A Rational Hierarchy to Capture Raw Material Attribute Variability in the Pharmaceutical Drug Product Development and Manufacturing Lifecycle.

Assessing the robustness of a drug product formulation and manufacturing process to variations in raw material (RM) properties is an essential aspect of pharmaceutical product development. Motivated by the need to demonstrate understanding of attribute-performance relationships at the time of new product registration and for subsequent process maintenance, we review practices to explore RM variations. We describe limitations that can arise when active ingredients and excipients invariably undergo changes during a drug product lifecycle. Historical approaches, such as Quality-by-Design (QbD) experiments, are useful for initial evaluations but can be inefficient and cumbersome to maintain once commercial manufacturing commences. The relatively miniscule data sets accessible in product development - used to predict response to a hypothetical risk of variation - become less relevant as real-world experience of actual variability in the commercial landscape grows. Based on our observations of development and manufacturing, we instead propose a holistic framework exploiting a hierarchy of RM variability, and challenge this with common failure modes. By explicitly incorporating higher ranking RM variations as perturbations, material-conserving experiments are shown to provide powerful and enduring robustness data. Case studies illustrate how correctly contextualizing such data in formulation and process development can avoid the traps of historical QbD approaches and become valuable for evaluating changes occurring later in the drug product lifecycle.

Rheological and solid-state NMR assessments of copovidone/clotrimazole model solid dispersions.

This study aims to assess several model solid dispersions by using dynamic oscillatory rheology, solid-state NMR and other solid phase characterization techniques, and correlate their viscoelastic responses with processing methods and microstructures. A model active pharmaceutical ingredient (API), clotrimazole, was compounded with copovidone to form solid dispersions via various techniques with different mixing capabilities. Physicochemical characterizations of the resulting solid dispersions demonstrated that simple physical mixing led to a poorly mixed blend manifested by existence of large API crystalline content and heterogeneous distribution. Cryogenic milling significantly improved mixing of two components as a result of reduced particle size and increased contact surface area, but produced limited amorphous content. In contrast, hot melt extrusion (HME) processing resulted in a homogenous amorphous solid dispersion because of its inherent mixing efficiency. Storage modulus and viscosities versus frequency of different solid dispersions indicated that the incorporation of API into the polymer matrix resulted in a plasticizing effect which reduced the viscosity. The crystalline/aggregated forms of API also exhibited more elastic response than its amorphous/dispersed counterpart. Temperature ramps of the physical mixture with high API concentration captured a critical temperature, at which a bump was observed in damping factor. This bump was attributed to the dissolution of crystalline API into the polymer. In addition, heating-cooling cycles of various solid dispersions suggested that cryomilling and HME processing could form a homogeneous solid dispersion at low API content, whereas high drug concentration led to a relatively unstable dispersion due to supersaturation of API in the polymer.

Load-induced transitions in the lubricity of adsorbed poly(L-lysine)-g-dextran as a function of polysaccharide chain density.

Chain-density gradients of poly(l-lysine)-graft-dextran (PLL-g-dex), a synthetic comblike copolymer with a poly(l-lysine) backbone grafted with dextran side chains, were fabricated on an oxidized silicon substrate. The influence of the changing dextran chain density along the gradient on the local coefficient of friction was investigated via colloidal-probe lateral force microscopy. Both in composition and structure, PLL-g-dex shares many similarities with bottlebrush biomolecules present in natural lubricating systems, while having the advantage of being well-characterized in terms of both architecture and adsorption behavior on negatively charged oxide surfaces. The results indicate that the transition of the dextran chain density from the mushroom into the brush regime coincides with a sharp reduction in friction at low loads. Above a critical load, the friction increases by more than an order of magnitude, likely signaling a pressure-induced change in the brush conformation at the contact area and a corresponding change in the mechanism of sliding. The onset of this higher-friction regime is moved to higher loads as the chain density of the film is increased. While in the low-load (and low-friction) regime, increased chain density leads to lower friction, in the high-load (high-friction) regime, increased chain density was found to lead to higher friction.

Complementary dimerization of microtubule-associated tau protein: Implications for microtubule bundling and tau-mediated pathogenesis.

Tau is an intrinsically unstructured microtubule (MT)-associated protein capable of binding to and organizing MTs into evenly spaced parallel assemblies known as "MT bundles." How tau achieves MT bundling is enigmatic because each tau molecule possesses only one MT-binding region. To dissect this complex behavior, we have used a surface forces apparatus to measure the interaction forces of the six CNS tau isoforms when bound to mica substrates in vitro. Two types of measurements were performed for each isoform: symmetric configuration experiments measured the interactions between two tau-coated mica surfaces, whereas "asymmetric" experiments examined tau-coated surfaces interacting with a smooth bare mica surface. Depending on the configuration (of which there were 12), the forces were weakly adhesive, strongly adhesive, or purely repulsive. The equilibrium spacing was determined mainly by the length of the tau projection domain, in contrast to the adhesion force/energy, which was determined by the number of repeats in the MT-binding region. Taken together, the data are incompatible with tau acting as a monomer; rather, they indicate that two tau molecules associate in an antiparallel configuration held together by an electrostatic "zipper" of complementary salt bridges composed of the N-terminal and central regions of each tau monomer, with the C-terminal MT-binding regions extending outward from each end of the dimeric backbone. This tau dimer determines the length and strength of the linker holding two MTs together and could be the fundamental structural unit of tau, underlying both its normal and pathological action.

