Experiment data: Human-in-the-loop decision support in process control rooms.

These datasets contain measures from multi-modal data sources. They include objective and subjective measures commonly used to determine cognitive states of workload, situational awareness, stress, and fatigue using data collection tools such as NASA-TLX, SART, eye tracking, EEG, Health Monitoring Watch, a survey to assess training, and a think-aloud situational awareness assessment following the SPAM methodology. Also, data from a simulation formaldehyde production plant based on the interaction of the participants in a controlled control room experimental setting is included. The interaction with the plant is based on a human-in-the-loop alarm handling and process control task flow, which includes Monitoring, Alarm Handling, Recovery planning, and intervention (Troubleshooting, Control and Evaluation). Data was collected from 92 participants, split into four groups while they underwent the described task flow. Each participant tested three scenarios lasting 15-18 min with a -10-min survey completion and break period in between using different combinations of decision support tools. The decision support tools tested and varied for each group include alarm prioritisation vs. none, paper-based vs. Digitised screen-based procedures, and an AI recommendation system. This is relevant to compare current practices in the industry and the impact on operators' performance and safety. It is also applicable to validate proposed solutions for the industry. A statistical analysis was performed on the dataset to compare the outcomes of the different groups. Decision-makers can use these datasets for control room design and optimisation, process safety engineers, system engineers, human factors engineers, all in process industries, and researchers in similar or close domains.

The Freeze-Drying of Pharmaceuticals in Vials Nested in a Rack System-Part II: Primary Drying Behaviour.

The freeze-drying of biopharmaceuticals is a common strategy to extend their shelf-life and facilitate the distribution of therapeutics. The drying phase is the most demanding one in terms of energy consumption and determines the overall process time. Our previous work showed how the loading configuration can impact freezing. This paper focuses on primary drying by comparing the thermal behaviour of vials loaded in direct contact with the shelf or nested in a rack system. The overall heat transfer coefficient from the apparatus to the product was evaluated at different chamber pressures (5-30 Pa) and shelf temperatures (from -10 °C to +30 °C), and in the case of various vial positions (central, semi-border, and border vials). Because of the suspended configuration, the heat transfer coefficient was less affected by chamber pressure in vials nested in a rack system. The two loading configurations displayed comparable heat transfer efficiency below 10 Pa. For higher chamber pressure, the heat transfer coefficients of nested vials were lower than those of vials in direct contact with the shelf. Nevertheless, the rack system was beneficial for reducing the inter-vial variability as it promoted higher uniformity in the heat transfer coefficients of central vials. Eventually, thermal image analyses highlighted limited temperature differences between the vials and the rack system.

New Trends in Freeze-Drying of Pharmaceutical Products.

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

A New Model-Based Approach for the Development of Freeze-Drying Cycles Using a Small-Scale Freeze-Dryer.

This paper presents a model-based approach for the design of the primary drying stage of a freeze-drying process using a small-scale freeze-dryer (MicroFD® by Millrock Technology Inc.). Gravimetric tests, coupled with a model of the heat transfer to the product in the vials that account also for the heat exchange between the edge vials and the central vials, are used to infer the heat transfer coefficient from the shelf to the product in the vial (Kv), that is expected to be (almost) the same in different freeze-dryers. Differently from other approaches previously proposed, the operating conditions in MicroFD® are not chosen to mimic the dynamics of another freeze-dryer: this allows saving time and resources as no experiments are needed in the large-scale unit, and no additional tests in the small-scale unit, apart from the three gravimetric tests usually needed to assess the effect of chamber pressure on Kv. With respect to the other model parameter, Rp, the resistance of the dried cake to mass transfer, it is not influenced by the equipment and, thus values obtained in a freeze-dryer may be used to simulate the drying in a different unit, provided the same filling conditions are used, as well as the same operating conditions in the freezing stage, and cake collapse (or shrinkage) is avoided. The method was validated considering ice sublimation in two types of vials (2R and 6R) and at different operating conditions (6.7, 13.3 and 26.7 Pa), with the freeze-drying of a 5% w/w sucrose solution as a test case. An accurate estimate for both Kv and Rp was obtained with respect to the values obtained in a pilot-scale equipment, determined through independent tests for validation purposes. Simulation of the product temperature and drying time in a different unit was then possible, and results were validated experimentally.

On the Use of Temperature Measurements as a Process Analytical Technology (PAT) for the Monitoring of a Pharmaceutical Freeze-Drying Process.

