1
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Janssen PHM, Fathollahi S, Dickhoff BHJ, Frijlink HW. Critical review on the role of excipient properties in pharmaceutical powder-to-tablet continuous manufacturing. Expert Opin Drug Deliv 2024:1-11. [PMID: 39129595 DOI: 10.1080/17425247.2024.2384698] [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: 05/15/2024] [Accepted: 07/22/2024] [Indexed: 08/13/2024]
Abstract
INTRODUCTION The pharmaceutical industry is gradually changing batch-wise manufacturing processes to continuous manufacturing processes, due to the advantages it has to offer. The final product quality and process efficiency of continuous manufacturing processes is among others impacted by the properties of the raw materials. Existing knowledge on the role of raw material properties in batch processing is however not directly transferable to continuous processes, due to the inherent differences between batch and continuous processes. AREAS COVERED A review is performed to evaluate the role of excipient properties for different unit operations used in continuous manufacturing processes. Unit operations that will be discussed include feeding, blending, granulation, final blending, and compression. EXPERT OPINION Although the potency of continuous manufacturing is widely recognized, full utilization still requires a number of challenges to be addressed effectively. An expert opinion will be provided that discusses those challenges and potential solutions to overcome those challenges. The provided overview can serve as a framework for the pharmaceutical industry to push ahead process optimization and formulation development for continuous manufacturing processes.
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Affiliation(s)
- Pauline H M Janssen
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, Groningen, The Netherlands
- Innovation & Technical Solutions, DFE Pharma, Goch, Germany
| | | | | | - Henderik W Frijlink
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, Groningen, The Netherlands
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2
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Stoffán G, Lőrincz Z, Pusztai É, Madarász L, Tacsi K, Marosi G, Pataki H. Development of Continuous Additive-Controlled MSMPR Crystallization by DoE-Based Batch Experiments. Ind Eng Chem Res 2024; 63:13709-13722. [PMID: 39130744 PMCID: PMC11311132 DOI: 10.1021/acs.iecr.4c01933] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2024] [Revised: 07/01/2024] [Accepted: 07/12/2024] [Indexed: 08/13/2024]
Abstract
Additive-controlled crystallization is a promising method to improve crystal morphology and produce solid drug particles with the desired technological and pharmacological properties. However, its adaptation to continuous operation is a hardly researched area. Accordingly, in this work, we aimed to come up with a methodology that provides the systematic and fast development of a continuous three-stage MSMPR cascade crystallizer. For that, a cooling crystallization of famotidine (FMT) from water, in the presence of a formulation additive, poly(vinylpyrrolidone) (PVP-K12), was developed. Process parameters with a significant impact on product quality and quantity were examined in batch mode through a 24-1 fractional factorial design for the implementation of additive-controlled continuous crystallization. These batch experiments represented one residence time of the continuous system. Based on the statistical analysis, the residence time (RT) had the highest effect on yield, while the polymer amount was critical from the product polymorphism, crystal size, and flowability points of view. The values of critical process parameters in continuous operation were fixed according to the batch results. Two continuous cooling crystallization experiments were carried out, one with 1.25 w/wFMT% PVP-K12 and one with no additive. A mixture of FMT polymorphs (Form A and Form B) crystallized without the additive through five residence times (>6.5 h) with 70.8% overall yield. On the other hand, the additive-controlled continuous experiment resulted pure and homogeneous Form A product with excellent flowability. The system could be operated for >6.5 h without clogging with a 71.1% overall yield and a 4-fold improvement in productivity compared to its batch equivalent.
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Affiliation(s)
- György
Nimród Stoffán
- Department
of Organic Chemistry and Technology, Faculty of Chemical Technology
and Biotechnology, Budapest University of
Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
| | - Zsolt Lőrincz
- Department
of Organic Chemistry and Technology, Faculty of Chemical Technology
and Biotechnology, Budapest University of
Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
| | - Éva Pusztai
- Department
of Chemical and Environmental Process Engineering, Faculty of Chemical
Technology and Biotechnology, Budapest University
of Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
| | - Lajos Madarász
- Department
of Organic Chemistry and Technology, Faculty of Chemical Technology
and Biotechnology, Budapest University of
Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
| | - Kornélia Tacsi
- Department
of Organic Chemistry and Technology, Faculty of Chemical Technology
and Biotechnology, Budapest University of
Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
| | - György Marosi
- Department
of Organic Chemistry and Technology, Faculty of Chemical Technology
and Biotechnology, Budapest University of
Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
| | - Hajnalka Pataki
- Department
of Organic Chemistry and Technology, Faculty of Chemical Technology
and Biotechnology, Budapest University of
Technology and Economics, Műegyetem rkp. 3, Budapest 1111, Hungary
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3
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Hou P, Besenhard MO, Halbert G, Naftaly M, Markl D. A continuous micro-feeder for cohesive pharmaceutical materials. Int J Pharm 2024; 662:124528. [PMID: 39069146 DOI: 10.1016/j.ijpharm.2024.124528] [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: 05/19/2024] [Revised: 07/24/2024] [Accepted: 07/25/2024] [Indexed: 07/30/2024]
Abstract
Over the past decade, continuous manufacturing has garnered significant attention in the pharmaceutical industry. Still, numerous continuous unit operations need developments, such as powder blending and feeding at low and high throughputs. Especially the continuous and consistent feeding of solid drug substances and excipients at low feed rates remains challenging. This study demonstrates a micro-feeder capable of feeding poorly-flowing pharmaceutical powders at low feed rates. The system performance was investigated using three grades of pharmaceutical powder: croscarmellose sodium (cohesive), magnesium stearate (very cohesive), and an active ingredient, paracetamol (non-flowing). The results show that the micro-feeder can continuously and consistently feed powders at low flow rates (<20 g/h) with low variability (<10 % for non-flowing materials and < 5 % for cohesive materials). Notably, the micro-feeder achieves these results without any feedback control and remains unaffected by refilling, making it a truly versatile and industry-relevant solution. The study's results demonstrate that this micro-feeder system effectively tackles the challenge of consistent and accurate powder feeding at low rates.
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Affiliation(s)
- P Hou
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M O Besenhard
- Department of Chemical Engineering, University College London, London WC1E 7JE, UK
| | - G Halbert
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M Naftaly
- National Physical Laboratory, Teddington TW11 0LW, UK
| | - D Markl
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK.
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4
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Mehta B, Gramadnikova E, Brown CJ, Mitchell NA, Ottoboni S. Integrated Filtration and Washing Modeling: Optimization of Impurity Rejection for Filtration and Washing of Active Pharmaceutical Ingredients. Org Process Res Dev 2024; 28:1089-1101. [PMID: 38660378 PMCID: PMC11036383 DOI: 10.1021/acs.oprd.3c00480] [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: 12/11/2023] [Revised: 02/07/2024] [Accepted: 02/28/2024] [Indexed: 04/26/2024]
Abstract
A digital design tool that can transfer material property information between unit operations to predict the product attributes in integrated purification processes has been developed to facilitate end-to-end integrated pharmaceutical manufacturing. This work aims to combine filtration and washing operations frequently using active pharmaceutical ingredient (API) isolation. This is achieved by coupling predicted and experimental data produced during the upstream crystallization process. To reduce impurities in the isolated cake, a mechanistic model-based workflow was used to optimize an integrated filtration and washing process model. The Carman-Kozeny filtration model has been combined with a custom washing model that incorporates diffusion and axial dispersion mechanisms. The developed model and approach were applied to two systems, namely, mefenamic acid and paracetamol, which are representative compounds, and various crystallization and wash solvents and related impurities were used. The custom washing model provides a detailed evolution of species concentration during washing, simulating the washing curve with the three stages of the wash curve: constant rate, intermediate stage, and diffusion stage. A model validation approach was used to estimate cake properties (e.g., specific cake resistance, cake volume, cake composition after washing, and washing curve). A global systems analysis was conducted by using the calibrated model to explore the design space and aid in the setup of the optimization decision variables. Qualitative optimization was performed in order to reduce the concentration of impurities in the final cake after washing. The findings of this work were translated into a final model to simulate the optimal isolation conditions.
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Affiliation(s)
- Bhavik
A. Mehta
- EPSRC
Future Continuous Manufacturing and Advanced Crystallisation Research
Hub, c/o Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 99 George Street, Glasgow G1 1RD, U.K.
- Siemens
Industry Software Limited, 6th Floor East, 26-28 Hammersmith Grove, London W6 7HA, U.K.
| | - Ekaterina Gramadnikova
- EPSRC
Future Continuous Manufacturing and Advanced Crystallisation Research
Hub, c/o Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 99 George Street, Glasgow G1 1RD, U.K.
| | - Cameron J. Brown
- EPSRC
Future Continuous Manufacturing and Advanced Crystallisation Research
Hub, c/o Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 99 George Street, Glasgow G1 1RD, U.K.
| | - Niall A. Mitchell
- Siemens
Industry Software Limited, 6th Floor East, 26-28 Hammersmith Grove, London W6 7HA, U.K.
| | - Sara Ottoboni
- EPSRC
Future Continuous Manufacturing and Advanced Crystallisation Research
Hub, c/o Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, 99 George Street, Glasgow G1 1RD, U.K.
- Department
of Chemical and Process Engineering, University
of Strathclyde, 75 Montrose Street, Glasgow G1 1XL, U.K.
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5
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Kuchler L, Spoerk M, Eder S, Doğan A, Khinast J, Sacher S. Liquid API feeding in pharmaceutical HME: Novel options in solid dosage manufacturing. Int J Pharm 2024; 650:123690. [PMID: 38081563 DOI: 10.1016/j.ijpharm.2023.123690] [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: 10/05/2023] [Revised: 12/06/2023] [Accepted: 12/07/2023] [Indexed: 12/24/2023]
Abstract
Hot melt extrusion (HME) is a common unit operation. It is broadly applicable in the pharmaceutical industry and can be implemented in a continuous manufacturing line. However, the conventional way of active pharmaceutical ingredient (API) feeding with a pre-blend consisting of a powdered API and a polymer does not allow the flexibility and agility to adjust the process parameters, which is generally an essential part of continuous manufacturing. In addition, this method of API feeding may result in the segregation of the individual powder components or agglomeration of highly cohesive materials, leading to an inhomogeneous API content in the extrudates, especially at low doses. In this study, the universal applicability of liquid side feeding in pharmaceutical HME was demonstrated using various APIs suspended or dissolved in water and fed as suspension or undersaturated, supersaturated, and highly concentrated solutions into anterior parts of the extruder. The extrudates were characterized in terms of their API content, residual moisture content, and solid-state of the API embedded in the polymer. The results show that a uniform API content without major deviations can be obtained via this method. Furthermore, the residual moisture content of the extrudates was low enough to have no significant influence on further processing of the final dosage form. In summary, this advanced way of feeding allows an accurate, flexible, and agile feeding of APIs, facilitating the production of personalized final dosage forms and a novel option to link the manufacturing of the drug substance and the drug product.
