1
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Sobral GG, Gomes Neto OC, Lima TC, Carneiro GF. Lyophilization as an alternative for conservation of equine plasma as a source of immunoglobulin G for neonatal foals. J Equine Vet Sci 2024; 141:105139. [PMID: 38964562 DOI: 10.1016/j.jevs.2024.105139] [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: 11/30/2023] [Revised: 06/19/2024] [Accepted: 06/26/2024] [Indexed: 07/06/2024]
Abstract
Providing plasma with immunoglobulins is essential for the health of foals with failure of passive transfer of immunity. The use of lyophilized plasma (LP) offers a simple and affordable option in terms of transportation and storage. This study aimed to measure the concentrations of immunoglobulin G (IgG), total protein (TP), and total solids (TS) in fresh equine plasma before and after lyophilization. Plasma was collected from six healthy male horses. The samples underwent freeze-drying and were reconstituted in deionized water to their original volume. The concentrations of IgG in both fresh and reconstituted LP were determined by simple radial immunodiffusion and TS and TP concentrations measured using refractometry. Results indicated that the IgG concentration in fresh plasma (8.9 ± 3.2 g/L) was not different from LP (7.1 ± 2.2 g/L; P > 0.05). The TP concentration in fresh plasma was 6.6 ± 0.5 g/dL, which decreased to 5.7 ± 0.2 g/dL after lyophilization (P < 0.05). The TS of fresh plasma were 7.5 ± 0.8 %, and also lower in LP 6.3 ± 0.5 % (P < 0.05). The findings revealed that the lyophilization process preserves IgG concentration with small losses in TS and TP upon reconstitution. The research supports the potential of lyophilized equine plasma as a promising treatment option, with future efforts focused on optimizing the product, validating its efficacy and stability through clinical trials, and developing practical packaging solutions for use in the equine industry.
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Affiliation(s)
- G G Sobral
- Department of Veterinary Medicine, School of Veterinary Medicine, Federal Rural University of Pernambuco, Dom Manuel de Medeiros, s/n - Dois Irmãos, Recife, PE, 52171-900, Brazil.
| | - O C Gomes Neto
- Central Monte Verde de Reprodução Equina, Fazenda Japecanga, s/n, Bezerros, PE, 55660-000, Brazil
| | - T C Lima
- Department of Veterinary Medicine, School of Veterinary Medicine, Federal Rural University of Pernambuco, Dom Manuel de Medeiros, s/n - Dois Irmãos, Recife, PE, 52171-900, Brazil
| | - G F Carneiro
- Department of Veterinary Medicine, School of Veterinary Medicine, Federal Rural University of Pernambuco, Dom Manuel de Medeiros, s/n - Dois Irmãos, Recife, PE, 52171-900, Brazil
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2
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Brom JA, Petrikis RG, Nieukirk GE, Bourque J, Pielak GJ. Protecting Lyophilized Escherichia coli Adenylate Kinase. Mol Pharm 2024; 21:3634-3642. [PMID: 38805365 DOI: 10.1021/acs.molpharmaceut.4c00356] [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] [Indexed: 05/30/2024]
Abstract
Drying protein-based drugs, usually via lyophilization, can facilitate storage at ambient temperature and improve accessibility but many proteins cannot withstand drying and must be formulated with protective additives called excipients. However, mechanisms of protection are poorly understood, precluding rational formulation design. To better understand dry proteins and their protection, we examine Escherichia coli adenylate kinase (AdK) lyophilized alone and with the additives trehalose, maltose, bovine serum albumin, cytosolic abundant heat soluble protein D, histidine, and arginine. We apply liquid-observed vapor exchange NMR to interrogate the residue-level structure in the presence and absence of additives. We pair these observations with differential scanning calorimetry data of lyophilized samples and AdK activity assays with and without heating. We show that the amino acids do not preserve the native structure as well as sugars or proteins and that after heating the most stable additives protect activity best.
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Affiliation(s)
- Julia A Brom
- Department of Chemistry, University of North Carolina at Chapel Hill (UNC-CH), 3250 Genome Sciences Building, Chapel Hill, North Carolina 27599-3290, United States
| | - Ruta G Petrikis
- Department of Chemistry, University of North Carolina at Chapel Hill (UNC-CH), 3250 Genome Sciences Building, Chapel Hill, North Carolina 27599-3290, United States
| | - Grace E Nieukirk
- Department of Chemistry, University of North Carolina at Chapel Hill (UNC-CH), 3250 Genome Sciences Building, Chapel Hill, North Carolina 27599-3290, United States
| | - Joshua Bourque
- Department of Chemistry, University of North Carolina at Chapel Hill (UNC-CH), 3250 Genome Sciences Building, Chapel Hill, North Carolina 27599-3290, United States
| | - Gary J Pielak
- Department of Chemistry, University of North Carolina at Chapel Hill (UNC-CH), 3250 Genome Sciences Building, Chapel Hill, North Carolina 27599-3290, United States
- Department of Biochemistry & Biophysics, UNC-CH, Chapel Hill, North Carolina 27599, United States
- Lineberger Cancer Center, UNC-CH, Chapel Hill, North Carolina 27599, United States
- Integrative Program for Biological and Genome Sciences, UNC-CH, Chapel Hill, North Carolina 27599, United States
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3
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Kang WY, Shin EK, Kim EH, Kang MH, Bang CY, Bang OY, Cha JM. Lyoprotectant Constituents Suited for Lyophilization and Reconstitution of Stem-Cell-Derived Extracellular Vesicles. Biomater Res 2024; 28:0005. [PMID: 38327614 PMCID: PMC10845601 DOI: 10.34133/bmr.0005] [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: 09/13/2023] [Accepted: 01/01/2024] [Indexed: 02/09/2024] Open
Abstract
Stem-cell-derived extracellular vesicles (EVs) are emerging as an alternative approach to stem cell therapy. Successful lyophilization of EVs could enable convenient storage and distribution of EV medicinal products at room temperature for long periods, thus considerably increasing the accessibility of EV therapeutics to patients. In this study, we aimed to identify an appropriate lyoprotectant composition for the lyophilization and reconstitution of stem-cell-derived EVs. MSC-derived EVs were lyophilized using different lyoprotectants, such as dimethyl sulfoxide, mannitol, trehalose, and sucrose, at varying concentrations. Our results revealed that a mixture of trehalose and sucrose at high concentrations could support the formation of amorphous ice by enriching the amorphous phase of the solution, which successfully inhibited the acceleration of buffer component crystallization during lyophilization. Lyophilized and reconstituted EVs were thoroughly evaluated for concentration and size, morphology, and protein and RNA content. The therapeutic effects of the reconstituted EVs were examined using a tube formation assay with human umbilical vein endothelial cells. After rehydration of the lyophilized EVs, most of their generic characteristics were well-maintained, and their therapeutic capacity recovered to levels similar to those of freshly collected EVs. The concentrations and morphologies of the lyophilized EVs were similar to the initial features of the fresh EV group until day 30 at room temperature, although their therapeutic capacity appeared to decrease after 7 days. Our study suggests an appropriate composition of lyoprotectants, particularly for EV lyophilization, which could encourage the applications of stem-cell-derived EV therapeutics in the health industry.
