1
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Kölbel J, Anuschek ML, Stelzl I, Santitewagun S, Friess W, Zeitler JA. Dynamical Transition in Dehydrated Proteins. J Phys Chem Lett 2024; 15:3581-3590. [PMID: 38527099 PMCID: PMC11000241 DOI: 10.1021/acs.jpclett.3c03584] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2023] [Revised: 03/16/2024] [Accepted: 03/19/2024] [Indexed: 03/27/2024]
Abstract
Terahertz time-domain spectroscopy and differential scanning calorimetry were used to study the role of the dynamics of biomolecules decoupled from solvent effects. Lyophilized sucrose exhibited steadily increasing absorption with temperature as anharmonic excitations commenced as the system emerged from a deep minimum of the potential energy landscape where harmonic vibrations dominate. The polypeptide bacitracin and two globular proteins, lysozyme and human serum albumin, showed a more complex temperature dependence. Further analysis focused on the spectral signature below and above the boson peak. We found evidence of the onset of anharmonic motions that are characteristic for partial unfolding and molecular jamming in the dry biomolecules. The activation of modes of the protein molecules at temperatures comparable to the protein dynamical transition temperature was observed in the absence of hydration. No evidence of Fröhlich coherence, postulated to facilitate biological function, was found in our experiments.
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Affiliation(s)
- Johanna Kölbel
- Department
of Chemical Engineering, University of Cambridge, Cambridge CB3 0AS, U.K.
| | - Moritz L. Anuschek
- Department
of Chemical Engineering, University of Cambridge, Cambridge CB3 0AS, U.K.
- Department
of Pharmacy - Center for Drug Research, Pharmaceutical Technology
and Biopharmaceutics, Ludwig-Maximilians
Universität, Butenandtstrasse
5, 81377 Munich, Germany
| | - Ivonne Stelzl
- Department
of Pharmacy - Center for Drug Research, Pharmaceutical Technology
and Biopharmaceutics, Ludwig-Maximilians
Universität, Butenandtstrasse
5, 81377 Munich, Germany
| | - Supawan Santitewagun
- Department
of Chemical Engineering, University of Cambridge, Cambridge CB3 0AS, U.K.
| | - Wolfgang Friess
- Department
of Pharmacy - Center for Drug Research, Pharmaceutical Technology
and Biopharmaceutics, Ludwig-Maximilians
Universität, Butenandtstrasse
5, 81377 Munich, Germany
| | - J. Axel Zeitler
- Department
of Chemical Engineering, University of Cambridge, Cambridge CB3 0AS, U.K.
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2
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Brandstetter D, Helbig C, Osawa K, Minemura H, Anzai Y, Torisu T, Uchiyama S, Menzen T, Friess W, Hawe A. Three-Dimensional Homodyne Light Detection (3D-HLD) for High-Throughput Submicron Particle Analysis in (Highly Concentrated) Protein Biopharmaceuticals, Viral Vectors, and LNPs. J Pharm Sci 2024; 113:891-899. [PMID: 37926233 DOI: 10.1016/j.xphs.2023.10.042] [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: 07/13/2023] [Revised: 10/27/2023] [Accepted: 10/27/2023] [Indexed: 11/07/2023]
Abstract
During biopharmaceutical development, particle monitoring and characterization are crucial. Notably, particles can be impurities considered as critical quality attribute, or active pharmaceutical ingredient (e.g., viral vectors) or drug delivery system (e.g., lipid nanoparticles) itself. Three-dimensional homodyne light detection (3D-HLD) is a novel technique that can characterize particles in the ∼0.2 µm to 2.0 µm size range. We evaluated 3D-HLD for the analysis of high concentration protein formulations (up to 200 mg/mL), where formulation refractive index and background noise became limiting factors with increasing protein concentration. Sample viscosity however did not impact 3D-HLD results, in contrast to comparative analyses with NTA and MRPS. We also applied 3D-HLD in high-throughput screenings at high protein concentration or of lipid nanoparticle and viral vector formulations, where impurities were analyzed in the presence of a small (<0.2 µm) particulate active pharmaceutical ingredient. 3D-HLD turned out to be in good agreement with or a good complement to other state-of-the-art particle characterization techniques, including BMI, MRPS, and DLS. The main application of 3D-HLD is high-throughput particle analysis at low sample volume. Follow-up investigation of the optimized particle sizing approach and of detection settings could further improve the understanding of the method and potentially increase ease of operation.
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Affiliation(s)
| | - Constanze Helbig
- Coriolis Pharma Research GmbH, Fraunhoferstr. 18 b, 82152 Martinsried, Germany
| | - Kentaro Osawa
- Hitachi High-Tech Corporation 1-17-1 Toranomon, Minato-ku, Tokyo 105-6409, Japan
| | - Hiroyuki Minemura
- Hitachi, Ltd., Research & Development Group, 1-280 Higashi-koigakubo, Kokubunji-shi, Tokyo 185-8601, Japan
| | - Yumiko Anzai
- Hitachi, Ltd., Research & Development Group, 1-280 Higashi-koigakubo, Kokubunji-shi, Tokyo 185-8601, Japan
| | - Tetsuo Torisu
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Susumu Uchiyama
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan; U-Medico Inc. 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Tim Menzen
- Coriolis Pharma Research GmbH, Fraunhoferstr. 18 b, 82152 Martinsried, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Ludwig-Maximilians-Universität München, Pharmaceutical Technology and Biopharmaceutics, Butenandtstr. 5-13, 81337 Munich, Germany
| | - Andrea Hawe
- Coriolis Pharma Research GmbH, Fraunhoferstr. 18 b, 82152 Martinsried, Germany.
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3
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Sarter T, Friess W. Molecular Dynamics Study of Protein Aggregation at Moving Interfaces. Mol Pharm 2024; 21:1214-1221. [PMID: 38321750 DOI: 10.1021/acs.molpharmaceut.3c00865] [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] [Indexed: 02/08/2024]
Abstract
Repeated compression and dilation of a protein film adsorbed to an interface lead to aggregation and entry of film fragments into the bulk. This is a major mechanism for protein aggregate formation in drug products upon mechanical stress, such as shaking or pumping. To gain a better understanding of these events, we developed a molecular dynamics (MD) setup, which would, in a later stage, allow for in silico formulation optimization. In contrast to previous approaches, the molecules of our model protein human growth hormone displayed realistic shapes, surfaces, and interactions with each other and the interface. This enabled quantitative assessment of protein cluster formation. Simulation outcomes aligned with experimental data on subvisible particles and turbidity, thereby validating the model. Computational and experimental results indicated that compression speed does not affect the aggregation behavior of preformed protein films but rather their regeneration. Protein clusters that formed during compression disassembled upon relaxation, suggesting that the particles originate from a partly compressed state. Desorption studies via steered MD revealed that proteins from compressed systems are more likely to detach as clusters, implying that compression effects at the interface translate into aggregates present in the bulk solution. With the possibility of studying the impact of different variables upon compression and dilation at the interface on a molecular level, our model contributes to the understanding of the mechanisms of protein aggregation at moving interfaces. It also enables further studies to change formulation parameters, interfaces, or proteins.
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Affiliation(s)
- Tim Sarter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
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4
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Vanbillemont B, Greiner AL, Ehrl V, Menzen T, Friess W, Hawe A. A model-based optimization strategy to achieve fast and robust freeze-drying cycles. Int J Pharm X 2023; 5:100180. [PMID: 37125084 PMCID: PMC10133743 DOI: 10.1016/j.ijpx.2023.100180] [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] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/05/2022] [Revised: 03/22/2023] [Accepted: 04/08/2023] [Indexed: 05/02/2023] Open
Abstract
Freeze-drying is a time and cost-intensive process. The primary drying phase is the main target in a process optimization exercise. Biopharmaceuticals require an amorphous matrix for stabilization, which may collapse during primary drying if the critical temperature of the formulation is exceeded. The risk of product collapse should be minimized during a process optimization to accomplish a robust process, while achieving an economical process time. Mechanistic models facilitate the search for an optimal primary drying protocol. We propose a novel two-stage shelf temperature optimization approach to maximize sublimation during the primary drying phase, without risking product collapse. The approach includes experiments to obtain high-resolution variability data of process parameters such as the heat transfer coefficient, vial dimensions and dried layer resistance. These process parameters variability data are incorporated into an uncertainty analysis to estimate the risk of failure of the protocol. This optimization approach enables to identify primary drying protocols that are faster and more robust than a classical approach. The methodology was experimentally verified using two formulations which allow for either aggressive or conservative freeze-drying of biopharmaceuticals.
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Affiliation(s)
- Brecht Vanbillemont
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
- Corresponding author.
| | | | - Vanessa Ehrl
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
| | - Tim Menzen
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig Maximilian University, Munich 81377, Germany
| | - Andrea Hawe
- Coriolis Pharma Research GmbH, Martinsried 82152, Germany
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5
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Moll F, Bechtold-Peters K, Friess W. Evaluation of a novel silicone oil free primary packaging system with PTFE-based barrier stopper for biologics. Eur J Pharm Biopharm 2023; 190:206-219. [PMID: 37536577 DOI: 10.1016/j.ejpb.2023.07.015] [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: 06/02/2023] [Revised: 07/21/2023] [Accepted: 07/27/2023] [Indexed: 08/05/2023]
Abstract
In order to overcome silicone oil related problems for biopharmaceuticals, novel container systems are of interest with a focus on the reduction, fixation or complete avoidance of silicone oil in the primary container. Ultimately, silicone oil free (SOF) container systems made from cyclic olefin (co-)polymer or glass combined with the respective silicone-oil free plungers were developed. In the following study we evaluated the potential of a SOF container system based on a glass barrel in combination with a fluoropolymer coated syringe plunger. In a long-term stability study, the system was compared to other alternative container systems in terms of functionality and particle formation when filled with placebo buffers. The system proved to be a valuable alternative to marketed siliconized container systems with acceptable and consistent break-loose gliding forces and it was clearly superior in terms of particle formation over storage time. Additionally, we evaluated the importance of the glass barrel surface for functionality. The interaction of the fill medium with the glass surface significantly impacted friction forces. Consequently, storage conditions and production processes like washing and sterilization, which can easily alter the surface properties, should be carefully evaluated, and controlled. The novel combination of non-lubricated glass barrel and fluoropolymer coated plunger provides a highly valuable SOF packaging alternative for biopharmaceuticals.
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Affiliation(s)
- Fabian Moll
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | | | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany.