The measurement of product temperature is one of the methods that can be adopted, especially in the pharmaceutical industry, to monitor the freeze-drying process and to obtain the values of the process parameters required by mathematical models useful for in-line (or off-line) optimization. Either a contact or a contactless device and a simple algorithm based on a mathematical model of the process can be employed to obtain a PAT tool. This work deeply investigated the use of direct temperature measurement for process monitoring to determine not only the product temperature, but also the end of primary drying and the process parameters (heat and mass transfer coefficients), as well as evaluating the degree of uncertainty of the obtained results. Experiments were carried out with thin thermocouples in a lab-scale freeze-dryer using two different model products, sucrose and PVP solutions; they are representative of two types of commonly freeze-dried products, namely those whose structures are strongly nonuniform in the axial direction, showing a variable pore size with the cake depth and a crust (leading to a strongly nonlinear cake resistance), as well as those whose structures are uniform, with an open structure and, consequently, a cake resistance varying linearly with thickness. The results confirm that the model parameters in both cases can be estimated with an uncertainty that is in agreement with that obtained with other more invasive and expensive sensors. Finally, the strengths and weaknesses of the proposed approach coupled with the use of thermocouples was discussed, comparing with a case using a contactless device (infrared camera).

Freeze-Drying of Pharmaceuticals in Vials Nested in a Rack System-Part I: Freezing Behaviour.

The distribution of biopharmaceuticals often requires either ultra-cold conditions or lyophilisation. In both cases, the drug product is frozen and, thus, exposed to similar stress conditions, which can be detrimental to its quality. However, these stresses can be inhibited or mitigated by a suitable formulation and/or an appropriate freezing design. This paper addresses how the key freezing parameters, i.e., ice nucleation temperature and cooling rate, impact the freezing behaviour of a sucrose-based formulation. The analysis included two loading configurations, vials directly resting on the shelf and nested in a rack system. The loading configuration affected the product freezing rate and the ice nucleation temperature distribution, resulting in larger ice crystals in the case of vials nested in a rack system. SEM micrographs and specific surface area measurements confirmed the different product morphology. Eventually, the different product morphology impacted the bioactivity recovery of lactate dehydrogenase.

Use of machine learning tools and NIR spectra to estimate residual moisture in freeze-dried products.

Residual Moisture (RM) in freeze-dried products is one of the most important critical quality attributes (CQAs) to monitor, since it affects the stability of the active pharmaceutical ingredient (API). The standard experimental method adopted for the measurements of RM is the Karl-Fischer (KF) titration, that is a destructive and time-consuming technique. Therefore, Near-Infrared (NIR) spectroscopy was widely investigated in the last decades as an alternative tool to quantify the RM. In the present paper, a novel method was developed based on NIR spectroscopy combined with machine learning tools for the prediction of RM in freeze-dried products. Two different types of models were used: a linear regression model and a neural network based one. The architecture of the neural network was chosen so as to optimize the prediction of the residual moisture, by minimizing the root mean square error with the dataset used in the learning step. Moreover, the parity plots and the absolute error plots were reported, allowing a visual evaluation of the results. Different factors were considered when developing the model, namely the range of wavelengths considered, the shape of the spectra and the type of model. The possibility of developing the model using a smaller dataset, obtained with just one product, that could be then applied to a wider range of products was investigated, as well as the performance of a model developed for a dataset encompassing several products. Different formulations were analyzed: the main part of the dataset was characterized by a different percentage of sucrose in solution (3%, 6% and 9% specifically); a smaller part was made up of sucrose-arginine mixtures at different percentages and only one formulation was characterized by another excipient, the trehalose. The product-specific model for the 6% sucrose mixture was found consistent for the prediction of RM in other sucrose containing mixtures and in the one containing trehalose, while failed for the dataset with higher percentage of arginine. Therefore, a global model was developed by including a certain percentage of all the available dataset in the calibration phase. Results presented and discussed in this paper demonstrate the higher accuracy and robustness of the machine learning based model with respect to the linear models.

Agar Plate Methods for Assessing the Antibacterial Activity of Thyme and Oregano Essential Oils against S. epidermidis and E. coli.