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Affiliation(s)
- Wu Young Kang
- Department of Biomedical & Robotics Engineering, College of Engineering,
Incheon National University, Incheon 22012, Republic of Korea
- 3D Stem Cell Bioengineering Laboratory, Research Institute for Engineering and Technology,
Incheon National University, Incheon 22012, Republic of Korea
| | | | - Eun Hee Kim
- S&E bio Co., Ltd., Seoul 06351, Republic of Korea
| | - Min-Ho Kang
- Department of BioMedical-Chemical Engineering (BMCE),
The Catholic University of Korea, Bucheon 14662, Republic of Korea
- Department of Biotechnology,
The Catholic University of Korea, Bucheon 14662, Republic of Korea
| | - Chi Young Bang
- Department of Plastic and Reconstructive Surgery,
Kangwon National University Hospital, Chuncheon 24341, Republic of Korea
| | - Oh Young Bang
- S&E bio Co., Ltd., Seoul 06351, Republic of Korea
- Department of Neurology, Samsung Medical Center,
Sungkyunkwan University School of Medicine, Seoul 06351, Republic of Korea
| | - Jae Min Cha
- Department of Biomedical & Robotics Engineering, College of Engineering,
Incheon National University, Incheon 22012, Republic of Korea
- 3D Stem Cell Bioengineering Laboratory, Research Institute for Engineering and Technology,
Incheon National University, Incheon 22012, Republic of Korea
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4
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Li J, Wang H, Wang L, Yu D, Zhang X. Stabilization effects of saccharides in protein formulations: A review of sucrose, trehalose, cyclodextrins and dextrans. Eur J Pharm Sci 2024; 192:106625. [PMID: 37918545 DOI: 10.1016/j.ejps.2023.106625] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/25/2023] [Revised: 10/13/2023] [Accepted: 10/30/2023] [Indexed: 11/04/2023]
Abstract
Saccharides are a popular group of stabilizers in liquid, frozen and freeze dried protein formulations. The current work reviewed the stabilization mechanisms of three groups of saccharides: (i) Disaccharides, specifically sucrose and trehalose; (ii) cyclodextrins (CDs), a class of cyclic oligosaccharides; and (iii) dextrans, a class of polysaccharides. Compared to sucrose, trehalose exhibits a more pronounced preferential exclusion effect in liquid protein formulations, due to its stronger interaction with water molecules. However, trehalose obtains higher phase separation and crystallization propensity in frozen solutions, resulting in the loss of its stabilization function. In lyophilized formulations, sucrose has a higher crystallization propensity. Besides, its glass matrix is less homogeneous than that of trehalose, thus undermining its lyoprotectant function. Nevertheless, the hygroscopic nature of trehalose may result in high water absorption upon storage. Among all the CDs, the β form is believed to have stronger interactions with proteins than the α- and γ-CDs. However, the stabilization effect, brought about by CD-protein interactions, is case-by-case - in some examples, such interactions can promote protein destabilization. The stabilization effect of hydroxypropyl-β-cyclodextrin (HPβCD) has been extensively studied. Due to its amphiphilic nature, it can act as a surface-active agent in preventing interfacial stresses. Besides, it is a dual functional excipient in freeze dried formulations, acting as an amorphous bulking agent and lyoprotectant. Finally, dextrans, when combined with sucrose or trehalose, can be used to produce stable freeze dried protein formulations. A strong stabilization effect can be realized by low molecular weight dextrans. However, the terminal glucose in dextrans yields protein glycation, which warrants extra caution during formulation development.
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Affiliation(s)
- Jinghan Li
- Department of Pharmaceutics, College of Pharmacy, University of Minnesota, Minneapolis, MN 55455, United States
| | - Hongyue Wang
- School of Functional Food and Wine, Shenyang Pharmaceutical University, Shenyang 110016, PR China
| | - Lushan Wang
- Department of Pharmaceutics, College of Pharmacy, University of Minnesota, Minneapolis, MN 55455, United States; Brain Barriers Research Center, College of Pharmacy, University of Minnesota, Minneapolis, MN 55455, United States
| | - Dongyue Yu
- Pharmaceutical Candidate Optimization, Bristol Myers Squibb, Route 206 and Province Line Road, Princeton, NJ 08540, USA
| | - Xiangrong Zhang
- School of Functional Food and Wine, Shenyang Pharmaceutical University, Shenyang 110016, PR China.