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6
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Moll F, Bechtold-Peters K, Friess W. Impact of Autoclavation on Baked-on Siliconized Containers for Biologics. Eur J Pharm Biopharm 2023; 187:184-195. [PMID: 37142129 DOI: 10.1016/j.ejpb.2023.04.018] [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: 12/01/2022] [Revised: 04/12/2023] [Accepted: 04/21/2023] [Indexed: 05/06/2023]
Abstract
Many pharmaceutical manufacturing units utilize pre-sterilized ready-to fill primary containers for parenterals. The containers may have been sterilized by the supplier via autoclavation. This process can change the physicochemical properties of the material and the subsequent product stability. We studied the impact of autoclavation on baked on siliconized glass containers for biopharmaceuticals. We characterized the container layers of different thickness before and after autoclavation for 15 min at 121 °C and 130 °C. Furthermore, we analyzed the adsorption of a mAb to the silicone layer and subjected filled containers to 12 weeks storage at 40 °C monitoring functionality and subvisible particle formation of the product. Autoclavation turned the initially homogenous silicone coating into an incoherent surface with uneven microstructure, changed surface roughness and energy, and increased protein adsorption. The effect was more pronounced at higher sterilization temperatures. We did not observe an effect of autoclavation on stability. Our results did not indicate any concerns for autoclavation at 121 °C for safety and stability of drug/device combination products using baked-on siliconized glass containers.
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Affiliation(s)
- Fabian Moll
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | | | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany.
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7
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Deiringer N, Leitner I, Friess W. Effect of the Tubing Material Used in Peristaltic Pumping in Tangential Flow Filtration Processes of Biopharmaceutics on Particle Formation and Flux. J Pharm Sci 2023; 112:665-672. [PMID: 36220395 DOI: 10.1016/j.xphs.2022.10.005] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [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: 08/16/2022] [Revised: 10/04/2022] [Accepted: 10/04/2022] [Indexed: 02/18/2023]
Abstract
Tangential flow filtration (TFF) is a central step in manufacturing of biopharmaceutics. Membrane clogging leads to decreased permeate flux, longer process time and potentially complete failure of the process. The effect of peristaltic pumping with tubings made of three different materials on protein particle formation during TFF was monitored via micro flow imaging, turbidity and photo documentation. At low protein concentrations, pumping with a membrane pump resulted in a stable flux with low protein particle concentration. Using a peristaltic pump led to markedly higher protein particle formation dependent on tubing type. With increasing protein particle formation propensity of the tubing, the permeate flux rate became lower and the process took longer. The protein particles formed in the pump were captured in the cassette and accumulated on the membrane leading to blocking. Using tubing with a hydrophilic copolymer modification counteracted membrane clogging and flux decrease by reducing protein particle formation. In ultrafiltration mode the permeate flux decrease was governed by the viscosity increase rather than by the protein aggregation; but using modified tubing is still beneficial due to a lower particle burden of the product. In summary, using tubing material for peristaltic pumping in TFF processes which leads a less protein particle formation, especially tubing material with hydrophilic modification, is highly beneficial for membrane flux and particle burden of the product.
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Affiliation(s)
- Natalie Deiringer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Imke Leitner
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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8
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Deiringer N, Friess W. Afraid of the wall of death? Considerations on monoclonal antibody characteristics that trigger aggregation during peristaltic pumping. Int J Pharm 2023; 633:122635. [PMID: 36690131 DOI: 10.1016/j.ijpharm.2023.122635] [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: 10/12/2022] [Revised: 01/17/2023] [Accepted: 01/18/2023] [Indexed: 01/21/2023]
Abstract
Protein aggregation is of major concern in manufacturing of biopharmaceutics. Protein aggregation upon peristaltic pumping for filtration, transfer or filling is triggered by protein adsorption to the tubing surface and subsequent film rupture during roller movement. While the impact of tubing type and formulation has been studied in more detail, the contribution of the protein characteristics is not fully resolved. We studied the aggregation propensity of six monoclonal antibodies during peristaltic pumping and characterized their colloidal and conformational stability, hydrophobicity, and surface activity. A high affinity to the surface resulting in faster adsorption and film renewal was key for the formation of protein particles ≥ 1 µm. Film formation and renewal were influenced by the antibody hydrophobicity, potential for electrostatic self-interaction and conformational stability. The initial interfacial pressure increase within the first minute can serve as a good predictor for antibody adsorption and particle formation propensity. Our results highlight the complexity of protein adsorption and emphasize the importance of formulation development to reduce protein particle formation by avoidance of adsorption to interfaces.
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Affiliation(s)
- Natalie Deiringer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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9
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Bluemel O, Anuschek M, Buecheler JW, Hoelzl G, Bechtold-Peters K, Friess W. The effect of mAb and excipient cryoconcentration on long-term frozen storage stability – Part 1: Higher molecular weight species and subvisible particle formation. Int J Pharm X 2022; 4:100108. [PMID: 35024603 PMCID: PMC8724966 DOI: 10.1016/j.ijpx.2021.100108] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/21/2021] [Accepted: 12/22/2021] [Indexed: 11/05/2022] Open
Abstract
Cryoconcentration upon large-scale freezing of monoclonal antibody (mAb) solutions leads to regions of different ratios of low molecular weight excipients, like buffer species or sugars, to protein. This study focused on the impact of the buffer species to mAb ratio on aggregate formation after frozen storage at −80 °C, −20 °C, and − 10 °C after 6 weeks, 6 months, and 12 months. An optimised sample preparation was established to measure Tg′ of samples with different mAb to histidine ratios via differential scanning calorimetry (DSC). After storage higher molecular weight species (HMWS) and subvisible particles (SVPs) were detected using size-exclusion chromatography (SEC) and FlowCam, respectively. For all samples, sigmoidal curves in DSC thermograms allowed to precisely determine Tg′ in formulations without glass forming sugars. Storage below Tg′ did not lead to mAb aggregation. Above Tg′, at −20 °C and − 10 °C, small changes in mAb and buffer concentration markedly impacted stability. Samples with lower mAb concentration showed increased formation of HMWS. In contrast, higher concentrated samples led to more SVPs. A shift in the mAb to histidine ratio towards mAb significantly increased overall stability. Cryoconcentration upon large-scale freezing affects mAb stability, although relative changes compared to the initial concentration are small. Storage below Tg′ completely prevents mAb aggregation and particle formation.
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10
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Bluemel O, Buecheler JW, Hauptmann A, Hoelzl G, Bechtold-Peters K, Friess W. The effect of mAb and excipient cryoconcentration on long-term frozen storage stability – part 2: Aggregate formation and oxidation. Int J Pharm X 2022; 4:100109. [PMID: 35024604 PMCID: PMC8724956 DOI: 10.1016/j.ijpx.2021.100109] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/21/2021] [Accepted: 12/22/2021] [Indexed: 11/18/2022] Open
Abstract
We examined the impact of monoclonal antibody (mAb) and buffer concentration, mimicking the cryoconcentration found upon freezing in a 2 L bottle, on mAb stability during frozen storage. Upon cryoconcentration, larger protein molecules and small excipient molecules freeze-concentrate differently, resulting in different protein to stabiliser ratios within a container. Understanding the impact of these shifted ratios on protein stability is essential. For two mAbs a set of samples with constant mAb (5 mg/mL) or buffer concentration (medium histidine/adipic acid) was prepared and stored for 6 months at −10 °C. Stability was evaluated via size-exclusion chromatography, flow imaging microscopy, UV/Vis spectroscopy at 350 nm, and protein A chromatography. Dynamic light scattering was used to determine kD values. Soluble aggregate levels were unaffected by mAb concentration, but increased with histidine concentration. No trend in optical density could be identified. In contrast, increasing mAb or buffer concentration facilitated the formation of subvisible particles. A trend towards attractive protein-protein interactions was seen with higher ionic strength. MAb oxidation levels were negatively affected by increasing histidine concentration, but became less with higher mAb concentration. Small changes in mAb and buffer composition had a significant impact on stability during six-month frozen storage. Thus, preventing cryoconcentration effects in larger freezing containers may improve long-term stability.
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Affiliation(s)
- Oliver Bluemel
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
| | - Jakob W. Buecheler
- Technical Research and Development, Novartis Pharma AG, 4002 Basel, Switzerland
| | | | | | | | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
- Corresponding author.
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11
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Deiringer N, Aleshkevich S, Müller C, Friess W. Modification of Tubings for Peristaltic Pumping of Biopharmaceutics. J Pharm Sci 2022; 111:3251-3260. [PMID: 36058256 DOI: 10.1016/j.xphs.2022.08.037] [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: 07/10/2022] [Revised: 08/30/2022] [Accepted: 08/30/2022] [Indexed: 01/05/2023]
Abstract
Protein particle formation during peristaltic pumping of biopharmaceuticals is due to protein film formation on the inner tubing surface followed by rupture of the film by the roller movement. Protein adsorption can be prevented by addition of surfactants as well as by increasing the hydrophilicity of the inner surface. Attempts based on covalent surface coating were mechanically not stable against the stress of roller movement. We successfully incorporated surface segregating smart polymers based on a polydimethylsiloxane (PDMS) backbone and polyethylene glycol (PEG) side blocks in the tubing wall matrix. For this we applied an easy, reproducible and cost-effective process based on soaking of tubing in toluene containing the PDMS-PEG copolymer. With this tubing modification we could drastically reduce protein particle formation during peristaltic pumping of a monoclonal antibody and human growth hormone (HGH) formulation in silicone and thermoplastic elastomer-based tubing. The modification did not impact the tubing integrity during pumping while hydrophilicity was increased and protein adsorption was prevented. Free PDMS-PEG copolymer might have an additional stabilizing effect, but less than 50 ppm of the PDMS-PEG copolymer leached from the modified tubing during 1 h of pumping in the experimental setup. In summary, we present a new method for the modification of tubings which reduces protein adsorption and particle formation during any operation involving peristaltic pumping, e.g. transfer, filling, or tangential flow filtration.
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Affiliation(s)
- Natalie Deiringer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University Munich, Munich, Germany
| | - Sofya Aleshkevich
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University Munich, Munich, Germany
| | - Christoph Müller
- Department of Pharmacy, Center for Drug Research, Ludwig-Maximilians-University Munich, Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University Munich, Munich, Germany.