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Affiliation(s)
- Lisa Kuchler
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Martin Spoerk
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
| | - Simone Eder
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Aygün Doğan
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Johannes Khinast
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria; Institute for Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/3, 8010 Graz, Austria
| | - Stephan Sacher
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.
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6
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Anuschek M, Kvistgaard Vilhelmsen T, Axel Zeitler J, Rantanen J. Towards simultaneous determination of tablet porosity and height by terahertz time-domain reflection spectroscopy. Int J Pharm 2023; 646:123424. [PMID: 37722493 DOI: 10.1016/j.ijpharm.2023.123424] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/22/2023] [Revised: 09/10/2023] [Accepted: 09/15/2023] [Indexed: 09/20/2023]
Abstract
The quality control of pharmaceutical tablets is still based on testing small sample numbers using at- and off-line testing methods. Traditional in-process controls, such as tablet mass, height, mechanical strength, and disintegration time are time- and resource-consuming and poorly suited to support an effective transition towards continuous manufacturing. Another suitable parameter to monitor during production would be tablet porosity. Porosity can be linked to mechanical strength and disintegration but typically requires knowledge of tablet dimensions and mass. Tablet porosity measurements based on terahertz time-domain spectroscopy (THz-TDS) offer a fast and non-destructive approach to in-process control testing for physical tablet properties. This study presents THz-TDS reflection measurements as an alternative to the previously reported transmission setup. It is shown that the proposed method can determine porosity based on the reflected amplitude from the tablet surface, but also allows for precise determination of tablet height in the same measurement. The tablet mass can be estimated by combining the height and porosity measurements. This opens up for the opportunity to determine the tablet's mechanical strength by using the possible correlation to the determined porosity.
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Affiliation(s)
- Moritz Anuschek
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark; Novo Nordisk A/S, ET Oral Product Development, Måløv, Denmark.
| | | | - J Axel Zeitler
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Cambridge, UK
| | - Jukka Rantanen
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark
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7
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Hebbink GA, Janssen PHM, Kok JH, Menarini L, Giatti F, Funaro C, Consoli SF, Dickhoff BHJ. Lubricant Sensitivity of Direct Compression Grades of Lactose in Continuous and Batch Tableting Process. Pharmaceutics 2023; 15:2575. [PMID: 38004554 PMCID: PMC10674241 DOI: 10.3390/pharmaceutics15112575] [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: 10/11/2023] [Revised: 10/30/2023] [Accepted: 11/01/2023] [Indexed: 11/26/2023] Open
Abstract
Modern pharmaceutical manufacturing based on Quality by Design and digitalisation is revolutionising the pharmaceutical industry. Continuous processes are promoted as they increase efficiency and improve quality control. Compared to batch blending, continuous blending is easier to scale and provides advantages for achieving blend homogeneity. One potential challenge of continuous blending is the risk of over-lubrication. In this study, blending homogeneity and lubricant sensitivity are investigated for both batch and continuous processes. Given their distinct chemical structures and morphologies, anhydrous lactose and granulated lactose are expected to exhibit varying sensitivities to changes in process settings across both technologies. The findings suggest that both lactose grades provide highly stable blends that can be safely utilised in both batch and continuous modes. Optimisation should focus on process variables, such as the quality of loss-in-weight feeders used for dosing low doses of ingredients. The most significant process parameter for lubricant sensitivity was the type of lactose used. Anhydrous lactose produced harder tablets than the more porous granulated lactose but was more sensitive to lubrication at the same settings. The magnesium stearate content and its interaction with the type of lactose are also critical factors, with magnesium stearate having a counterproductive impact on tabletability.
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Affiliation(s)
| | - Pauline H. M. Janssen
- DFE Pharma GmbH & Co. KG, 47574 Goch, Germany (B.H.J.D.)
- Department of Pharmaceutical Technology and Biopharmacy, University of Groningen, 9713 AV Groningen, The Netherlands
| | - Jurjen H. Kok
- DFE Pharma GmbH & Co. KG, 47574 Goch, Germany (B.H.J.D.)
| | - Lorenzo Menarini
- IMA S.p.A. Active Division, 40064 Ozzano dell’Emilia Bologna, Italy; (L.M.)
| | - Federica Giatti
- IMA S.p.A. Active Division, 40064 Ozzano dell’Emilia Bologna, Italy; (L.M.)
| | - Caterina Funaro
- IMA S.p.A. Active Division, 40064 Ozzano dell’Emilia Bologna, Italy; (L.M.)
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8
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Jones-Salkey O, Nicusan AL, Windows-Yule CRK, Ingram A, Werner D, Clifford S, Reynolds GK. Application of Positron Emission Particle Tracking (PEPT) for the evaluation of powder behaviour in an incline linear blender for Continuous Direct Compression (CDC). Int J Pharm 2023; 645:123361. [PMID: 37673280 DOI: 10.1016/j.ijpharm.2023.123361] [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: 05/01/2023] [Revised: 08/11/2023] [Accepted: 08/31/2023] [Indexed: 09/08/2023]
Abstract
Positron Emission Particle Tracking (PEPT) is a non-invasive measurement technique which offers the ability to track the motion of individual particles with high temporal and spatial resolution, and thus build up an understanding of the bulk behaviour of a system from its microscopic (particle level) dynamics. Using this measurement technique, we have developed a series of novel metrics to better understand the behaviours of powders during the steady-state operation of a continuous blender system. Results are presented concerning the response of particle motion to processing parameters (mixing blade configuration and RPM), quantifying the motion in terms of predicted mixing performance. It was found that both increasing rpm and increasing hold-up mass (by selecting fewer transport blades and more mixing blades) provided improved mixing conditions. Interestingly, under specific conditions, there is evidence of convection-like mixing occurring at the interface of the transport and mixing region. This suggests the existence of a potential 'folding region' whereby powder is transported up the barrel (and away from the powder bulk bed) before being reconstituted back into the bulk mass. The results also provide valuable experimental data for the development, calibration and validation of future Discrete Element Method (DEM) simulations.
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Affiliation(s)
- O Jones-Salkey
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK.
| | - A L Nicusan
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - C R K Windows-Yule
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - A Ingram
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - D Werner
- School of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, UK; School of Physics and Astronomy, University of Birmingham, Edgbaston, Birmingham, UK
| | - S Clifford
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
| | - G K Reynolds
- Oral Product Development, Pharmaceutical Technology & Development, Operations, AstraZeneca, Macclesfield, UK
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9
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Kakhi M, Li J, Dorantes A. Regulatory Experience with Continuous Manufacturing and Real Time Release Testing for Dissolution in New Drug Applications. J Pharm Sci 2023; 112:2604-2614. [PMID: 37572781 DOI: 10.1016/j.xphs.2023.08.004] [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: 06/06/2023] [Revised: 08/07/2023] [Accepted: 08/07/2023] [Indexed: 08/14/2023]
Abstract
Regulatory submissions involving the use of continuous manufacturing (CM)1 and/or real-time release testing for dissolution (RTRT-D) to the United States Food and Drug Administration (FDA) were identified spanning several years. The submissions were for orally administered IR tablets and they were examined from a biopharmaceutics perspective to highlight commonly occurring issues which the FDA's assessment teams identified with the proposed use of CM and/or RTRT-D. The objective of this study is to provide recommendations for best practices that will help advance the field by (i) generating greater opportunities for (drug) Applicants2 to benefit from the implementation of advanced manufacturing approaches, (ii) improving high quality regulatory submissions involving CM and RTRT-D, and thus (iii) lessening the regulatory review burden. This paper has identified several common deficiencies, such as inadequate strategies for stratified sampling of drug product (DP) units, inappropriate design of experiments (DoE), inability of the proposed RTRT-D model to account for dissolution variability and to predict the entire time course of dissolution, insufficient documentation, and unsuitable in vitro dissolution methods.
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Affiliation(s)
- Maziar Kakhi
- Division of Product Quality Research, Office of Testing and Research, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, US Food and Drug Administration, Silver Spring, MD, USA.
| | - Jing Li
- Division of Biopharmaceutics, Office of New Drug Products, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, US Food and Drug Administration, Silver Spring, MD, USA
| | - Angelica Dorantes
- Division of Biopharmaceutics, Office of New Drug Products, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, US Food and Drug Administration, Silver Spring, MD, USA
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10
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Wang H, Chen Y, Wang L, Liu Q, Yang S, Wang C. Advancing herbal medicine: enhancing product quality and safety through robust quality control practices. Front Pharmacol 2023; 14:1265178. [PMID: 37818188 PMCID: PMC10561302 DOI: 10.3389/fphar.2023.1265178] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/22/2023] [Accepted: 09/15/2023] [Indexed: 10/12/2023] Open
Abstract
This manuscript provides an in-depth review of the significance of quality control in herbal medication products, focusing on its role in maintaining efficiency and safety. With a historical foundation in traditional medicine systems, herbal remedies have gained widespread popularity as natural alternatives to conventional treatments. However, the increasing demand for these products necessitates stringent quality control measures to ensure consistency and safety. This comprehensive review explores the importance of quality control methods in monitoring various aspects of herbal product development, manufacturing, and distribution. Emphasizing the need for standardized processes, the manuscript delves into the detection and prevention of contaminants, the authentication of herbal ingredients, and the adherence to regulatory standards. Additionally, it highlights the integration of traditional knowledge and modern scientific approaches in achieving optimal quality control outcomes. By emphasizing the role of quality control in herbal medicine, this manuscript contributes to promoting consumer trust, safeguarding public health, and fostering the responsible use of herbal medication products.
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Affiliation(s)
- Hongting Wang
- Anhui Provincial Engineering Laboratory for Screening and Re-evaluation of Active Compounds of Herbal Medicines in Southern Anhui, Anhui Provincial Engineering Research Center for Polysaccharide Drugs, Anhui Innovative Center for Drug Basic Research of Metabolic Diseases, School of Pharmacy, Wannan Medical College, Wuhu, China
| | | | | | | | | | - Cunqin Wang
- Anhui Provincial Engineering Laboratory for Screening and Re-evaluation of Active Compounds of Herbal Medicines in Southern Anhui, Anhui Provincial Engineering Research Center for Polysaccharide Drugs, Anhui Innovative Center for Drug Basic Research of Metabolic Diseases, School of Pharmacy, Wannan Medical College, Wuhu, China
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11
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Zhao Y, Tang Y, Wasalathanthri D, Xu J, Ding J. An adaptive modeling approach using spiking-augmentation method to improve chemometric model performance in bioprocess monitoring. Biotechnol Prog 2023; 39:e3349. [PMID: 37102507 DOI: 10.1002/btpr.3349] [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: 03/21/2023] [Revised: 04/12/2023] [Accepted: 04/14/2023] [Indexed: 04/28/2023]
Abstract
Intensified and continuous processes require fast and robust methods and technologies to monitor product titer for faster analytical turnaround time, process monitoring, and process control. The current titer measurements are mostly offline chromatography-based methods which may take hours or even days to get the results back from the analytical labs. Thus, offline methods will not meet the requirement of real time titer measurements for continuous production and capture processes. FTIR and chemometric based multivariate modeling are promising tools for real time titer monitoring in clarified bulk (CB) harvests and perfusate lines. However, empirical models are known to be vulnerable to unseen variability, specifically a FTIR chemometric titer model trained on a given biological molecule and process conditions often fails to provide accurate predictions of titer in another molecule under different process conditions. In this study, we developed an adaptive modeling strategy: the model was initially built using a calibration set of available perfusate and CB samples and then updated by augmenting spiking samples of the new molecules to the calibration set to make the model robust against perfusate or CB harvest of the new molecule. This strategy substantially improved the model performance and significantly reduced the modeling effort for new molecules.