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5
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Härdter N, Geidobler R, Presser I, Winter G. Microwave-Assisted Freeze-Drying: Impact of Microwave Radiation on the Quality of High-Concentration Antibody Formulations. Pharmaceutics 2023; 15:2783. [PMID: 38140123 PMCID: PMC10747838 DOI: 10.3390/pharmaceutics15122783] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/02/2023] [Revised: 11/22/2023] [Accepted: 12/11/2023] [Indexed: 12/24/2023] Open
Abstract
Microwave-assisted freeze-drying (MFD) offers significant time savings compared to conventional freeze-drying (CFD). While a few studies have investigated the stability of biopharmaceuticals with low protein concentrations after MFD and storage, the impact of MFD on high-concentration monoclonal antibody (mAb) formulations remains unclear. In this study, we systematically examined the effect of protein concentration in MFD and assessed protein stability following MFD, CFD, and subsequent storage using seven protein formulations with various stabilizers and concentrations. We demonstrated that microwaves directly interact with the active pharmaceutical ingredient (API), leading to decreased physical stability, specifically aggregation, in high-concentration antibody formulations. Furthermore, typically used sugar:protein ratios from CFD were insufficient for stabilizing mAbs when applying microwaves. We identified the intermediate drying phase as the most critical for particle formation, and cooling the samples provided some protection for the mAb. Our findings suggest that MFD technology may not be universally applicable to formulations well tested in CFD and could be particularly beneficial for formulations with low API concentrations requiring substantial amounts of glass-forming excipients, such as vaccines and RNA-based products.
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Affiliation(s)
- Nicole Härdter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Raimund Geidobler
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Ingo Presser
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Gerhard Winter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
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6
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Coussot G, Le Postollec A, Delbecq S, Dobrijevic M. Freeze-drying of few microliters of antibody formulations to implement 384-wells homogeneous instant assays. Anal Chim Acta 2023; 1277:341660. [PMID: 37604613 DOI: 10.1016/j.aca.2023.341660] [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: 05/19/2023] [Revised: 07/03/2023] [Accepted: 07/25/2023] [Indexed: 08/23/2023]
Abstract
Enzyme-linked immunosorbent assay protocols have traditionally complex workflows with several intensive wash steps. Analytical tools with both shorter time-to-result and hands-on-time using smaller sample and assays reagents volumes are now investigated. In this context, fluorescence resonance energy transfer (FRET)-based assays are emerging as one of the most promising analytical tools in high-throughput screening (HTS). These immunoassays allow fast quantification of antigens at the nano-gram level in a final assay volume of only a few μL. We used a homogeneous time-resolved FRET (called HTRF) assay to develop a freeze-dried screening and ready-to-use format with only one rehydration step called "instant assay". To assure optimal performance of the developed homogeneous instant assay, we investigated the critical quality attributes by studying the functionality and stability of the critical reagents and fluorophores. The cyclic adenosine 3'-5'-monophosphate (cAMP) was selected as the antigen target. We tested various formulations (with different buffers, sugars, bulking reagents, surfactants and co-solvants) combined with a slow freezing and the use of an aluminium plate holder during the freeze-drying of few microliter of bioreagents. The optimized freeze-drying procedure permits to preserve more than 70% of Ab recognition properties. The developed off-the-shelf homogeneous FRET immunoassay allows direct and fast quantification of cAMP at a nanogram level.
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Affiliation(s)
- G Coussot
- Faculté des Sciences Pharmaceutiques et Biologiques, Université de Montpellier, 15 Avenue Charles Flahault, 34090, Montpellier, France.
| | - A Le Postollec
- Laboratoire d'astrophysique de Bordeaux (LAB), CNRS UMR 5804, Université de Bordeaux, B18N, allée Geoffroy Saint-Hilaire, 33615, Pessac, France
| | - S Delbecq
- Centre de Biologie Structurale (CBS), INSERM U1054, CNRS UMR 5048, Université de Montpellier, 34090, Montpellier, France
| | - M Dobrijevic
- Laboratoire d'astrophysique de Bordeaux (LAB), CNRS UMR 5804, Université de Bordeaux, B18N, allée Geoffroy Saint-Hilaire, 33615, Pessac, France
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7
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Kharatyan T, Igawa S, Gopireddy SR, Ogawa T, Kodama T, Scherließ R, Urbanetz NA. Impact of Post-Freeze Annealing on Shrinkage of Sucrose and Trehalose Lyophilisates. Int J Pharm 2023; 641:123051. [PMID: 37196881 DOI: 10.1016/j.ijpharm.2023.123051] [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: 10/11/2022] [Revised: 04/30/2023] [Accepted: 05/11/2023] [Indexed: 05/19/2023]
Abstract
Freeze-drying of pharmaceuticals produces lyophilisates with properties that depend on both the formulation and the process. Characterisation of the lyophilisate in terms of appearance is necessary not only to produce a visually appealing product, but also to gain insight into the freeze-drying process. The present study investigates the impact of post-freeze annealing on the volume of lyophilisates. For this purpose, sucrose and trehalose solutions were freeze-dried with different annealing conditions and the resulting lyophilisates were analysed with a 3D structured light scanner. The external structure of the lyophilisates was found to be dependent on the bulk materials as well as the choice of vials, while the volume was influenced by the annealing time and temperature. Additionally, differential scanning calorimetry was used to determine glass transition temperatures of frozen samples. As a novelty, the volumes of the lyophilisates and their corresponding glass transition temperatures were compared. This resulted in a correlation supporting the theory that the shrinkage of lyophilisates depends on the amount of residual water in the freeze-concentrated amorphous phase before drying. Understanding the volume change of lyophilisates, in combination with material properties such as glass transition temperature, forms the basis for relating physicochemical properties to process parameters in lyophilisation.
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Affiliation(s)
- Tigran Kharatyan
- Department of Pharmaceutics and Biopharmaceutics, Kiel University, 24118 Kiel, Germany; Pharmaceutical Development, Daiichi-Sankyo Europe GmbH, 85276 Pfaffenhofen an der Ilm, Germany.
| | - Shunya Igawa
- Formulation Technology Research Laboratories, Daiichi Sankyo Co. Ltd., Hiratsuka 254-0014, Japan.
| | - Srikanth R Gopireddy
- Pharmaceutical Development, Daiichi-Sankyo Europe GmbH, 85276 Pfaffenhofen an der Ilm, Germany.
| | - Toru Ogawa
- Pharmaceutical Development, Daiichi-Sankyo Europe GmbH, 85276 Pfaffenhofen an der Ilm, Germany.
| | - Tatsuhiro Kodama
- Formulation Technology Research Laboratories, Daiichi Sankyo Co. Ltd., Hiratsuka 254-0014, Japan.
| | - Regina Scherließ
- Department of Pharmaceutics and Biopharmaceutics, Kiel University, 24118 Kiel, Germany.
| | - Nora A Urbanetz
- Pharmaceutical Development, Daiichi-Sankyo Europe GmbH, 85276 Pfaffenhofen an der Ilm, Germany.