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12
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Nishiumi H, Deiringer N, Krause N, Yoneda S, Torisu T, Menzen T, Friess W, Uchiyama S. Utility of Three Flow Imaging Microscopy Instruments for Image Analysis in Evaluating four Types of Subvisible Particle in Biopharmaceuticals. J Pharm Sci 2022; 111:3017-3028. [PMID: 35948157 DOI: 10.1016/j.xphs.2022.08.006] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/19/2022] [Revised: 08/04/2022] [Accepted: 08/04/2022] [Indexed: 12/14/2022]
Abstract
Subvisible particles (SVPs) are a critical quality attribute of parenteral and ophthalmic products. United States Pharmacopeia recommends the characterizations of SVPs which are classified into intrinsic, extrinsic, and inherent particles. Flow imaging microscopy (FIM) is useful as an orthogonal method in both the quantification and classification of SVPs because FIM instruments provide particle images. In addition to the conventionally used FlowCam (Yokogawa Fluid Imaging Technologies) and Micro-Flow Imaging (Bio-Techne) instruments, the iSpect DIA-10 (Shimadzu) instrument has recently been released. The three instruments have similar detection principles but different optical settings and image processing, which may lead to different results of the quantification and classification of SVPs based on the information from particle images. The present study compares four types of SVP (protein aggregates, silicone oil droplets, and surrogates for solid free-fatty-acid particles, milled-lipid particles, and sprayed-lipid particles) to compare the results of size distributions and classification abilities obtained using morphological features and a deep-learning approach. Although the three FIM instruments were effective in classifying the four types of SVP through convolutional neural network analysis, there was no agreement on the size distribution for the same protein aggregate solution, suggesting that using the classifiers of the FIM instruments could result in different evaluations of SVPs in the field of biopharmaceuticals.
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Affiliation(s)
- Haruka Nishiumi
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Natalie Deiringer
- Department of Pharmacy; Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universitaet Muenchen, Munich, Germany
| | - Nils Krause
- Coriolis Pharma Research GmbH, Fraunhoferstr. 18 b, 82152, Martinsried, Germany
| | - Saki Yoneda
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Tetsuo Torisu
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
| | - Tim Menzen
- Coriolis Pharma Research GmbH, Fraunhoferstr. 18 b, 82152, Martinsried, Germany
| | - Wolfgang Friess
- Department of Pharmacy; Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universitaet Muenchen, Munich, Germany
| | - Susumu Uchiyama
- Department of Biotechnology, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan; U-medico Inc., 2-1 Yamadaoka, Suita, Osaka, 565-0871, Japan.
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13
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Keil TWM, Deiringer N, Friess W, Merkel OM. Evaluation of adsorption of DNA/PEI polyplexes to tubing materials. Eur J Pharm Biopharm 2022; 179:58-64. [PMID: 36041597 PMCID: PMC7613709 DOI: 10.1016/j.ejpb.2022.08.014] [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: 05/29/2022] [Revised: 08/22/2022] [Accepted: 08/24/2022] [Indexed: 11/24/2022]
Abstract
Nucleic acid drugs hold great promise for potential treatment of a variety of diseases. But efficient delivery is still the major challenge impeding translation. Nanoformulations based on polymers and lipids require preparation processes such as microfluidic mixing, spray drying or final filling, where pumping is a crucial step. Here, we studied the effect of pumping on the component and overall loss of a binary polyplex formulation made of DNA and polyethyleneimine (PEI). We varied tubing length and material with a focus on subsequent spray drying. Interestingly, product loss increased with the length of silicon tubing. Losses of DNA were prevented by using Pumpsil. The following spray drying process did not affect DNA content but caused PEI loss. Characterization of the different tubing materials revealed similar hydrophobicity of all tubing materials and showed neutral Pumpsil® surface charge, negative Santoprene™ surface charge, and a positive Silicon surface charge. Hence, adsorption of DNA onto tubing material was concluded to be the root cause for DNA loss after pumping and is based upon an interplay of ionic and hydrophobic interactions between polyplexes and tubing material. Overall, selecting the appropriate tubing material for processing nucleic acid nanoparticles is key to achieving satisfactory product quality.
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Affiliation(s)
- Tobias W M Keil
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Natalie Deiringer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Olivia M Merkel
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, 81377 Munich, Germany.
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14
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Bluemel O, Pavlišič A, Likozar B, Rodrigues MA, Geraldes V, Bechtold-Peters K, Friess W. Computational Fluid Dynamic Simulations of Temperature, Cryoconcentration, and Stress Time during Large-Scale Freezing and Thawing of Monoclonal Antibody Solutions. Eur J Pharm Biopharm 2022; 177:107-112. [PMID: 35764219 DOI: 10.1016/j.ejpb.2022.06.007] [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: 03/01/2022] [Revised: 05/24/2022] [Accepted: 06/16/2022] [Indexed: 11/04/2022]
Abstract
PURPOSE Large-scale freezing and thawing experiments of monoclonal antibody (mAb) solutions are time and material consuming. Computational Fluid Dynamic (CFD) modeling of temperature, solute composition as well as the stress time, defined as the time between start of freezing and reaching Tg' at any point in the container, could be a promising approach to ease and speed up process development. METHODS Temperature profiles at six positions were recorded during freezing and thawing of a 2L rectangular bottle and compared to CFD simulations via OpenFOAM. Furthermore, cryoconcentration upon freezing and concentration gradients upon thawing of a mAb solution were predicted and the stress time calculated. RESULTS Temperature profiles during freezing were accurately matched by the CFD simulation. Thawing time was only 45min to 60 min longer in the model. The macroscopic cryoconcentration of the mAb was also matched by the simulation; only a highly concentrated region in the top and a diluted core in the geometrical centre of the 2 L bottle were not well reflected in the simulation. The concentration gradient after thawing obtained by simulation as well agreed with the experimental result. In addition, CFD simulations allowed to extract the global temperature distribution, the formation of ice, and thus the distribution of stress in the freezing liquid. CONCLUSION CFD simulations via OpenFOAM are a promising tool to describe large-scale freezing and thawing of mAb solutions and can help to generate a deeper understanding and to improve testing of the robustness of the processes.
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Affiliation(s)
- Oliver Bluemel
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
| | - Andraž Pavlišič
- Laboratory of Catalysis and Chemical Reaction Engineering, National Institute of Chemistry, 1000 Ljubljana, Slovenia
| | - Blaž Likozar
- Laboratory of Catalysis and Chemical Reaction Engineering, National Institute of Chemistry, 1000 Ljubljana, Slovenia
| | - Miguel A Rodrigues
- Centro de Química Estrutural, Department of Chemical Engineering, Instituto Superior Técnico, Lisboa 1049-001, Portugal
| | - Vitor Geraldes
- CeFEMA, Department of Chemical Engineering, Instituto Superior Técnico, Lisboa 1049-001, Portugal
| | | | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
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15
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Meyer RM, Aleshkevich S, Berger L, Nerkamp J, Scheler S, Friess W. Characterization of the Aggregation Propensity of Charge Variants of Recombinant Human Growth Hormone. Int J Pharm 2022; 621:121760. [DOI: 10.1016/j.ijpharm.2022.121760] [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] [Received: 11/28/2021] [Revised: 04/16/2022] [Accepted: 04/19/2022] [Indexed: 10/18/2022]
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16
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Trenkenschuh E, Richter M, Heinrich E, Koch M, Fuhrmann G, Friess W. Enhancing the Stabilization Potential of Lyophilization for Extracellular Vesicles. Adv Healthc Mater 2022; 11:e2100538. [PMID: 34310074 DOI: 10.1002/adhm.202100538] [Citation(s) in RCA: 10] [Impact Index Per Article: 5.0] [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: 03/22/2021] [Revised: 06/18/2021] [Indexed: 01/08/2023]
Abstract
Extracellular vesicles (EV) are an emerging technology as immune therapeutics and drug delivery vehicles. However, EVs are usually stored at -80 °C which limits potential clinical applicability. Freeze-drying of EVs striving for long-term stable formulations is therefore studied. The most appropriate formulation parameters are identified in freeze-thawing studies with two different EV types. After a freeze-drying feasibility study, four lyophilized EV formulations are tested for storage stability for up to 6 months. Freeze-thawing studies revealed improved colloidal EV stability in presence of sucrose or potassium phosphate buffer instead of sodium phosphate buffer or phosphate-buffered saline. Less aggregation and/or vesicle fusion occurred at neutral pH compared to slightly acidic or alkaline pH. EVs colloidal stability can be most effectively preserved by addition of low amounts of poloxamer 188. Polyvinyl pyrrolidone failed to preserve EVs upon freeze-drying. Particle size and concentration of EVs are retained over 6 months at 40 °C in lyophilizates containing 10 mm K- or Na-phosphate buffer, 0.02% poloxamer 188, and 5% sucrose. The biological activity of associated beta-glucuronidase is maintained for 1 month, but decreased after 6 months. Here optimized parameters for lyophilization of EVs that contribute to generate long-term stable EV formulations are presented.
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Affiliation(s)
- Eduard Trenkenschuh
- Pharmaceutical Technology and Biopharmaceutics Department of Pharmacy Ludwig‐Maximilians‐Universitaet Muenchen Munich 81377 Germany
| | - Maximilian Richter
- Helmholtz Centre for Infection Research (HZI) Biogenic Nanotherapeutics Group (BION) Helmholtz Institute for Pharmaceutical Research Saarland (HIPS) Campus E8.1 Saarbruecken 66123 Germany
- Department of Pharmacy Saarland University Campus E8.1 Saarbruecken 66123 Germany
| | - Eilien Heinrich
- Helmholtz Centre for Infection Research (HZI) Biogenic Nanotherapeutics Group (BION) Helmholtz Institute for Pharmaceutical Research Saarland (HIPS) Campus E8.1 Saarbruecken 66123 Germany
- Department of Pharmacy Saarland University Campus E8.1 Saarbruecken 66123 Germany
| | - Marcus Koch
- INM – Leibniz Institute for New Materials Campus D2 2 Saarbruecken 66123 Germany
| | - Gregor Fuhrmann
- Helmholtz Centre for Infection Research (HZI) Biogenic Nanotherapeutics Group (BION) Helmholtz Institute for Pharmaceutical Research Saarland (HIPS) Campus E8.1 Saarbruecken 66123 Germany
- Department of Pharmacy Saarland University Campus E8.1 Saarbruecken 66123 Germany
| | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics Department of Pharmacy Ludwig‐Maximilians‐Universitaet Muenchen Munich 81377 Germany
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17
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Moll F, Bechtold-Peters K, Mellman J, Sigg JÜ, Friess W. Replacing the Emulsion for Bake-on Siliconization of Containers-Comparison of Emulsion Stability and Container Performance in the Context of Protein Formulations. PDA J Pharm Sci Technol 2022; 76:89-108. [PMID: 35365551 DOI: 10.5731/pdajpst.2020.012640] [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] [Indexed: 11/05/2022]
Abstract
Pre-filled syringes have simplified parenteral administration of protein drugs. To ensure an easy and consistent movement of the plunger, the inner glass container surface is typically siliconized. For bake-on siliconization, emulsions are sprayed on and heat treated. Due to the European Union regulation REACh (Regulation concerning the R egistration, E valuation, A uthorisation and Restriction of Ch emicals) the use of certain emulsion components, partially constituting the gold standard LiveoTM 365 35% Dimethicone NF Emulsion (LiveoTM 365), becomes restricted and LiveoTM 366 35% Dimethicone NF Emulsion (LiveoTM 366) has been introduced as an alternative. This change may affect the handling properties as well as the silicone layer formed. The purpose of these studies was to identify any differences that may influence the stability and safety of the final drug/device combination product to enable the use of the new emulsion. We compared silicone emulsions LiveoTM 365 and LiveoTM 366 and dilutions focusing on 1) their general physical stability, 2) the thermal degradation process of the emulsions and their components, and 3) the resulting silicone layer concerning chemistry, morphology, and functionality. The results were linked to the assessment of the final product regarding particle formation and short-term stability. A comparison of the emulsions LiveoTM 365 and LiveoTM 366 for bake-on siliconization is presented to support the transition of the latter as it becomes mandatory with REACh. Our studies show that the two emulsions do not significantly differ with respect to handling and stability, the resultant silicone layer characteristics as well as its functionality. We conclude that the transition to the new emulsion will not significantly impact the final product or the layer performance upon storage and with respect to particle formation.
