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Conway SL, Rosenberg KJ, Sotthivirat S, Goldfarb DJ. A Rational Hierarchy to Capture Raw Material Attribute Variability in the Pharmaceutical Drug Product Development and Manufacturing Lifecycle. J Pharm Sci 2024; 113:523-538. [PMID: 37838275 DOI: 10.1016/j.xphs.2023.10.014] [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: 06/14/2023] [Revised: 10/09/2023] [Accepted: 10/09/2023] [Indexed: 10/16/2023]
Abstract
Assessing the robustness of a drug product formulation and manufacturing process to variations in raw material (RM) properties is an essential aspect of pharmaceutical product development. Motivated by the need to demonstrate understanding of attribute-performance relationships at the time of new product registration and for subsequent process maintenance, we review practices to explore RM variations. We describe limitations that can arise when active ingredients and excipients invariably undergo changes during a drug product lifecycle. Historical approaches, such as Quality-by-Design (QbD) experiments, are useful for initial evaluations but can be inefficient and cumbersome to maintain once commercial manufacturing commences. The relatively miniscule data sets accessible in product development - used to predict response to a hypothetical risk of variation - become less relevant as real-world experience of actual variability in the commercial landscape grows. Based on our observations of development and manufacturing, we instead propose a holistic framework exploiting a hierarchy of RM variability, and challenge this with common failure modes. By explicitly incorporating higher ranking RM variations as perturbations, material-conserving experiments are shown to provide powerful and enduring robustness data. Case studies illustrate how correctly contextualizing such data in formulation and process development can avoid the traps of historical QbD approaches and become valuable for evaluating changes occurring later in the drug product lifecycle.
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Affiliation(s)
- Stephen L Conway
- Center for Materials Science and Engineering, MMD, Merck & Co., Inc., Rahway, NJ, USA; Current affiliation Packaging Commercialization, MMD Merck & Co., Inc., Rahway, NJ, USA.
| | - Kenneth J Rosenberg
- Center for Materials Science and Engineering, MMD, Merck & Co., Inc., Rahway, NJ, USA; Formerly of Merck & Co., Inc., Rahway, NJ, USA
| | - Sutthilug Sotthivirat
- Oral Formulation Sciences and Technology, MRL, Merck & Co., Inc., Rahway, NJ, USA; Formerly of Merck & Co., Inc., Rahway, NJ, USA
| | - David J Goldfarb
- Center for Materials Science and Engineering, MMD, Merck & Co., Inc., Rahway, NJ, USA
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Obeidat WM, Lahlouh IK, Gharaibeh SF. Investigations on Compaction Behavior of Kollidon ®SR-Based Multi-component Directly Compressed Tablets for Preparation of Controlled Release Diclofenac Sodium. AAPS PharmSciTech 2023; 24:225. [PMID: 37945987 DOI: 10.1208/s12249-023-02685-7] [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: 08/17/2023] [Accepted: 10/20/2023] [Indexed: 11/12/2023] Open
Abstract
The physics of tablets mixtures has gained much attention lately. The purpose of this work is to evaluate the compaction properties of Kollidon® SR (KSR) in the presence of different excipients such as Microcrystalline cellulose (MCC), Monohydrous lactose (MH Lactose), Poly (vinyl acetate) (PVA100), and a water-soluble drug Diclofenac sodium (DNa) to prepare once daily formulation. Tablets were prepared using direct compression and were compressed into flat-faced tablets using hydraulic press at various pressures. The combination of MCC and KSR in the tablets showed reduced porosity, and almost constant low Py values as KSR levels increased; also, KSR-DNa tablets had higher percentage porosity and crushing strength values than KSR-MH Lactose tablets. The crushing strengths of KSR-MCC tablets were larger than those of KSR-DNa tablets. Ternary mixture tablets comprised of KSR-MCC-DNa showed decreased porosities and low Py values as the percentage of KSR increased especially at high compression pressures but had higher crushing strengths compared to KSR-DNa or MCC-DNa binary tablets. KSR-MH Lactose-DNa ternary tablets experienced lower porosities and crushing strengths compared to KSR-MCC-DNa tablets. Quaternary tablets of KSR-PVA100-MCC-DNa showed lower porosity and Py values than quaternary tablets obtained using similar proportion of MH Lactose instead of MCC. In conclusion, optimum quaternary tablets were obtained with optimum crushing strengths, relatively low Py, and moderate percentage porosities among all prepared quaternary tablets. The drug release of the optimum quaternary tablets demonstrated similar in vitro release profile compared to that of the marketed product with a mechanism of release that follows Korsmeyer-Peppas model.