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8
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Härdter N, Geidobler R, Presser I, Winter G. Accelerated Production of Biopharmaceuticals via Microwave-Assisted Freeze-Drying (MFD). Pharmaceutics 2023; 15:pharmaceutics15051342. [PMID: 37242584 DOI: 10.3390/pharmaceutics15051342] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2023] [Revised: 04/23/2023] [Accepted: 04/24/2023] [Indexed: 05/28/2023] Open
Abstract
Recently, attention has been drawn to microwave-assisted freeze-drying (MFD), as it drastically reduces the typically long drying times of biopharmaceuticals in conventional freeze-drying (CFD). Nevertheless, previously described prototype machines lack important attributes such as in-chamber freezing and stoppering, not allowing for the performance of representative vial freeze-drying processes. In this study, we present a new technical MFD setup, designed with GMP processes in mind. It is based on a standard lyophilizer equipped with flat semiconductor microwave modules. The idea was to enable the retrofitting of standard freeze-dryers with a microwave option, which would reduce the hurdles of implementation. We aimed to collect process data with respect to the speed, settings, and controllability of the MFD processes. Moreover, we studied the performance of six monoclonal antibody (mAb) formulations in terms of quality after drying and stability after storage for 6 months. We found drying processes to be drastically shortened and well controllable and observed no signs of plasma discharge. The characterization of the lyophilizates revealed an elegant cake appearance and remarkably good stability in the mAb after MFD. Furthermore, overall storage stability was good, even when residual moisture was increased due to high concentrations of glass-forming excipients. A direct comparison of stability data following MFD and CFD demonstrated similar stability profiles. We conclude that the new machine design is highly advantageous, enabling the fast-drying of excipient-dominated, low-concentrated mAb formulations in compliance with modern manufacturing technology.
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Affiliation(s)
- Nicole Härdter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Raimund Geidobler
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Ingo Presser
- Boehringer Ingelheim Pharma GmbH & Co. KG, Pharmaceutical Development Biologicals, 88397 Biberach an der Riß, Germany
| | - Gerhard Winter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
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9
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Emami S, Ebrahimi M. Bioactive wound powders as wound healing dressings and drug delivery systems. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118501] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 04/03/2023]
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10
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Part I: Significant reduction of lyophilization process times by using novel matrix based scaffolds. Eur J Pharm Biopharm 2023; 184:248-261. [PMID: 36529257 DOI: 10.1016/j.ejpb.2022.12.008] [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: 09/18/2022] [Revised: 12/02/2022] [Accepted: 12/12/2022] [Indexed: 12/23/2022]
Abstract
To improve the long-term stability of drugs with limited stability (e.g., biologicals such as monoclonal antibodies, antibody drug conjugates or peptides), some pharmaceuticals endure a lengthy and cost-intensive process called lyophilization. While the shelf life of lyophilized drugs may be prolonged compared to their liquid form, the drawbacks come in the form of intensified manufacturing, preparation, and dosing efforts. The use of glass vials as the primary container unit for lyophilized products hinders their complication-free, fast and flexible use, as they require a skilled healthcare professional and an aseptic environment in which to prepare them. The feasibility of substituting glass vials with novel container designs offering the complete transfer of the lyophilizate cake into modern administration devices, while reducing the economic footprint of the lyophilization process, was investigated. The lyophilization process of a monoclonal antibody solution was studied by assessing primary drying conditions, homogeneity of the drying process, and critical quality attributes after successful lyophilization. The creation of novel container designs utilized vacuum-forming to generate confined containers with removable bottoms and rapid prototyping, including subtractive and additive manufacturing methods, to generate porous 3D structures for drug housing. The novel container designs generated lyophilizates twice as fast and achieved a threefold faster reconstitution compared to their vial counterparts, without adaptation of the processing conditions. We conclude that the use of intermediate process containers offers significant relief for healthcare professionals in terms of reduced probability of handling errors, while drug manufacturers benefit from the accelerated processing times, increased batch homogeneity, and sustainability.
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11
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Dauer K, Werner C, Lindenblatt D, Wagner KG. Impact of process stress on protein stability in highly-loaded solid protein/PEG formulations from small-scale melt extrusion. Int J Pharm X 2022; 5:100154. [PMID: 36632069 PMCID: PMC9826855 DOI: 10.1016/j.ijpx.2022.100154] [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: 09/23/2022] [Revised: 12/22/2022] [Accepted: 12/23/2022] [Indexed: 12/31/2022] Open
Abstract
As protein-based therapeutics often exhibit a limited stability in liquid formulations, there is a growing interest in the development of solid protein formulations due to improved protein stability in the solid state. We used small-scale (<3 g) ram and twin-screw extrusion for the solid stabilization of proteins (Lysozyme, BSA, and human insulin) in PEG-matrices. Protein stability after extrusion was systematically investigated using ss-DSC, ss-FTIR, CD spectroscopy, SEM-EDX, SEC, RP-HPLC, and in case of Lysozyme an activity assay. The applied analytical methods offered an accurate assessment of protein stability in extrudates, enabling the comparison of different melt extrusion formulations and process parameters (e.g., shear stress levels, screw configurations, residence times). Lysozyme was implemented as a model protein and was completely recovered in its active form after extrusion. Differences seen between Lysozyme- and BSA- or human insulin-loaded extrudates indicated that melt extrusion could have an impact on the conformational stability. In particular, BSA and human insulin were more susceptible to heat exposure and shear stress compared to Lysozyme, where shear stress was the dominant parameter. Consequently, ram extrusion led to less conformational changes compared to TSE. Ram extrusion showed good protein particle distribution resulting in the preferred method to prepare highly-loaded solid protein formulations.