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Affiliation(s)
- Fabian Moll
- Department of Pharmacy, Pharmaceutical Technology & Biopharmaceutics, Ludwig-Maximilians-University Munich, Germany
| | | | - James Mellman
- Technical Research and Development (TRD) Biologics, Novartis Pharma AG, Basel, Switzerland; and.,SHL Medical AG, Zug, Switzerland
| | - JÜrgen Sigg
- Technical Research and Development (TRD) Biologics, Novartis Pharma AG, Basel, Switzerland; and
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology & Biopharmaceutics, Ludwig-Maximilians-University Munich, Germany;
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18
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Deiringer N, Friess W. Proteins on the rack: Mechanistic studies on protein particle formation during peristaltic pumping. J Pharm Sci 2022; 111:1370-1378. [PMID: 35122831 DOI: 10.1016/j.xphs.2022.01.035] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [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: 11/23/2021] [Revised: 01/29/2022] [Accepted: 01/29/2022] [Indexed: 02/08/2023]
Abstract
Peristaltic pumping can cause protein particle formation. The expected causes were unfolding by heat in the pump head, oxidative stress by cavitation generated during roller movement, interfacial adsorption to the tubing wall and mechanical stress by stretching of the tubing itself. The pump head reached 28°C during experiments stayed well below the onset of the melting point of the proteins. Thus, heat may only be a relevant root cause for proteins containing domains with very low unfolding temperature. Analysis by terephthalic acid dosimetry and protein oxidation via RP-HPLC ruled out major induction of reactive hydroxyl radicals by pumping, indicating that cavitation does not play a significant role in particle generation. Addition of surfactants suppresses protein adsorption to the tubing wall and drastically reduced protein particle formation. This indicates that interfacial protein adsorption is a key element. Repeated stretching of tubing filled with protein solution led to the formation of protein particles, demonstrating that expansion and compression of the protein film on the tubing surface is the second key component for particle formation. Thus, protein particle generation during peristaltic pumping originates from the formation of a protein film on the tubing surface which gets stretched and compressed, leading to film fragments entering the bulk solution. This interplay of protein film formation and its rupture has been also observed at liquid/liquid or liquid/air interfaces.
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Affiliation(s)
- Natalie Deiringer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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19
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Bluemel O, Rodrigues MA, Buecheler JW, Geraldes V, Hoelzl G, Hauptmann A, Bechtold-Peters K, Friess W. Evaluation of Two Novel Scale-Down Devices for Testing Monoclonal Antibody Aggregation During Large-Scale Freezing. J Pharm Sci 2022; 111:1973-1983. [PMID: 35007568 DOI: 10.1016/j.xphs.2022.01.003] [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: 11/15/2021] [Revised: 01/05/2022] [Accepted: 01/05/2022] [Indexed: 11/28/2022]
Abstract
There is a need for representative small volume devices that reflect monoclonal antibody (mAb) aggregation during freezing and thawing (FT) in large containers. We characterised two novel devices that aim to mimic the stress in rectangular 2 L bottles. The first scale-down device (SDD) consists of a 125 mL bottle surrounded by a 3D printed cover that manipulates heat exchange. The second device, a micro scale-down device (mSDD), adapts cooling and heating of 10 mL vials to extend stress time. MAb aggregation upon repeated FT was evaluated considering formation of higher molecular weight species, subvisible particles, and the increase in hydrodynamic radius, polydispersity index, and optical density at 350 nm. Three different mAb solutions were processed. Both an unshielded 125 mL bottle and the SDD can be used to predict aggregation during FT in 2 L bottles. In specific cases the unshielded 125 mL bottle underestimates whereas the SDD slightly overestimates soluble aggregate formation. The mSDD increases aggregation compared to 10 mL vials but is less representative than the SDD. Ultimately, both SDDs enable characterisation of protein sensitivity to large-scale FT with two orders of magnitude less volume and are superior to simply using smaller bottles.
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Affiliation(s)
- Oliver Bluemel
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
| | - Miguel A Rodrigues
- Centro de Química Estrutural, Department of Chemical Engineering, Instituto Superior Técnico, Lisboa 1049-001, Portugal
| | - Jakob W Buecheler
- Technical Research and Development, Novartis Pharma AG, 4002 Basel, Switzerland
| | - Vitor Geraldes
- CeFEMA, Department of Chemical Engineering, Instituto Superior Técnico, Lisboa 1049-001, Portugal
| | | | | | | | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
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20
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Bluemel O, Buecheler JW, Hauptmann A, Hoelzl G, Bechtold-Peters K, Friess W. Scaling Down Large-Scale Thawing of Monoclonal Antibody Solutions: 3D Temperature Profiles, Changes in Concentration, and Density Gradients. Pharm Res 2021; 38:1977-1989. [PMID: 34729702 PMCID: PMC8688388 DOI: 10.1007/s11095-021-03117-6] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/19/2021] [Accepted: 09/18/2021] [Indexed: 11/30/2022]
Abstract
PURPOSE Scale-down devices (SDD) are designed to simulate large-scale thawing of protein drug substance, but require only a fraction of the material. To evaluate the performance of a new SDD that aims to predict thawing in large-scale 2 L bottles, we characterised 3D temperature profiles and changes in concentration and density in comparison to 125 mL and 2 L bottles. Differences in diffusion between a monoclonal antibody (mAb) and histidine buffer after thawing were examined. METHODS Temperature profiles at six distinct positions were recorded with type T thermocouples. Size-exclusion chromatography allowed quantification of mAb and histidine. Polysorbate 80 was quantified using a fluorescent dye assay. In addition, the solution's density at different locations in bottles and the SDD was identified. RESULTS The temperature profiles in the SDD and the large-scale 2 L bottle during thawing were similar. Significant concentration gradients were detected in the 2 L bottle leading to marked density gradients. The SDD slightly overestimated the dilution in the top region and the maximum concentrations at the bottom. Fast diffusion resulted in rapid equilibration of histidine. CONCLUSION The innovative SDD allows a realistic characterisation and helps to understand thawing processes of mAb solutions in large-scale 2 L bottles. Only a fraction of material is needed to gain insights into the thawing behaviour that is associated with several possible detrimental limitations.
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Affiliation(s)
- Oliver Bluemel
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universitaet Muenchen, 81377, Munich, Germany
| | - Jakob W Buecheler
- Technical Research and Development, Novartis Pharma AG, 4002, Basel, Switzerland
| | | | | | | | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universitaet Muenchen, 81377, Munich, Germany.
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21
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Roche A, Gentiluomo L, Sibanda N, Roessner D, Friess W, Trainoff SP, Curtis R. Towards an improved prediction of concentrated antibody solution viscosity using the Huggins coefficient. J Colloid Interface Sci 2021; 607:1813-1824. [PMID: 34624723 DOI: 10.1016/j.jcis.2021.08.191] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [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: 06/04/2021] [Revised: 07/28/2021] [Accepted: 08/29/2021] [Indexed: 01/12/2023]
Abstract
The viscosity of a monoclonal antibody solution must be monitored and controlled as it can adversely affect product processing, packaging and administration. Engineering low viscosity mAb formulations is challenging as prohibitive amounts of material are required for concentrated solution analysis, and it is difficult to predict viscosity from parameters obtained through low-volume, high-throughput measurements such as the interaction parameter, kD, and the second osmotic virial coefficient, B22. As a measure encompassing the effect of intermolecular interactions on dilute solution viscosity, the Huggins coefficient, kh, is a promising candidate as a parameter measureable at low concentrations, but indicative of concentrated solution viscosity. In this study, a differential viscometry technique is developed to measure the intrinsic viscosity, [η], and the Huggins coefficient, kh, of protein solutions. To understand the effect of colloidal protein-protein interactions on the viscosity of concentrated protein formulations, the viscometric parameters are compared to kD and B22 of two mAbs, tuning the contributions of repulsive and attractive forces to the net protein-protein interaction by adjusting solution pH and ionic strength. We find a strong correlation between the concentrated protein solution viscosity and the kh but this was not observed for the kD or the b22, which have been previously used as indicators of high concentration viscosity. Trends observed in [η] and kh values as a function of pH and ionic strength are rationalised in terms of protein-protein interactions.
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Affiliation(s)
- Aisling Roche
- Manchester Institute of Biotechnology, University of Manchester, 131 Princess Street, School of Chemical Engineering and Analytical Science, Manchester M1 7DN, UK; Currently at: National Institute for Biological Standards and Control, South Mimms, Potters Bar, Herts EN6 3QG, UK
| | - Lorenzo Gentiluomo
- Wyatt Technology Europe GmbH, Hochstrasse 18, 56307 Dernbach, Germany; Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Butenandtstrasse 5, 81377 Munich, Germany; Currently at: Coriolis Pharma, Fraunhoferstraße 18B, 82152 Munich, Germany
| | - Nicole Sibanda
- Manchester Institute of Biotechnology, University of Manchester, 131 Princess Street, School of Chemical Engineering and Analytical Science, Manchester M1 7DN, UK
| | - Dierk Roessner
- Wyatt Technology Europe GmbH, Hochstrasse 18, 56307 Dernbach, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Butenandtstrasse 5, 81377 Munich, Germany
| | - Steven P Trainoff
- Wyatt Technology Corporation, 6330 Hollister Ave, Goleta, CA 93117, United States
| | - Robin Curtis
- Manchester Institute of Biotechnology, University of Manchester, 131 Princess Street, School of Chemical Engineering and Analytical Science, Manchester M1 7DN, UK.
