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Schenck L, Risteen B, Johnson LM, Koynov A, Bonaga L, Orr R, Hancock B. A Commentary on Co-Processed API as a Promising Approach to Improve Sustainability for the Pharmaceutical Industry. J Pharm Sci 2024; 113:306-313. [PMID: 38065243 DOI: 10.1016/j.xphs.2023.11.034] [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: 10/06/2023] [Revised: 11/28/2023] [Accepted: 11/29/2023] [Indexed: 01/22/2024]
Abstract
Pharmaceutical products represent a meaningful target for sustainability improvement and emissions reduction. It is proposed here that rethinking the standard, and often linear, approach to the synthesis of Active Pharmaceutical Ingredients (API) and subsequent formulation and drug product processing will deliver transformational sustainability opportunities. The greatest potential arguably involves API that have challenging physico-chemical properties. These can require the addition of excipients that can significantly exceed the weight of the API in the final dosage unit, require multiple manufacturing steps to achieve materials amenable to delivering final dosage units, and need highly protective packaging for final product stability. Co-processed API are defined as materials generated via addition of non-covalently bonded, non-active components during drug substance manufacturing steps, differing from salts, solvates and co-crystals. They are an impactful example of provocative re-thinking of historical regulatory and quality precedents, blurring drug substance and drug product operations, with sustainability opportunities. Successful examples utilizing co-processed API can modify properties with use of less excipient, while simultaneously reducing processing requirements by delivering material amenable to continuous manufacturing. There are also opportunities for co-processed API to reduce the need for highly protective packaging. This commentary will detail the array of sustainability impacts that can be delivered, inclusive of business, regulatory, and quality considerations, with discussion on potential routes to more comprehensively commercialize co-processed API technologies.
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Affiliation(s)
- Luke Schenck
- Oral Formulation Sciences, Merck & Co., Inc., Rahway, New Jersey 07065, United States.
| | - Bailey Risteen
- Pharma Solutions, BASF Corporation, Florham Park, New Jersey 07932, United States
| | | | - Athanas Koynov
- Process Research & Development, Merck & Co., Inc., Rahway, New Jersey 07065, United States
| | - Llorente Bonaga
- CMC Pharmaceutical Development and New Products, Merck & Co., Inc., Rahway, New Jersey 07065, United States
| | - Robert Orr
- CMC Pharmaceutical Development and New Products, Merck & Co., Inc., Rahway, New Jersey 07065, United States
| | - Bruno Hancock
- Drug Product Development, Pfizer Inc., Groton CT 06340, United States
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2
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Manghnani PN, Schenck L, Khan SA, Doyle PS. Templated Reactive Crystallization of Active Pharmaceutical Ingredient in Hydrogel Microparticles Enabling Robust Drug Product Processing. J Pharm Sci 2023; 112:2115-2123. [PMID: 37160228 DOI: 10.1016/j.xphs.2023.05.004] [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: 02/21/2023] [Revised: 05/04/2023] [Accepted: 05/04/2023] [Indexed: 05/11/2023]
Abstract
Commercialization of most promising active pharmaceutical ingredients (APIs) is impeded either by poor bioavailability or challenging physical properties leading to costly manufacture. Bioavailability of ionizable hydrophobic APIs can be enhanced by its conversion to salt form. While salt form of the API presents higher solution concentration than the non-ionized form, poor physical properties resulting from particle anisotropy or non-ideal morphology (needles) and particle size distribution not meeting dissolution rate targets can still inhibit its commercial translation. In this regard, API physical properties can be improved through addition of non-active components (excipients or carriers) during API manufacture. In this work, a facile method to perform reactive crystallization of an API salt in presence of the microporous environment of a hydrogel microparticle is presented. Specifically, the reaction between acidic antiretroviral API, raltegravir and base potassium hydroxide is performed in the presence of polyethylene glycol diacrylamide hydrogel microparticles. In this bottom-up approach, the spherical template hydrogel microparticles for the reaction lead to monodisperse composites loaded with inherently micronized raltegravir-potassium crystals, thus improving API physical properties without hampering bioavailability. Overall, this technique provides a novel approach to reactive crystallization while maintaining the API polymorph and crystallinity.