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Affiliation(s)
- Wasfy M Obeidat
- Faculty of Pharmacy, Department of Pharmaceutical Technology, Jordan University of Science and Technology, B. O. Box 3030, Irbid, 22110, Jordan.
| | - Ishraq K Lahlouh
- Faculty of Pharmacy, Department of Pharmaceutical Technology, Jordan University of Science and Technology, B. O. Box 3030, Irbid, 22110, Jordan
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Quality by design approach with multivariate analysis and artificial neural network models to understand and control excipient variability. JOURNAL OF PHARMACEUTICAL INVESTIGATION 2022. [DOI: 10.1007/s40005-022-00608-5] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
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A Multivariate Methodology for Material Sparing Characterization and Blend Design in Drug Product Development. Int J Pharm 2022; 621:121801. [DOI: 10.1016/j.ijpharm.2022.121801] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/23/2021] [Revised: 04/28/2022] [Accepted: 04/30/2022] [Indexed: 11/20/2022]
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Meng-Lund H, Holm TP, Poso A, Jorgensen L, Rantanen J, Grohganz H. Exploring the chemical space for freeze-drying excipients. Int J Pharm 2019; 566:254-263. [PMID: 31145963 DOI: 10.1016/j.ijpharm.2019.05.065] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/19/2019] [Revised: 05/22/2019] [Accepted: 05/25/2019] [Indexed: 10/26/2022]
Abstract
Commonly, a limited number of generally accepted bulking agents and lyoprotectants are used for freeze-drying; predominantly mannitol, glycine, sucrose and trehalose. The purpose of this study was to combine a theoretical approach using molecular descriptors with a large scale experimental screening to evaluate the suitability of a broad range of excipients for freeze-drying. A large selection of sugars, polyols and amino acids was characterized by modulated differential scanning calorimetry (mDSC) and X-ray powder diffraction (XRPD) after well-plate based freeze-drying. The calculated molecular descriptors were investigated with both hierarchical cluster analysis and principal component analysis. A clear clustering of the excipients according to the size-related and weight-related descriptors was observed; however other relevant descriptors could also be identified. From a practical perspective, a trend was observed with regard to a higher likelihood for amorphisation and a higher glass transition temperature of the maximally freeze-concentrated solution with increasing molecular size. A translation of the molecular descriptors on pharmaceutical performance was more successful for lyoprotectants than for bulking agents. Additionally, in the course of the experimental screening, several new potential bulking agents and lyoprotectants were identified.
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Affiliation(s)
- Helena Meng-Lund
- Department of Pharmacy, University of Copenhagen, Universitetsparken 2, 2100 Copenhagen, Denmark
| | - Tobias Palle Holm
- Department of Pharmacy, University of Copenhagen, Universitetsparken 2, 2100 Copenhagen, Denmark
| | - Antti Poso
- University of Eastern Finland, School of Pharmacy, Yliopistonranta 1, P.O. Box 1627, FI-70211 Kuopio, Finland; University Hospital Tübingen, Department of Internal Medicine VIII, Otfried-Müller-Strasse 14, 72076 Tübingen, Germany
| | - Lene Jorgensen
- Department of Pharmacy, University of Copenhagen, Universitetsparken 2, 2100 Copenhagen, Denmark
| | - Jukka Rantanen
- Department of Pharmacy, University of Copenhagen, Universitetsparken 2, 2100 Copenhagen, Denmark
| | - Holger Grohganz
- Department of Pharmacy, University of Copenhagen, Universitetsparken 2, 2100 Copenhagen, Denmark.