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22
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Moll F, Bechtold-Peters K, Mellman J, Sigg J, Friess W. Replacing the emulsion for bake-on siliconization of containers - comparison of emulsion stability and container performance in the context of protein formulations. PDA J Pharm Sci Technol 2021; 76:pdajpst.2021.012640. [PMID: 34400526 DOI: 10.5731/pdajpst.2021.012640] [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: 03/12/2021] [Accepted: 07/23/2021] [Indexed: 11/05/2022]
Abstract
Pre-filled syringes have simplified parenteral administration of protein drugs. To ensure an easy and consistent movement of the plunger, the inner glass container surface is typically siliconized. For bake-on siliconization emulsions are sprayed on and heat treated. Due to the European Union regulation REACh (Regulation concerning the Registration, Evaluation, Authorisation and Restriction of Chemicals) the use of certain emulsion components, partially constituting the gold standard Liveo™ 365 35% Dimethicone NF Emulsion (Liveo™ 365), becomes restricted and Liveo™ 366 35% Dimethicone NF Emulsion (Liveo™ 366) has been introduced as an alternative. This change may affect the handling properties as well as the silicone layer formed. The purpose of these studies was to identify any differences that may influence the stability and safety of the final drug/device combination product to enable the use of the new emulsion. We compared silicone emulsions Liveo™ 365 and Liveo™ 366 and dilutions focusing on I) their general physical stability, II) the thermal degradation process of the emulsions and their components, and III) the resulting silicone layer concerning chemistry, morphology, and functionality. The results were linked to the assessment of the final product regarding particle formation and long-term stability. A comparison of the emulsions Liveo™ 365 and Liveo™ 366 for bake-on siliconization is presented to support the transition of the latter as it becomes mandatory with REACh. Our studies show that the two emulsions do not significantly differ with respect to handling and stability, the resultant silicone layer characteristics as well as its functionality. We conclude that the transition to the new emulsion will not significantly impact the final product or the layer performance upon storage and with respect to particle formation.
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Affiliation(s)
- Fabian Moll
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-University Munich, Germany
| | | | - James Mellman
- Technical Research and Development (TRD) Biologics, Novartis Pharma AG, Basel, Switzerland / SHL Medical AG, Zug, Switzerland
| | - Jurgen Sigg
- Technical Research and Development (TRD) Biologics, Novartis Pharma AG, Basel, Switzerland
| | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-University Munich, Germany;
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23
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Trenkenschuh E, Friess W. Freeze-thaw stability of aluminum oxide nanoparticles. Int J Pharm 2021; 606:120932. [PMID: 34310956 DOI: 10.1016/j.ijpharm.2021.120932] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [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: 04/12/2021] [Revised: 07/19/2021] [Accepted: 07/21/2021] [Indexed: 11/26/2022]
Abstract
The use of inorganic nanoparticles (NPs) gains interest for pharmaceutical applications, e.g. as adjuvants or drug delivery vehicles. Colloidal stability of NPs in aqueous suspensions is a major development challenge. Both frozen and lyophilized liquids are alternative presentations to liquid dispersion. To improve the basic understanding, we investigated the freeze-thawing stability of model α-Al2O3 NPs. Freeze-thawing was conducted in three different buffer types at pH5 and 8 without and with additives to determine fundamental formulation principles. Before freeze-thawing, α-Al2O3 NPs could be stabilized in sodium citrate buffer at pH5 and 8, and in sodium or potassium phosphate at pH8. Particles revealed low zeta potential values in phosphate buffers at pH5 indicating insufficient electrostatic stabilization. After freeze-thawing, an increase in NP size was strongly reduced in potassium phosphate and sodium citrate buffers. Subsequent pH measurements upon freezing revealed a drastic acidic pH shift in sodium phosphate which was further demonstrated to destabilize NPs. The ionic stabilizers gelatin A/B, Na-CMC, and SDS, were suitable to improve colloidal stability in phosphate buffers at pH5 highlighting the importance of charge stabilization. Freeze-thawing stability was best in presence of gelatin A/B, followed by PVA, mannitol, or sucrose. Depletion and steric stabilization were insufficient using PEG and surfactants respectively. Thus, we could identify the fundamental formulation principles to preserve inorganic NPs upon freezing: i) sufficient charge stabilization, ii) a maintained pH during freezing, and iii) the addition of a suitable stabilizer, preferably gelatin, not necessarily surfactants. This forms the basis for future studies, e.g. on lyophilization.
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Affiliation(s)
- Eduard Trenkenschuh
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
| | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany.
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24
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Trenkenschuh E, Savšek U, Friess W. Formulation, process, and storage strategies for lyophilizates of lipophilic nanoparticulate systems established based on the two models paliperidone palmitate and solid lipid nanoparticles. Int J Pharm 2021; 606:120929. [PMID: 34303819 DOI: 10.1016/j.ijpharm.2021.120929] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [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: 06/14/2021] [Revised: 07/19/2021] [Accepted: 07/20/2021] [Indexed: 11/16/2022]
Abstract
Lyophilization formulation and process development for lipophilic nanoparticle (NPs) products is highly challenging as the NPs have a low colloidal stability. We compared two different NP types, pure paliperidone palmitate nanocrystals and trimyristin solid lipid nanoparticles regarding formulation, process, and storage stability aspects. Freeze-thaw studies were conducted to investigate the basic formulation aspects such as buffer type, pH, and ionic strength as well as different cryoprotectants. In freeze-drying conventional ramp freezing was performed and compared to freezing with an annealing step added or with controlled ice nucleation. Different formulations were lyophilized and tested for short-term storage stability up to 6 weeks. Samples were analyzed for particle size, subvisible particle number, specific surface area, residual moisture, crystallinity, and glass transition temperature. Sucrose significantly better stabilized both NP types against freeze-thaw stress compared to mannitol demonstrating the importance of a fully amorphous matrix. While the impact of buffer type and pH was negligible, the aggregation propensity of NPs was reduced in presence of NaCl. The freezing step also impacted NP aggregation but the effect was less important than the formulation design. Surfactants did not necessarily improve the colloidal stability but resulted in a lower glass transition temperature of the lyophilizates and may cause phase separation which limits storage stability. This hurdle can be overcome by using a hydroxypropyl-β-cyclodextrin/ sucrose mixture as cryoprotectant. In general, we could show a similar freeze-drying behavior of the two NP types. Thus, we established a formulation and process approach to achieve stable lyophilizates of lipophilic NPs based on two different types of NPs. The general rules should be transferable to other NPs facilitating lyophilization development.
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Affiliation(s)
- Eduard Trenkenschuh
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Ula Savšek
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany
| | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universität München, 81377 Munich, Germany.
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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] [What about the content of this article? (0)] [Affiliation(s)] [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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26
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Keil TWM, Zimmermann C, Baldassi D, Adams F, Friess W, Mehta A, Merkel OM. Impact of crystalline and amorphous matrices on successful spray drying of siRNA polyplexes for inhalation of nano-in-microparticles. Adv Ther (Weinh) 2021; 4:2100073. [PMID: 34337144 PMCID: PMC7611418 DOI: 10.1002/adtp.202100073] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/15/2021] [Indexed: 11/09/2022]
Abstract
To develop stable and inhalable dry powder formulations with long shelf life, we spray dried polyplexes consisting of siRNA and a polyethylenimine based block copolymer in presence of mannitol or trehalose. We investigated the effect of inlet (T-In) and outlet (T-Out) temperature on the recovery of siRNA as well as adsorption effects within the tubing material. Choosing a low abrasion silicon tubing prevented siRNA loss due to adsorption. Mannitol and trehalose formulations preserved siRNA integrity regardless of excipient concentration and temperature at T-Out below the siRNA melting temperature. Trehalose formulations allowed full siRNA recovery whereas mannitol formulations resulted in spray drying induced losses of ~20 % siRNA and of 50-60 % polymer. Mannitol formulations showed optimal aerodynamic characteristics as confirmed by next generation impaction analysis based upon siRNA content. All spray dried formulations resulted in GFP silencing comparable or better than freshly prepared polyplexes. To test if the observed results could be transferred, formulations of siRNA and transferrin-PEI conjugates were spray dried, characterized and used to transfect primary human T cells ex vivo. Results confirmed successful silencing of the Th2 transcription factor GATA3 in primary CD4+ T cells with spray dried formulations as a potential treatment for severe asthma.
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Affiliation(s)
- Tobias WM Keil
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Christoph Zimmermann
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Domizia Baldassi
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Friederike Adams
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Aditi Mehta
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
| | - Olivia M Merkel
- Department of Pharmacy, Pharmaceutical Technology and Biopharmacy, Ludwig-Maximilians Universität München, 81377 Munich, Germany
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27
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Trenkenschuh E, Friess W. Freeze-drying of nanoparticles: How to overcome colloidal instability by formulation and process optimization. Eur J Pharm Biopharm 2021; 165:345-360. [PMID: 34052428 DOI: 10.1016/j.ejpb.2021.05.024] [Citation(s) in RCA: 54] [Impact Index Per Article: 18.0] [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: 03/04/2021] [Revised: 05/03/2021] [Accepted: 05/23/2021] [Indexed: 11/29/2022]
Abstract
Lyophilization of nanoparticle (NP) suspensions is a promising technology to improve stability, especially during long-term storage, and offers new routes of administration in solid state. Although considered as a gentle drying process, freeze-drying is also known to cause several stresses leading to physical instability, e.g. aggregation, fusion, or content leakage. NPs are heterogeneous regarding their physico-chemical properties which renders them different in their sensitivity to lyophilization stress and upon storage. But still basic concepts can be deducted. We summarize basic colloidal stabilization mechanisms of NPs in the liquid and the dried state. Furthermore, we give information about stresses occurring during the freezing and the drying step of lyophilization. Subsequently, we review the most commonly investigated NP types including lipophilic, polymeric, or vesicular NPs regarding their particle properties, stabilization mechanisms in the liquid state, and important freeze-drying process, formulation and storage strategies. Finally, practical advice is provided to facilitate purposeful formulation and process development to achieve NP lyophilizates with high colloidal stability.
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Affiliation(s)
- Eduard Trenkenschuh
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany
| | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-Universitaet Muenchen, 81377 Munich, Germany.