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Affiliation(s)
- Purnima N Manghnani
- Singapore-MIT Alliance for Research and Technology, 1 CREATE Way, #04-13/14 Enterprise Wing 138602, Singapore
| | - Luke Schenck
- Process Research and Development, Merck & Co., Inc., 126 E. Lincoln Ave Rahway NJ 07065, USA
| | - Saif A Khan
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore 117585, Singapore; Singapore-MIT Alliance for Research and Technology, 1 CREATE Way, #04-13/14 Enterprise Wing 138602, Singapore.
| | - Patrick S Doyle
- Singapore-MIT Alliance for Research and Technology, 1 CREATE Way, #04-13/14 Enterprise Wing 138602, Singapore; Department of Chemical Engineering, Massachusetts Institute of Technology, 77 Massachusetts Avenue Room E17-504F, Cambridge, MA, 02139 USA; Harvard Medical School Initiative for RNA Medicine, Boston, MA, 02115 USA.
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3
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Needles to Spheres: Evaluation of inkjet printing as a particle shape enhancement tool. Eur J Pharm Biopharm 2023; 184:92-102. [PMID: 36707008 DOI: 10.1016/j.ejpb.2023.01.016] [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: 12/07/2022] [Revised: 01/20/2023] [Accepted: 01/21/2023] [Indexed: 01/26/2023]
Abstract
Active pharmaceutical ingredients (APIs) often reveal shapes challenging to process, e.g. acicular structures, and exhibit reduced bioavailability induced by slow dissolution rate. Leveraging the API particles' surface and bulk properties offers an attractive pathway to circumvent these challenges. Inkjet printing is an attractive processing technique able to tackle these limitations already in initial stages when little material is available, while particle properties are maintained over the entire production scale. Additionally, it is applicable to a wide range of formulations and offers the possibility of co-processing with a variety of excipients to improve the API's bioavailability. This study addresses the optimization of particle shapes for processability enhancement and demonstrates the successful application of inkjet printing to engineer spherical lacosamide particles, which are usually highly acicular. By optimizing the ink formulation, adapting the substrate-liquid interface and tailoring the heat transfer to the particle, spherical particles in the vicinity of 100 µm, with improved flow properties compared to the bulk material, were produced. Furthermore, the particle size was tailored reproducibly by adjusting the deposited ink volume per cycle and the number of printing cycles. Therefore, the present study shows a novel, reliable, scalable and economical strategy to overcome challenging particle morphologies by co-processing an API with suitable excipients.
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Myślińska M, Stocker MW, Ferguson S, Healy AM. A Comparison of Spray-Drying and Co-Precipitation for the Generation of Amorphous Solid Dispersions (ASDs) of Hydrochlorothiazide and Simvastatin. J Pharm Sci 2023:S0022-3549(23)00064-3. [PMID: 36805392 DOI: 10.1016/j.xphs.2023.02.012] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/15/2022] [Revised: 02/13/2023] [Accepted: 02/13/2023] [Indexed: 02/19/2023]
Abstract
Co-processing of APIs, the practice of creating multi-component APIs directly in chemical processing facilities used to make drug substance, is gaining increased attention with a view to streamlining manufacturing, improving supply chain robustness and accessing enhanced product attributes in terms of stability and bioavailability. Direct co-precipitation of amorphous solid dispersions (ASDs) at the final step of chemical processing is one such example of co-processing. The purpose of this work was to investigate the application of different advanced solvent-based processing techniques - direct co-precipitation (CP) and the benchmark well-established spray-drying (SD) process - to the production of ASDs comprised of a drug with a high Tg (hydrochlorothiazide, HCTZ) or a low Tg (simvastatin, SIM) molecularly dispersed in a PVP/VA 64 or Soluplus® matrix. ASDs of the same composition were manufactured by the two different methods and were characterised using powder X-ray diffraction (PXRD), modulated differential scanning calorimetry (mDSC), attenuated total reflectance Fourier transform infrared spectroscopy (ATR-FTIR) and scanning electron microscopy (SEM). Both methods produced ASDs that were PXRD amorphous, with some differences, depending on the process used, in glass transition temperature and particle size distribution. Irrespective of manufacturing method used, all ASDs remained PXRD amorphous when subjected to high relative humidity conditions (75% RH, 25°C) for four weeks, although changes in the colour and physical characteristics were observed on storage for spray-dried systems with SIM and PVP/VA 64 copolymer. The particle morphology differed for co-precipitated compared to spray dried systems, with powder generated by the former process being comprised of more irregularly shaped particles of larger particle size when compared to the equivalent spray-dried systems which may enable more streamlined drug product processes to be used for CP materials. These differences may have implications in downstream drug product processing. A limitation identified when applying the solvent/anti-solvent co-precipitation method to SIM was the high antisolvent to solvent ratios required to effect the precipitation process. Thus, while similar outcomes may arise for both co-precipitation and spray drying processes in terms of ASD critical quality attributes, practical implications of applying the co-precipitation method and downstream processability of the resulting ASDs should be considered when choosing one solvent-based ASD production process over another.
