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Tchessalov S, Shalaev E, Bhatnagar B, Nail S, Alexeenko A, Jameel F, Srinivasan J, Dekner M, Sahni E, Schneid S, Kazarin P, McGarvey O, Van Meervenne B, Kshirsagar V, Pande P, Philipp J, Sacha G, Wu K, Azzarella J, Shivkumar G, Bhatt S, Mehta SB. Best Practices and Guidelines (2022) for Scale-up and Technology Transfer in Freeze Drying Based on Case Studies. Part 2: Past Practices, Current Best Practices, and Recommendations. AAPS PharmSciTech 2023; 24:96. [PMID: 37012545 DOI: 10.1208/s12249-023-02553-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/13/2023] [Accepted: 03/06/2023] [Indexed: 04/05/2023] Open
Abstract
Scale-up and transfer of lyophilization processes remain very challenging tasks considering the technical challenges and the high cost of the process itself. The challenges in scale-up and transfer were discussed in the first part of this paper and include vial breakage during freezing at commercial scale, cake resistance differences between scales, impact of differences in refrigeration capacities, and geometry on the performance of dryers. The second part of this work discusses successful and unsuccessful practices in scale-up and transfer based on the experience of the authors. Regulatory aspects of scale-up and transfer of lyophilization processes were also outlined including a topic on the equivalency of dryers. Based on an analysis of challenges and a summary of best practices, recommendations on scale-up and transfer of lyophilization processes are given including projections on future directions in this area of the freeze drying field. Recommendations on the choice of residual vacuum in the vials were also provided for a wide range of vial capacities.
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Affiliation(s)
| | | | | | | | - Alina Alexeenko
- Birck Nanotechnology Center, Purdue University, 1205 W State St., West Lafayette, Indiana, 47907, USA
| | | | | | | | | | | | - Petr Kazarin
- Birck Nanotechnology Center, Purdue University, 1205 W State St., West Lafayette, Indiana, 47907, USA.
| | | | | | | | | | | | | | - Ke Wu
- AbbVie, Irvine, California, USA
| | | | | | | | - Shyam B Mehta
- Teva Pharmaceuticals, West Chester, Pennsylvania, USA
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Ganguly A, Hardwick L, Tchessalov S, Nail SL, Dixon D, Kanka F, Guidinas A, Thompson TN, Reiter C, Yusoff Z, Tharp T, Azzarella J, Sharma P, Kazarin P, Alexeenko A, Pikal MJ. Recommended Best Practices in Freeze Dryer Equipment Performance Qualification: 2022. AAPS PharmSciTech 2023; 24:45. [PMID: 36703029 DOI: 10.1208/s12249-023-02506-x] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/30/2021] [Accepted: 01/03/2023] [Indexed: 01/27/2023] Open
Abstract
Best practices for performing freeze dryer equipment qualification are recommended, focusing on identifying methods to quantify shelf thermal uniformity (also known as "shelf surface uniformity"), equipment capability, and performance metrics of the freeze dryer essential to the pharmaceutical Quality by Design paradigm. Specific guidelines for performing shelf temperature mapping, freeze dryer equipment limit testing (the capability curve), and condenser performance metrics have been provided. Concerning shelf temperature mapping and equipment capability measurements, the importance of paying attention to the test setup and the use of appropriate testing tools are stressed. In all the guidelines provided, much attention has been paid to identifying the balance between obtaining useful process knowledge, logistical challenges associated with testing in the production environment vs that at laboratory scale, and the frequency of the testing necessary to obtain such useful information. Furthermore, merits and demerits of thermal conditions maintained on the cooled surfaces of the freeze dryer condenser have been discussed identifying the specific influence of the condenser surface temperature on the process conditions using experimental data to support the guidelines. Finally, guidelines for systematic leak rate testing criteria for a freeze dryer are presented. These specific procedural recommendations are based on calculations, measurements, and experience to provide useful process and equipment knowledge.
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Affiliation(s)
| | - Lisa Hardwick
- Baxter Medical Products R&D, Bloomington, Indiana, USA
| | | | - Steven L Nail
- Baxter Medical Products R&D, Bloomington, Indiana, USA
| | - Dan Dixon
- Pfizer Global Research, Andover, Massachusetts, USA
| | - Frank Kanka
- Pfizer Global Supply, Kalamazoo, Michigan, USA
| | | | | | | | | | - Ted Tharp
- AbbVie Inc., North Chicago, Illinois, USA
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Tchessalov S, Shalaev E, Bhatnagar B, Nail S, Alexeenko A, Jameel F, Srinivasan J, Dekner M, Sahni E, Schneid S, Kazarin P, McGarvey O, Van Meervenne B, Kshirsagar V, Pande P, Philipp J, Sacha G, Wu K, Azzarella J, Shivkumar G, Bhatt S. Best Practices and Guidelines (2022) for Scale-Up and Tech Transfer in Freeze-Drying Based on Case Studies. Part 1: Challenges during Scale Up and Transfer. AAPS PharmSciTech 2022; 24:11. [PMID: 36451057 DOI: 10.1208/s12249-022-02463-x] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/23/2022] [Accepted: 11/08/2022] [Indexed: 12/02/2022] Open
Abstract
The freeze-drying process scale-up and transfer remain a complicated and non-uniform practice. We summarized inefficient and good practices in these papers and provided some practical advice. It was demonstrated that using the same process set points/times in laboratory and commercial scale dryers may lead to loss of product quality (collapse or vial breakage). The emerging modeling approach demonstrated practical advantages. However, the upfront generation of some input parameters (vial heat transfer coefficient, minimum controllable pressure, and maximum sublimation rate) is essential for model utilization. While the primary drying step can be transferred with a high degree of confidence (e.g., using modeling), and secondary drying is usually fairly straightforward, predicting potential changes in product behavior during freezing remains challenging.