The resistance to antimicrobials (AMR), especially antibiotics, represents a serious problem and, at the same time, a challenge. In the last decade, a growing interest in the use of essential oils (EOs) as antimicrobial substances was observed. Commercial thyme and oregano EOs are reported to be the main responsible of the oil antimicrobial efficacy against both Gram-positive and Gram-negative pathogenic bacteria. The aim of the present work was to study the efficacy of EOs against Staphylococcus epidermidis and Escherichia coli in long-time treatments. In a preliminary microdilution test, a MIC value was obtained for thyme EO against S. epidermidis and E. coli. After that, disk diffusion and disk volatilization tests were set up to study the influence of main cultural parameters on EO activity in liquid or vapor phase. Both bacteria were inhibited by thyme and oregano EOs when applied pure (100% v/v) or diluted (75% and 50% v/v): a higher inhibition was observed in a disk diffusion test in which the antimicrobial effect was due to both liquid and vapor phase components. Finally, a comparison with literature data was carried out even if it was not so easy because standard methods are usually modified and adapted to specific case study. For this reason, the results have to be interpreted in relation to the analytical method applied.

Evaluation of the Robustness of A Novel NIR-based Technique to Measure the Residual Moisture In Freeze-dried Products.

(Bio)pharmaceutical products freeze-dried in vials must meet stringent quality specifications: among these, the residual moisture (RM) is crucial. The most common techniques adopted for measuring the RM are destructive, e.g. Karl Fisher titration, thus few samples from each batch are tested. Being a high intra-batch variability an intrinsic feature of batch freeze-drying, a high number of samples needs to be tested to get a representative measurement. Near-Infrared (NIR) spectroscopy was extensively applied in the past as a non-invasive method to quantify the RM. In this paper, an accurate Partial Least Square (PLS) model was developed and calibrated with a single product, focusing on a small but significative wavelength range of NIR spectra (model SR), characteristic of the water and not of the product. The salient feature of this approach is that the model SR appears to provide fairly accurate estimates with the same product but at a higher concentration, with other excipients and in presence of an amino acid at high concentration, without requiring any additional calibration with KF analysis, as in previous techniques; the irrelevance of the vial shape was also shown. This approach was compared to a simpler one, based on a single-variable linear regression, and to more complex one, using a wider wavelength range or calibrating the PLS model with several products. Model SR definitely ended up as the most accurate, and it appeared to have a great potential as a robust model, suitable also for products that were not involved in the calibration step.

Investigation of the Freezing Phenomenon in Vials Using an Infrared Camera.

The freezing phenomenon has a dramatic impact on the quality of freeze-dried products. Several freezing models applied to solutions in vials have been proposed to predict the resulting product morphology and describe heat transfer mechanisms. However, there is a lack of detailed experimental observations of the freezing phenomenon in vials in the literature. Thus, the present work offers new experimental observations of the freezing phenomenon in vials by infrared (IR) thermography. IR imaging allowed each vial's whole axial temperature profile to be collected during freezing, providing significant insights into the process. Spontaneous nucleation and vacuum-induced surface freezing (VISF), as a controlled nucleation technique, are investigated. Batches having vials in direct contact with the shelf (exchanging heat mainly through conduction) as well as suspended (exchanging heat mainly through natural convection and radiation) were tested. The study used three solutions: sucrose 5%, mannitol 5%, and dextran 10%. SEM images coupled with an automated image segmentation technique were also performed to examine possible correlations between the freezing observations and the resulting pore size distributions. IR thermography was found to be a promising tool for experimentally predicting the resulting product morphology in-line.

Application of Near-Infrared Spectroscopy to statistical control in freeze-drying processes.

Batch freeze-drying of pharmaceutical products in vials may result in a high degree of intra-batch variability due to several reasons, e.g. non uniform heating rate in the drying chamber. Therefore, product quality in the final product has to be checked in a statistically significant number of samples, in particular in the stage of process development. Here, Fourier-Transform Near-Infrared Spectroscopy is proposed as a fast, non-destructive technique for an off-line Statistical Quality Control application. At first, results obtained in a batch where product features are satisfactory are used to identify a target quality threshold. Then, a statistical controller is developed in such a way that in a production run it is possible to quickly check if product quality exceeds the desired threshold or not. Two approaches based on multivariate analysis are presented: one employs the Hotelling T2 and Mahalanobis statistics to calculate control charts, the other is an application of Partial Least Squares for discriminant analysis (PLS-DA). Control charts and PLS-DA were trained with samples obtained in a run where sucrose solution was processed and validated in other runs where the final product was known to have the desired qualitative characteristics or not. Overall, out-of-specification samples can be predicted by control charts and PLS-DA with 99% and 98% accuracy respectively. PLS-DA was shown to be able to better identify samples correctly processed, while the control charts where more accurate to identify vials where something went wrong. Focusing on residual moisture of the final product, all samples where it was higher than the target value were always correctly identified.