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Key Words
- BSA, bovine serum albumin
- BSE, backscattered electron
- CD, circular dichroism
- DSC, Differential Scanning Calorimetry
- EDX, energy-dispersive X-ray detector
- EVA, Ethylene-vinyl acetate
- FTIR, Fourier transformation infrared spectroscopy
- HME, hot-melt extrusion
- HMWS, high molecular weight species
- Hot-melt extrusion
- PEG, polyethylene glycol
- PEO, polyethylene oxide
- PLGA, Poly Lactic-co-Glycolic Acid
- Protein stability
- SEM, scanning electron microscopy
- Small-scale
- Solid-state characterization
- TSE, twin-screw extrusion
- ss, solid-state
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Affiliation(s)
- Katharina Dauer
- University of Bonn, Department of Pharmaceutics, Institute of Pharmacy, Bonn, Germany
| | - Christian Werner
- University of Cologne, Department of Chemistry, Institute of Biochemistry, Cologne, Germany
| | - Dirk Lindenblatt
- University of Cologne, Department of Chemistry, Institute of Biochemistry, Cologne, Germany
| | - Karl Gerhard Wagner
- University of Bonn, Department of Pharmaceutics, Institute of Pharmacy, Bonn, Germany
- Corresponding author at: University of Bonn, Department of Pharmaceutics, 53121 Bonn, Germany.
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12
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Palmkron SB, Bergenståhl B, Håkansson S, Wahlgren M, Fureby AM, Larsson E. Quantification of structures in freeze-dried materials using X-ray microtomography. Colloids Surf A Physicochem Eng Asp 2022. [DOI: 10.1016/j.colsurfa.2022.130726] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/02/2022]
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13
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Kommineni N, Butreddy A, Sainaga Jyothi VG, Angsantikul P. Freeze-drying for the preservation of immunoengineering products. iScience 2022; 25:105127. [PMID: 36267916 PMCID: PMC9576584 DOI: 10.1016/j.isci.2022.105127] [Citation(s) in RCA: 7] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022] Open
Abstract
Immunoengineering technologies harness the power of immune system modulators such as monoclonal antibodies, cytokines, and vaccines to treat myriad diseases. Immunoengineering innovations have showed great promise in various practices including oncology, infectious disease, autoimmune diseases, and transplantation. Despite the countless successes, the majority of immunoengineering products contain active moieties that are prone to instability. The current review aims to feature freeze-drying as a robust and scalable solution to the inherent stability challenges in immunoengineering products by preventing the active moiety from degradation. Furthermore, this review describes the stability issues related to immunoengineering products and the utility of the lyophilization process to preserve the integrity and efficacy of immunoengineering tools ranging from biologics to nanoparticle-based vaccines. The concept of the freeze-drying process is described highlighting the quality by design (QbD) for robust process optimization. Case studies of lyophilized immunoengineering technologies and relevant clinical studies using immunoengineering products are discussed.
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Affiliation(s)
| | - Arun Butreddy
- Department of Pharmaceutics and Drug Delivery, School of Pharmacy, The University of Mississippi, Oxford, MS 38677, USA
| | - Vaskuri G.S. Sainaga Jyothi
- Department of Pharmaceutics, National Institute of Pharmaceutical Education and Research, Hyderabad, Telangana 500037, India
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Hsein H, Auffray J, Noel T, Tchoreloff P. Recent advances and persistent challenges in the design of freeze-drying process for monoclonal antibodies. Pharm Dev Technol 2022; 27:942-955. [PMID: 36206457 DOI: 10.1080/10837450.2022.2131818] [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: 10/24/2022]
Abstract
Monoclonal antibodies constitute nowadays an important therapeutic class and the number of approved molecules for clinical uses continues to increase, achieving considerable part of the therapeutic market. Yet, the stability in solution of these biopharmaceuticals is often low. That's why freeze-drying has been and remains the method of choice to obtain monoclonal antibodies in the solid state and to improve their stability. The design of freeze-drying process and its optimization are still topical subjects of interest and the pharmaceutical industry is regularly challenged by the requirements of quality, safety and efficiency set by the regulatory authorities. These requirements imply a deep understanding of each step of the freeze-drying process, developing techniques to control the critical parameters and to monitor the quality of the intermediate and the final product. In addition to quality issues, the optimization of the freeze-drying process in order to reduce the cycle length is of great interest since freeze-drying is known to be an energy-expensive and time consuming process. In this review, we will present the recent literature dealing with the freeze-drying of monoclonal antibodies and focus on the process parameters and strategies used to improve the stability of these molecules and to optimize the FD process.