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Affiliation(s)
- Monika Myślińska
- School of Pharmacy and Pharmaceutical Sciences, Panoz Institute, Trinity College Dublin, Dublin 2, Ireland; SSPC, The Science Foundation Ireland Research Centre for Pharmaceuticals, Ireland; EPSRC-SFI Centre for Doctoral Training in Transformative Pharmaceutical Technologies, Ireland
| | - Michael W Stocker
- School of Chemical and Bioprocess Engineering, University College Dublin, Dublin 4, Ireland; SSPC, The Science Foundation Ireland Research Centre for Pharmaceuticals, Ireland
| | - Steven Ferguson
- School of Chemical and Bioprocess Engineering, University College Dublin, Dublin 4, Ireland; SSPC, The Science Foundation Ireland Research Centre for Pharmaceuticals, Ireland; EPSRC-SFI Centre for Doctoral Training in Transformative Pharmaceutical Technologies, Ireland; I-Form, The SFI Research Centre for Advanced Manufacturing, School of Chemical and Bioprocess Engineering, University College Dublin, Dublin 4, Ireland; National Institute for Bioprocess Research and Training, Dublin, Ireland
| | - Anne Marie Healy
- School of Pharmacy and Pharmaceutical Sciences, Panoz Institute, Trinity College Dublin, Dublin 2, Ireland; SSPC, The Science Foundation Ireland Research Centre for Pharmaceuticals, Ireland; EPSRC-SFI Centre for Doctoral Training in Transformative Pharmaceutical Technologies, Ireland.
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5
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Ahmed B, Arjmandi-Tash O, Litster JD, Smith RM. Mechanistic modelling of spherical agglomeration processes. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118254] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/18/2023]
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Frank DS, Punia A, Fahy M, Dalton C, Rowe J, Schenck L. Densifying Co-Precipitated Amorphous Dispersions to Achieve Improved Bulk Powder Properties. Pharm Res 2022; 39:3197-3208. [PMID: 36271203 DOI: 10.1007/s11095-022-03416-6] [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: 07/25/2022] [Accepted: 10/11/2022] [Indexed: 12/27/2022]
Abstract
PURPOSE Precipitation of amorphous solid dispersions has gained traction in the pharmaceutical industry given its application to pharmaceuticals with varying physicochemical properties. Although preparing co-precipitated amorphous dispersions (cPAD) in high-shear rotor-stator devices allows for controlled shear conditions during precipitation, such aggressive mixing environments can result in materials with low bulk density and poor flowability. This work investigated annealing cPAD after precipitation by washing with heated anti-solvent to improve bulk powder properties required for downstream drug product processing. METHODS Co-precipitation dispersions were prepared by precipitation into pH-modified aqueous anti-solvent. Amorphous dispersions were washed with heated anti-solvent and assessed for bulk density, flowability, and dissolution behavior relative to both cPAD produced without a heated wash and spray dried intermediate. RESULTS Washing cPAD with a heated anti-solvent resulted in an improvement in flowability and increased bulk density. The mechanism of densification was ascribed to annealing over the wetted Tg of the material, which lead to collapse of the porous co-precipitate structure into densified granules without causing crystallization. In contrast, an alternative approach to increase bulk density by precipitating the ASD using low shear conditions showed evidence of crystallinity. The dissolution rate of the densified cPAD granules was lower than that of the low-bulk density dispersions, although both samples reached concentrations equivalent to that of the spray dried intermediate after 90 min dissolution. CONCLUSIONS Hot wash densification was a tenable route to produce co-precipitated amorphous dispersions with improved properties for downstream processing compared to non-densified powders.
