Development and Application of a Mechanistic Cooling and Freezing Model of the Spin Freezing Step within the Framework of Continuous Freeze-Drying

Relevance of controlled cooling and freezing phases in T-cell cryopreservation

When cells are cryopreserved, they go through a freezing process with several distinct phases (i.e., cooling until nucleation, ice nucleation, ice crystal growth and cooling to a final temperature). Conventional cell freezing approaches often employ a single cooling rate to describe and optimize the entire freezing process, which neglects its complexity and does not provide insight into the effects of the different freezing phases. The aim of this work was to elucidate the impact of each freezing phase by varying different process parameters per phase. Hereto, spin freezing was used to freeze Jurkat T cells in either a Me2SO-based or Me2SO-free formulation. The cooling rates before ice nucleation and after total ice crystallization impacted cell viability, resulting in viability ranging from 26.7% to 52.8% for the Me2SO-free formulation, and 22.5%-42.6% for the Me2SO-based formulation. Interestingly, the degree of supercooling upon nucleation did not exhibit a significant effect on cell viability in this work. However, the rate of ice crystal formation emerged as a crucial factor, with viability ranging from 2.4% to 53.2% for the Me2SO-free formulation, and 0.3%-53.2% for the Me2SO-based formulation, depending on the freezing rate. A morphological study of the cells post-cryopreservation was performed using confocal microscopy, and it was found that cytoskeleton integrity and cell volume were impacted, depending on the formulation-process parameter combination. These findings underscore the importance of scrutinizing all cooling and freezing phases, as each phase impacted post-thaw viability in a distinct way, depending of the specific formulation used.

New Trends in Freeze-Drying of Pharmaceutical Products

Freeze-drying, also known as lyophilization, is a process that facilitates the removal of water through sublimation from a frozen product (primary drying) [...].

Evaluation of a PAT-based in-line control system for a continuous spin freeze-drying process

Continuous spin freeze-drying provides a range of opportunities regarding the implementation of several in-line process analytical technologies (PAT) to control and optimize the freeze-drying process at the individual vial level. In this work, two methods were developed to (1) control the freezing phase by separately controlling the cooling and freezing rate and (2) control the drying phase by controlling the vial temperature (and hence the product temperature) to setpoint values and monitoring the residual moisture content. During the freezing phase, the vial temperature closely followed the decreasing setpoint temperature during the cooling phases, and the crystallization phase was reproducibly controlled by regulating the freezing rate. During both primary and secondary drying, vial temperature could be maintained on the setpoint temperature which resulted in an elegant cake structure after every run. By being able to accurately control the freezing rate and the vial temperature, a homogeneous drying time (SD = 0.07-0.09 h) between replicates was obtained. Applying a higher freezing rate significantly increased primary drying time. On the other hand, fast freezing rates increased the desorption rate. Finally, the residual moisture of the freeze-dried formulation could be monitored in-line with a high accuracy providing insight on the required length of the secondary drying phase. .

Recent Advances in Freeze-Drying: Variables, Cycle Optimization, and Innovative Techniques

Freeze-drying (FD) is the most substantial drying technique utilized in the pharmaceutical and biopharmaceutical industries. It is a drying process where the solvent is crystallized at low temperatures and then sublimed from the solid-state directly into the vapor phase. Although FD possesses several merits as its suitability for thermolabile materials and its ability to produce dry products with high-quality attributes, it is a complex and prolonged process that requires optimization of both; process and formulation variables. This review attains to disassemble freeze-drying complications through a detailed explanation of the lyophilization concept, stages, the factors influencing the process including controlled ice nucleation, and the modified and innovative freeze-drying technologies proposed in recent years to overcome the shortage of traditional freeze-drying. In addition, this work points out the quality by design (QbD), critical quality of attributes (CQAs), limitations, and drawbacks of lyophilization.HighlightsLyophilization is a propitious drying technique for thermolabile materials.Optimizing the lyophilization cycle requires controlling the process parameters.The formulation excipients and the dispersion medium play crucial roles in designing a successful process.Numerous approaches were developed to ameliorate the lyophilization performance.