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Affiliation(s)
- Hassana Hsein
- Univ. Bordeaux, CNRS, Arts et Metiers Institute of Technology, Bordeaux INP, INRAE, I2M Bordeaux, F-33400 Talence, France
| | - Julie Auffray
- Univ. Bordeaux, CNRS, Arts et Metiers Institute of Technology, Bordeaux INP, INRAE, I2M Bordeaux, F-33400 Talence, France.,Univ. Bordeaux, CNRS, Microbiologie Fondamentale et Pathogénicité, UMR 5234, Bordeaux, France
| | - Thierry Noel
- Univ. Bordeaux, CNRS, Microbiologie Fondamentale et Pathogénicité, UMR 5234, Bordeaux, France
| | - Pierre Tchoreloff
- Univ. Bordeaux, CNRS, Arts et Metiers Institute of Technology, Bordeaux INP, INRAE, I2M Bordeaux, F-33400 Talence, France
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Zhang H, Hong S, Tan SSK, Peng T, Goh LYH, Lam KH, Chow KT, Gokhale R. Polysorbates versus Hydroxypropyl Beta-Cyclodextrin (HPβCD): Comparative Study on Excipient Stability and Stabilization Benefits on Monoclonal Antibodies. Molecules 2022; 27:molecules27196497. [PMID: 36235038 PMCID: PMC9572940 DOI: 10.3390/molecules27196497] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/30/2022] [Revised: 09/23/2022] [Accepted: 09/28/2022] [Indexed: 11/09/2022] Open
Abstract
Polysorbates (PS 20 and PS 80) are the most widely used surfactants in biopharmaceutical formulations to protect proteins from denaturation, aggregation, and surface adsorption. To date, around 70% of marketed therapeutic antibodies contain either PS 20 or PS 80 in their formulations. However, polysorbates are chemically diverse mixtures, which are prone to degradation by oxidation and hydrolysis to produce peroxides and fatty acids, which, in turn, induce protein oxidation, aggregation, and insoluble particle formation. These will negatively impact protein quality and stability. Thus, polysorbate degradation has emerged as one of the major challenges in the development and commercialization of therapeutic protein products. KLEPTOSE® HPβCD (hydroxypropyl beta-cyclodextrin), a new multifunctional excipient, has been shown to provide protein stabilization functions in biopharmaceutical downstream processes and in their final formulations. This study aims to evaluate HPβCD, a new molecule of its class, against polysorbates as a stabilizer in biologics formulations. In this study, the chemical stability of KLEPTOSE® HPβCDs is compared with polysorbates (20 and 80) under various stress conditions. When subjected to heat stress, HPβCDs show little change in product recovery (90.7–100.7% recovery for different HPβCDs), while polysorbates 20 and 80 show significant degradation, with only 11.5% and 7.3% undegraded product remaining, respectively. When subjected to other chemical stressors, namely, autoclave, light, and oxidative stresses, HPβCD remains almost stable, while polysorbates show more severe degradation, with 95.5% to 98.8% remaining for polysorbate 20 and 85.5% to 97.4% remaining for polysorbate 80. Further, profiling characterization and degradation analysis reveal that chemical structures of HPβCDs remain intact, while polysorbates undergo significant hydrolytic degradation and oxidation. Lastly, the physicochemical stability of monoclonal antibodies in formulations is investigated. When subjected to light stress, adalimumab, as a model mAb, formulated in the presence of HPβCD, shows a significant decrease in protein aggregation, and superior monomer and total protein recovery compared to PS 80-containing formulations. HPβCD also reduces both agitation and thermal stress-induced protein aggregation and prevents subvisible particle formation compared to PS 80.
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Affiliation(s)
- Hailong Zhang
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
- Correspondence: (H.Z.); (R.G.)
| | - Shiqi Hong
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
| | - Sarah Si Kai Tan
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
| | - Tao Peng
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
| | - Lucas Yuan Hao Goh
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
| | - Kwan Hang Lam
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
| | - Keat Theng Chow
- Pharma Applied Sciences, Roquette Asia Pacific Pte Ltd., Singapore 138588, Singapore
| | - Rajeev Gokhale
- Global Pharmaceutical Sciences, Roquette America Inc., 2211 Innovation Drive, Geneva, IL 60134, USA
- Correspondence: (H.Z.); (R.G.)
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16
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Spray-Dried and Spray-Freeze-Dried Powder Formulations of an Anti-Interleukin-4Rα Antibody for Pulmonary Delivery. Pharm Res 2022; 39:2291-2304. [PMID: 35879500 DOI: 10.1007/s11095-022-03331-w] [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: 05/01/2022] [Accepted: 07/03/2022] [Indexed: 10/16/2022]
Abstract
OBJECTIVE The therapeutic options for severe asthma are limited, and the biological therapies are all parenterally administered. The purpose of this study was to formulate a monoclonal antibody that targets the receptor for IL-4, an interleukin implicated in the pathogenesis of severe asthma, into a dry powder intended for delivery via inhalation. METHODS Dehydration was achieved using either spray drying or spray freeze drying, which exposes the thermolabile biomacromolecules to stresses such as shear and adverse temperatures. 2-hydroxypropyl-beta-cyclodextrin was incorporated into the formulation as protein stabiliser and aerosol performance enhancer. The powder formulations were characterised in terms of physical and aerodynamic properties, while the antibody was assessed with regard to its structural stability, antigen-binding ability, and in vitro biological activity after drying. RESULTS The spray-freeze-dried formulations exhibited satisfactory aerosol performance, with emitted fraction exceeding 80% and fine particle fraction of around 50%. The aerosolisation of the spray-dried powders was hindered possibly by high residual moisture. Nevertheless, the antigen-binding ability and inhibitory potency were unaffected for the antibody in the selected spray-dried and spray-freeze-dried formulations, and the antibody was physically stable even after one-year storage at ambient conditions. CONCLUSIONS The findings of this study establish the feasibility of developing an inhaled dry powder formulation of an anti-IL-4R antibody using spray drying and spray freeze drying techniques with potential for the treatment of severe asthma.
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Ghaemmaghamian Z, Zarghami R, Walker G, O'Reilly E, Ziaee A. Stabilizing vaccines via drying: Quality by design considerations. Adv Drug Deliv Rev 2022; 187:114313. [PMID: 35597307 DOI: 10.1016/j.addr.2022.114313] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/03/2022] [Revised: 02/26/2022] [Accepted: 04/26/2022] [Indexed: 12/12/2022]
Abstract
Pandemics and epidemics are continually challenging human beings' health and imposing major stresses on the societies particularly over the last few decades, when their frequency has increased significantly. Protecting humans from multiple diseases is best achieved through vaccination. However, vaccines thermal instability has always been a hurdle in their widespread application, especially in less developed countries. Furthermore, insufficient vaccine processing capacity is also a major challenge for global vaccination programs. Continuous drying of vaccine formulations is one of the potential solutions to these challenges. This review highlights the challenges on implementing the continuous drying techniques for drying vaccines. The conventional drying methods, emerging technologies and their adaptation by biopharmaceutical industry are investigated considering the patented technologies for drying of vaccines. Moreover, the current progress in applying Quality by Design (QbD) in each of the drying techniques considering the critical quality attributes (CQAs), critical process parameters (CPPs) are comprehensively reviewed. An expert advice is presented on the required actions to be taken within the biopharmaceutical industry to move towards continuous stabilization of vaccines in the realm of QbD.