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Affiliation(s)
- Derek S Frank
- Process Research & Development, Merck & Co., Inc., Rahway, NJ, USA.
| | - Ashish Punia
- Analytical Research & Development, Merck & Co., Inc., Rahway, NJ, USA
| | - Mairead Fahy
- Pharmaceutical Commercialization Technology, Merck & Co., Inc., Rahway, NJ, USA
| | - Chad Dalton
- Formulation Sciences, Merck & Co., Inc., Rahway, NJ, USA
| | - Jasmine Rowe
- Formulation Sciences, Merck & Co., Inc., Rahway, NJ, USA
| | - Luke Schenck
- Process Research & Development, Merck & Co., Inc., Rahway, NJ, USA
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High Bulk-Density Amorphous Dispersions to Enable Direct Compression of Reduced Tablet Size Amorphous Dosage Units. J Pharm Sci 2022:S0022-3549(22)00409-9. [PMID: 36115592 DOI: 10.1016/j.xphs.2022.09.007] [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: 07/11/2022] [Revised: 09/08/2022] [Accepted: 09/09/2022] [Indexed: 11/24/2022]
Abstract
Amorphous solid dispersions (ASDs) are an attractive option to improve the bioavailability of poorly water-soluble compounds. However, the material attributes of ASDs can present formulation and processability challenges, which are often mitigated by the addition of excipients albeit at the expense of tablet size. In this work, an ASD manufacturing train combining co-precipitation and thin film evaporation (TFE) was used to generate high bulk-density co-precipitated amorphous dispersion (cPAD). The cPAD/TFE material was directly compressed into tablets at amorphous solid dispersion loadings up to 89 wt%, representing a greater than 60% reduction in tablet size relative to formulated tablets containing spray dried intermediate (SDI). This high ASD loading was possible due to densification of the amorphous dispersion during drying by TFE. Pharmacokinetic performance of the TFE-isolated, co-precipitated dispersion was shown to be equivalent to an SDI formulation. These data highlight the downstream advantages of this novel ASD manufacturing pathway to facilitate reduced tablet size via high ASD loading in directly compressed tablets.
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8
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Zhu A, Mao C, Luner PE, Lomeo J, So C, Marchal S, Zhang S. Investigation of Quantitative X-ray Microscopy for Assessment of API and Excipient Microstructure Evolution in Solid Dosage Processing. AAPS PharmSciTech 2022; 23:117. [PMID: 35441297 DOI: 10.1208/s12249-022-02271-3] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/26/2021] [Accepted: 04/03/2022] [Indexed: 11/30/2022] Open
Abstract
Assessment and understanding of changes in particle size of active pharmaceutical ingredients (API) and excipients as a function of solid dosage form processing is an important but under-investigated area that can impact drug product quality. In this study, X-ray microscopy (XRM) was investigated as a method for determining the in situ particle size distribution of API agglomerates and an excipient at different processing stages in tablet manufacturing. An artificial intelligence (AI)-facilitated XRM image analysis tool was applied for quantitative analysis of thousands of individual particles, both of the API and the major filler component of the formulation, microcrystalline cellulose (MCC). Domain size distributions for API and MCC were generated along with the calculation of the porosity of each respective component. The API domain size distributions correlated with laser diffraction measurements and sieve analysis of the API, formulation blend, and granulation. The XRM analysis demonstrated that attrition of the API agglomerates occurred secondary to the granulation stage. These results were corroborated by particle size distribution and sieve potency data which showed generation of an API fines fraction. Additionally, changes in the XRM-calculated size distribution of MCC particles in subsequent processing steps were rationalized based on the known plastic deformation mechanism of MCC. The XRM data indicated that size distribution of the primary MCC particles, which make up the larger functional MCC agglomerates, is conserved across the stages of processing. The results indicate that XRM can be successfully applied as a direct, non-invasive method to track API and excipient particle properties and microstructure for in-process control samples and in the final solid dosage form. The XRM and AI image analysis methodology provides a data-rich way to interrogate the impact of processing stresses on API and excipients for enhanced process understanding and utilization for Quality by Design (QbD).