Recent progress in understanding hydrophobic interactions.

We present here a brief review of direct force measurements between hydrophobic surfaces in aqueous solutions. For almost 70 years, researchers have attempted to understand the hydrophobic effect (the low solubility of hydrophobic solutes in water) and the hydrophobic interaction or force (the unusually strong attraction of hydrophobic surfaces and groups in water). After many years of research into how hydrophobic interactions affect the thermodynamic properties of processes such as micelle formation (self-assembly) and protein folding, the results of direct force measurements between macroscopic surfaces began to appear in the 1980s. Reported ranges of the attraction between variously prepared hydrophobic surfaces in water grew from the initially reported value of 80-100 Angstrom to values as large as 3,000 Angstrom. Recent improved surface preparation techniques and the combination of surface force apparatus measurements with atomic force microscopy imaging have made it possible to explain the long-range part of this interaction (at separations >200 Angstrom) that is observed between certain surfaces. We tentatively conclude that only the short-range part of the attraction (<100 Angstrom) represents the true hydrophobic interaction, although a quantitative explanation for this interaction will require additional research. Although our force-measuring technique did not allow collection of reliable data at separations <10 Angstrom, it is clear that some stronger force must act in this regime if the measured interaction energy curve is to extrapolate to the measured adhesion energy as the surface separation approaches zero (i.e., as the surfaces come into molecular contact).

The deformation and adhesion of randomly rough and patterned surfaces.

Using a surface forces apparatus (SFA) and an atomic force microscope (AFM) we have studied the effects of surface roughness (root-mean-square (RMS) roughness between 0.3 and 220 nm) on the "contact mechanics", which describes the deformations and loading and unloading adhesion forces, of various polymeric surfaces. For randomly rough, moderately stiff, elastomeric surfaces, the force-distance curves on approach and separation are nearly reversible and almost perfectly exponentially repulsive, with an adhesion on separation that decreases only slightly with increasing RMS. Additionally, the magnitude of the preload force is seen to play a large role in determining the measured adhesion. The exponential repulsion likely arises from the local compressions (fine-grained nano- or submicron-scale deformations) of the surface asperities. The resulting characteristic decay lengths of the repulsion scale with the RMS roughness and correlate very well with a simple finite element method (FEM) analysis based on actual AFM topographical images of the surfaces. For "patterned" surfaces, with a nonrandom terraced structure, no similar exponential repulsion is observed, suggesting that asperity height variability or random roughness is required for the exponential behavior. However, the adhesion force or energy between two "patterned" surfaces fell off dramatically and roughly exponentially as the RMS increased, likely owing to a significant decrease in the contact area which in turn determines their adhesion. For both types of rough surfaces, random and patterned, the coarse-grained (global, meso- or macroscopic) deformations of the initially curved surfaces appear to be Hertzian.

Further studies on the effect of degassing on the dispersion and stability of surfactant-free emulsions.

Recently reported results indicate that the formation of surfactant-free, oil-in-water emulsions can be significantly enhanced by the almost complete removal of dissolved gases and that the reintroduction of dissolved gases does not immediately destabilize the already-formed emulsions. These initial experiments have been repeated and extended to include a wider range of organic liquids and the application of light scattering to determine droplet size and distribution. The earlier observations have been confirmed. In addition, a systematic trend was found between the solubility of the oil in water and the stability (lifetime) of the degassed oil droplets in water. The lower the solubility, the more stable the emulsion, and for oils that are sparingly soluble in water such as squalane, the small droplets remain stable for several weeks, with buoyancy separation being the main cause of instability of the large droplets with time. The addition of electrolytes, up to molar concentrations, substantially reduces the enhancement of the dispersions on degassing but appears to have little effect on the stability of the already-formed emulsions. The reduction of pH to about 2 significantly reduces both the enhancement of the dispersions on degassing and the stability of the already-formed emulsions. In contrast, the increase of pH to about 11 hardly affects the enhancement of the dispersions on degassing or the stability of the already-formed emulsions. We have confirmed the importance of dissolved gas and its association with the electrostatic effects, but we still cannot provide a complete explanation for the effect of degassing on the hydrophobic dispersions.