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Leane M, Pitt K, Reynolds GK, Dawson N, Ziegler I, Szepes A, Crean AM, Dall Agnol R, The Manufacturing Classification System McS Working Group. Manufacturing classification system in the real world: factors influencing manufacturing process choices for filed commercial oral solid dosage formulations, case studies from industry and considerations for continuous processing. Pharm Dev Technol 2018; 23:964-977. [PMID: 30320539 DOI: 10.1080/10837450.2018.1534863] [Citation(s) in RCA: 50] [Impact Index Per Article: 8.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
Abstract
Following the first Manufacturing Classification System (MCS) paper, the team conducted surveys to establish which active pharmaceutical ingredient (API) properties were important when selecting or modifying materials to enable an efficient and robust pharmaceutical manufacturing process. The most commonly identified factors were (1) API particle size: small particle sizes are known to increase risk of processing issues; (2) Drug loading in the formulation: high drug loadings allow less opportunity to mitigate poor API properties through the use of excipients. The next step was to establish linkages with process decisions by identifying publicly-available proxies for these important parameters: dose (in place of drug loading) and BCS class (in place of particle size). Poorly-soluble API were seen as more likely to have controlled (smaller) particle size than more highly soluble API. Analysis of 435 regulatory filings revealed that higher doses and more poorly-soluble API was associated with more complex processing routes. Replacing the proxy factors with the original parameters should give the opportunity to demonstrate stronger trends. This assumption was tested by accessing a dataset relating to commercial tablet products. This showed that, for dry processes, a larger particle size was associated with higher achievable drug loading as determined by percolation threshold.
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Affiliation(s)
- Michael Leane
- a Drug Product Science & Technology (DPST), Bristol-Myers Squibb , Moreton , UK
| | - Kendal Pitt
- b Global Manufacturing and Supply, GlaxoSmithKline , Ware , UK
| | | | - Neil Dawson
- d Global Research and Development, Pfizer , Sandwich , UK
| | - Iris Ziegler
- e Corden Pharma International GmbH , Plankstadt , Germany
| | - Aniko Szepes
- f Research and Development Division, F. Hoffmann-La Roche AG , Basel , Switzerland
| | - Abina M Crean
- g Pharmaceutical Manufacturing Technology Centre, School of Pharmacy , University College Cork - National University of Ireland , Cork , Ireland.,h Synthesis and Solid State Pharmaceutical Centre, School of Pharmacy , University College Cork - National University of Ireland , Cork , Ireland
| | - Rafaela Dall Agnol
- i Curso de Farmácia, Centro de Ciências Biológicas e da Saúde , Universidade de Caxias do Sul , Caxias do Sul , Brazil
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Ferreira AP, Gamble JF, Leane MM, Park H, Olusanmi D, Tobyn M. Enhanced Understanding of Pharmaceutical Materials Through Advanced Characterisation and Analysis. AAPS PharmSciTech 2018; 19:3462-3480. [PMID: 30411240 DOI: 10.1208/s12249-018-1198-6] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/04/2018] [Accepted: 09/26/2018] [Indexed: 11/30/2022] Open
Abstract
The impact of pharmaceutical materials properties on drug product quality and manufacturability is well recognised by the industry. An ongoing effort across industry and academia, the Manufacturing Classification System consortium, aims to gather the existing body of knowledge in a common framework to provide guidance on selection of appropriate manufacturing technologies for a given drug and/or guide optimization of the physical properties of the drug to facilitate manufacturing requirements for a given processing route. Simultaneously, material scientists endeavour to develop characterisation methods such as size, shape, surface area, density, flow and compactibility that enable a stronger understanding of materials powder properties. These properties are routinely tested drug product development and advances in instrumentation and computing power have enabled novel characterisation methods which generate larger, more complex data sets leading to a better understanding of the materials. These methods have specific requirements in terms of data management and analysis. An appropriate data management strategy eliminates time-consuming data collation steps and enables access to data collected for multiple methods and materials simultaneously. Methods ideally suited to extract information from large, complex data sets such as multivariate projection methods allow simpler representation of the variability contained within the data and easier interpretation of the key information it contains. In this review, an overview of the current knowledge and challenges introduced by modern pharmaceutical material characterisation methods is provided. Two case studies illustrate how the incorporation of multivariate analysis into the material sciences workflow facilitates a better understanding of materials.
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Tobyn M, Ferreira AP, Lightfoot J, Martin EB, Ghimire M, Vesey C, Kasuboski-Freeman A, Rajabi-Siahboomi A. Multivariate analysis as a method to understand variability in a complex excipient, and its contribution to formulation performance. Pharm Dev Technol 2018; 23:1146-1155. [PMID: 30303433 DOI: 10.1080/10837450.2018.1534862] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
Abstract
A key part of the Risk Assessment of excipients is to understand how raw material variability could (or does) contribute to differences in performance of the drug product. Here we demonstrate an approach which achieves the necessary understanding for a complex, functional, excipient. Multivariate analysis (MVA) of the certificates of analysis of an ethylcellulose aqueous dispersion (Surelease) formulation revealed low overall variability of the properties of the systems. Review of the scores plot to highlight batches manufactured using the same ethylcellulose raw material in the formulation, indicated that these batches tend to be more closely related than other randomly selected batches. This variability could result in potential differences in the quality of drug product lots made from these batches. Manufacture of a model drug product from Surelease batches coated using different lots of starting material revealed small differences in the release of a model drug, which could be detected by certain model dependent dissolution modeling techniques, but they were not observed when using model-independent techniques. This illustrates that the techniques are suitable for detecting and understanding excipient variability, but that, in this case, the product was still robust.