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9
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Ng DZL, Nelson AZ, Ward G, Lai D, Doyle PS, Khan SA. Control of Drug-Excipient Particle Attributes with Droplet Microfluidic-based Extractive Solidification Enables Improved Powder Rheology. Pharm Res 2022; 39:411-421. [PMID: 35119593 DOI: 10.1007/s11095-021-03155-0] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/19/2021] [Accepted: 12/10/2021] [Indexed: 11/30/2022]
Abstract
PURPOSE Industrial implementation of continuous oral solid dosage form manufacturing has been impeded by the poor powder flow properties of many active pharmaceutical ingredients (APIs). Microfluidic droplet-based particle synthesis is an emerging particle engineering technique that enables the production of neat or composite microparticles with precise control over key attributes that affect powder flowability, such as particle size distribution, particle morphology, composition, and the API's polymorphic form. However, the powder properties of these microparticles have not been well-studied due to the limited mass throughputs of available platforms. In this work, we produce spherical API and API-composite microparticles at high mass throughputs, enabling characterization and comparison of the bulk powder flow properties of these materials and greater understanding of how particle-scale attributes correlate with powder rheology. METHODS A multi-channel emulsification device and an extractive droplet-based method are harnessed to synthesize spherical API and API-excipient particles of artemether. As-received API and API crystallized in the absence of droplet confinement are used as control cases. Particle attributes are characterized for each material and correlated with a comprehensive series of powder rheology tests. RESULTS The droplet-based processed artemether particles are observed to be more flowable, less cohesive, and less compressible than conventionally synthesized artemether powder. Co-processing the API with polycaprolactone to produce composite microparticles reduces the friction of the powder on stainless steel, a common equipment material. CONCLUSIONS Droplet-based extractive solidification is an attractive particle engineering technique for improving powder processing and may aid in the implementation of continuous solid dosage form manufacturing.
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Affiliation(s)
- Denise Z L Ng
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore, 117576, Singapore.,Critical Analytics for Manufacturing Personalized-Medicine, Singapore-MIT Alliance for Research and Technology, Singapore, 138602, Singapore.,Campus for Research Excellence and Technological Enterprise, Singapore, 138602, Singapore
| | - Arif Z Nelson
- Critical Analytics for Manufacturing Personalized-Medicine, Singapore-MIT Alliance for Research and Technology, Singapore, 138602, Singapore.,Campus for Research Excellence and Technological Enterprise, Singapore, 138602, Singapore
| | - Gareth Ward
- GSK Medicines Research Centre, Gunnels Wood Road, Stevenage, Hertfordshire, SG12NY, UK
| | - David Lai
- GlaxoSmithKline LLC, Product and Process Engineering, 709 Swedeland Road, King of Prussia, Pennsylvania, 19406, USA.,GlaxoSmithKline LLC, Advanced Manufacturing Technologies, 830 Winter Street, Waltham, Massachusetts, 02451, USA
| | - Patrick S Doyle
- Critical Analytics for Manufacturing Personalized-Medicine, Singapore-MIT Alliance for Research and Technology, Singapore, 138602, Singapore. .,Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts, 02139, USA.
| | - Saif A Khan
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore, 117576, Singapore. .,Campus for Research Excellence and Technological Enterprise, Singapore, 138602, Singapore.
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10
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Allada R, See HH. Myths and Facts Regarding Particle Size Analysis of Pharmaceutical Powders. RECENT ADVANCES IN DRUG DELIVERY AND FORMULATION 2022; 16:82-83. [PMID: 35794746 DOI: 10.2174/2667387816666220704124635] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/28/2022] [Revised: 05/10/2022] [Accepted: 05/23/2022] [Indexed: 06/15/2023]
Affiliation(s)
- Ravikiran Allada
- Centre for Sustainable Nanomaterials, Ibnu Sina Institute for Scientific and Industrial Research, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia
- Department of Analytical Science and Technology Transfer, Novugen Pharma Malaysia) Sdn. Bhd., No 3, Jalan Jururancang U1/21, Hicom Glenmarie, 40150 Shah Alam, Selangor, Malaysia
| | - Hong Heng See
- Centre for Sustainable Nanomaterials, Ibnu Sina Institute for Scientific and Industrial Research, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia
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11
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Parkes A, Ziaee A, Walker G, O'Reilly E. Controlled isolation and stabilisation of pure metastable carbamazepine form IV by droplet-confinement via a continuous manufacturing route. CrystEngComm 2022. [DOI: 10.1039/d2ce01041k] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
This study outlines a systematic approach to control the polymorphism of carbamazepine (CBZ) and isolate the metastable polymorph CBZ form IV as a function of droplet size using spray drying as a continuous method of manufacture.