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Affiliation(s)
- Yuxiang Zhao
- Global Product Development and Supply, Bristol-Myers Squibb Company, Devens, Massachusetts, USA
| | - Yawen Tang
- Global Product Development and Supply, Bristol-Myers Squibb Company, Devens, Massachusetts, USA
| | - Dhanuka Wasalathanthri
- Global Product Development and Supply, Bristol-Myers Squibb Company, Devens, Massachusetts, USA
| | - Jianlin Xu
- Global Product Development and Supply, Bristol-Myers Squibb Company, Devens, Massachusetts, USA
| | - Julia Ding
- Global Product Development and Supply, Bristol-Myers Squibb Company, Devens, Massachusetts, USA
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12
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Nikam AN, Jacob A, Raychaudhuri R, Fernandes G, Pandey A, Rao V, Ahmad SF, Pannala AS, Mutalik S. Topical Micro-Emulsion of 5-Fluorouracil by a Twin Screw Processor-Based Novel Continuous Manufacturing Process for the Treatment of Skin Cancer: Preparation and In Vitro and In Vivo Evaluations. Pharmaceutics 2023; 15:2175. [PMID: 37765146 PMCID: PMC10534867 DOI: 10.3390/pharmaceutics15092175] [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: 07/28/2023] [Revised: 08/18/2023] [Accepted: 08/19/2023] [Indexed: 09/29/2023] Open
Abstract
5-Fluorouracil (5-FU), a BCS class III drug, has low oral bioavailability and is cytotoxic in nature causing severe systemic side effects when administered through the intravenous route. Topical drug delivery could potentially mitigate the systemic side-effects. Microemulsions (MEs) would be an apt solution due to enhanced partitioning of the drug to the skin. However, conventional methods for preparing MEs are inefficient since they are not continuous and are very tedious and time-consuming processes hence revealing the need for the development of continuous manufacturing technology. In our study, 5-FU MEs were prepared using a continuous manufacturing Twin Screw Process (TSP) and its efficiency in the treatment of skin cancer was evaluated. Water-in-oil MEs were prepared using isopropyl myristate as the oil phase and Aerosol OT and Tween 80 as the surfactants. The average particle size was observed to be 178 nm. Transmission electron microscopy was employed to confirm the size and shape of the MEs. FTIR study proved no physical or chemical interaction between the excipients and the drug. In vitro drug release using vertical diffusion cells and ex vivo skin permeation studies showed that the drug was released sustainably and permeated across the skin, respectively. In in vitro cytotoxicity studies, 5-FU MEs were accessed in HaCat and A431 cell lines to determine percentage cell viability and IC50. Skin irritation and histopathological examination implied that the 5-FU MEs did not cause any significant irritation to the skin. In vivo pharmacodynamics studies in rats suggested that the optimised formulation was effective in treating squamous cell carcinoma (SCC). Therefore, 5-FU MEs efficiently overcame the various drawbacks faced during oral and intravenous drug delivery. Also, TSP proved to be a technique that overcomes the various problems associated with the conventional methods of preparing MEs.
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Affiliation(s)
- Ajinkya Nitin Nikam
- Department of Pharmaceutics, Manipal College of Pharmaceutical Sciences, Manipal Academy of Higher Education, Manipal 576104, Karnataka State, India; (A.N.N.); (A.J.); (R.R.); (G.F.); (A.P.)
| | - Angela Jacob
- Department of Pharmaceutics, Manipal College of Pharmaceutical Sciences, Manipal Academy of Higher Education, Manipal 576104, Karnataka State, India; (A.N.N.); (A.J.); (R.R.); (G.F.); (A.P.)
| | - Ruchira Raychaudhuri
- Department of Pharmaceutics, Manipal College of Pharmaceutical Sciences, Manipal Academy of Higher Education, Manipal 576104, Karnataka State, India; (A.N.N.); (A.J.); (R.R.); (G.F.); (A.P.)
| | - Gasper Fernandes
- Department of Pharmaceutics, Manipal College of Pharmaceutical Sciences, Manipal Academy of Higher Education, Manipal 576104, Karnataka State, India; (A.N.N.); (A.J.); (R.R.); (G.F.); (A.P.)
| | - Abhijeet Pandey
- Department of Pharmaceutics, Manipal College of Pharmaceutical Sciences, Manipal Academy of Higher Education, Manipal 576104, Karnataka State, India; (A.N.N.); (A.J.); (R.R.); (G.F.); (A.P.)
| | - Vinay Rao
- STEERLife India Private Limited, No. 290, 4th Main Road, Ganapathy Nagar, Phase 3, Peenya Industrial Area, Peenya, Bangalore 560058, Karnataka State, India;
| | - Sheikh F. Ahmad
- Department of Pharmacology and Toxicology, College of Pharmacy, King Saud University, Riyadh 11451, Saudi Arabia;
| | - Ananth S. Pannala
- Biomaterials and Drug Delivery Research Group, School of Applied Sciences, University of Brighton, Brighton BN2 4GJ, UK;
| | - Srinivas Mutalik
- Department of Pharmaceutics, Manipal College of Pharmaceutical Sciences, Manipal Academy of Higher Education, Manipal 576104, Karnataka State, India; (A.N.N.); (A.J.); (R.R.); (G.F.); (A.P.)
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13
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Lang T, Bramböck A, Thommes M, Bartsch J. Material Transport Characteristics in Planetary Roller Melt Granulation. Pharmaceutics 2023; 15:2039. [PMID: 37631253 PMCID: PMC10458212 DOI: 10.3390/pharmaceutics15082039] [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: 06/15/2023] [Revised: 07/20/2023] [Accepted: 07/27/2023] [Indexed: 08/27/2023] Open
Abstract
Melt granulation for improving material handling by modifying particle size distribution offers significant advantages compared to the standard methods of dry and wet granulation in dust reduction, obviating a subsequent drying step. Furthermore, current research in pharmaceutical technology aims for continuous methods, as these have an enhanced potential to reduce product quality fluctuations. Concerning both aspects, the use of a planetary roller granulator is consequential. The process control with these machines benefits from the enhanced ratio of heated surface to processed volume, compared to the usually-applied twin-screw systems. This is related to the unique concept of planetary spindles flowing around a central spindle in a roller cylinder. Herein, the movement pattern defines the transport characteristics, which determine the energy input and overall processing conditions. The aim of this study is to investigate the residence time distribution in planetary roller melt granulation (PRMG) as an indicator for the material transport. By altering feed rate and rotation speed, the fill level in the granulator is adjusted, which directly affects the average transport velocity and mixing volume. The two-compartment model was utilized to reflect these coherences, as the model parameters symbolize the sub-processes of axial material transport and mixing.
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Affiliation(s)
- Tom Lang
- Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering, TU Dortmund University, 44227 Dortmund, Germany (M.T.)
| | | | - Markus Thommes
- Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering, TU Dortmund University, 44227 Dortmund, Germany (M.T.)
| | - Jens Bartsch
- Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering, TU Dortmund University, 44227 Dortmund, Germany (M.T.)
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14
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Anuschek M, Skelbæk-Pedersen AL, Kvistgaard Vilhelmsen T, Skibsted E, Zeitler JA, Rantanen J. Terahertz time-domain spectroscopy for the investigation of tablets prepared from roller compacted granules. Int J Pharm 2023; 642:123165. [PMID: 37356510 DOI: 10.1016/j.ijpharm.2023.123165] [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: 04/28/2023] [Revised: 06/19/2023] [Accepted: 06/20/2023] [Indexed: 06/27/2023]
Abstract
Roller compaction before tableting is a common unit operation to increase the processability of powders. Terahertz time-domain spectroscopy (THz-TDS) has recently been introduced as a potential process analytical technology (PAT) for measuring tablet porosity based on the refractive index of the tablet. Tablet porosity is a governing parameter for tablet disintegration and dissolution. The first aim of this study was to investigate tablets prepared from roller-compacted materials with THz-TDS to explore its usefulness for particle size evaluation of granules in tablets. Secondly, the impact of roller compaction and granule size before tablet compression on the established THz-TDS based measurement of tablet porosity was investigated. Microcrystalline cellulose and α-lactose monohydrate were roller compacted separately at five specific compaction forces (2, 4, 8, 12, and 16 kN cm-1) and fractionated into three size fractions. Tablets were prepared from the fractionated and unfractionated granules at twelve tableting pressures and subjected to THz-TDS transmission measurements. It was possible to use the scattering behaviour of the tablets at terahertz frequencies to describe the granulated materials' particle size changes during tableting. At the same time, prediction of porosity was impaired due to the deviation of the refractive index in strongly scattering samples. A correction method was introduced in which the porosity error was corrected based on the tablet's scattering behaviour, resulting in an improved prediction of tablet porosity. In conclusion, THz-TDS is considered a promising technique for the process monitoring of tableting based on its sensitivity to porosity and particle size changes within the tablet non-destructively, with a possible application as part of an in-process control strategy of the tableting of granulated or non-granulated materials.
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Affiliation(s)
- Moritz Anuschek
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark; ET Oral Product Development, Novo Nordisk A/S, Måløv, Denmark.
| | | | | | - Erik Skibsted
- ET Oral Product Development, Novo Nordisk A/S, Måløv, Denmark
| | - J Axel Zeitler
- Department of Chemical Engineering and Biotechnology, University of Cambridge, Cambridge, UK
| | - Jukka Rantanen
- Department of Pharmacy, University of Copenhagen, Copenhagen, Denmark
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15
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Chen Y, Sampat C, Huang YS, Ganesh S, Singh R, Ramachandran R, Reklaitis GV, Ierapetritou M. An integrated data management and informatics framework for continuous drug product manufacturing processes: A case study on two pilot plants. Int J Pharm 2023:123086. [PMID: 37257793 DOI: 10.1016/j.ijpharm.2023.123086] [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: 03/06/2023] [Revised: 05/23/2023] [Accepted: 05/24/2023] [Indexed: 06/02/2023]
Abstract
The pharmaceutical industry continuously looks for ways to improve its development and manufacturing efficiency. In recent years, such efforts have been driven by the transition from batch to continuous manufacturing and digitalization in process development. To facilitate this transition, integrated data management and informatics tools need to be developed and implemented within the framework of Industry 4.0 technology. In this regard, the work aims to guide the data integration development of continuous pharmaceutical manufacturing processes under the Industry 4.0 framework, improving digital maturity and enabling the development of digital twins. This paper demonstrates two instances where a data integration framework has been successfully employed in academic continuous pharmaceutical manufacturing pilot plants. Details of the integration structure and information flows are comprehensively showcased. Approaches to mitigate concerns in incorporating complex data streams, including integrating multiple process analytical technology tools and legacy equipment, connecting cloud data and simulation models, and safeguarding cyber-physical security, are discussed. Critical challenges and opportunities for practical considerations are highlighted.