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28
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Marschall C, Witt M, Hauptmeier B, Friess W. Powder suspensions in non-aqueous vehicles for delivery of therapeutic proteins. Eur J Pharm Biopharm 2021; 161:37-49. [PMID: 33548460 DOI: 10.1016/j.ejpb.2021.01.014] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [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: 07/21/2020] [Revised: 01/18/2021] [Accepted: 01/23/2021] [Indexed: 10/22/2022]
Abstract
Formulating biopharmaceuticals is a challenging task due to their complex and sensitive nature. Protein drugs are typically marketed either as an aqueous solution or as a lyophilizate. Usually aqueous solutions are preferred as neither drying nor reconstitution are required. But it may be unfeasible if the protein features low stability. An interesting alternative to avoid at least reconstitution are protein powder suspensions in non-aqueous vehicles. Such formulations combine the ready-to-use approach with the high protein stability in the solid state. Additionally, protein powder suspensions offer a potentially lower viscosity compared to aqueous solutions at high protein concentrations. Besides injection, other application routes might also benefit from the protein powder approach such as topical or inhalational delivery. Protein powders, which can be dispersed in the non-aqueous suspension vehicle, are usually prepared by spray-drying or freeze-drying with an additional milling step, but other techniques have also been described in literature. An ideal powder preparation technique results in minimum protein damage and yields particle sizes in the lower micrometre range and homogeneous particle size distribution enabling subcutaneous or intramuscular injection through hypodermic needles. As suspension vehicles traditional non-aqueous injectable liquids, such as plant oils, may be selected. But they show an inherent high viscosity, which can lead to unacceptable glide forces during injection. Furthermore, the vehicle should provide high product stability with respect to protein integrity and suspension resuspendability. This review will describe how proteins can be formulated as protein powder suspensions in non-aqueous vehicles for subcutaneous injection including potential vehicles, protein powder preparation techniques, protein and suspension physical stability, as well as the use in the field of high concentration protein formulations.
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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)
| | - 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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29
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Meyer RM, Berger L, Nerkamp J, Scheler S, Nehring S, Friess W. Identification of monoclonal antibody variants involved in aggregate formation - Part 2: Hydrophobicity variants. Eur J Pharm Biopharm 2021; 160:134-142. [PMID: 33524536 DOI: 10.1016/j.ejpb.2021.01.006] [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: 10/26/2020] [Revised: 01/08/2021] [Accepted: 01/13/2021] [Indexed: 11/29/2022]
Abstract
Monoclonal antibodies (mAbs) are valuable tools both in therapy and in diagnostic. Their tendency to aggregate is a serious concern. Since a mAb drug substance (DS) is composed of different variants, it is important for manufacturers to know the behavior and stability not only of the mAb as a whole, but also of the variants contained in the product. We present a method to separate hydrophobicity variants of a mAb and subsequently analyzed these variants for stability and aggregation propensity. We identified a potentially aggregation prone hydrophilic variant which is interrelated with another previously identified aggregation prone acidic charge variant. Additionally, we assessed the risk posed by the aggregation prone variant to the DS by spiking hydrophobicity variants into DS and did not observe an enhanced aggregation propensity. Thus we present an approach to separate, characterize and analyze the criticality of aggregation prone variants in protein DS which is a step forward to further assure drug safety.
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Affiliation(s)
- Robina M Meyer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, University of Munich, Butenandtstr. 5, 81377 Munich, Germany
| | - Lukas Berger
- Sandoz Biopharmaceutics, Biochemiestr. 10, 6336 Langkampfen, Austria
| | - Joerg Nerkamp
- Sandoz Biopharmaceutics, Biochemiestr. 10, 6336 Langkampfen, Austria
| | - Stefan Scheler
- Sandoz Biopharmaceutics, Biochemiestr. 10, 6336 Langkampfen, Austria
| | - Sebastian Nehring
- Sandoz Biopharmaceutics, Biochemiestr. 10, 6336 Langkampfen, Austria
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, University of Munich, Butenandtstr. 5, 81377 Munich, Germany.
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30
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Ehlers S, Schroeder R, Friess W. Process optimization and transfer of freeze-drying in nested vial systems. Eur J Pharm Biopharm 2021; 159:143-150. [PMID: 33429009 DOI: 10.1016/j.ejpb.2021.01.002] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [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: 07/17/2020] [Revised: 10/29/2020] [Accepted: 01/04/2021] [Indexed: 11/28/2022]
Abstract
Scale-up and transfer of freeze-drying processes is a crucial challenge in biopharma industry. With the success of small batch processing lines utilizing rack vial holding systems, further detailed knowledge about freeze-drying cycles and their scale-up for vials in a rack is required. Therefore, product temperature (TP) profiles as well as Kv values of vials nested in a Polyetheretherketon (PEEK) rack were compared to those of vials placed in a commonly used stainless steel tray. Additionally, both setups were challenged with varying fill volume and partially versus fully loaded rack. Additionally, a process developed for rack was compared to a tray freeze-drying cycle. Freeze-drying in vials placed in the rack is markedly faster for center vials and more homogeneous compared to vials in bulk tray setting, as indicated by TP and Kv values. Due to the more homogeneous drying the rack is more flexible regarding variation of the fill volume. The key point for the transfer of a freeze-drying cycle from rack to tray is to consider the higher sublimation rates in the rack by adapting chamber pressure or shelf temperature for the tray. Furthermore, transfer from one rack per shelf in a laboratory freeze-dryer to pilot scale with four racks per shelf was successful. Thus, understanding of the process in rack and tray setup was enhanced to ensure efficient scale-up and transfer of freeze-drying processes.
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Affiliation(s)
- Sarah Ehlers
- AbbVie Deutschland GmbH & Co. KG, Knollstraße 50, 67061 Ludwigshafen, Germany.
| | - Rudolf Schroeder
- AbbVie Deutschland GmbH & Co. KG, Knollstraße 50, 67061 Ludwigshafen, Germany
| | - Wolfgang Friess
- Department of Pharmacy; Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, Butenandtstrasse 5, D-81377 Muenchen, Germany.
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Ehlers S, Friess W, Schroeder R. Impact of chamber wall temperature on energy transfer during freeze-drying. Int J Pharm 2021; 592:120025. [PMID: 33137451 DOI: 10.1016/j.ijpharm.2020.120025] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [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: 05/30/2020] [Revised: 10/23/2020] [Accepted: 10/24/2020] [Indexed: 11/18/2022]
Abstract
Minimization of radiation coming from the chamber wall during lyophilization has the potential to reduce the edge-vial-effect. The edge-vial-effect is a phenomenon in which vials positioned at the shelf edges and corners tend to run warmer compared to center vials. A higher product temperature may result in product collapse in these vials. Consequently, more conservative and time-consuming freeze-drying cycles with lower shelf temperatures and pressures are chosen to ensure a product temperature below the collapse temperature in all vials. The edge-vial-effect is of even higher impact in small batches, where the ratio of corner and edge to center vials is higher compared to large scale manufacturing. The chamber wall is often discussed as the primary source of radiation impacting corner and edge vials. A radiation cage was set at different low temperatures to determine the impact of chamber wall temperatures below 0 °C on product temperature. At the end of primary drying, product temperature of corner vials could be reduced by 6 °C through the radiation cage but primary drying was elongated. Compared to vials in a tray, the chamber wall temperature had less impact on vials nested in a rack system due to a shielding effect of the rack itself. Corner and center vials ran more homogeneous with radiation cage since the edge and corner vials were slowed down. The difference in primary drying time between corner and center vials in the tray could be significantly reduced by 18% by means of 7 h when the radiation cage was controlled at product temperature and combined with a higher shelf temperature. In summary, the radiation cage is a useful tool for a more homogeneous batch with the potential to reduce primary drying time. Nevertheless, the drying difference between corner and center vials could only be reduced and was not completely eliminated.
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Affiliation(s)
- Sarah Ehlers
- AbbVie Deutschland GmbH & Co. KG, Knollstraße 50, 67061 Ludwigshafen, Germany.
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, Butenandtstrasse 5, D-81377 Muenchen, Germany.
| | - Rudolf Schroeder
- AbbVie Deutschland GmbH & Co. KG, Knollstraße 50, 67061 Ludwigshafen, Germany
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Seifert I, Friess W. The effect of residual moisture on a monoclonal antibody stability in L-arginine based lyophilisates. Eur J Pharm Biopharm 2021; 158:53-61. [DOI: 10.1016/j.ejpb.2020.11.003] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/16/2020] [Revised: 10/18/2020] [Accepted: 11/07/2020] [Indexed: 10/23/2022]
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33
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Meyer RM, Berger L, Nerkamp J, Scheler S, Nehring S, Friess W. Identification of monoclonal antibody variants involved in aggregate formation – Part 1: Charge variants. Eur J Pharm Biopharm 2021; 158:123-131. [DOI: 10.1016/j.ejpb.2020.10.020] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/16/2020] [Revised: 10/20/2020] [Accepted: 10/26/2020] [Indexed: 11/27/2022]
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Seifert I, Bregolin A, Fissore D, Friess W. The Influence of Arginine and Counter-Ions: Antibody Stability during Freeze-Drying. J Pharm Sci 2020; 110:2017-2027. [PMID: 33316241 DOI: 10.1016/j.xphs.2020.12.009] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [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: 06/21/2020] [Revised: 12/01/2020] [Accepted: 12/07/2020] [Indexed: 11/16/2022]
Abstract
Amino acids, for example L-arginine, are used in lyophilisation as crystalline bulking, buffering, viscosity reducing or stabilising excipients. In this study, arginine was formulated with different counter ions (hydrochloride, citrate, lactobionate, phosphate, and succinate). A monoclonal antibody was investigated in sugar-free arginine formulations and mixtures with sucrose regarding cake appearance and protein aggregation and fragmentation. Arginine hydrochloride formulations collapsed during lyophilisation due to its low Tg' and partially crystallised during storage, but provided the best protein stability at low antibody concentration, followed by arginine succinate. Arginine citrate/phosphate/lactobionate formulations resulted in amorphous elegant cakes, but inferior protein stability. Addition of sucrose improved cake appearance and protein stability. Arginine phosphate with sucrose resulted in similar protein stability as the sucrose reference. Mixtures of sucrose with arginine hydrochloride/lactobionate/succinate provided better stability than sucrose alone. While 50 mg/mL antibody improved the cake appearance, only arginine lactobionate provided sufficient protein stability next to sucrose. Overall, sugar-free arginine hydrochloride and lactobionate lyophilisates stabilised the antibody comparably or better than sucrose depending on antibody concentration. The best protein stability was found for mixtures of arginine hydrochloride/lactobionate/succinate with sucrose.
