Tuesday, April 24, 2012

DELIVERY - Nanoparticles | Creating Nanostructures for Oral Drug Delivery



Neil Canavan
Creating Nanostructures for Oral Drug Delivery

Platforms prove elusive, but research persists

What the pharmaceutical industry needs is a plug-and-play nanotechnology plat- form, a suite of constituent parts and instructions that can facilitate the realization of new oral drug formulations. Just don’t hold your breath waiting for it.
“Even if all parts remain the same, the API may affect how the whole process works,” warned Ravi Kumar, PhD, professor of drug delivery, Strathclyde Institute of Pharmacy and Biomedical Sciences, University of Strathclyde, Glasgow, U.K.
Dr. Kumar spoke from knowledge of recent efforts: The first attempt looked at nanoparticle formulation of the immunosuppressant drug cyclosporine A, with a multi-block copolymer of lactic acid and ethylene glycol; the second used a similar approach with the chemotherapy agent paclitaxel and a charged surfactant.1,2 His most recent work was with amphotericin B (AMB), a polyene antibiotic administered intravenously to treat invasive aspergillosis, a life-threatening infection, and leishmaniasis, a condition caused by a parasite endemic to many developing countries. An oral formulation could increase bioavailability, potentially reducing the amount of drug needed and the cost due to ease of drug manufacture and administration.
In the most recent investigation, AMB was combined with poly(lactide-co-glycolode), dimethyl sulfoxide, and vitamin E TPGS, a non-ionic surfactant, to create nanoparticles of 113±20 nm in size with 70% entrapment efficiency at 30% AMB w/w of polymer.3
The resulting formulation was effective in murine models of aspergillosis; however, data for leishmaniasis was not as encouraging. Dr. Kumar suspects there are issues with the formulation’s release profile. “With leishmaniaisis, you would probably require a very fast release initially to combat the protozoa’s growth rate,” and to accommodate this would require a separate balancing act between drug loading and particle size—thus, not quite a platform.
For now, Dr. Kumar advises gaining a true understanding of the properties of the drug molecule itself first, and then studying what the drug is being used for. Once you have an idea about the delivery vehicle, “the simpler you can keep the formulation the better.” And always keep an eye on scale up—for instance, using TPGS facilitated the use of filters, rather than centrifugation, to harvest large quantities of nanoparticles.
Dr. Kumar also requested scientists working in the field to be more comprehensive in their reporting. “This is a key issue. Lots of publishing on this work doesn’t really describe how they are freeze drying these formulations.” Stating that the material was lyophilized is not enough; all players need to know the myriad tweaks that got you there.
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Case Study: Scaling Down for Faster Pain Relief?

A recent experiment performed by end Research in Bend, Ore., in collaboration Pfizer Pharmaceuticals, demonstrated the potential of drug/nanoparticle constructs for increasing the rate and extent of oral absorption of low solubility, high-permeability drugs—in this case, the anti-inflammatory agent celecoxib.1
FIGURE 1
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FIGURE 1
“There was at least a two-fold purpose for choosing celecoxib,” said Michael Morgen, PhD, director of new technology development at Bend. “The first is that it serves as a model for showing the broad applicability of this technology to low-solubility, BCS class 2 compounds, and second, since celecoxib is used for pain relief, you can imagine wanting to increase the rate of absorption to achieve faster onset.”
Dr. Morgen and his team are creating drug/nanoparticles using high surface area dispersions of celecoxib, in combination with ethyl cellulose and either sodium caseinate or bile salt. This approach has previously been shown to be particularly well suited to rapid-release, rapid-onset applications.2
The architecture of the particle is such that the drug molecule is dispersed within the polymer matrix, with the stabilizing excipients located primarily on the exterior (see Figure 1).
“We used a variety of surface-stabilizing agents to help keep the particles from aggregating—for the in vivo experiments we used casein, which is a naturally occurring, charged polymer.”
Once prepared, Dr. Morgen’s nanoparticles proved in his in vivo study to have higher systemic exposure and faster attainment of peak plasma concentrations than commercial celecoxib capsules.
The technique, though successful, does not suggest a clear path forward. “The raw technical performance was pretty good, but we had a lot of difficulty trying to scale up just to do a small clinical study,” said Dr. Morgen. And he sees this problem in broader terms. “The particles could be broadly applicable, but there isn’t the developed infrastructure yet in the industry to handle the process development.” To perform large-scale trials, more emphasis must be placed on the commercial-scale manufacture of the small.

