Identification of Surfactant Impact on a Monoclonal Antibody Characterization via HPLC-Separation Based and Biophysical Methods.

PURPOSE OR OBJECTIVE: Surfactants, including polysorbates and poloxamers, play a crucial role in the formulation of therapeutic proteins by acting as solubilizing and stabilizing agents. They help prevent protein aggregation and adsorption, thereby enhancing the stability of drug substance and products., However, it is important to note that utilizing high concentrations of surfactants in protein formulations can present significant analytical challenges, which can ultimately affect the product characterization. METHODS: In our study, we specifically investigated the impact of elevated surfactant concentrations on the characterization of monoclonal antibodies. We employed various analytical techniques including size-exclusion chromatography (SEC), capillary electrophoresis (CE-SDS), a cell based functional assay, and biophysical characterization. RESULTS: The findings of our study indicate that higher levels of Polysorbate 80 (PS-80) have adverse effects on the measured purity, biological activity, and biophysical characterization of biologic samples. Specifically, the elevated levels of PS-80 cause analytical interferences, which can significantly impact the accuracy and reliability of analytical studies. CONCLUSIONS: Our study results highlight a significant risk in analytical investigations, especially in studies involving the isolation and characterization of impurities. It is important to be cautious of surfactant concentrations, as they can become more concentrated during common sample manipulations like buffer exchange. Indeed, the research presented in this work emphasizes the necessity to evaluate the impact on analytical assays when there are substantial alternations in the matrix composition. By doing so, valuable insights can be gained regarding potential challenges associated with assay development and characterization of biologics with complex formulations.

In-situ biophysical characterization of high-concentration protein formulations using wNMR.

High-concentration protein formulation is of paramount importance in patient-centric drug product development, but it also presents challenges due to the potential for enhanced aggregation and increased viscosity. The analysis of critical quality attributes often necessitates the transfer of samples from their primary containers together with sample dilution. Therefore, there is a demand for noninvasive, in situ biophysical methods to assess protein drug products directly in primary sterile containers, such as prefilled syringes, without dilution. In this study, we introduce a novel application of water proton nuclear magnetic resonance (wNMR) to evaluate the aggregation propensity of a high-concentration drug product, Dupixent® (dupilumab), under stress conditions. wNMR results demonstrate a concentration-dependent, reversible association of dupilumab in the commercial formulation, as well as irreversible aggregation when exposed to accelerated thermal stress, but gradually reversible aggregation when exposed to freeze and thaw cycles. Importantly, these results show a strong correlation with data obtained from established biophysical analytical tools widely used in the pharmaceutical industry. The application of wNMR represents a promising approach for in situ noninvasive analysis of high-concentration protein formulations directly in their primary containers, providing valuable insights for drug development and quality assessment.

Characterizing Silicone Oil-Induced Protein Aggregation with Stimulated Raman Scattering Imaging.

Particles in biopharmaceutical products present high risks due to their detrimental impacts on product quality and safety. Identification and quantification of particles in drug products are important to understand particle formation mechanisms, which can help develop control strategies for particle formation during the formulation development and manufacturing process. However, existing analytical techniques such as microflow imaging and light obscuration measurement lack the sensitivity and resolution to detect particles with sizes smaller than 2 µm. More importantly, these techniques are not able to provide chemical information to determine particle composition. In this work, we overcome these challenges by applying the stimulated Raman scattering (SRS) microscopy technique to monitor the C-H Raman stretching modes of the proteinaceous particles and silicone oil droplets formed in the prefilled syringe barrel. By comparing the relative signal intensity and spectral features of each component, most particles can be classified as protein-silicone oil aggregates. We further show that morphological features are poor indicators of particle composition. Our method has the capability to quantify aggregation in protein therapeutics with chemical and spatial information in a label-free manner, potentially allowing high throughput screening or investigation of aggregation mechanisms.

Variables Impacting Silicone Oil Migration and Biologics in Prefilled Syringes.

