Quality by design: optimization of a freeze-drying cycle via design space in case of heterogeneous drying behavior and influence of the freezing protocol.

PURPOSE: This paper shows how to optimize the primary drying phase, for both product quality and drying time, of a parenteral formulation via design space. METHODS: A non-steady state model, parameterized with experimentally determined heat and mass transfer coefficients, is used to define the design space when the heat transfer coefficient varies with the position of the vial in the array. The calculations recognize both equipment and product constraints, and also take into account model parameter uncertainty. RESULTS: Examples are given of cycles designed for the same formulation, but varying the freezing conditions and the freeze-dryer scale. These are then compared in terms of drying time. Furthermore, the impact of inter-vial variability on design space, and therefore on the optimized cycle, is addressed. With this regard, a simplified method is presented for the cycle design, which reduces the experimental effort required for the system qualification. CONCLUSIONS: The use of mathematical modeling is demonstrated to be very effective not only for cycle development, but also for solving problem of process transfer. This study showed that inter-vial variability remains significant when vials are loaded on plastic trays, and how inter-vial variability can be taken into account during process design.

Sucrose solution freezing studied by magnetic resonance imaging.

Ice formation of a 20% w/v sucrose solution was monitored during the freezing process by magnetic resonance imaging (MRI). An original experimental setup was designed with oil as a cooling fluid that allows accurate control of the temperature. The NMR signal intensity of particular sampled volumes was observed during the entire cooling period, from 0 to -50 degrees C, showing a peak characteristic to a transition before the loss of the signal. Moreover, spatial ice distribution of the frozen matrix was observed by high resolution MRI with an isotropic resolution of 78x78x78microm(3). MRI has proved to be a novel technique for determining the glass transition temperature of frozen sucrose solutions, in the concentration range where calorimetric measurements are not feasible.

Formulation approach for the development of a stable, lyophilized formaldehyde-containing vaccine.

Formaldehyde has been used in the inactivation of a number of viral and bacterial toxins used in vaccines. In some cases, a small amount of formaldehyde may be necessary in order to prevent reversion back to the toxic state during storage. When a lyophilized preparation is required, care must be taken to ensure that formaldehyde is not lost during the process in order to ensure safety of the product. A design of experiments (DOEs) approach was taken to devise a stable, lyophilized, vaccine formulation. A formaldehyde-inactivated bacterial toxin was used as a model antigen. Entrapment of formaldehyde in an amorphous matrix and/or interactions with amorphous components was found to be required for complete recovery of formaldehyde during lyophilization. In formulations consisting of sucrose and citrate, formaldehyde could be recovered across a wide range of excipient concentrations. Stability of the antigen was dependent on formaldehyde concentration, with antigen stability decreasing with increasing formaldehyde concentration. This is in contrast to the risk of reversion which increases with decreasing concentrations of formaldehyde. Finally, variations in temperatures during annealing, primary drying, and secondary drying had no impact on formaldehyde recovery.