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Affiliation(s)
- Yingjie Chen
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, U.S
| | - Chaitanya Sampat
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, U.S
| | - Yan-Shu Huang
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, U.S
| | - Sudarshan Ganesh
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, U.S
| | - Ravendra Singh
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, U.S
| | - Rohit Ramachandran
- Department of Chemical and Biochemical Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, U.S
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, U.S
| | - Marianthi Ierapetritou
- Department of Chemical and Biomolecular Engineering, University of Delaware, Newark, DE 19716, U.S.
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16
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Tanzini A, Ruggeri M, Bianchi E, Valentino C, Vigani B, Ferrari F, Rossi S, Giberti H, Sandri G. Robotics and Aseptic Processing in View of Regulatory Requirements. Pharmaceutics 2023; 15:1581. [PMID: 37376030 DOI: 10.3390/pharmaceutics15061581] [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: 04/28/2023] [Revised: 05/19/2023] [Accepted: 05/20/2023] [Indexed: 06/29/2023] Open
Abstract
Several nanomedicine based medicinal products recently reached the market thanks to the drive of the COVID-19 pandemic. These products are characterized by criticality in scalability and reproducibility of the batches, and the manufacturing processes are now being pushed towards continuous production to face these challenges. Although the pharmaceutical industry, because of its deep regulation, is characterized by slow adoption of new technologies, recently, the European Medicines Agency (EMA) took the lead in pushing for process improvements using technologies already established in other manufacturing sectors. Foremost among these technologies, robotics is a technological driver, and its implementation in the pharma field should cause a big change, probably within the next 5 years. This paper aims at describing the regulation changes mainly in aseptic manufacturing and the use of robotics in the pharmaceutical environment to fulfill GMP (good manufacturing practice). Special attention is therefore paid at first to the regulatory aspect, explaining the reasons behind the current changes, and then to the use of robotics that will characterize the future of manufacturing especially in aseptic environments, moving from a clear overview of robotics to the use of automated systems to design more efficient processes, with reduced risk of contamination. This review should clarify the regulation and technological scenario and provide pharmaceutical technologists with basic knowledge in robotics and automation, as well as engineers with regulatory knowledge to define a common background and language, and enable the cultural shift of the pharmaceutical industry.
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Affiliation(s)
- Andrea Tanzini
- Staubli Robotics, Staubli Italia S.p.A, Via Rivera 55, 20841 Carate Brianza, Italy
| | - Marco Ruggeri
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
| | - Eleonora Bianchi
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
| | - Caterina Valentino
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
| | - Barbara Vigani
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
| | - Franca Ferrari
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
| | - Silvia Rossi
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
| | - Hermes Giberti
- Department of Electrical, Computer and Biomedical Engineering, University of Pavia, Via Ferrata, 27100 Pavia, Italy
| | - Giuseppina Sandri
- Department of Drug Sciences, University of Pavia, Viale Taramelli 12, 27100 Pavia, Italy
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17
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Conway SL, Rosas JG, Overton P, Tugby N, Cryan P, Witulski F, Hurley S, Wareham L, Tantuccio A, Ramasamy M, Lalloo A, Gibbs M, Meyer RF. Implementation of a Fully Integrated Continuous Manufacturing Line for Direct Compression and Coating at a Commercial Pharmaceutical Facility - Part 1: Operational Considerations and Control Strategy. Int J Pharm 2023:122820. [PMID: 37028572 DOI: 10.1016/j.ijpharm.2023.122820] [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: 10/29/2022] [Revised: 03/04/2023] [Accepted: 03/08/2023] [Indexed: 04/09/2023]
Abstract
We implement a fully integrated continuous manufacturing (CM) line for direct compression and coating of a pharmaceutical oral solid dosage form in a commercial production facility. In this first paper of a two-part series, we describe process design and operational choices made to introduce CM using infrastructure originally intended for batch operations. Consistent with lean manufacturing principles, we select equipment, facilities, and novel process analytical technologies that meet production agility goals alongside an existing batch process. Choices address process risks, are aligned with existing quality systems, yet allow exploration of CM agility benefits in commercial operations. We outline how operating procedures, control schemes, and release criteria from the historical batch process are adapted for CM with modified lot and yield definitions based on patient demand. We devise a hierarchy of complementary controls including real-time process interrogation, predictive residence time distribution models of tablet concentration, real-time product release testing using automated tablet NIR spectroscopy, active rejection and diversion, and throughput-based sampling. Results from lots produced under normal operational conditions confirm our CM process provides assurance of product quality. Qualification strategies to achieve lot size flexibility aims are also described. Finally, we consider CM extensions to formulations with differing risk profiles. Further analysis of results for lots produced under normal operational conditions is provided in part 2 (Rosas 2022).
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Affiliation(s)
- Stephen L Conway
- Pharmaceutical Technical Operations, MSD, Cramlington UK; Cramlington Operations, Cramlington MSD, UK.
| | - Juan G Rosas
- Pharmaceutical Technical Operations, MSD, Cramlington UK; Organon, Ltd., Cramlington, UK
| | - Paul Overton
- Pharmaceutical Technical Operations, MSD, Cramlington UK; Organon, Ltd., Cramlington, UK
| | - Neil Tugby
- Pharmaceutical Technical Operations, MSD, Cramlington UK; Organon, Ltd., Cramlington, UK
| | - Phillip Cryan
- Quality Operations, MSD, Cramlington, UK; Organon, Ltd., Cramlington, UK
| | - Frank Witulski
- Global Pharmaceutical Commercialization, MMD, Merck & Co., Inc., Rahway, NJ, USA
| | - Samantha Hurley
- Global Pharmaceutical Commercialization, MMD, Merck & Co., Inc., Rahway, NJ, USA
| | - Laura Wareham
- Global Pharmaceutical Commercialization, MMD, Merck & Co., Inc., Rahway, NJ, USA
| | - Anthony Tantuccio
- Global Pharmaceutical Commercialization, MMD, Merck & Co., Inc., Rahway, NJ, USA; Lonza, NJ, USA
| | - Manoharan Ramasamy
- Analytical Chemistry in Development and Supply, MMD, Merck & Co. Inc, Rahway, NJ, USA
| | - Anita Lalloo
- Regulatory-CMC, MRL, Merck & Co., Inc., Rahway NJ, USA
| | - Mason Gibbs
- Global Engineering Solutions, MMD, Merck & Co., Inc Rahway, NJ, USA; University of Delaware, DE, USA
| | - Robert F Meyer
- Global Pharmaceutical Commercialization, MMD, Merck & Co., Inc., Rahway, NJ, USA
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18
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Hou P, Besenhard MO, Halbert G, Naftaly M, Markl D. Development and implementation of a pneumatic micro-feeder for poorly-flowing solid pharmaceutical materials. Int J Pharm 2023; 635:122691. [PMID: 36764420 DOI: 10.1016/j.ijpharm.2023.122691] [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: 11/21/2022] [Revised: 01/31/2023] [Accepted: 02/02/2023] [Indexed: 02/11/2023]
Abstract
Consistent powder micro-feeding (<100 g/h) is a significant challenge in manufacturing solid oral dosage forms. The low dose feeding can well control the content consistency of the dosage forms, which improves drug efficiency and reduces manufacturing waste. Current commercial micro-feeders are limited in their ability to feed < 20 g/h of cohesive (i.e. powders of poor flowability) active pharmaceutical ingredients (API) and excipients (e.g. lubricants) with low fluctuation. To breach this gap, this study presents an advanced micro-feeder design capable of feeding a range of pharmaceutical-grade powders consistently at flow rates as low as 0.7 g/h with <20 % flow rate variation. This was possible due to a novel powder conveying concept utilising particle re-entrainment to minimise flow rate variations. This work details the design of this pneumatic micro-feeder and its excellent micro-feeding performance even for cohesive powders. The experimental studies investigated the influence of the process parameters (air pressure and air flow rate) and equipment configurations (insert size and plug position) on the feeding performance of different pharmaceutical-relevant powders, i.e., microcrystalline cellulose (MCC), croscarmellose sodium (CCS), crospovidone (XPVP) and paracetamol (APAP). It was shown that the system is capable of delivering consistent powder flow rates with good repeatability and stability.
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Affiliation(s)
- P Hou
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M O Besenhard
- Department of Chemical Engineering, University College London, London WC1E 7JE, UK
| | - G Halbert
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK
| | - M Naftaly
- National Physical Laboratory, Teddington TW11 0LW, UK
| | - D Markl
- Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow G1 1XQ, UK; Centre for Continuous Manufacturing and Advanced Crystallisation (CMAC), University of Strathclyde, Glasgow G1 1RD, UK.
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19
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Kreiser MJ, Wabel C, Wagner KG. Direct Tableting on a Continuous Manufacturing Line-Impact of Mixing Parameters, Material Densities, and Drug Load on Subsequent Process Parameters and Tablet Quality. AAPS PharmSciTech 2023; 24:70. [PMID: 36805870 DOI: 10.1208/s12249-023-02525-8] [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: 11/11/2022] [Accepted: 01/26/2023] [Indexed: 02/19/2023] Open
Abstract
The continuous manufacturing (CM) of solid oral dosage forms has received increased attention in recent years and has become a leading technology in the pharmaceutical industry. A model has been developed based on process data from two design of experiments (DoEs), where the impact of the mixer process parameters, throughput (THR), hold up mass (HUM), impeller speed (IMP), and the input raw material bulk density (BDi), on the continuous process and the resulting drug product has been investigated. These statistical models revealed equations, describing process parameter interactions for optimization purposes. For the exit valve opening width (EV) at the bottom of the continuous mixer (CMT), the combination of high throughput (30 kg/h) and low impeller speed (300 rpm) resulted in optimal process conditions. Apparent bulk density of the blend (BD) within the process, fill depth (FD), and tensile strength (TS) were mainly impacted by input bulk density (BDi) of the tableting mixture, emphasizing the role of material attributes on the continuous manufacturing process. The apparent bulk density itself was, other than from the input bulk density, equally dependent from THR and IMP in opposite deflections. However, process parameters (THR and IMP) revealed a minor impact on the apparent BD compared to the input bulk density. FD was impacted mainly by THR ahead of IMP and the TS by IMP and THR to a similar extend, in opposite deflections. A simplified linear model to estimate the input bulk density revealed satisfactory prediction quality when included in the derived statistical model equations.