Micro Freeze-Dryer and Infrared-Based PAT: Novel Tools for Primary Drying Design Space Determination of Freeze-Drying Processes.

PURPOSE: Present (i) an infrared (IR)-based Process Analytical Technology (PAT) installed in a lab-scale freeze-dryer and (ii) a micro freeze-dryer (MicroFD®) as effective tools for freeze-drying design space calculation of the primary drying stage. METHODS: The case studies investigated are the freeze-drying of a crystalline (5% mannitol) and of an amorphous (5% sucrose) solution processed in 6R vials. The heat (Kv) and the mass (Rp) transfer coefficients were estimated: tests at 8, 13 and 26 Pa were carried out to assess the chamber pressure effect on Kv. The design space of the primary drying stage was calculated using these parameters and a well-established model-based approach. The results obtained using the proposed tools were compared to the ones in case Kv and Rp were estimated in a lab-scale unit through gravimetric tests and a thermocouple-based method, respectively. RESULTS: The IR-based method allows a non-gravimetric estimation of the Kv values while with the micro freeze-dryer gravimetric tests require a very small number of vials. In both cases, the obtained values of Kv and Rp, as well as the resulting design spaces, were all in very good agreement with those obtained in a lab-scale unit through the gravimetric tests (Kv) and the thermocouple-based method (Rp). CONCLUSIONS: The proposed tools can be effectively used for design space calculation in substitution of other well-spread methods. Their advantages are mainly the less laborious Kv estimation process and, as far as the MicroFD® is concerned, the possibility of saving time and formulation material when evaluating Rp.

Temperature/end point monitoring and modelling of a batch freeze-drying process using an infrared camera.

Temperature monitoring and accurate drying end time determination are crucial for final product quality in vacuum freeze-drying of pharmaceuticals. Whether crystalline or amorphous solutes are used in the formulation, product temperature during ice sublimation should be kept below a threshold limit to avoid damage to the product structure. Hence, there is a need to continuously monitor product temperature throughout this process. Current monitoring tools, such as thermocouples and Pirani gauge pressure sensors, have several limitations such as affecting product dynamics or imprecise end point determination. In this work, a monitoring tool based on infrared (IR) thermography is used for batch freeze-drying processes. Batches using three different vial sizes, with up to 157 vials, were studied, allowing to extend and better describe the representativeness of IR thermography for this application. The detailed axial temperature profiles obtained through IR imaging allowed not only a comprehensive non-invasive temperature monitoring of the product, but also tracking of the sublimation interface. IR temperature measurements and primary drying end point determination were compared to standard methods and thus verified. Parameters important for freeze drying design space calculation, namely the global heat coefficient (Kv) and cake resistance to vapor flow (Rp), were also accurately estimated with the proposed method.

The Influence of Arginine and Counter-Ions: Antibody Stability during Freeze-Drying.

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.

Method development and analysis of the water content of the maximally freeze concentrated solution suitable for protein lyophilisation.

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.

A new mathematical model for monitoring the temporal evolution of the ice crystal size distribution during freezing in pharmaceutical solutions.

The freezing step plays a key role in the overall economy of the vacuum freeze-drying of pharmaceuticals, since the nucleation and crystal growth kinetics determine the number and size distribution of the crystals formed. In this work, a new mathematical model of the freezing step of a (bio)pharmaceutical solution is developed and validated. Both nucleation and crystal growth kinetics are modeled and included in a one-dimensional population balance (1D-PBM) that describes, given the product temperature measurement, the evolution of the pore size distribution during freezing. The developed model is coupled with the real-time measurements obtained from an infrared video camera. The ending time of the primary drying stage, and the maximum temperature inside the material, simulated through a simplified model of the process and the pore distribution forecast, resulted in good agreement with experimental values. The resulting Process Analytical Technology (PAT) has the potential to boost the development and optimization of a freeze-drying cycle and the implementation of a physically grounded Quality-by-Design approach in the manufacturing of pharmaceuticals. A more general mathematical model, including the aforementioned population balance, of a vial filled with a solution of sucrose was also developed and used to further validate the approach.

