi
East, Mumbai 400 080, India
| | - Salvatore Mascia
- CONTINUUS Pharmaceuticals, 25R Olympia Avenue, Woburn, Massachusetts 01801, United States
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Hu C, Testa CJ, Wu W, Shvedova K, Shen DE, Sayin R, Halkude BS, Casati F, Hermant P, Ramnath A, Born SC, Takizawa B, O'Connor TF, Yang X, Ramanujam S, Mascia S. An automated modular assembly line for drugs in a miniaturized plant. Chem Commun (Camb) 2020; 56:1026-1029. [PMID: 31854390 DOI: 10.1039/c9cc06945c] [Citation(s) in RCA: 20] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Abstract
We report here a fully automated, end-to-end, integrated continuous manufacturing process for a small-molecule generic medication with built-in quality assurance. The entire process fits into a box of 30.7 m2 modular footprint and a total residence time of less than 30 h, with a throughput up to 40.3 × 106 tablets per year.
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Affiliation(s)
- Chuntian Hu
- CONTINUUS Pharmaceuticals, 25R Olympia Ave, Woburn, MA 01801, USA.
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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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Hu C, Testa CJ, Shores BT, Wu W, Shvedova K, Born SC, Chattopadhyay S, Takizawa B, Mascia S. An experimental study on polymorph control and continuous heterogeneous crystallization of carbamazepine. CrystEngComm 2019. [DOI: 10.1039/c9ce00908f] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
Influences of superstaturation, stirring, anti-solvent, and polymer type on polymorph are investigated.
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Affiliation(s)
| | | | | | - Wei Wu
- CONTINUUS Pharmaceuticals
- Woburn
- USA
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