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Affiliation(s)
- Marius J Kreiser
- Product and Process Development, Pfizer Manufacturing Deutschland GmbH, 79108, Freiburg, Germany.,Department of Pharmaceutics, University of Bonn, Gerhard-Domagk-Str. 3, 53121, Bonn, Germany
| | - Christoph Wabel
- Product and Process Development, Pfizer Manufacturing Deutschland GmbH, 79108, Freiburg, Germany
| | - Karl G Wagner
- Department of Pharmaceutics, University of Bonn, Gerhard-Domagk-Str. 3, 53121, Bonn, Germany.
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20
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Schwaiger KN, Nidetzky B. Continuous process technology for bottom-up synthesis of soluble cello-oligosaccharides by immobilized cells co-expressing three saccharide phosphorylases. Microb Cell Fact 2022; 21:265. [PMID: 36536394 PMCID: PMC9764710 DOI: 10.1186/s12934-022-01984-1] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/19/2022] [Accepted: 12/06/2022] [Indexed: 12/23/2022] Open
Abstract
BACKGROUND Continuous processing with enzyme reuse is a well-known engineering strategy to enhance the efficiency of biocatalytic transformations for chemical synthesis. In one-pot multistep reactions, continuous processing offers the additional benefit of ensuring constant product quality via control of the product composition. Bottom-up production of cello-oligosaccharides (COS) involves multistep iterative β-1,4-glycosylation of glucose from sucrose catalyzed by sucrose phosphorylase from Bifidobacterium adeloscentis (BaScP), cellobiose phosphorylase from Cellulomonas uda (CuCbP) and cellodextrin phosphorylase from Clostridium cellulosi (CcCdP). Degree of polymerization (DP) control in the COS product is essential for soluble production and is implemented through balance of the oligosaccharide priming and elongation rates. A whole-cell E. coli catalyst co-expressing the phosphorylases in high yield and in the desired activity ratio, with CdP as the rate-limiting enzyme, was reported previously. RESULTS Freeze-thaw permeabilized E. coli cells were immobilized in polyacrylamide (PAM) at 37-111 mg dry cells/g material. PAM particles (0.25-2.00 mm size) were characterized for COS production (~ 70 g/L) in mixed vessel with catalyst recycle and packed-bed reactor set-ups. The catalyst exhibited a dry mass-based overall activity (270 U/g; 37 mg cells/g material) lowered by ~ 40% compared to the corresponding free cells due to individual enzyme activity loss, CbP in particular, caused by the immobilization. Temperature studies revealed an operational optimum at 30 °C for stable continuous reaction (~ 1 month) in the packed bed (volume: 40 mL; height: 7.5 cm). The optimum reflects the limits of PAM catalyst structural and biological stability in combination with the requirement to control COS product solubility in order to prevent clogging of the packed bed. Using an axial flow rate of 0.75 cm- 1, the COS were produced at ~ 5.7 g/day and ≥ 95% substrate conversion (sucrose 300 mM). The product stream showed a stable composition of individual oligosaccharides up to cellohexaose, with cellobiose (48 mol%) and cellotriose (31 mol%) as the major components. CONCLUSIONS Continuous process technology for bottom-up biocatalytic production of soluble COS is demonstrated based on PAM immobilized E. coli cells that co-express BaScP, CuCbP and CcCdP in suitable absolute and relative activities.
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Affiliation(s)
- Katharina N. Schwaiger
- grid.432147.70000 0004 0591 4434acib - Austrian Centre of Industrial Biotechnology, Krenngasse 37, 8010 Graz, Austria
| | - Bernd Nidetzky
- grid.432147.70000 0004 0591 4434acib - Austrian Centre of Industrial Biotechnology, Krenngasse 37, 8010 Graz, Austria ,grid.410413.30000 0001 2294 748XInstitute of Biotechnology and Biochemical Engineering, NAWI Graz, Graz University of Technology, Petersgasse 12, 8010, Graz, Austria
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21
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Jaspers M, Kulkarni SS, Tegel F, Roelofs TP, de Wit MT, Janssen PH, Meir B, Weinekötter R, Dickhoff BH. Batch versus continuous blending of binary and ternary pharmaceutical powder mixtures. Int J Pharm X 2022; 4:100111. [PMID: 35028558 PMCID: PMC8739470 DOI: 10.1016/j.ijpx.2021.100111] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2021] [Revised: 12/15/2021] [Accepted: 12/30/2021] [Indexed: 12/03/2022] Open
Abstract
The material properties of excipients and active pharmaceutical ingredients (API's) are important parameters that affect blend uniformity of pharmaceutical powder formulations. With the current shift from batch to continuous manufacturing in the pharmaceutical industry, blending of excipients and API is converted to a continuous process. The relation between material properties and blend homogeneity, however, is generally based on batch-wise blending trials. Limited information is available on how material properties affect blending performance in a continuous process. Here, blending of API and excipients is studied in both a batch and a continuous process. Homogeneity of the resulting mixtures is analyzed, which reveals that the impact of material properties is very different in a continuous process. Where parameters such as particle size, density and flowability have significant impact on blending performance in a traditional batch process, continuous blending is more robust resulting in uniform blends for a large variety of blend compositions. Continuous mixing improves blend uniformity of pharmaceutical powder mixtures. Blend uniformity is highly dependent on excipient properties in a batch process. Continuous mixing is more robust, with little impact of material properties. Powder bulk density strongly affects blend homogeneity in a batch process. Blending of low API dosages is more challenging in a continuous process.
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22
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Instability Challenges and Stabilization Strategies of Pharmaceutical Proteins. Pharmaceutics 2022; 14:pharmaceutics14112533. [PMID: 36432723 PMCID: PMC9699111 DOI: 10.3390/pharmaceutics14112533] [Citation(s) in RCA: 13] [Impact Index Per Article: 6.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/13/2022] [Revised: 11/13/2022] [Accepted: 11/17/2022] [Indexed: 11/22/2022] Open
Abstract
Maintaining the structure of protein and peptide drugs has become one of the most important goals of scientists in recent decades. Cold and thermal denaturation conditions, lyophilization and freeze drying, different pH conditions, concentrations, ionic strength, environmental agitation, the interaction between the surface of liquid and air as well as liquid and solid, and even the architectural structure of storage containers are among the factors that affect the stability of these therapeutic biomacromolecules. The use of genetic engineering, side-directed mutagenesis, fusion strategies, solvent engineering, the addition of various preservatives, surfactants, and additives are some of the solutions to overcome these problems. This article will discuss the types of stress that lead to instabilities of different proteins used in pharmaceutics including regulatory proteins, antibodies, and antibody-drug conjugates, and then all the methods for fighting these stresses will be reviewed. New and existing analytical methods that are used to detect the instabilities, mainly changes in their primary and higher order structures, are briefly summarized.
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Croci F, Vilím J, Adamopoulou T, Tseliou V, Schoenmakers PJ, Knaus T, Mutti FG. Continuous Flow Biocatalytic Reductive Amination by Co-Entrapping Dehydrogenases with Agarose Gel in a 3D-Printed Mould Reactor. Chembiochem 2022; 23:e202200549. [PMID: 36173971 PMCID: PMC9828473 DOI: 10.1002/cbic.202200549] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2022] [Revised: 09/28/2022] [Indexed: 02/03/2023]
Abstract
Herein, we show how the merge of biocatalysis with flow chemistry aided by 3D-printing technologies can facilitate organic synthesis. This concept was exemplified for the reductive amination of benzaldehyde catalysed by co-immobilised amine dehydrogenase and formate dehydrogenase in a continuous flow micro-reactor. For this purpose, we investigated enzyme co-immobilisation by covalent binding, or ion-affinity binding, or entrapment. Entrapment in an agarose hydrogel turned out to be the most promising solution for this biocatalytic reaction. Therefore, we developed a scalable and customisable approach whereby an agarose hydrogel containing the co-entrapped dehydrogenases was cast in a 3D-printed mould. The reactor was applied to the reductive amination of benzaldehyde in continuous flow over 120 h and afforded 47 % analytical yield and a space-time yield of 7.4 g L day-1 using 0.03 mol% biocatalysts loading. This work also exemplifies how rapid prototyping of enzymatic reactions in flow can be achieved through 3D-printing technology.
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Affiliation(s)
- Federico Croci
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
| | - Jan Vilím
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
| | - Theodora Adamopoulou
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
| | - Vasilis Tseliou
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
| | - Peter J. Schoenmakers
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
| | - Tanja Knaus
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
| | - Francesco G. Mutti
- van' t Hoff Institute for Molecular Sciences HIMS-Biocat & Analytical ChemistryUniversity of AmsterdamScience Park 9041098 XHAmsterdamThe Netherlands
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Digital twin of a continuous direct compression line for drug product and process design using a hybrid flowsheet modelling approach. Int J Pharm 2022; 628:122336. [DOI: 10.1016/j.ijpharm.2022.122336] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/13/2022] [Revised: 10/19/2022] [Accepted: 10/20/2022] [Indexed: 11/06/2022]
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25
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Murakami Y, Inoue K, Akiyama R, Orita Y, Shimoyama Y. LipTube: Liposome Formation in the Tube Process Using Supercritical CO 2. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.2c02095] [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]
Affiliation(s)
- Yuya Murakami
- Department of Industrial Chemistry, Tokyo University of Science, 6-3-1 Niijuku, Katsushika-ku, Tokyo125-8585, Japan
| | - Keita Inoue
- Department of Chemical Science and Engineering, Tokyo Institute of Technology, Ookayama 2-12-1 S1-33, Meguro-ku, Tokyo152-8550, Japan
| | - Ryunosuke Akiyama
- Department of Chemical Science and Engineering, Tokyo Institute of Technology, Ookayama 2-12-1 S1-33, Meguro-ku, Tokyo152-8550, Japan
| | - Yasuhiko Orita
- Department of Chemical Science and Engineering, Tokyo Institute of Technology, Ookayama 2-12-1 S1-33, Meguro-ku, Tokyo152-8550, Japan
| | - Yusuke Shimoyama
- Department of Chemical Science and Engineering, Tokyo Institute of Technology, Ookayama 2-12-1 S1-33, Meguro-ku, Tokyo152-8550, Japan
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26
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Nambiar AG, Singh M, Mali AR, Serrano DR, Kumar R, Healy AM, Agrawal AK, Kumar D. Continuous Manufacturing and Molecular Modeling of Pharmaceutical Amorphous Solid Dispersions. AAPS PharmSciTech 2022; 23:249. [PMID: 36056225 DOI: 10.1208/s12249-022-02408-4] [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: 06/25/2022] [Accepted: 08/24/2022] [Indexed: 11/30/2022] Open
Abstract
Amorphous solid dispersions enhance solubility and oral bioavailability of poorly water-soluble drugs. The escalating number of drugs with poor aqueous solubility, poor dissolution, and poor oral bioavailability is an unresolved problem that requires adequate interventions. This review article highlights recent solubility and bioavailability enhancement advances using amorphous solid dispersions (ASDs). The review also highlights the mechanism of enhanced dissolution and the challenges faced by ASD-based products, such as stability and scale-up. The role of process analytical technology (PAT) supporting continuous manufacturing is highlighted. Accurately predicting interactions between the drug and polymeric carrier requires long experimental screening methods, and this is a space where computational tools hold significant potential. Recent advancements in data science, computational tools, and easy access to high-end computation power are set to accelerate ASD-based research. Hence, particular emphasis has been given to molecular modeling techniques that can address some of the unsolved questions related to ASDs. With the advancement in PAT tools and artificial intelligence, there is an increasing interest in the continuous manufacturing of pharmaceuticals. ASDs are a suitable option for continuous manufacturing, as production of a drug product from an ASD by direct compression is a reality, where the addition of multiple excipients is easy to avoid. Significant attention is necessary for ongoing clinical studies based on ASDs, which is paving the way for the approval of many new ASDs and their introduction into the market.