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Affiliation(s)
- Zahra Ghaemmaghamian
- Pharmaceutical Engineering Research Laboratory, Pharmaceutical Process Centers of Excellence, School of Chemical Engineering, University of Tehran, Tehran, Iran
| | - Reza Zarghami
- Pharmaceutical Engineering Research Laboratory, Pharmaceutical Process Centers of Excellence, School of Chemical Engineering, University of Tehran, Tehran, Iran
| | - Gavin Walker
- SSPC, The SFI Research Centre of Pharmaceuticals, Bernal Institute, Department of Chemical Sciences, University of Limerick, Limerick, Ireland
| | - Emmet O'Reilly
- SSPC, The SFI Research Centre of Pharmaceuticals, Bernal Institute, Department of Chemical Sciences, University of Limerick, Limerick, Ireland
| | - Ahmad Ziaee
- SSPC, The SFI Research Centre of Pharmaceuticals, Bernal Institute, Department of Chemical Sciences, University of Limerick, Limerick, Ireland.
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18
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Marschall C, Graf G, Witt M, Hauptmeier B, Friess W. Preparation of high concentration protein powder suspensions by milling of lyophilizates. Eur J Pharm Biopharm 2021; 166:75-86. [PMID: 34058328 DOI: 10.1016/j.ejpb.2021.04.023] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/12/2021] [Revised: 04/19/2021] [Accepted: 04/29/2021] [Indexed: 01/28/2023]
Abstract
Pharmaceutical formulations utilizing protein drugs as powders can be used as drug delivery systems in various ways. Besides powders for inhalation, another promising approach is their use as suspensions in non-aqueous liquids for subcutaneous administration providing high protein stability and good injectability. In this study protein powder suspensions were prepared using a swing-mill. Milling of lyophilizates containing a model monoclonal antibody in presence of the suspension vehicle was compared to cryogenic dry milling. Wet media milling led to injectable suspensions, but resulted in monomer loss and increase in protein aggregation. When the lyophilizates were cryogenic dry ball milled less aggregation and monomer loss were detected. Differences related to protein integrity were found for different process parameters, which were successfully optimized. If not cooled with liquid nitrogen, dry milling resulted in increased damage to the mAb. The type of polyol stabilizer, as well as the protein to stabilizer ratio, did not affect the preservation of protein integrity. As finding the right milling duration is time and resource intensive, a correlation between lyophilizate cake hardness and milling duration was established. Based on this approach high concentration lyophilizates were successfully micronized. Suspensions of cryogenic milled powders lead to clogging of 25G needles, which could be prevented by an additional sieving step. Depending on the suspension vehicle, low viscosity formulations (<10 mPa·s) even at high concentrations (≥100 mg/ml protein concentration) were obtained featuring good injectability.
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Affiliation(s)
- Christoph Marschall
- Ludwig-Maximilians-Universität München, Department of Pharmacy, Pharmaceutical Technology and Biopharmceutics, Butenandtstraße 5, D-81377 München, Germany; AbbVie Deutschland GmbH, Knollstraße 50, D-67061 Ludwigshafen, Germany(1)
| | - Gesche Graf
- Novaliq GmbH, Im Neuenheimer Feld 515, D-69120 Heidelberg, Germany; Merz Pharma GmbH & Co KGaA, Eckenheimer Landstraße 100, D-60318 Frankfurt am Main, Germany(1)
| | - Madlen Witt
- Novaliq GmbH, Im Neuenheimer Feld 515, D-69120 Heidelberg, Germany; Merck KGaA, Frankfurter Straße 250, D-64293 Darmstadt, Germany(1)
| | - Bernhard Hauptmeier
- Novaliq GmbH, Im Neuenheimer Feld 515, D-69120 Heidelberg, Germany; Boehringer Ingelheim, Vetmedica GmbH, Binger Straße 173, D-55216 Ingelheim am Rhein, Germany(1)
| | - Wolfgang Friess
- Ludwig-Maximilians-Universität München, Department of Pharmacy, Pharmaceutical Technology and Biopharmceutics, Butenandtstraße 5, D-81377 München, Germany.
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19
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Effects of monoclonal antibody concentration and type of bulking agent on critical quality attributes of lyophilisates. J Drug Deliv Sci Technol 2021. [DOI: 10.1016/j.jddst.2021.102510] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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20
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Opportunities in an Evolving Pharmaceutical Development Landscape: Product Differentiation of Biopharmaceutical Drug Products. Pharm Res 2021; 38:739-757. [PMID: 33903976 DOI: 10.1007/s11095-021-03037-5] [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: 02/17/2021] [Accepted: 03/29/2021] [Indexed: 10/21/2022]
Abstract
The current perspective reviews the biopharmaceutical market until end of 2020 and highlights the transforming biopharmaceutical landscape during the recent decade. In particular, the rise of biosimilars and the development of new therapeutic modalities through recent advancement in molecular biology research sustainably change the product scenery. The present manuscript describes opportunities for pharmaceutical technical development, highlighting concepts such as product differentiation to succeed in a competitive product landscape. Product differentiation offers the opportunity for numerous life-cycle options and market exclusivity through incremental improvements in standard of care treatment. In particular, different formulation options and formulation-device combinations are described, focusing on systemic delivery of monoclonal antibody products and patient-centered development. The concept of product differentiation is exemplified in a case study about HER2+ breast cancer therapy, underlining pharmaceutical technical solutions and major improvements for the patient.