Prefilled syringes (PFS) as a primary container for parenteral drug products offer significant advantages, such as fast delivery time, ease of self-administration and fewer dosing errors. Despite the benefits that PFS can provide to patients, the silicone oil pre-coated on the glass barrels has shown migration into the drug product, which can impact particle formation and syringe functionality. Health authorities have urged product developers to better understand the susceptibility of drug products to particle formation in PFS due to silicone oil. In the market, there are multiple syringe sources provided by various PFS suppliers. Due to current supply chain shortages and procurement preferences for commercial products, the PFS source may change in the middle of development. Additionally, health authorities require establishing source duality. Therefore, it is crucial to understand how different syringe sources and formulation compositions impact the drug product quality. Here, several design of experiments (DOE) are executed that focus on the risk of silicone oil migration induced by syringe sources, surfactants, protein types, stress, etc. We utilized Resonant Mass Measurement (RMM) and Micro Flow Imaging (MFI) to characterize silicone oil and proteinaceous particle distribution in both micron and submicron size ranges, as well as ICP-MS to quantify silicon content. The protein aggregation and PFS functionality were also monitored in the stability study. The results show that silicone oil migration is impacted more by syringe source, siliconization process and surfactant (type & concentration). The break loose force and extrusion force across all syringe sources increase significantly as protein concentration and storage temperature increase. Protein stability is found to be impacted by its molecular properties and is less impacted by the presence of silicone oil, which is the same inference drawn in other literatures. A detailed evaluation described in this paper enables a thorough and optimal selection of primary container closure and de-risks the impact of silicone oil on drug product stability.

The Impact of Syringe Age Prior to Filling on Migration of Subvisible Silicone-Oil Particles into Drug Product.

Silicone oil is often applied to the inner surface of glass syringes and cartridges to reduce friction between the glass surface and elastomeric plunger stopper. This oil can appear as intrinsic and non-proteinaceous particles in the ejected fluid or drug product. Limited data is available to understand the impact of age (time between syringe manufacture and filling) on silicone oil migration into the drug product. This study compares subvisible particle count and extrusion force of siliconized syringes from two different manufacturers stored at ambient condition for 2-3 (fresh syringes) and 13-14 (aged syringes) months then filled and placed at 40°C for an additional three months. The fresh syringes exhibit a 2.5-fold increase in subvisible particle count compared to those aged ones. Moreover, the fresh syringes exhibit up to a 2-fold increase in extrusion force. These findings suggest the degree and amount of silicone oil migration is influenced by the time in storage of the glass syringe prior to filling. This rapid communication highlights syringe storage time prior to filling as a factor to be considered during development.

Characterization of Spray Dried Particles Through Microstructural Imaging.

Spray drying is commonly used to produce amorphous solid dispersions (ASD) to improve the bioperformance of poorly water-soluble drugs. In this study, imaging techniques such as focused ion beam-scanning electron microscopy (FIB-SEM) and X-ray microcomputed tomography (XRCT) were used to study the microstructure of spray dried (SD) particles. Spray drying at higher outlet temperature (Tout) was found to produce more spherical hollow particles with smooth surface and thinner walls, while more raisin-like particles with thicker walls were generated at lower Tout. For the first time, an artificial intelligence-facilitated XRCT image analysis tool was developed to make quantitative analysis of thousands of particles individually possible. The particle size distribution through XRCT image analysis is generally in line with what is measured by laser diffraction. The image analysis reveals envelope density as a more sensitive physical attribute for process change than conventional bulk/tap density. Further, the tensile strength of SD particle compacts correlates with the particle wall thickness, and this is likely caused by the larger interparticle contact area generated by more deformation of particles with thinner walls. The knowledge gained here can help enable SD particle engineering and drug product with more robust process and optimized performance.

The Effect of Inorganic Salt on Disintegration of Tablets with High Loading of Amorphous Solid Dispersion Containing Copovidone.