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Affiliation(s)
- Amritha G Nambiar
- Department of Pharmaceutical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, 221005, India
| | - Maan Singh
- Department of Pharmaceutical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, 221005, India
| | - Abhishek R Mali
- Department of Pharmaceutical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, 221005, India
| | | | - Rajnish Kumar
- Department of Pharmaceutical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, 221005, India
| | - Anne Marie Healy
- School of Pharmacy and Pharmaceutical Sciences, Trinity College Dublin, Dublin 2, Ireland
| | - Ashish Kumar Agrawal
- Department of Pharmaceutical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, 221005, India
| | - Dinesh Kumar
- Department of Pharmaceutical Engineering and Technology, Indian Institute of Technology (BHU), Varanasi, 221005, India.
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27
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Zheng C, Li L, Nitert BJ, Govender N, Chamberlain T, Zhang L, Wu CY. Investigation of granular dynamics in a continuous blender using the GPU-enhanced discrete element method. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117968] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/31/2022]
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28
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Effect of batch-to-batch variation of spray dried lactose on the performance of feeders. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117776] [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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29
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Nicholas RJ, McGuire MA, Hyun SH, Cullison MN, Thompson DH. Development of an Efficient, High Purity Continuous Flow Synthesis of Diazepam. FRONTIERS IN CHEMICAL ENGINEERING 2022. [DOI: 10.3389/fceng.2022.877498] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022] Open
Abstract
In an effort to strengthen the resiliency of supply chains for active pharmaceutical ingredients (API), continuous manufacturing processes may be optimized with respect to improved chemoselectivity, production rate, yield, and/or process intensity. We report an efficient two-step continuous flow synthesis of diazepam, an agent on the World Health Organization’s (WHO) list of essential medicines. Different conditions were rapidly screened in microfluidic chip reactors by varying residence times, temperatures, solvents, and ammonia sources to identify the best telescoped reaction conditions. We report a telescoped flow synthesis that uses two microreactors in series set to 0°C and 60°C, respectively, to produce a 96% yield of 91% pure diazepam within 15 min using an NH4Br/NH4OH solution in the second step. Diazepam of >98% purity was obtained after a single recrystallization.
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Vinet L, Di Marco L, Kairouz V, Charette AB. Process Intensive Synthesis of Propofol Enabled by Continuous Flow Chemistry. Org Process Res Dev 2022. [DOI: 10.1021/acs.oprd.1c00416] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/05/2023]
Affiliation(s)
- Laurent Vinet
- Centre in Green Chemistry and Catalysis, Center for Continuous Flow Synthesis, Department of Chemistry, Université de Montréal, 1375, av. Thérèse Lavoie-Roux, Montréal, Québec H2V 0B3, Canada
| | - Lorenzo Di Marco
- Centre in Green Chemistry and Catalysis, Center for Continuous Flow Synthesis, Department of Chemistry, Université de Montréal, 1375, av. Thérèse Lavoie-Roux, Montréal, Québec H2V 0B3, Canada
| | - Vanessa Kairouz
- Centre in Green Chemistry and Catalysis, Center for Continuous Flow Synthesis, Department of Chemistry, Université de Montréal, 1375, av. Thérèse Lavoie-Roux, Montréal, Québec H2V 0B3, Canada
| | - André B. Charette
- Centre in Green Chemistry and Catalysis, Center for Continuous Flow Synthesis, Department of Chemistry, Université de Montréal, 1375, av. Thérèse Lavoie-Roux, Montréal, Québec H2V 0B3, Canada
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31
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Roche P, Jones RC, Glennon B, Donnellan P. Binary Solvent Swap Processing in a Bubble Column in Batch and Continuous Modes. Org Process Res Dev 2022; 26:1191-1201. [PMID: 35464823 PMCID: PMC9016759 DOI: 10.1021/acs.oprd.1c00455] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2021] [Indexed: 11/28/2022]
Abstract
![]()
A lab-scale
bubble
column was investigated as an alternative means
to achieve a low-temperature binary solvent swap of solutions containing
pharmaceutical materials at atmospheric pressure, for batch and continuous
configurations. The rate of solvent evaporation was predicted by first-principles
vapor–liquid equilibrium (VLE) thermodynamic modeling and compared
to experimentally achieved results. For batch configurations, evaporation
rates of up to 5 g/min were achieved at gas flow rates up to 2.5 L/min
(0.21 m/s superficial velocity) and temperatures up to 50 °C.
This achieved 99 mol % purity of the desired solvent within three
“put and take” evaporations from a 50:50 starting mixture.
The evaporation rate profiles for the duration of the experiments
were calculated, and the changing concentration profile was predicted
within satisfactory error margins of <5%. Continuous process modeling
explored a multistage equilibrium configuration and could predict
the approach to attaining steady-state operation for various operating
conditions. All rates of evaporation and resulting changes in solution
concentration were measured, and direct comparison of model predictions
fell within instrumentation error margins, as previously. This underlined
the capability of the model to provide accurate representations of
predicted evaporation rates and binary solution concentration changes
during operation.
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Affiliation(s)
- Phillip Roche
- School of Chemical & Bioprocess Engineering, University College Dublin, Dublin 4, Ireland
| | - Roderick C Jones
- School of Chemical & Bioprocess Engineering, University College Dublin, Dublin 4, Ireland
| | - Brian Glennon
- School of Chemical & Bioprocess Engineering, University College Dublin, Dublin 4, Ireland
| | - Philip Donnellan
- School of Chemical & Bioprocess Engineering, University College Dublin, Dublin 4, Ireland
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32
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Destro F, Barolo M. A review on the modernization of pharmaceutical development and manufacturing - Trends, perspectives, and the role of mathematical modeling. Int J Pharm 2022; 620:121715. [PMID: 35367580 DOI: 10.1016/j.ijpharm.2022.121715] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2022] [Revised: 03/23/2022] [Accepted: 03/29/2022] [Indexed: 01/20/2023]
Abstract
Recently, the pharmaceutical industry has been facing several challenges associated to the use of outdated development and manufacturing technologies. The return on investment on research and development has been shrinking, and, at the same time, an alarming number of shortages and recalls for quality concerns has been registered. The pharmaceutical industry has been responding to these issues through a technological modernization of development and manufacturing, under the support of initiatives and activities such as quality-by-design (QbD), process analytical technology, and pharmaceutical emerging technology. In this review, we analyze this modernization trend, with emphasis on the role that mathematical modeling plays within it. We begin by outlining the main socio-economic trends of the pharmaceutical industry, and by highlighting the life-cycle stages of a pharmaceutical product in which technological modernization can help both achieve consistently high product quality and increase return on investment. Then, we review the historical evolution of the pharmaceutical regulatory framework, and we discuss the current state of implementation and future trends of QbD. The pharmaceutical emerging technology is reviewed afterwards, and a discussion on the evolution of QbD into the more effective quality-by-control (QbC) paradigm is presented. Further, we illustrate how mathematical modeling can support the implementation of QbD and QbC across all stages of the pharmaceutical life-cycle. In this respect, we review academic and industrial applications demonstrating the impact of mathematical modeling on three key activities within pharmaceutical development and manufacturing, namely design space description, process monitoring, and active process control. Finally, we discuss some future research opportunities on the use of mathematical modeling in industrial pharmaceutical environments.
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Affiliation(s)
- Francesco Destro
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy
| | - Massimiliano Barolo
- CAPE-Lab - Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, via Marzolo 9, 35131 Padova PD, Italy.
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33
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Hlávka Z, Míchal P, Otava M. Confidence intervals for point-of-stabilization of content uniformity. Pharm Stat 2022; 21:944-959. [PMID: 35347839 DOI: 10.1002/pst.2207] [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: 06/17/2021] [Revised: 01/12/2022] [Accepted: 03/08/2022] [Indexed: 11/11/2022]
Abstract
Within the framework of continuous pharmaceutical manufacturing, we are interested in statistical modeling of the initial behavior of the production line. Assuming a gradually changing sequence of a suitable product quality characteristic (e.g., the content uniformity), we estimate the so-called point-of-stabilization (PoSt) and construct corresponding confidence regions based on appropriate asymptotic distributions and bootstrap. We investigate linear, quadratic, and nonlinear gradual change models both in homoscedastic and heteroscedastic setup. We propose a new nonlinear Emax gradual change model and show that it is applicable even if the true model is linear. Asymptotic distribution of the PoSt estimator is known only in a homoscedastic linear and quadratic model and, therefore, bootstrap approximations are used to construct one-sided PoSt confidence intervals.
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Affiliation(s)
- Zdeněk Hlávka
- Department of Statistics, Faculty of Mathematics and Physics, Charles University, Czech Republic
| | - Petr Míchal
- Department of Statistics, Faculty of Mathematics and Physics, Charles University, Czech Republic
| | - Martin Otava
- Quantitative Sciences, Janssen-Cilag s.r.o., Janssen Pharmaceutical Companies of Johnson & Johnson, Czech Republic
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34
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Bodák B, Mazzotti M. Solid-State Deracemization via Temperature Cycles in Continuous Operation: Model-Based Process Design. CRYSTAL GROWTH & DESIGN 2022; 22:1846-1856. [PMID: 35264910 PMCID: PMC8895372 DOI: 10.1021/acs.cgd.1c01398] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/28/2021] [Revised: 01/28/2022] [Indexed: 06/14/2023]
Abstract
Solid-state deracemization via temperature cycles converts a racemic crystal mixture into an enantiopure product by periodic cycling of the temperature in the presence of a racemization catalyst. A continuous counterpart of this conventional batch-operated process is proposed that can be performed in mixed suspension mixed product removal crystallizers (MSMPRCs). More specifically, three different configurations are described to perform periodic forcing via temperature cycles, which differ from each other in the type of the feed and in the withdrawal system. We have developed a model by extending our recent population balance equation model of batch solid-state deracemization via temperature cycles, and we exploit this tool to analyze the start-up and periodic steady-state behavior. Moreover, we compare the performance of the different configurations based on the selected key performance indicators, namely, average periodic steady-state enantiomeric excess and productivity. The process with solution feed yields pure enantiomers, while the solid and suspension-fed process alternatives result in highly enantiomerically enriched crystals. We further design an MSMPRC cascade to overcome this purity limitation. This work discusses guidelines on how to transform the batch process of temperature cycles into a continuous operation, which enables stable, unattended operation and chiral crystal production with consistent product quality.