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Affiliation(s)
- Alice Parkes
- Department of Chemical Sciences, SSPC The SFI Research Centre for Pharmaceuticals, Bernal Institute, University of Limerick, Ireland
| | - Ahmad Ziaee
- Department of Chemical Sciences, SSPC The SFI Research Centre for Pharmaceuticals, Bernal Institute, University of Limerick, Ireland
| | - Gavin Walker
- Department of Chemical Sciences, SSPC The SFI Research Centre for Pharmaceuticals, Bernal Institute, University of Limerick, Ireland
| | - Emmet O'Reilly
- Department of Chemical Sciences, SSPC The SFI Research Centre for Pharmaceuticals, Bernal Institute, University of Limerick, Ireland
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12
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Strotman NA, Schenck L. Coprecipitated Amorphous Dispersions as Drug Substance: Opportunities and Challenges. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00380] [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)
- Neil A. Strotman
- Process Research and Development, Merck & Co., Inc., Rahway, New Jersey 07065, United States
| | - Luke Schenck
- Process Research and Development, Merck & Co., Inc., Rahway, New Jersey 07065, United States
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13
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Schenck L, Neri C, Jia X, Schafer W, Axnanda S, Canfield N, Li F, Shah V. A Co-Processed API Approach for a Shear Sensitive Compound Affording Improved Chemical Stability and Streamlined Drug Product Processing. J Pharm Sci 2021; 110:3238-3245. [PMID: 34089710 DOI: 10.1016/j.xphs.2021.05.013] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2021] [Revised: 05/28/2021] [Accepted: 05/28/2021] [Indexed: 11/15/2022]
Abstract
The physical properties of active pharmaceutical ingredients (API) are critical to both drug substance (DS) isolation and drying operations, as well as streamlined drug product (DP) processing and the quality of final dosage units. High aspect ratio, low bulk density, API 'needles' in particular are a hindrance to efficient processing, with a low probability that conventional crystallization routes can modify the challenging morphology. The compound evaluated in this manuscript demonstrated this non-ideal morphology, with the added complexity of shear sensitivity. Modest shear exposure resulted in conversion of the thermodynamically stable crystalline phase to the amorphous phase, with the amorphous phase then undergoing accelerated chemical degradation. Slow filtration during DS isolation resulted in uncontrolled and elevated amorphous levels, while subsequent DP operations including blending, densification and compression increased amorphous content still further. A chemically stable final dosage unit would ideally involve a high bulk density, free flowing API that did not require densification in order to be commercialized as an oral dosage form with direct encapsulation of a single dosage unit. Despite every effort to modify the crystallization process, the physical properties of the API could not be improved. Here, an innovative isolation strategy using a thin film evaporation (TFE) process in the presence of a water soluble polymer alleviated filtration and drying risks and consistently achieved a high bulk density, free flowing co-processed API amenable to direct encapsulation. Characterization of the engineered materials suggested the lower amorphous levels and reduced shear sensitivity were achieved by coating surfaces of the API at relatively low polymer loads. This particle engineering route blurred conventional DS/DP boundaries that not only achieved improved chemical stability but also resulted in a optimized material, with simplified and more robust processing operations for both drug substance and drug product.
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Affiliation(s)
- Luke Schenck
- Process Research & Development, Merck & Co., Inc., Kenilworth, NJ, USA.
| | - Claudia Neri
- Analytical Sciences, Pharmaceutical Sciences, Merck & Co., Inc., Kenilworth, NJ, USA.
| | - Xiujuan Jia
- Analytical Sciences, Pharmaceutical Sciences, Merck & Co., Inc., Kenilworth, NJ, USA
| | - Wes Schafer
- Process Research & Development, Merck & Co., Inc., Kenilworth, NJ, USA
| | - Stephanus Axnanda
- Process Research & Development, Merck & Co., Inc., Kenilworth, NJ, USA
| | - Nicole Canfield
- Preformulation, Pharmaceutical Sciences, Merck & Co., Inc., Kenilworth, NJ, USA
| | - Feng Li
- Oral Formulation Sciences, Pharmaceutical Sciences, Merck & Co., Inc., Kenilworth, NJ, USA
| | - Vivek Shah
- Analytical Sciences, Pharmaceutical Sciences, Merck & Co., Inc., Kenilworth, NJ, USA
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14
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Wang B, Liu F, Xiang J, He Y, Zhang Z, Cheng Z, Liu W, Tan S. A critical review of spray-dried amorphous pharmaceuticals: Synthesis, analysis and application. Int J Pharm 2020; 594:120165. [PMID: 33309835 DOI: 10.1016/j.ijpharm.2020.120165] [Citation(s) in RCA: 18] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/04/2020] [Accepted: 12/06/2020] [Indexed: 12/12/2022]
Abstract
New drugs are frequently found with poor water-solubility in recent pharmaceutical projects, which brings difficulties of bioavailability for the clinical development of new drugs. When these drug compounds in a crystalline state are absorbed by gastrointestinal tract, their dissolution rates and absorption rates are very limited. Nowadays, various methods have been developed to improve the solubility, dissolution and bioavailability of drugs. According to the characteristics of drugs, this work suggests the use of spray drying technology to amorphize APIs (active pharmaceutical ingredients) to improve their bioavailability. This work reviews the properties of the spray-dried amorphous drugs, the progress made in drug synthesis and application, and the existing problems.