References

  1. Morgen M, Bloom C, Beyerinck R, et al. Polymeric nanoparticles for increased oral bioavailability and rapid absorption using celecoxib as a model of a low-solubility, high-permeability drug. Pharm Res. 2012;29(2):427-440.
  2. Yang W, Tam J, Miller DA, et al. High bioavailability from nebulized itraconazole nanoparticle dispersions with biocompatible stabilizers. Int J Pharm. 2008;361(1-2):177–188.

Sticky Situation

Unlike most of those working with oral formulations, Kevin Pojasek, PhD, vice president of corporate development for Kala Pharmaceuticals in Waltham, Mass., isn’t looking to increase systemic bioavailability. He would rather the drug’s activity remain on site.
In a recent investigation, AMB was combined with poly(lactide-co-glycolode), dimethyl sulfoxide, and vitamin E TPGS, a non-ionic surfactant, to create nanoparticles of 113±20 nm in size with 70% entrapment efficiency at 30% AMB w/w of polymer.
“At Kala, we’re looking at how can we better treat diseases of the GI tract through topical administration—essentially trapping the API at the site of infection or inflammation.” That goal first requires a thorough understanding of the mucosal lining of the GI tract, a knowledge foundation revealed and recently reviewed by Kala investigators.4 “We started with the engineering principles of mucus, the rheology,” said Dr. Pojasek, and then combined that with the observed properties of certain viruses that are able to penetrate a mucosal barrier. Taken together, these data guided the researchers to an effective GI-targeting nanoparticle design.
Leaving out proprietary details, proof-of-principle for this approach, described by Yang and colleagues, used Pluronic block copolymers to enable membrane translocation. Mindful of eventual marketing, the techniques evolving from this approach are only incorporating pre-FDA approved moieties, minimizing regulatory hurdles by skirting the definition of new chemical entities.5
Though still in early development, there is something resembling a platform in this work. “In essence, the secret sauce of what we do is engineering the coating on the outside of the particles,” said Dr. Pojasek. As for the core, “we can tailor the release kinetics to meet the challenge of whatever mucosal disease we’re trying to treat.”

References

  1. Ankola DD, Battisti A, Solaro R, Kumar MN. Nanoparticles made of multi-block copolymer of lactic acid and ethylene glycol containing periodic side-chain carboxyl groups for oral delivery of cyclosporine A. J R Soc Interface. 2010;7 Suppl 4:S475-S481.
  2. Bhardwaj V, Plumb JA, Cassidy J, Ravi Kumar MNV. Evaluating the potential of polymer nanoparticles for oral delivery of paclitaxel in drug-resistant cancer. Cancer Nanotechnol. 2010;1(1-6)29-34.
  3. Italia JL, Sharp A, Carter KC, Warn P, Kumar MN. Peroral amphotericin B polymer nanoparticles lead to comparable or superior in vivo antifungal activity to that of intravenous Ambisome® or Fungizone™. PLoS One. 2011;6(10):e25744.
  4. Ensign LM, Cone R, Hanes J. Oral drug delivery with polymeric nanoparticles: the gastrointestinal mucus barriers [published online ahead of print Dec. 24, 2011]. Adv Drug Deliv Rev.
  5. Yang M, Lai SK, Wang YY, et al. Biodegradable nanoparticles composed entirely of safe materials that rapidly penetrate human mucus. Angew Chem Int Ed Engl. 2011;50(11):2597-2600.
Neil Canavan a science/medical writer based in Brooklyn, N.Y., is a frequent contributor to PFQ and holds a master’s degree in molecular biology. In addition to covering medical meetings, he has been writing about pharmaceutical science for more than 10 years. Reach him at ncanavan@hotmail.com.
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Editor’s Choice