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Affiliation(s)
| | - Marco Mazzotti
- E-mail: . Phone: +41 44 632 24 56. Fax: +41 44 632 11
41
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35
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Harper KC, Zhang EX, Liu ZQ, Grieme T, Towne TB, Mack DJ, Griffin J, Zheng SY, Zhang NN, Gangula S, Yuan JL, Miller R, Huang PZ, Gage J, Diwan M, Ku YY. Commercial-Scale Visible Light Trifluoromethylation of 2-Chlorothiophenol Using CF3I Gas. Org Process Res Dev 2022. [DOI: 10.1021/acs.oprd.1c00436] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/08/2023]
Affiliation(s)
- Kaid C. Harper
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - En-Xuan Zhang
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Zhi-Qing Liu
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Timothy Grieme
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - Timothy B. Towne
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - Daniel J. Mack
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - Jeremy Griffin
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - Song-Yuan Zheng
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Ning-Ning Zhang
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Srinivas Gangula
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Jia-Long Yuan
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Robert Miller
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - Ping-Zhong Huang
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - James Gage
- Asymchem Laboratories (Tianjin) Company Limited, TEDA, Tianjin 300457, P. R. China
| | - Moiz Diwan
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
| | - Yi-Yin Ku
- Abbvie Process Research & Development, 1401 N. Sheridan Road, North Chicago, Illinois 60064, United States
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36
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Huang YS, Medina-González S, Straiton B, Keller J, Marashdeh Q, Gonzalez M, Nagy Z, Reklaitis GV. Real-Time Monitoring of Powder Mass Flowrates for Plant-Wide Control of a Continuous Direct Compaction Tablet Manufacturing Process. J Pharm Sci 2022; 111:69-81. [PMID: 34126119 PMCID: PMC10009918 DOI: 10.1016/j.xphs.2021.06.005] [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: 03/02/2021] [Revised: 06/02/2021] [Accepted: 06/02/2021] [Indexed: 11/28/2022]
Abstract
While measurement and monitoring of powder/particulate mass flow rate are not essential to the execution of traditional batch pharmaceutical tablet manufacturing, in continuous operation, it is an important additional critical process parameter. It has a key role both in establishing that the process is in a state of control, and as a controlled variable in process control system design. In current continuous tableting line operations, the pharmaceutical community relies on loss-in-weight feeders to monitor and understand upstream powder flow dynamics. However, due to the absence of established sensing technologies for measuring particulate flow rates, the downstream flow of the feeders is monitored and controlled using various indirect strategies. For example, the hopper level of the tablet press is maintained as a controlled process output by adjusting the turret speed of the tablet press, which indirectly controlling the flow rate. This gap in monitoring and control of the critical process flow motivates our investigation of a novel PAT tool, a capacitance-based sensor (ECVT), and its effective integration into the plant-wide control of a direct compaction process. First, the results of stand-alone experimental studies are reported, which confirm that the ECVT sensor can provide real-time measurements of mass flow rate with measurement error within -1.8 ~ 3.3% and with RMSE of 0.1 kg/h over the range of flow rates from 2 to 10 kg/h. The key caveat is that the powder flowability has to be good enough to avoid powder fouling on the transfer line walls. Next, simulation case studies are carried out using a dynamic flowsheet model of a continuous direct compression line implemented in Matlab/Simulink to demonstrate the potential structural and performance advantages in plant-wide process control enabled by mass flow sensing. Finally, experimental studies are performed on a direct compaction pilot plant in which the ECVT sensor is located at the exit of the blender, to confirm that the powder flow can be monitored instantaneously and controlled effectively at the specified setpoint within a plant-wide feedback controller system.
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Affiliation(s)
- Yan-Shu Huang
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States.
| | - Sergio Medina-González
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | | | | | | | - Marcial Gonzalez
- School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Zoltan Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
| | - Gintaras V Reklaitis
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47907, United States
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37
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Moritz P, Simon B, Meier R, Gerhard S. Tracking raw material flow through a continuous direct compression line. Part II of II: Predicting dynamic changes in quality attributes of tablets due to disturbances in raw material properties using an independent residence time distribution model. Int J Pharm 2022; 615:121528. [DOI: 10.1016/j.ijpharm.2022.121528] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/05/2021] [Revised: 01/23/2022] [Accepted: 01/26/2022] [Indexed: 10/19/2022]
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38
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Capellades G, Bonsu JO, Myerson AS. Impurity incorporation in solution crystallization: diagnosis, prevention, and control. CrystEngComm 2022. [DOI: 10.1039/d1ce01721g] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/14/2023]
Abstract
This work highlights recent advances in the diagnosis, prevention, and control of impurity incorporation during solution crystallization.
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Affiliation(s)
- Gerard Capellades
- Department of Chemical Engineering, Henry M. Rowan College of Engineering, Rowan University, Glassboro, New Jersey 08028, USA
| | - Jacob O. Bonsu
- Department of Chemical Engineering, Henry M. Rowan College of Engineering, Rowan University, Glassboro, New Jersey 08028, USA
| | - Allan S. Myerson
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, USA
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39
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Talicska CN, O'Connell EC, Ward HW, Diaz AR, Hardink MA, Foley DA, Connolly D, Girard KP, Ljubicic T. Process analytical technology (PAT): applications to flow processes for active pharmaceutical ingredient (API) development. REACT CHEM ENG 2022. [DOI: 10.1039/d2re00004k] [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
Process analytical technology (PAT) applications pertaining to Pfizer's Flexible API Supply Technology (FAST) initiative.
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Affiliation(s)
- Courtney N. Talicska
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
| | - Eamon C. O'Connell
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
| | - Howard W. Ward
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
| | - Angel R. Diaz
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
| | - Mark A. Hardink
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
| | - David A. Foley
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
- Employed at Pfizer during the time of this work, now at Merck Research and Development, 90 E Scott Ave, Rahway, New Jersey 07065, USA
| | - Douglas Connolly
- Contingent Worker, Eurofins Scientific for Pfizer Worldwide Research and Development, 445 Eastern Point Rd, Groton, Connecticut, 06340, USA
| | - Kevin P. Girard
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
| | - Tomislav Ljubicic
- Analytical Research and Development, Pfizer Worldwide Research and Development, 445 Eastern Point Road, Groton, Connecticut 06340, USA
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40
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Aulakh PK, Settanni E, Srai JS. Continuous manufacturing technologies in upstream pharmaceutical supply chains: Combining engineering and managerial criteria. JOURNAL OF MULTI-CRITERIA DECISION ANALYSIS 2021. [DOI: 10.1002/mcda.1775] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Parminder Kaur Aulakh
- Department of Engineering, Institute for Manufacturing, Centre for International Manufacturing University of Cambridge Cambridge UK
| | - Ettore Settanni
- Department of Engineering, Institute for Manufacturing, Centre for International Manufacturing University of Cambridge Cambridge UK
| | - Jagjit Singh Srai
- Department of Engineering, Institute for Manufacturing, Centre for International Manufacturing University of Cambridge Cambridge UK
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41
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Miyai Y, Formosa A, Armstrong C, Marquardt B, Rogers L, Roper T. PAT Implementation on a Mobile Continuous Pharmaceutical Manufacturing System: Real-Time Process Monitoring with In-Line FTIR and Raman Spectroscopy. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00299] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
Affiliation(s)
- Yuma Miyai
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia 23284-2512, United States
| | - Anna Formosa
- OnDemand Pharmaceuticals, Rockville, Maryland 20850, United States
| | - Cameron Armstrong
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia 23284-2512, United States
| | | | - Luke Rogers
- OnDemand Pharmaceuticals, Rockville, Maryland 20850, United States
| | - Thomas Roper
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia 23284-2512, United States
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42
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De la Rosa MVG, Báez JPF, Romañach RJ, López-Mejías V, Stelzer T. Real-time concentration monitoring using a compact composite sensor array for in situ quality control of aqueous formulations. J Pharm Biomed Anal 2021; 206:114386. [PMID: 34607202 DOI: 10.1016/j.jpba.2021.114386] [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: 04/14/2021] [Revised: 08/29/2021] [Accepted: 09/15/2021] [Indexed: 11/25/2022]
Abstract
Recent advancements have demonstrated the feasibility of refrigerator-sized pharmaceutical manufacturing platforms (PMPs) for integrated end-to-end manufacturing of active pharmaceutical ingredients (APIs) into formulated drug products. Unlike typical laboratory- or industrial-scale setups, PMPs present unique requirements for process analytical technology (PAT) with respect to versatility, flexibility, and physical size to fit into the PMP space constraints. In this proof of principle study, a novel compact composite sensor array (CCSA) combining ultraviolet (UV) and near infrared (NIR) features at four different wavelengths (280, 340, 600, 860 nm) with temperature measuring capability in a 380 × 30 mm housing (length x diameter, 7 mm diameter at the probe head), were evaluated. The results indicate that the CCSA prototype is capable of measuring the solution and suspension concentrations in aqueous formulations of four model APIs (warfarin sodium isopropanol solvate, lidocaine hydrochloride monohydrate, 6-mercaptopurine monohydrate, acetaminophen) in situ and in real-time with similar accuracy as an established Raman spectrometer commonly applied for method development.