PURPOSE: While including amorphous solid dispersion (ASD) in tablet formulations is increasingly common, tablets containing high ASD loading are associated with slow disintegration, which presents a challenge to control pill burden for less potent compounds. METHODS: We use a model ASD, composed of a hydrophobic drug with copovidone and a non-ionic surfactant, to explore formulation options that can prevent slow disintegration. RESULTS: In addition to the ASD loading, the pH of the disintegration medium and the inclusion of inorganic salts in the tablet also have an impact on the tablet disintegration time. Certain kosmotropic salts, when added in the formulation, can significantly accelerate tablet disintegration, though the rank order in their effectiveness does not exactly follow the Hofmeister series at pH 1.8. The particle size and dissolution rate of the salt can contribute to its overall effectiveness. CONCLUSION: We provided a mechanistic explanation of the disintegration process: fast-dissolving kosmotropic salt results in a concentrated salt solution inside the restrained tablet matrix, thus inhibiting the dissolution of copovidone and preventing polymer gelling which is the main cause leading the slow disintegration. The outcome of this study has enabled the design of a higher ASD loading platform formulation for copovidone based ASD. Graphical Abstract MicroCT aids the mechanistic understanding of the role of inorganic salt in the tablet disintegration of amorphous solid dispersion based formulation.

Application of Deep Learning Convolutional Neural Networks for Internal Tablet Defect Detection: High Accuracy, Throughput, and Adaptability.

Tablet defects encountered during the manufacturing of oral formulations can result in quality concerns, timeline delays, and elevated financial costs. Internal tablet cracking is not typically measured in routine inspections but can lead to batch failures such as tablet fracturing. X-ray computed tomography (XRCT) has become well-established to analyze internal cracks of oral tablets. However, XRCT normally generates very large quantities of image data (thousands of 2D slices per data set) which require a trained professional to analyze. A user-guided manual analysis is laborious, time-consuming, and subjective, which may result in a poor statistical representation and inconsistent results. In this study, we have developed an analysis program that incorporates deep learning convolutional neural networks to fully automate the XRCT image analysis of oral tablets for internal crack detection. The computer program achieves robust quantification of internal tablet cracks with an average accuracy of 94%. In addition, the deep learning tool is fully automated and achieves a throughput capable of analyzing hundreds of tablets. We have also explored the adaptability of the deep learning analysis program toward different products (e.g., different types of bottles and tablets). Finally, the deep learning tool is effectively implemented into the industrial pharmaceutical workflow.

Designing an ADME liquid formulation with matching exposures to an amorphous dosage form.

Amorphous Solid Dispersion (ASD) based formulations have been frequently used to improve the bioavailability of poorly water soluble drugs, however, common processes to produce ASDs are not feasible for Absorption, Distribution, Metabolism and Excretion (ADME) studies with radio-labeled Active Pharmaceutical Ingredients (API) due to the complications associated with radioactive material handling. Liquid formulations are routinely used to support the ADME studies, though bridging the bioperformance between a liquid formulation to the amorphous dosage form for poorly soluble compounds has not been well studied, and can be challenging due to the potentially rapid in vitro and in vivo recrystallization and precipitation. Here we report the development of a fit for purpose liquid formulation that could accommodate the radioactive API and provide comparable bioavailability relative to the amorphous formulation without the need for dose adjustment. A number of formulation approaches were explored and the prototype formulations were evaluated by dissolution and preclinical pharmacokinetic studies. A PolyEthylene Glycol 400 (PEG 400) based solution formulation impregnated with a polymer, HydroxyPropyl MethylCellulose Acetate Succinate-L (HPMCAS-L), was identified as the lead formulation. It was found that the bioavailability of the formulation can be compromised by the presence of undissolved crystalline seeds, and the inclusion of HPMCAS-L can mitigate this effect, as well as potentially facilitate the nanoparticle formation. During the study, it is also noted that although dissolution test is instrumental in the formulation development, the in vitro study over predicted the extent of in vivo precipitation for PEG 400 formulation containing no crystalline seeds.

Fast Crystal Growth in o-Terphenyl Glasses: A Possible Role for Fracture and Surface Mobility.