  1. Batrakova EV, Kabanov AV. Pluronic block copolymers: evolution of drug delivery concept from inert nanocarriers to biological response modifiers. J Control Release. 2008;130(2):98-106.
  2. Cai Z, Wang Y, Zhu LJ, Liu ZQ. Nanocarriers: a general strategy for enhancement of oral bioavailability of poorly absorbed or pre-systemically metabolized drugs. Curr Drug Metab. 2010 Feb;11(2):197-207.
  3. Wawrezinieck A, Péan JM, Wüthrich P, Benoit JP. Oral bioavailability and drug/carrier particulate systems [in French]. Med Sci (Paris). 2008;24(6-7):659-664.
  4. Roger E, Lagarce F, Garcion E, Benoit JP. Biopharmaceutical parameters to consider in order to alter the fate of nanocarriers after oral delivery. Nanomedicine (Lond). 2010;5(2):287-306.
  5. Yamanaka YJ, Leong KW. Engineering strategies to enhance nanoparticle-mediated oral delivery. J Biomater Sci Polym Ed. 2008;19(12):1549-1570.

FORMULATION - Proteins and Peptides | PEGylation Hurdles Prompt Innovative Approaches



Tim Donald
PEGylation Hurdles Prompt Innovative Approaches

Reversible and noncovalent methods enhancing protein and peptide performance

PEGylation—the covalent attachment of polyethylene glycol groups to proteins and peptides—is a strategy commonly used to improve the performance of these therapeutic molecules in vivo. However, successful drug development using PEGylation can pose a number of challenges, not least of which is that the process of attaching PEG covalently can alter the activity of the protein or peptide itself.
In response to these challenges, a number of novel variations on PEGylation have been developed in recent years, including reversible PEGylation and noncovalent PEGylation. There has also been the realization that there is “nothing magical” about PEG, in the words of one researcher, and that other biomolecules, such as starches, can be used to change pharmacokinetic qualities.

Challenges of Formulation

While PEGylation can extend the in vivo circulatory half-life and medicinal effect of proteins or peptides, any such chemical modification can also alter these molecules’ physical properties. These changes introduce challenges in creating a drug, said Mark C. Manning, PhD, chief scientific officer of Legacy BioDesign, a contract formulation service in Johnstown, Colo.
At least eight PEGylated protein and peptide therapeutics have been developed and reached the market, beginning with Adagen in 1990.
“If you take a protein and chemically modify it, whether it’s by PEGylation or something else, then you’ve introduced new chemistry, and that then affects the manufacturing, the approval process, and so on. It complicates the analytical methods you have to use, it changes the evaluation of [active pharmaceutical ingredient] purity, it affects formulation, and so on,” he said.
Dr. Manning and colleagues recently reviewed the challenges to drug development with PEGylated proteins.1 They noted that the chemistry of attaching PEG to the protein is the critical issue affecting product development. In addition, the quality of the starting materials and the coupling process must be carefully controlled, and these issues become exacerbated as the scale is increased and the chemistry must be performed under current good manufacturing practice (cGMP) conditions. Further, a suitable purification method must be selected for the potentially complex mixture of multiple isomers of the PEGylated compound. Once the purified drug substance is obtained, proper analytical methods must be chosen to characterize the material.
“These are all things that drug developers should think about as they embark along these lines,” Dr. Manning said. “We say this technology is well-established and can provide benefit, which is true, but it comes at a cost, a price in terms of the time required to characterize these materials.”
Despite these challenges, at least eight PEGylated protein and peptide therapeutics have been developed and reached the market, beginning with Adagen (pegademase bovine, Enzon) in 1990, and more than two dozen PEGylated peptides and proteins of interest have been described in the literature.1 A recently introduced PEGylated product, Cimzia (certolizumab pegol, UCB), is discussed in the case study.
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Case Study: PEGylation Increases Half-Life of TNF Blocker

Despite the challenges of using PEGylation to create useful therapeutic entities, at least eight PEGylated therapeutic products have reached the market, and many more molecules of interest have been described in the literature. One of the most recently approved PEGylated therapeutics is Cimzia (certolizumab pegol, UCB), a tumor necrosis factor blocker indicated for treatment of Crohn’s disease and rheumatoid arthritis.1
Certolizumab pegol is a recombinant, humanized antibody Fab’ fragment with specificity for human TNF-alpha, conjugated to an approximately 40 kDa polyethylene glycol. The Fab’ fragment is manufactured in E. coli and subsequently subjected to purification and conjugation to the PEG to generate certolizumab pegol. The molecular weight of certolizumab pegol is approximately 91 kDa.1
PEGylation is an essential factor in the formulation of certolizumab pegol because of the instability of the active molecule, said Mark C. Manning, PhD.
“Without PEGylation, the active ingredient would be cleared in minutes, in vivo. It’s a very unstable molecule,” he said. “Once it is PEGylated, it can reside in the body for hours.”
Even though many PEGylated proteins exhibit compromised efficacy—a possible side effect of PEGylation—this could be an acceptable tradeoff in return for longer in vivo stability, Dr. Manning said.
“Even if you compromise the intrinsic activity a bit, you’re willing to pay that price because the overall effectiveness for the patient is going to increase significantly,” he said. —TD