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21
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Harguindeguy M, Fissore D. Micro Freeze-Dryer and Infrared-Based PAT: Novel Tools for Primary Drying Design Space Determination of Freeze-Drying Processes. Pharm Res 2021; 38:707-719. [PMID: 33686561 PMCID: PMC8057969 DOI: 10.1007/s11095-021-03023-x] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/17/2020] [Accepted: 02/23/2021] [Indexed: 11/30/2022]
Abstract
PURPOSE Present (i) an infrared (IR)-based Process Analytical Technology (PAT) installed in a lab-scale freeze-dryer and (ii) a micro freeze-dryer (MicroFD®) as effective tools for freeze-drying design space calculation of the primary drying stage. METHODS The case studies investigated are the freeze-drying of a crystalline (5% mannitol) and of an amorphous (5% sucrose) solution processed in 6R vials. The heat (Kv) and the mass (Rp) transfer coefficients were estimated: tests at 8, 13 and 26 Pa were carried out to assess the chamber pressure effect on Kv. The design space of the primary drying stage was calculated using these parameters and a well-established model-based approach. The results obtained using the proposed tools were compared to the ones in case Kv and Rp were estimated in a lab-scale unit through gravimetric tests and a thermocouple-based method, respectively. RESULTS The IR-based method allows a non-gravimetric estimation of the Kv values while with the micro freeze-dryer gravimetric tests require a very small number of vials. In both cases, the obtained values of Kv and Rp, as well as the resulting design spaces, were all in very good agreement with those obtained in a lab-scale unit through the gravimetric tests (Kv) and the thermocouple-based method (Rp). CONCLUSIONS The proposed tools can be effectively used for design space calculation in substitution of other well-spread methods. Their advantages are mainly the less laborious Kv estimation process and, as far as the MicroFD® is concerned, the possibility of saving time and formulation material when evaluating Rp.
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Affiliation(s)
- Maitê Harguindeguy
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy.
| | - Davide Fissore
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
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22
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Wu HH, Garidel P, Michaela B. HP-β-CD for the formulation of IgG and Ig-based biotherapeutics. Int J Pharm 2021; 601:120531. [PMID: 33775727 DOI: 10.1016/j.ijpharm.2021.120531] [Citation(s) in RCA: 14] [Impact Index Per Article: 4.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/22/2021] [Revised: 03/11/2021] [Accepted: 03/20/2021] [Indexed: 12/14/2022]
Abstract
The main challenge to develop HCF for IgG and Ig-based therapeutics is to achieve essential solubility, viscosity and stability of these molecules in order to maintain product quality and meet regulatory requirement during manufacturing, production, storage, shipment and administration processes. The commonly used and FDA approved excipients for IgG and Ig -based therapeutics may no longer fulfil the challenge of HCF development for these molecules to certain extent, especially for some complex Ig-based platforms. 2-Hydroxypropyl beta-cyclodextrin (HP-β-CD) is one of the promising excipients applied recently for HCF development of IgG and Ig-based therapeutics although it has been used for formulation of small synthesized chemical drugs for more than thirty years. This review describes essential aspects about application of HP-β-CD as excipient in pharmaceutical formulation, including physico-chemical properties of HP-β-CD, supply chain, regulatory, patent landscape, marketed drugs with HP-β-CD, analytics and analytical challenges, stability and control strategies, and safety concerns. It also provides an overview of different studies, and outcomes thereof, regarding formulation development for IgGs and Ig-based molecules in liquid and solid (lyophilized) dosage forms with HP-β-CD. The review specifically highlights the challenges for formulation manufacturing of IgG and Ig-based therapeutics with HP-β-CD and identifies areas for future work in pharmaceutical and formulation development.
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Affiliation(s)
- Helen Haixia Wu
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, Pharmaceutical Development Biologicals, Biberach an der Riss, Germany.
| | - Patrick Garidel
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, Pharmaceutical Development Biologicals, Biberach an der Riss, Germany
| | - Blech Michaela
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, Pharmaceutical Development Biologicals, Biberach an der Riss, Germany
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23
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Investigation of lyophilized formulation susceptible to the ramp rate of shelf temperature in the primary drying process. J Drug Deliv Sci Technol 2021. [DOI: 10.1016/j.jddst.2020.102285] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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24
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Controlling Ice Nucleation during Lyophilization: Process Optimization of Vacuum-Induced Surface Freezing. Processes (Basel) 2020. [DOI: 10.3390/pr8101263] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
Abstract
Biopharmaceuticals are often lyophilized to improve their storage stability. Controlling ice nucleation during the freezing step of the lyophilization process is desired to increase homogeneity of product properties across a drug product batch and shorten the primary drying time. The present communication summarizes the process optimization of the freezing process when using vacuum-induced surface freezing to control ice nucleation, in particular for amorphous samples. We characterized freeze-dried samples for solid state properties, and compared these to uncontrolled nucleated samples using bovine serum albumin (BSA) as a model protein. Freezing parameters were optimized to obtain complete nucleation, adequate cake resistance during the subsequent lyophilization cycle, and elegant cakes. We highlight the challenges associated with vacuum-induced surface freezing and propose optimized freezing parameters to control ice nucleation, enabling manufacturing of amorphous samples.
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25
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Goethals W, Vanbillemont B, Lammens J, De Beer T, Vervaet C, Boone MN. In-Situ X-ray Imaging Of Sublimating Spin-Frozen Solutions. MATERIALS 2020; 13:ma13132953. [PMID: 32630310 PMCID: PMC7378758 DOI: 10.3390/ma13132953] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/03/2020] [Revised: 06/22/2020] [Accepted: 06/29/2020] [Indexed: 11/28/2022]
Abstract
Spin-freeze-drying is a promising technique to enable long-term storage of pharmaceutical unit doses of aqueous drug solutions. To investigate the sublimation of the ice during the primary phase of freeze-drying, X-ray imaging can yield crucial temporally resolved information on the local dynamics. In this paper, we describe a methodology to investigate the sublimation front during single unit-dose freeze-drying using 4D in-situ X-ray imaging. Three spin-frozen samples of different solutions were imaged using this methodology and the process characteristics were analysed and reduced to two-dimensional feature maps.
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Affiliation(s)
- Wannes Goethals
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, B-9000 Gent, Belgium;
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, B-9000 Gent, Belgium
- Correspondence:
| | - Brecht Vanbillemont
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (B.V.); (T.D.B.)
| | - Joris Lammens
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (J.L.); (C.V.)
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology (LPPAT), Department of Pharmaceutical Analysis, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (B.V.); (T.D.B.)
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, B-9000 Gent, Belgium; (J.L.); (C.V.)
| | - Matthieu N. Boone
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, B-9000 Gent, Belgium;
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, B-9000 Gent, Belgium
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