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Affiliation(s)
- Mike Tobyn
- a Drug Product Science & Technology , Bristol-Myers Squibb , Moreton, Wirral , UK
| | | | - Jane Lightfoot
- b Department of Chemical Engineering and Advanced Materials , University of Newcastle , Newcastle , UK
| | - Elaine B Martin
- b Department of Chemical Engineering and Advanced Materials , University of Newcastle , Newcastle , UK
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Chattoraj S, Daugherity P, McDermott T, Olsofsky A, Roth WJ, Tobyn M. Sticking and Picking in Pharmaceutical Tablet Compression: An IQ Consortium Review. J Pharm Sci 2018; 107:2267-2282. [DOI: 10.1016/j.xphs.2018.04.029] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/06/2018] [Revised: 04/23/2018] [Accepted: 04/27/2018] [Indexed: 12/20/2022]
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Xu X, Mack C, Cleland ZJ, Vallabh CKP, Dave VS, Cetinkaya C. Correlation of solid dosage porosity and tensile strength with acoustically extracted mechanical properties. Int J Pharm 2018. [DOI: 10.1016/j.ijpharm.2018.03.018] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
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Hertrampf A, Müller H, Menezes J, Herdling T. Advanced qualification of pharmaceutical excipient suppliers by multiple analytics and multivariate analysis combined. Int J Pharm 2015; 495:447-458. [DOI: 10.1016/j.ijpharm.2015.08.098] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/20/2015] [Revised: 08/27/2015] [Accepted: 08/29/2015] [Indexed: 10/23/2022]
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12
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Understanding the impact of microcrystalline cellulose physicochemical properties on tabletability. Int J Pharm 2015; 490:47-54. [DOI: 10.1016/j.ijpharm.2015.05.026] [Citation(s) in RCA: 46] [Impact Index Per Article: 5.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/03/2015] [Revised: 05/07/2015] [Accepted: 05/09/2015] [Indexed: 11/22/2022]
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Dave VS, Saoji SD, Raut NA, Haware RV. Excipient Variability and Its Impact on Dosage Form Functionality. J Pharm Sci 2015; 104:906-15. [DOI: 10.1002/jps.24299] [Citation(s) in RCA: 64] [Impact Index Per Article: 7.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/15/2014] [Revised: 10/30/2014] [Accepted: 11/14/2014] [Indexed: 11/08/2022]
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Thoorens G, Krier F, Leclercq B, Carlin B, Evrard B. Microcrystalline cellulose, a direct compression binder in a quality by design environment—A review. Int J Pharm 2014; 473:64-72. [DOI: 10.1016/j.ijpharm.2014.06.055] [Citation(s) in RCA: 231] [Impact Index Per Article: 23.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/26/2014] [Revised: 06/22/2014] [Accepted: 06/27/2014] [Indexed: 10/25/2022]
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Ferreira AP, Tobyn M. Multivariate analysis in the pharmaceutical industry: enabling process understanding and improvement in the PAT and QbD era. Pharm Dev Technol 2014; 20:513-27. [DOI: 10.3109/10837450.2014.898656] [Citation(s) in RCA: 60] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022]
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16
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Kushner J, Langdon BA, Hicks I, Song D, Li F, Kathiria L, Kane A, Ranade G, Agarwal K. A Quality-by-Design Study for an Immediate-Release Tablet Platform: Examining the Relative Impact of Active Pharmaceutical Ingredient Properties, Processing Methods, and Excipient Variability on Drug Product Quality Attributes. J Pharm Sci 2014; 103:527-38. [DOI: 10.1002/jps.23810] [Citation(s) in RCA: 28] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/31/2013] [Revised: 10/22/2013] [Accepted: 10/29/2013] [Indexed: 11/10/2022]
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