Development of Freeze-Drying Cycles for Pharmaceutical Products Using a Micro Freeze-Dryer.

This article aims to investigate how a small-scale freeze-dryer can be used for process design. The system encompasses a temperature controlled metallic ring that surrounds a small batch of vials, in contact with the external vials through removable thermal conductors. The temperature of the ring can be modified to keep a constant difference with the temperature of one or more vials of the batch. In this article, an extensive validation of the system is given, considering 10% w/w sucrose and 5% w/w mannitol solutions, processed in different types of vials (6 R and 20 R) and in different operating conditions. The micro freeze-dryer was also shown to be able to provide accurate estimates of the overall heat transfer coefficient from the shelf to the product in the vials (Kv) and of the resistance of the dried cake to vapor flux (Rp): both values appeared to be very close to those obtained for the same case studies in a pilot-scale unit. Finally, the use of the micro freeze-dryer to control product temperature and drying time values to simulate a pilot-scale unit was addressed, thus demonstrating the adequacy of this system for process scaleup.

Monitoring of the freezing stage in a freeze-drying process using IR thermography.

This paper presents a new Process Analytical Technology based on the use of an infrared camera and a mathematical model to estimate the ice crystal size distribution obtained at the end of the freezing stage of a vial freeze-drying process. Both empirical laws and first-principle based equations, already presented in the Literature, may be used to this purpose, if the temperature gradient in the frozen product and the freezing front rate are obtained from the analysis of the thermal images. The resistance of the dried product to vapor flux may be then calculated from the distribution of the ice crystal diameters, thus enabling the use of a one-dimensional model for process simulation and optimization. Freeze-drying of 5% and 10% w/w aqueous sucrose solutions, and of 5% w/w aqueous mannitol solutions, were considered as case study. The results were validated comparing the calculated diameters of the pores of the dried cake, corresponding to the ice crystal diameters, with the results experimentally obtained from the analysis of the SEM images, and comparing the values of drying duration and maximum product temperature calculated with the mathematical model with those measured experimentally. Results evidences the effectiveness of the proposed system for process monitoring.

On the use of a micro freeze-dryer for the investigation of the primary drying stage of a freeze-drying process.

This paper deals with the use of a small-scale freeze-dryer, where very few vials are loaded (e.g. 19, each 10 mL, or 7, each 20 mL), for freeze-drying cycle investigation. The system has a metallic ring surrounding the batch of vials, in contact with the external ones, and its temperature is manipulated independently from that of the shelf on the basis of the temperature of the product measured by thermocouples in some vials of the batch. The experimental study was carried out using two sucrose solutions (5% and 10% w/w), aiming to verify the homogeneity of the batch. Both product temperature and the weight loss after 6 h from the onset of the primary drying stage were selected as key parameters. Experiments were carried out according to a 2 N design of experiments, with two values of chamber pressure (60 and 90 mTorr) and two values of shelf temperature (-20 and 0 °C). Satisfactory results may be obtained by selecting a ring temperature 5 °C lower than that of the monitored samples in case of both products investigated. Besides, the system appears to be useful for the estimation of the coefficient of heat transfer to the product (Kv) and of the resistance of the dried cake to vapour flux (Rp), thus enabling the use of mathematical modelling for process design and optimization.

On the Use of Infrared Thermography for Monitoring a Vial Freeze-Drying Process.

Monitoring a vial freeze-drying process without interfering with product dynamics is a challenging issue. This article presents a novel device constituted by an infrared camera designed to be placed inside the drying chamber, able to monitor the temperature of the vials, very close to that of the product inside. By this way it is possible to estimate the ending point of the primary drying, the heat transfer coefficient to the product (Kv), and the resistance of the dried product to vapor flux (Rp). Experiments were carried out in a pilot-scale freeze-dryer, processing 5% and 10% sucrose solutions at different values of shelf temperature and chamber pressure, using both thermocouples and the IR camera to track product dynamics. Results evidence that the measurements (of temperature) and the estimates (of the ending point of the main drying and of Kv and Rp) obtained using the 2 systems are very close, thus validating the IR camera as an effective process analytical technologies for the freeze-drying process. Besides, it was shown that the presence of the IR camera in the chamber is not responsible for any additional heating to the product and that monitored vials are representative of the majority of the vials of the batch.