Molecular liquids can develop a fast mode of crystal growth ("GC growth") near the glass transition temperature. This phenomenon remains imperfectly understood with several explanations proposed. We report that GC growth in o-terphenyl conserves the overall volume, despite a 5% higher density of the crystal, and produces fine crystal grains with the same unit cell as normally grown crystals. These results indicate that GC growth continuously creates voids and free surfaces, possibly by fracture. This aspect of the phenomenon has not been considered by previous treatments and is a difficulty for those models that hypothesize a 5% strain without voids. Given the existence of even faster crystal growth on the free surface of molecular glasses, we consider the possibility that GC growth is facilitated by fracture and surface mobility. This notion has support from the fact that GC growth and surface growth are both highly correlated with surface diffusivity and with fast crystal growth along preformed cracks in the glass.

Development of a HPMC-based controlled release formulation with hot melt extrusion (HME).

The objective of this study was to develop hydroxypropyl methylcellulose (HPMC) based controlled release (CR) formulations via hot melt extrusion (HME) with a highly soluble crystalline active pharmaceutical ingredient (API) embedded In the polymer phase. HPMC is considered a challenging CR polymer for extrusion due to its high glass transition temperature (Tg), low degradation temperature, and high viscosity. These problems were partially overcome by plasticizing the HPMC with up to 40% propylene glycol (PG). Theophylline was selected as the model API. By using differential scanning calorimetry (DSC), thermal gravimetric analysis (TGA), dynamic mechanical analysis (DMA), and X-ray powder diffraction (XRPD), the physical properties of the formulations were systematically characterized. Five grades of HPMC (Methocel(®)) - E6, K100LV, K4M, K15M, and K100M - were tested. The extrusion trials were conducted on a 16 mm twIn screw extruder with HPMC/PG placebo and formulations containing theophylline/HPMC/PG (30:42:28, w/w/w). The dissolution results showed sustained release profiles without burst release for the HPMC K4M, K15M, and K100M formulations. The extrudates have good dissolution stability after being stressed for 2 weeks under 40°C/75% RH open dish conditions and the crystalline API form did not change upon storage. Overall, the processing windows were established for the HPMC based HME-CR formulations.

Diffusion-controlled and "diffusionless" crystal growth near the glass transition temperature: relation between liquid dynamics and growth kinetics of seven ROY polymorphs.

The liquid dynamics of 5-methyl-2-[(2-nitrophenyl)amino]-3-thiophenecarbonitrile, named ROY for its red, orange, and yellow crystal polymorphs, was characterized by dielectric spectroscopy and differential scanning calorimetry. Four of these polymorphs show fast "diffusionless" crystal growth at low temperatures while three others do not. ROY was found to be a typical fragile organic liquid. Its alpha relaxation process has time-temperature superposition symmetry across the viscous range (tau(alpha)=100 s-100 ns) with the width of the relaxation peak characterized by a constant beta(KWW) of 0.73. No secondary relaxation peak was observed, even with glasses made by fast quenching. For the polymorphs not showing fast crystal growth in the glassy state, the growth rate has a power-law relation with tau(alpha), u proportional to tau(alpha)(-xi), where xi approximately = 0.7. For the polymorphs showing fast crystal growth in the glassy state, the growth is so fast near and below the glass transition temperature T(g) that thousands of molecular layers can be added to the crystalline phase during one structural relaxation time of the liquid. In the glassy state, this mode of growth slows slightly over time. This slowdown is not readily explained by the effect of physical aging on the thermodynamic driving force of crystallization, the glass vapor pressure, or the rate of structural relaxation. This study demonstrates that from the same liquid or glass, the growth of some polymorphs is accurately described as being limited by the rate of structural relaxation or bulk diffusion, whereas the growth of other polymorphs is too fast to be under such control.

Diffusion-controlled and diffusionless crystal growth in liquid o-terphenyl near its glass transition temperature.