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Affiliation(s)
- Ivonne Seifert
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Alessandro Bregolin
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Turin, Italy
| | - Davide Fissore
- Dipartimento di Scienza Applicata e Tecnologia, Politecnico di Torino, Turin, Italy
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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35
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Deiringer N, Haase C, Wieland K, Zahler S, Haisch C, Friess W. Finding the Needle in the Haystack: High-Resolution Techniques for Characterization of Mixed Protein Particles Containing Shed Silicone Rubber Particles Generated During Pumping. J Pharm Sci 2020; 110:2093-2104. [PMID: 33307040 DOI: 10.1016/j.xphs.2020.12.002] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [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: 07/16/2020] [Revised: 11/19/2020] [Accepted: 12/02/2020] [Indexed: 12/29/2022]
Abstract
During the manufacturing process of biopharmaceuticals, peristaltic pumps are employed at different stages for transferring and dosing of the final product. Commonly used silicone tubings are known for particle shedding from the inner tubing surface due to friction in the pump head. These nanometer sized silicone rubber particles could interfere with proteins. Until now, only mixed protein particles containing micrometer-sized contaminations such as silicone oil have been characterized, detected, and quantified. To overcome the detection limits in particle sizes of contaminants, this study aimed for the definite identification of protein particles containing nanometer sized silicone particles in qualitative and quantitative manner. The mixed particles consisted of silicone rubber particles either coated with a protein monolayer or embedded into protein aggregates. Confocal Raman microscopy allows label free chemical identification of components and 3D particle imaging. Labeling the tubing enables high-resolution imaging via confocal laser scanning microscopy and counting of mixed particles via Imaging Flow Cytometry. Overall, these methods allow the detection and identification of particles of unknown origin and composition and could be a forensic tool for solving problems with contaminations during processing of biopharmaceuticals.
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Affiliation(s)
- Natalie Deiringer
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Christian Haase
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Karin Wieland
- Chair for Analytical Chemistry, Technische Universität München, Munich, Germany
| | - Stefan Zahler
- Department of Pharmacy, Pharmaceutical Biology, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Christoph Haisch
- Chair for Analytical Chemistry, Technische Universität München, Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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36
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Seifert I, Friess W. Freeze concentration during freezing: How does the maximally freeze concentrated solution influence protein stability? Int J Pharm 2020; 589:119810. [PMID: 32866649 DOI: 10.1016/j.ijpharm.2020.119810] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [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: 06/18/2020] [Revised: 08/19/2020] [Accepted: 08/20/2020] [Indexed: 11/17/2022]
Abstract
During freeze drying of biologics, a highly viscous freeze concentrate (FC) is formed upon the initial freezing due to the crystallisation of ice. Protein stability in this freeze concentrated phase is not yet well understood, but can decide upon the success of the lyophilisation itself. Protein stability may be high below the Tg' as it is typically the case during primary drying but decreases above Tg', e.g. during annealing or during aggressive freeze drying above Tg' in presence of a crystalline bulking agent or, beyond freeze drying, during storage of frozen bulk. Different FCs containing monoclonal antibody, sucrose, histidine or phosphate buffer and sodium chloride were prepared via partial freeze drying and analysed for protein aggregation. No solute crystallisation is visible and the systems are vitrifying during cooling. Increasing sugar or buffer concentration showed positive effects on either melting and aggregation temperature or on protein self-interaction as indicated by A2 values. Protein integrity in the FC was not affected by 1 month storage at temperatures above Tg'. Thus, upconcentration of solutes during freezing does not negatively impact protein stability. Exceeding Tg' during freeze drying e.g. upon annealing or, intentionally or unintentionally, during primary drying does not lead to protein aggregation.
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Affiliation(s)
- Ivonne Seifert
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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37
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Seifert I, Friess W. Improvement of arginine hydrochloride based antibody lyophilisates. Int J Pharm 2020; 589:119859. [DOI: 10.1016/j.ijpharm.2020.119859] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/21/2020] [Revised: 09/02/2020] [Accepted: 09/03/2020] [Indexed: 01/06/2023]
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38
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Ehlers S, Schroeder R, Friess W. Trouble With the Neighbor During Freeze-Drying: Rivalry About Energy. J Pharm Sci 2020; 110:1219-1226. [PMID: 33069707 DOI: 10.1016/j.xphs.2020.10.024] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [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: 07/20/2020] [Revised: 09/17/2020] [Accepted: 10/12/2020] [Indexed: 11/18/2022]
Abstract
Batch homogeneity during lyophilization is crucial to ensure products with high quality. Known as edge-vial-effect, vials at the corners and edges tend to run warmer than center vials during primary drying. This is associated with risk of collapse or increased costs due to use of more conservative, longer drying conditions resulting in lower product temperature. The edge-vial-effect has been attributed to radiation coming from the chamber wall. We could show that the neighbor vial has a dominant impact on product temperature during lyophilization. Depending on the number of neighbors as well as the distance to a neighbor vial, the neighbor vial exerts a remarkable cooling effect. Energy transfer by gas conduction enables the cooling effect of a neighboring vial over a distance up to 10 mm. This not only leads to prolonged primary drying but also impacts cake appearance. Thus, to avoid trouble during lyophilization you have to watch out for the neighborhood.
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Affiliation(s)
- Sarah Ehlers
- AbbVie Deutschland GmbH & Co. KG, Knollstraße 50, 67061 Ludwigshafen.
| | - Rudolf Schroeder
- AbbVie Deutschland GmbH & Co. KG, Knollstraße 50, 67061 Ludwigshafen
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians Universität München, Butenandtstrasse 5, D-81377 Muenchen
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Grapentin C, Müller C, Kishore RS, Adler M, ElBialy I, Friess W, Huwyler J, Khan TA. Protein-Polydimethylsiloxane Particles in Liquid Vial Monoclonal Antibody Formulations Containing Poloxamer 188. J Pharm Sci 2020; 109:2393-2404. [DOI: 10.1016/j.xphs.2020.03.010] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/06/2020] [Revised: 02/24/2020] [Accepted: 03/12/2020] [Indexed: 12/17/2022]
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Pohl C, Zalar M, Bialy IE, Indrakumar S, Peters GHJ, Friess W, Golovanov AP, Streicher WW, Noergaard A, Harris P. The Effect of Point Mutations on the Biophysical Properties of an Antimicrobial Peptide: Development of a Screening Protocol for Peptide Stability Screening. Mol Pharm 2020; 17:3298-3313. [DOI: 10.1021/acs.molpharmaceut.0c00406] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Christin Pohl
- Novozymes A/S, Krogshoejvej 36, 2880 Bagsvaerd, Denmark
- Department of Chemistry, Technical University of Denmark, Kemitorvet 207, 2800 Kongens, Lyngby, Denmark
| | - Matja Zalar
- Manchester Institute of Biotechnology and Department of Chemistry, Faculty of Science and Engineering, The University of Manchester, 131 Princess Street, Manchester M1 7DN, United Kingdom
| | - Inas El Bialy
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universitaet Muenchen, Butenandtstrasse 5, 81377 Muenchen, Germany
| | - Sowmya Indrakumar
- Department of Chemistry, Technical University of Denmark, Kemitorvet 207, 2800 Kongens, Lyngby, Denmark
| | - Günther H. J. Peters
- Department of Chemistry, Technical University of Denmark, Kemitorvet 207, 2800 Kongens, Lyngby, Denmark
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universitaet Muenchen, Butenandtstrasse 5, 81377 Muenchen, Germany
| | - Alexander P. Golovanov
- Manchester Institute of Biotechnology and Department of Chemistry, Faculty of Science and Engineering, The University of Manchester, 131 Princess Street, Manchester M1 7DN, United Kingdom
| | | | | | - Pernille Harris
- Department of Chemistry, Technical University of Denmark, Kemitorvet 207, 2800 Kongens, Lyngby, Denmark
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Seifert I, Bregolin A, Fissore D, Friess W. Method development and analysis of the water content of the maximally freeze concentrated solution suitable for protein lyophilisation. Eur J Pharm Biopharm 2020; 153:36-42. [PMID: 32526356 DOI: 10.1016/j.ejpb.2020.05.027] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [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: 03/06/2020] [Revised: 05/20/2020] [Accepted: 05/26/2020] [Indexed: 11/28/2022]
Abstract
During freeze-drying of a liquid formulation, a freeze-concentrate is formed in the first phase, the freezing step. Understanding the composition of the maximally freeze concentrated solution can help to judge the process stability of biopharmaceuticals during lyophilisation. Our objective was to develop a suitable method to determine the water content of the maximally freeze concentrated solution using differential scanning calorimetry (DSC). Three different methods were compared: (i) the intercept of the glass transition temperature of the maximally freeze concentrated solution Tg' and the melting temperature Tm for a concentration series, (ii) the linear regression of the melting enthalpy starting from the onset of Tg' until the end of the melting event for a concentration series, and (iii) a one-point determination of the amount of unfrozen water. While Method 1 is accurate but requires the analysis of a high number of samples, Method 3 requires only one single sample, with a loss of accuracy. Method 2 works best taking sample preparation and accuracy into account. Various systems containing sugar (sucrose, trehalose) and other excipients (histidine buffer, phosphate buffer, sodium chloride, arginine hydrochloride, arginine citrate) were evaluated with different antibody concentrations to evaluate the composition of the maximally freeze concentrated solution. The freeze concentrates exhibited a water content of 20-30%, slightly dependent on the excipients, but independent of the antibody concentration. The methodology we developed is broadly applicable for the analysis of the composition of maximally freeze concentrated solutions and can help to elucidate protein stability during lyophilisation.
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Affiliation(s)
- Ivonne Seifert
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany
| | - Alessandro Bregolin
- Department of Applied Science and Technology, Politecnico di Torino, Torino, Italy
| | - Davide Fissore
- Department of Applied Science and Technology, Politecnico di Torino, Torino, Italy
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität München, Munich, Germany.
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Haeuser C, Goldbach P, Huwyler J, Friess W, Allmendinger A. Excipients for Room Temperature Stable Freeze-Dried Monoclonal Antibody Formulations. J Pharm Sci 2020; 109:807-817. [PMID: 31622600 DOI: 10.1016/j.xphs.2019.10.016] [Citation(s) in RCA: 34] [Impact Index Per Article: 8.5] [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: 08/12/2019] [Revised: 10/09/2019] [Accepted: 10/09/2019] [Indexed: 01/26/2023]
Abstract
Sucrose is a common cryoprotectant and lyoprotectant to stabilize labile biopharmaceuticals during freeze-drying and storage. Sucrose-based formulations require low primary drying temperatures to avoid collapse and monoclonal antibody (mAb) containing products need to be stored refrigerated. The objective of this study is to investigate different excipients enabling storage at room temperature and aggressive, shorter lyophilization cycles. We studied combinations of 2-hydroxypropyl-beta-cyclodextrin (CD), recombinant human albumin, polyvinylpyrroldione (PVP), dextran 40 kDa (Dex), and sucrose (Suc) using 2 mAbs. Samples were characterized for collapse temperature (Tc), glass transition temperature of the liquid (Tg') and freeze-dried formulation (Tg), cake appearance, residual moisture, and reconstitution time. Freeze-dried formulations were stored at 5°C, 25°C, and 40°C for up to 9 months and mAb stability was analyzed for color, turbidity, visible and sub-visible particles, and monomer content. Formulations with CD/Suc or CD/PVP/Suc were superior to pure Suc formulations for long-term storage at 40°C. When using aggressive freeze-drying cycles, these formulations were characterized by pharmaceutically elegant cakes, short reconstitution times, higher Tg', Tc, and Tg. We conclude that the addition of CD allows for shorter freeze-drying cycles with improved cake appearance and enables storage at room temperature, which might reduce costs of goods substantially.