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Affiliation(s)
- Mery Vet George De la Rosa
- Department of Pharmaceutical Sciences, 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
| | - Jean P Feng Báez
- Department of Pharmaceutical Sciences, 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
| | - Vilmalí López-Mejías
- Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA; Department of Chemistry, University of Puerto Rico, Río Piedras Campus, San Juan, PR 00931, USA.
| | - Torsten Stelzer
- Department of Pharmaceutical Sciences, 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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43
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Destro F, Hur I, Wang V, Abdi M, Feng X, Wood E, Coleman S, Firth P, Barton A, Barolo M, Nagy ZK. Mathematical modeling and digital design of an intensified filtration-washing-drying unit for pharmaceutical continuous manufacturing. Chem Eng Sci 2021; 244:116803. [PMID: 38229929 PMCID: PMC10790184 DOI: 10.1016/j.ces.2021.116803] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Abstract
This paper introduces a comprehensive mathematical model of a novel integrated filter-dryer carousel system, designed for continuously filtering, washing and drying a slurry stream into a crystals cake. The digital twin includes models for dead-end filtration, cake washing and convective cake drying, based on dynamic multi-component mass, energy and momentum balances. For set of feed conditions and control inputs, the model allows tracking the solvents and impurities content in the cake (critical quality attributes, CQAs) throughout the whole process. The model parameters were identified for the isolation of paracetamol from a multi-component slurry, containing a non-volatile impurity. The calibrated model was used for identifying the probabilistic design space and maximum throughput for the process, expressing the combinations of the carousel feed conditions and control inputs for which the probability of meeting the target CQAs is acceptable.
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Affiliation(s)
- Francesco Destro
- CAPE-Lab – Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, 35131 Padova PD, Italy
| | - Inyoung Hur
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
| | - Vivian Wang
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Mesfin Abdi
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Xin Feng
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | - Erin Wood
- Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food & Drug Administration, Silver Spring, MD, USA
| | | | - Paul Firth
- Alconbury Weston Ltd, Stoke-on-Trent, UK
| | | | - Massimiliano Barolo
- CAPE-Lab – Computer-Aided Process Engineering Laboratory, Department of Industrial Engineering, University of Padova, 35131 Padova PD, Italy
| | - Zoltan K. Nagy
- Davidson School of Chemical Engineering, Purdue University, West Lafayette, IN 47906, USA
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44
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Jiang M, Liu M, Huang H, Chen F. Fully Continuous Flow Synthesis of 5-(Aminomethyl)-2-methylpyrimidin-4-amine: A Key Intermediate of Vitamin B 1. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00253] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
Affiliation(s)
- Meifen Jiang
- Shanghai Engineering Center of Industrial Asymmetric Catalysis for Chiral Drugs, Engineering center of Catalysis and Synthesis for Chiral Molecules, Department of Chemistry, Fudan University, Shanghai 200433, China
| | - Minjie Liu
- Department of Petroleum and Chemical Engineering, Fuzhou University, Fuzhou, Fujian Province 350108, China
| | - Huashan Huang
- Department of Petroleum and Chemical Engineering, Fuzhou University, Fuzhou, Fujian Province 350108, China
| | - Fener Chen
- Shanghai Engineering Center of Industrial Asymmetric Catalysis for Chiral Drugs, Engineering center of Catalysis and Synthesis for Chiral Molecules, Department of Chemistry, Fudan University, Shanghai 200433, China
- Department of Petroleum and Chemical Engineering, Fuzhou University, Fuzhou, Fujian Province 350108, China
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45
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Jiang M, Liu M, Yu C, Cheng D, Chen F. Fully Continuous Flow Synthesis of 3-Chloro-4-oxopentyl Acetate: An Important Intermediate for Vitamin B1. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00065] [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)
- Meifen Jiang
- Shanghai Engineering Center of Industrial Asymmetric Catalysis for Chiral Drugs, Engineering Center of Catalysis and Synthesis for Chiral Molecules, Department of Chemistry, Fudan University, Shanghai 200433, China
| | - Minjie Liu
- Department of Petroleum and Chemical Engineering, Fuzhou University, Fuzhou, Fujian Province 350108, China
| | - Chao Yu
- Department of Petroleum and Chemical Engineering, Fuzhou University, Fuzhou, Fujian Province 350108, China
| | - Dang Cheng
- Shanghai Engineering Center of Industrial Asymmetric Catalysis for Chiral Drugs, Engineering Center of Catalysis and Synthesis for Chiral Molecules, Department of Chemistry, Fudan University, Shanghai 200433, China
| | - Fener Chen
- Shanghai Engineering Center of Industrial Asymmetric Catalysis for Chiral Drugs, Engineering Center of Catalysis and Synthesis for Chiral Molecules, Department of Chemistry, Fudan University, Shanghai 200433, China
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46
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A Guideline to Set Up Cascaded Continuous Cultivation with E. coli Bl21 (DE3). METHODS IN MOLECULAR BIOLOGY (CLIFTON, N.J.) 2021; 2436:223-240. [PMID: 34519978 DOI: 10.1007/7651_2021_424] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
Abstract
Continuous processing allows to maximize space-time yields and is implemented in many industrial branches. However, in manufacturing of value added compounds produced with microbial hosts, continuous processing is not state-of-the-art yet. This is because fluctuating productivity causes unwanted process deviations. Cascaded continuous bioprocessing, unlike conventional continuous process modes, was found to result in stable productivity. This manuscript serves as a guideline how to set up a cascaded continuous cultivation with Escherichia coli BL21 DE(3).
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47
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Apostol I, Bondarenko PV, Ren D, Semin DJ, Wu CH, Zhang Z, Goudar CT. Enabling development, manufacturing, and regulatory approval of biotherapeutics through advances in mass spectrometry. Curr Opin Biotechnol 2021; 71:206-215. [PMID: 34508981 DOI: 10.1016/j.copbio.2021.08.001] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/21/2021] [Revised: 07/20/2021] [Accepted: 08/04/2021] [Indexed: 10/20/2022]
Abstract
Rapid technological advances have significantly improved the capability, versatility, and robustness of mass spectrometers which has led to them playing a central role in the development, characterization, and regulatory filings of biopharmaceuticals. Their application spans the entire continuum of drug development, starting with discovery research through product development, characterization, and marketing authorization and continues well into product life cycle management. The scope of application extends beyond traditional protein characterization and includes elements like clone selection, cell culture physiology and bioprocess optimization, investigation support, and process analytical technology. More recently, advances in the MS-based multi-attribute method are enabling the introduction of MS in a cGMP environment for routine release and stability testing. While most applications of MS to date have been for monoclonal antibodies, the successes and learnings should translate to the characterization of next-gen biotherapeutics where modalities like multispecifics could be more prevalent. In this review, we describe the most significant advances in MS and correlate them to the broad spectrum of applications to biotherapeutic development. We anticipate rapid technological improvements to continue that will further accelerate widespread deployment of MS, thereby elevating our overall understanding of product quality and enabling attribute-focused product development.
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Affiliation(s)
- Izydor Apostol
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States
| | - Pavel V Bondarenko
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States
| | - Da Ren
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States
| | - David J Semin
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States
| | - Chao-Hsiang Wu
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States
| | - Zhongqi Zhang
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States
| | - Chetan T Goudar
- Attribute Sciences, Process Development, Amgen Inc., 1 Amgen Center Drive, Thousand Oaks, CA 91320, United States.
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Szabó E, Záhonyi P, Gyürkés M, Nagy B, Galata DL, Madarász L, Hirsch E, Farkas A, Andersen SK, Vígh T, Verreck G, Csontos I, Marosi G, Nagy ZK. Continuous downstream processing of milled electrospun fibers to tablets monitored by near-infrared and Raman spectroscopy. Eur J Pharm Sci 2021; 164:105907. [PMID: 34118411 DOI: 10.1016/j.ejps.2021.105907] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/27/2021] [Revised: 04/30/2021] [Accepted: 06/07/2021] [Indexed: 10/21/2022]
Abstract
Electrospinning is a technology for manufacture of nano- and micro-sized fibers, which can enhance the dissolution properties of poorly water-soluble drugs. Tableting of electrospun fibers have been demonstrated in several studies, however, continuous manufacturing of tablets have not been realized yet. This research presents the first integrated continuous processing of milled drug-loaded electrospun materials to tablet form supplemented by process analytical tools for monitoring the active pharmaceutical ingredient (API) content. Electrospun fibers of an amorphous solid dispersion (ASD) of itraconazole and poly(vinylpyrrolidone-co-vinyl acetate) were produced using high speed electrospinning and afterwards milled. The milled fibers with an average fiber diameter of 1.6 ± 0.9 µm were continuously fed with a vibratory feeder into a twin-screw blender, which was integrated with a tableting machine to prepare tablets with ~ 10 kN compression force. The blend of fibers and excipients leaving the continuous blender was characterized with a bulk density of 0.43 g/cm3 and proved to be suitable for direct tablet compression. The ASD content, and thus the API content was determined in-line before tableting and at-line after tableting using near-infrared and Raman spectroscopy. The prepared tablets fulfilled the USP <905> content uniformity requirement based on the API content of ten randomly selected tablets. This work highlights that combining the advantages of electrospinning (e.g. less solvent, fast and gentle drying, low energy consumption, and amorphous products with high specific surface area) and the continuous technologies opens a new and effective way in the field of manufacturing of the poorly water-soluble APIs.
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Affiliation(s)
- Edina Szabó
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Petra Záhonyi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Martin Gyürkés
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Brigitta Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Dorián L Galata
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Lajos Madarász
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Edit Hirsch
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Attila Farkas
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Sune K Andersen
- Oral Solids Development, Janssen R&D, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - Tamás Vígh
- Oral Solids Development, Janssen R&D, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - Geert Verreck
- Oral Solids Development, Janssen R&D, B-2340 Beerse, Turnhoutseweg 30, Belgium
| | - István Csontos
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - György Marosi
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary
| | - Zsombor K Nagy
- Department of Organic Chemistry and Technology, Budapest University of Technology and Economics (BME), H-1111, Budapest, Műegyetem rakpart 3, Hungary.
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49
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Wahlich J. Review: Continuous Manufacturing of Small Molecule Solid Oral Dosage Forms. Pharmaceutics 2021; 13:1311. [PMID: 34452272 PMCID: PMC8400279 DOI: 10.3390/pharmaceutics13081311] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/29/2021] [Revised: 07/29/2021] [Accepted: 08/19/2021] [Indexed: 01/04/2023] Open
Abstract
Continuous manufacturing (CM) is defined as a process in which the input material(s) are continuously fed into and transformed, and the processed output materials are continuously removed from the system. CM can be considered as matching the FDA's so-called 'Desired State' of pharmaceutical manufacturing in the twenty-first century as discussed in their 2004 publication on 'Innovation and Continuous Improvement in Pharmaceutical Manufacturing'. Yet, focused attention on CM did not really start until 2014, and the first product manufactured by CM was only approved in 2015. This review describes some of the benefits and challenges of introducing a CM process with a particular focus on small molecule solid oral dosage forms. The review is a useful introduction for individuals wishing to learn more about CM.
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Affiliation(s)
- John Wahlich
- Academy of Pharmaceutical Sciences, c/o Bionow, Greenheys Business Centre, Manchester Science Park, Pencroft Way, Manchester M15 6JJ, UK
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50
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Domokos A, Pusztai É, Madarász L, Nagy B, Gyürkés M, Farkas A, Fülöp G, Casian T, Szilágyi B, Nagy ZK. Combination of PAT and mechanistic modeling tools in a fully continuous powder to granule line: Rapid and deep process understanding. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.04.059] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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