o-terphenyl is one of the organic liquids in which a fast mode of crystal growth is activated near the glass transition temperature T(g) and continues deep in the glassy state. This growth mode, termed glass-crystal (GC), is not limited by molecular diffusion in the bulk liquid, in contrast to the diffusion-controlled growth at higher temperatures. The GC mode has been previously described as abruptly emerging near T(g) and having a constant growth rate at a fixed temperature, two features important for testing its various explanations. We report here that the GC mode already exists in the equilibrium liquid of o-terphenyl up to 1.15T(g) (T(g)=246 K) in the form of loose, fast-growing fibers and that its growth rate is constant at T(g)+2 K, but decreases by 30% in 10 h at T(g)-13 K, during which time the glass' fictive temperature decreases by 6 K. The slow down of GC growth becomes less noticeable over time so that fast growth is still observable after long annealing. The fiber growth, similar to the fully activated GC growth that yields compact spherulites, is also not limited by bulk diffusion. Crystal growth in the GC mode has a comparable activation energy as liquid desorption but a much faster rate, properties in common with polymorphic conversions. The time dependence of GC growth is not readily explained by the effect of physical aging on the thermodynamic driving force of crystallization, the liquid desorption, the primary structural relaxation, or a secondary relaxation. The secondary dielectric relaxation observed by dielectric spectroscopy in glassy o-terphenyl disappears too quickly for its molecular motions to be responsible for GC growth.

Crystallization near glass transition: transition from diffusion-controlled to diffusionless crystal growth studied with seven polymorphs.

A remarkable property of certain glass-forming liquids is that a fast mode of crystal growth is activated near the glass transition temperature Tg and continues in the glassy state. This growth mode, termed GC (glass-crystal), is so fast that it is not limited by molecular diffusion in the bulk liquid. We have studied the GC mode by growing seven polymorphs from the liquid of ROY, currently the top system for the number of coexisting polymorphs of known structures. Some polymorphs did not show GC growth, while others did, with the latter having higher density and more isotropic molecular packing. The polymorphs not showing GC growth grew as compact spherulites at all temperatures; their growth rates near Tg decreased smoothly with falling temperature. The polymorphs showing GC growth changed growth morphologies with temperature, from faceted single crystals near the melting points, to fiber-like crystals near Tg, and to compact spherulites in the GC mode; in the GC mode, they grew at rates 3-4 orders of magnitude faster with activation energies 2-fold smaller than the polymorphs not showing GC growth. The GC mode had rates and activation energies similar to those of a polymorphic transformation observed near Tg. The GC mode was disrupted by the onset of the liquid's structural relaxation but could persist well above Tg (up to 1.15 Tg) in the form of fast-growing fibers. We consider various explanations for the GC mode and suggest that it is solid-state transformation enabled by local molecular motions native to the glassy state and disrupted by the liquid's structural relaxation (the alpha process).

Diffusionless crystal growth from glass has precursor in equilibrium liquid.

A remarkable property of certain glass-forming liquids is that a fast mode of crystal growth is suddenly activated near the glass transition temperature, Tg, and continues in the glassy state. This mode of growth, termed GC (glass-crystal), is so fast that it is not limited by molecular diffusion in the bulk liquid. We have studied the GC growth by growing multiple crystal polymorphs from the liquid of ROY, currently the top system for the number of coexisting polymorphs of known structures. We observed a new feature of GC growth that conflicts with its current description in the literature. We found that the GC mode is not truly a new growth mode suddenly appearing near Tg but one already existing in the equilibrium liquid up to approximately 1.15 Tg, in the form of fast-growing fibers. This finding is relevant to testing different explanations for GC growth and favors the view that GC growth is enabled by molecular motions that are native to the glass but still persist in the viscous liquid.

Cross-nucleation between ROY polymorphs.

Cross-nucleation between polymorphs is a newly discovered phenomenon important for understanding and controlling crystal polymorphism. It contradicts Ostwald's law of stages and other theories of crystallization in polymorphic systems. We studied the phenomenon in the spontaneous and seeded melt crystallization of 5-methyl-2-[(2-nitrophenyl)amino]-3-thiophenecarbonitrile (ROY), currently the most polymorphic system of known structures. We observed extensive and sometimes selective cross-nucleation between ROY polymorphs. Certain polymorphs could not nucleate without the aid of others. The new polymorph was found to be more or less thermodynamically stable than the initial one but to always grow faster than or as fast as the initial one. The temperature and surface characteristics of the seed crystals affected the occurrence of cross-nucleation. Our results show that the pathway of crystallization in polymorphic systems is not determined solely by the initial nucleation, but also by cross-nucleation between polymorphs and the different growth rates of polymorphs. This study identified a new metastable polymorph of ROY, the 10th of the family.