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Affiliation(s)
- Christina Haeuser
- Late Stage Pharmaceutical and Processing Development, Pharmaceutical Development & Supplies, Pharma Technical Development Biologics EU, F. Hoffmann-La Roche Ltd., Basel 4070, Switzerland; Division of Pharmaceutical Technology, Department of Pharmaceutical Sciences, University of Basel, Basel 4056, Switzerland
| | - Pierre Goldbach
- Late Stage Pharmaceutical and Processing Development, Pharmaceutical Development & Supplies, Pharma Technical Development Biologics EU, F. Hoffmann-La Roche Ltd., Basel 4070, Switzerland
| | - Joerg Huwyler
- Division of Pharmaceutical Technology, Department of Pharmaceutical Sciences, University of Basel, Basel 4056, Switzerland
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University Munich, 81377 Munich, Germany
| | - Andrea Allmendinger
- Late Stage Pharmaceutical and Processing Development, Pharmaceutical Development & Supplies, Pharma Technical Development Biologics EU, F. Hoffmann-La Roche Ltd., Basel 4070, Switzerland.
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Haeuser C, Goldbach P, Huwyler J, Friess W, Allmendinger A. Be Aggressive! Amorphous Excipients Enabling Single-Step Freeze-Drying of Monoclonal Antibody Formulations. Pharmaceutics 2019; 11:E616. [PMID: 31744221 PMCID: PMC6920930 DOI: 10.3390/pharmaceutics11110616] [Citation(s) in RCA: 21] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2019] [Revised: 10/30/2019] [Accepted: 11/12/2019] [Indexed: 12/02/2022] Open
Abstract
Short freeze-drying cycles for biopharmaceuticals are desirable. Formulations containing an amorphous disaccharide, such as sucrose, are prone to collapse upon aggressive primary drying at higher shelf temperature. We used 2-hydroxypropyl-betacyclodextrin (HPBCD) in combination with sucrose and polyvinylpyrrolidone (PVP) to develop an aggressive lyophilization cycle for low concentration monoclonal antibody (mAb) formulations. Glass transition temperature and collapse temperature of the formulations were determined, and increasingly aggressive cycle parameters were applied. Using a shelf temperature of +30 °C during primary drying, the concept of combining sublimation and desorption of water in a single drying step was investigated. Cake appearance was evaluated visually and by micro-computed tomography. Lyophilisates were further analyzed for reconstitution time, specific surface area, residual moisture, and glass transition temperature. We demonstrated the applicability of single-step freeze-drying, shortening the total cycle time by 50% and providing elegant lyophilisates for pure HPBCD and HPBCD/sucrose formulations. HPBCD/PVP/sucrose showed minor dents, while good mAb stability at 10 mg/mL was obtained for HPBCD/sucrose and HPBCD/PVP/sucrose when stored at 40 °C for 3 months. We conclude that HPBCD-based formulations in combination with sucrose are highly attractive, enabling aggressive, single-step freeze-drying of low concentration mAb formulations, while maintaining elegant lyophilisates and ensuring protein stability at the same time.
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Affiliation(s)
- Christina Haeuser
- Late Stage Pharmaceutical and Processing Development, Pharmaceutical Development & Supplies, Pharma Technical Development Biologics EU, F. Hoffmann-La Roche Ltd., 4070 Basel, Switzerland; (C.H.); (P.G.)
- Division of Pharmaceutical Technology, Department of Pharmaceutical Sciences, University of Basel, 4056 Basel, Switzerland;
| | - Pierre Goldbach
- Late Stage Pharmaceutical and Processing Development, Pharmaceutical Development & Supplies, Pharma Technical Development Biologics EU, F. Hoffmann-La Roche Ltd., 4070 Basel, Switzerland; (C.H.); (P.G.)
| | - Joerg Huwyler
- Division of Pharmaceutical Technology, Department of Pharmaceutical Sciences, University of Basel, 4056 Basel, Switzerland;
| | - Wolfgang Friess
- Pharmaceutical Technology and Biopharmaceutics, Department of Pharmacy, Ludwig-Maximilians-University Munich, 81377 Munich, Germany;
| | - Andrea Allmendinger
- Late Stage Pharmaceutical and Processing Development, Pharmaceutical Development & Supplies, Pharma Technical Development Biologics EU, F. Hoffmann-La Roche Ltd., 4070 Basel, Switzerland; (C.H.); (P.G.)
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De Meyer L, Lammens J, Vanbillemont B, Van Bockstal PJ, Corver J, Vervaet C, Friess W, De Beer T. Dual chamber cartridges in a continuous pharmaceutical freeze-drying concept: Determination of the optimal dynamic infrared heater temperature during primary drying. Int J Pharm 2019; 570:118631. [DOI: 10.1016/j.ijpharm.2019.118631] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/02/2019] [Revised: 08/12/2019] [Accepted: 08/17/2019] [Indexed: 10/26/2022]
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Kasper JC, Hedtrich S, Friess W. Lyophilization of Synthetic Gene Carriers. Methods Mol Biol 2019; 1943:211-225. [PMID: 30838619 DOI: 10.1007/978-1-4939-9092-4_14] [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] [Indexed: 02/04/2023]
Abstract
Lyophilization, also known as freeze drying, is a widely used method for stabilization, improvement of long-term storage stability, and simplification of handling of drugs and/or carrier systems. Lyophilization is time-consuming and energy-consuming, and hence optimized processes are required to avoid time loss and higher costs without compromising product stability. Beginning from the last decade, nonviral, synthetic carriers for gene delivery have been of increasing interest. However, these systems suffer from poor physical stability in aqueous solution or suspension. Hence, to ensure long-term storage stability lyophilization of the gene carrier systems is favored. This chapter gives an overview of the basic steps and troubleshooting for successful lyophilization of synthetic gene carriers. Furthermore, the required excipients and their mechanism of action are summarized.
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Affiliation(s)
- Julia Christina Kasper
- Bioprocess and Pharmaceutical Development Biologicals, Boehringer Ingelheim Pharma GmbH and Co. KG, Biberach, Germany
| | - Sarah Hedtrich
- Institute for Pharmacy, Pharmacology & Toxicology, Freie Universität Berlin, Berlin, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-Universität, Munich, Germany.
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Higel F, Sandl T, Kao CY, Pechinger N, Sörgel F, Friess W, Wolschin F, Seidl A. N-glycans of complex glycosylated biopharmaceuticals and their impact on protein clearance. Eur J Pharm Biopharm 2019; 139:123-131. [DOI: 10.1016/j.ejpb.2019.03.018] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/18/2018] [Revised: 01/24/2019] [Accepted: 03/21/2019] [Indexed: 02/01/2023]
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Duerr C, Friess W. Antibody-drug conjugates- stability and formulation. Eur J Pharm Biopharm 2019; 139:168-176. [DOI: 10.1016/j.ejpb.2019.03.021] [Citation(s) in RCA: 23] [Impact Index Per Article: 4.6] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/29/2018] [Revised: 03/28/2019] [Accepted: 03/29/2019] [Indexed: 01/01/2023]
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Yoneda S, Niederleitner B, Wiggenhorn M, Koga H, Totoki S, Krayukhina E, Friess W, Uchiyama S. Quantitative Laser Diffraction for Quantification of Protein Aggregates: Comparison With Resonant Mass Measurement, Nanoparticle Tracking Analysis, Flow Imaging, and Light Obscuration. J Pharm Sci 2019; 108:755-762. [DOI: 10.1016/j.xphs.2018.09.004] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/05/2018] [Revised: 09/05/2018] [Accepted: 09/06/2018] [Indexed: 01/20/2023]
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Vollrath I, Friess W, Freitag A, Hawe A, Winter G. Comparison of ice fog methods and monitoring of controlled nucleation success after freeze-drying. Int J Pharm 2018; 558:18-28. [PMID: 30597272 DOI: 10.1016/j.ijpharm.2018.12.056] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [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: 08/14/2018] [Revised: 11/19/2018] [Accepted: 12/13/2018] [Indexed: 11/28/2022]
Abstract
Improving freeze-drying processes regarding drying time and batch homogeneity is subject of ongoing research work. In this context, controlled nucleation raised great expectations. However, practically we face some challenges, e.g. how to non-destructively monitor successfully performed controlled nucleation. The question if different controlled nucleation methods lead to comparable products, as not every method can easily be implemented in lab and production scale equipment, is also of high interest. Additionally, the optimal nucleation temperature for controlled nucleation is an open question. In our study, we addressed these challenges. We successfully evaluated frequency modulated spectroscopy as a fast and non-destructive method to monitor controlled nucleation success and batch homogeneity. We found that the better homogeneity generated by controlled nucleation during the freezing step did not sustain in the dried product. Lyophilizates produced by three different ice fog methods for controlled nucleation were characterized by comparable specific surface areas but differed in residual moisture content. To investigate the impact of the ice nucleation temperature (TN) on the resulting specific surface area, we performed controlled nucleation at -3 °C and -10 °C. We concluded that TN is not the only specific surface area determining factor and a high TN does not necessarily lead to larger pores but poses a higher risk of not-nucleating vials.
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Affiliation(s)
- Ilona Vollrath
- Coriolis Pharma Research GmbH, D-82152 Martinsried, Germany; Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University, D-81377 Munich, Germany
| | - Wolfgang Friess
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University, D-81377 Munich, Germany
| | | | - Andrea Hawe
- Coriolis Pharma Research GmbH, D-82152 Martinsried, Germany.
| | - Gerhard Winter
- Department of Pharmacy, Pharmaceutical Technology and Biopharmaceutics, Ludwig-Maximilians-University, D-81377 Munich, Germany
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Svilenov H, Gentiluomo L, Friess W, Roessner D, Winter G. A New Approach to Study the Physical Stability of Monoclonal Antibody Formulations—Dilution From a Denaturant. J Pharm Sci 2018; 107:3007-3013. [DOI: 10.1016/j.xphs.2018.08.004] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/05/2018] [Revised: 07/25/2018] [Accepted: 08/07/2018] [Indexed: 11/30/2022]
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