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Affiliation(s)
- Bo Wang
- Xiangya School of Pharmaceutical Sciences, Central South University, Changsha, Hunan 410013, China
| | - Fenglin Liu
- Xiangya School of Pharmaceutical Sciences, Central South University, Changsha, Hunan 410013, China
| | - Jia Xiang
- Xiangya School of Pharmaceutical Sciences, Central South University, Changsha, Hunan 410013, China
| | - Yongju He
- School of Materials Science and Engineering, Central South University, Changsha, Hunan 410013, China
| | - Zhibin Zhang
- Research and Development Department, Jiangsu Dawning Pharmaceutical Co., Ltd., Changzhou, Jiangsu 213162, China
| | - Zeneng Cheng
- Xiangya School of Pharmaceutical Sciences, Central South University, Changsha, Hunan 410013, China
| | - Wenjie Liu
- Xiangya School of Pharmaceutical Sciences, Central South University, Changsha, Hunan 410013, China
| | - Songwen Tan
- Xiangya School of Pharmaceutical Sciences, Central South University, Changsha, Hunan 410013, China.
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15
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Schenck L, Erdemir D, Saunders Gorka L, Merritt JM, Marziano I, Ho R, Lee M, Bullard J, Boukerche M, Ferguson S, Florence AJ, Khan SA, Sun CC. Recent Advances in Co-processed APIs and Proposals for Enabling Commercialization of These Transformative Technologies. Mol Pharm 2020; 17:2232-2244. [DOI: 10.1021/acs.molpharmaceut.0c00198] [Citation(s) in RCA: 23] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Luke Schenck
- Process Research and Development, Merck & Co. Inc., 126 East Lincoln Avenue, Rahway, New Jersey 07065, United States
| | - Deniz Erdemir
- Drug Product Development, Bristol-Myers Squibb, 1 Squibb Drive, New Brunswick New Jersey 08903, United States
| | | | - Jeremy M. Merritt
- Small Molecule Design and Development, Lilly Research Laboratories, Eli Lilly and Company, Indianapolis, Indiana 46221, United States
| | - Ivan Marziano
- Pfizer R&D UK Limited, Discovery Park, Ramsgate Road, Sandwich CT13 9NJ, United Kingdom
| | - Raimundo Ho
- Solid State Chemistry, AbbVie Inc., 1 North Waukegan Road, Chicago, Illinois 60064, United States
| | - Mei Lee
- Chemical Development, Product Development and Supply, GlaxoSmithKline, Gunnelswood Road, Stevenage SG1 2NY, United Kingdom
| | - Joseph Bullard
- Vertex Pharmaceuticals Incorporated, 50 Northern Avenue, Boston, Massachusetts 02210, United States
| | - Moussa Boukerche
- Center of Excellence for Isolation and Separation Technologies, AbbVie Inc., 1 North Waukegan Road, Chicago, Illinois 60064, United States
| | - Steven Ferguson
- SSPC, The SFI Centre for Pharmaceuticals, School of Chemical and Bioprocess Engineering, University College Dublin, Belifield, Dublin 4, Ireland
| | - Alastair J. Florence
- EPSRC Future Continuous Manufacturing and Advanced Crystallization Hub, CMAC, University of Strathclyde Glasgow, Glasgow, United Kingdom
| | - Saif A. Khan
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 4 Engineering Drive 4, Singapore 117576, Singapore
| | - Changquan Calvin Sun
- Pharmaceutical Materials Science and Engineering Laboratory, Department of Pharmaceutics, College of Pharmacy, University of Minnesota, Minneapolis, Minnesota 55455, United States
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