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Affiliation(s)
| | | | | | | | - Alina Alexeenko
- Birck Nanotechnology Center, Purdue University, 1205 W State St, West Lafayette, California, 47907, USA
| | - Feroz Jameel
- Gilead Sciences, Plaines, Morris, New Jersey, USA
| | | | | | | | | | - Petr Kazarin
- Birck Nanotechnology Center, Purdue University, 1205 W State St, West Lafayette, California, 47907, USA.
| | | | | | | | | | | | | | - Ke Wu
- AbbVie, Irvine, California, USA
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Jameel F, Alexeenko A, Bhambhani A, Sacha G, Zhu T, Tchessalov S, Sharma P, Moussa E, Iyer L, Luthra S, Srinivasan J, Tharp T, Azzarella J, Kazarin P, Jalal M. Recommended Best Practices for Lyophilization Validation 2021 Part II: Process Qualification and Continued Process Verification. AAPS PharmSciTech 2021; 22:266. [PMID: 34750693 PMCID: PMC8575750 DOI: 10.1208/s12249-021-02107-6] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/06/2021] [Accepted: 07/31/2021] [Indexed: 11/30/2022] Open
Abstract
This work describes the lyophilization process validation and consists of two parts. Part one (Part I: Process Design and Modeling) focuses on the process design and is described in the previous paper, while the current paper is devoted to process qualification and continued process verification. The goal of the study is to show the cutting edge of lyophilization validation based on the integrated community-based opinion and the industrial perspective. This study presents best practices for batch size determination and includes the effect of batch size on drying time, process parameters selection strategies, and batch size overage to compensate for losses during production. It also includes sampling strategies to demonstrate batch uniformity as well as the use of statistical models to ensure adequate sampling. Based on the LyoHUB member organizations survey, the best practices in determining the number of PPQ runs are developed including the bracketing approach with minimum and maximum loads. Standard practice around CQA and CPP selection is outlined and shows the advantages of using control charts and run charts for process trending and quality control. The case studies demonstrating the validation strategy for monoclonal antibody and the impact of the loading process on the lyophilization cycle and product quality as well as the special case of lyophilization for dual-chamber cartridge system are chosen to illustrate the process validation. The standard practices in the validation of the lyophilization process, special lyophilization processes, and their impact on the validation strategy are discussed.
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Jameel F, Alexeenko A, Bhambhani A, Sacha G, Zhu T, Tchessalov S, Kumar L, Sharma P, Moussa E, Iyer L, Fang R, Srinivasan J, Tharp T, Azzarella J, Kazarin P, Jalal M. Correction to: Recommended Best Practices for Lyophilization Validation-2021 Part I: Process Design and Modeling. AAPS PharmSciTech 2021; 22:250. [PMID: 34664114 DOI: 10.1208/s12249-021-02129-0] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022] Open
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Jameel F, Alexeenko A, Bhambhani A, Sacha G, Zhu T, Tchessalov S, Kumar L, Sharma P, Moussa E, Iyer L, Fang R, Srinivasan J, Tharp T, Azzarella J, Kazarin P, Jalal M. Recommended Best Practices for Lyophilization Validation-2021 Part I: Process Design and Modeling. AAPS PharmSciTech 2021; 22:221. [PMID: 34409506 PMCID: PMC8373746 DOI: 10.1208/s12249-021-02086-8] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/05/2021] [Accepted: 06/29/2021] [Indexed: 12/02/2022] Open
Abstract
Abstract This work describes lyophilization process validation and consists of two parts. Part I focuses on the process design and is described in the current paper, while part II is devoted to process qualification and continued process verification. The intent of these articles is to provide readers with recent updates on lyophilization validation in the light of community-based combined opinion on the process and reflect the industrial prospective. In this paper, the design space approach for process design is described in details, and examples from practice are provided. The approach shows the relationship between the process inputs; it is based on first principles and gives a thorough scientific understanding of process and product. The lyophilization process modeling and scale-up are also presented showing the impact of facility, equipment, and vial heat transfer coefficient. The case studies demonstrating the effect of batch sizes, fill volume, and dose strength to show the importance of modeling as well as the effect of controlled nucleation on product resistance are discussed. Graphical abstract ![]()
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