References

  1. UCB, Inc. Cimzia [package insert]. Available at: http://cimzia.com/?v=GOOG&WT.srch=1&gclid=COurlfa35a4CFWYJRQodISNRvQ. Accessed March 13, 2012.

Reversible PEGylation

One of the potential drawbacks of protein or peptide PEGylation is that the attachment of the PEG polymer may block the active sites of these therapeutic molecules. Linking a PEG or another polymer to protein drugs often yields derivatives that are largely or completely devoid of biologic potency, and therefore pharmacologically ineffective, said Matityahu Fridkin, PhD, the Lester B. Pearson Professorial Chair of Protein Research in the department of organic chemistry at the Weizmann Institute of Science in Rehovot, Israel.
“Classical PEGylation of peptides and proteins often leads to prevention of binding and activation of certain specific receptors, as for instance is known to occur with interferon,” Dr. Fridkin said.
In order to overcome this phenomenon, Dr. Fridkin and colleagues have used a process called reversible PEGylation, in which chain-like spacers are used to link PEG to the protein drug. This attachment turns the short-acting protein or peptide drug into a long-acting prodrug, which maintains circulating levels for extended periods after administration. The reversible chemical bonds dissolve slowly under physiologic conditions, releasing the active drug slowly over time, Dr. Fridkin and colleagues have shown.
“Reversible PEGylation leads to the slow release of the intact parent drug with full bioactivity,” Dr. Fridkin said.
He noted that the group’s work with insulin has demonstrated the potential advantages of reversible PEGylation. In a 2008 publication, the researchers engineered a long-acting prodrug of insulin that released biologically active insulin with a half-life of 30 hours under physiologic conditions.2 By contrast, conventional PEGylation of insulin led to inactivation of the hormone.
In addition to PEG, other molecules can be used to improve the PK of proteins and peptides in vivo. A number of biomolecules are being investigated and used in this way, including polyglycine and, increasingly, several types of starches.
The preparation of large-scale amounts of reversibly PEGylated conjugates remains beyond the researchers’ current capability, Dr. Fridkin said. “This will be the major direction in our near future research,” he said. “We are attempting to simplify the current synthetic methodology to achieve this goal.”

Noncovalent PEGylation

Another approach to obtaining stable biologically active compounds in vivo is to use noncovalent bonds to attach PEG to proteins and peptides.
Researchers at the University of Kansas, led by Cory J. Berkland, PhD, recently used noncovalent PEGylation by polyanion complexation to improve the in vivo stability of keratinocyte growth factor-2.3
“Normally, we use a covalent chemical bond to conjugate the PEG onto the protein, and that can affect the activity of the protein. We thought that if we can use a noncovalent bond to put the PEG on the protein, when the formulation goes into the body the protein can be released from the PEG quite easily, and that would not interfere with the protein activity. That was the starting point of our work,” said Supang Khondee, PhD, first author of the paper on noncovalent PEGylation of KGF-2.3 Now a research fellow in internal medicine at the University of Michigan Medical School, she was a graduate student at the University of Kansas under Dr. Berkland at the time of this research.
Using the polyanions pentosan polysulfate and dextran sulfate, the researchers attached PEG noncovalently to KGF-2, a heparin-binding protein with regenerative properties. This increased the melting temperature and improved the stability of the compound. The researchers suggested that this approach can be used with other heparin-binding proteins.

Related Technologies

In addition to PEG, other molecules can be used to improve the PK of proteins and peptides in vivo, Dr. Manning noted.
“There’s nothing magical about PEG,” he said. “In general, if you attach another polymer to a protein, you will increase its circulating half-life. So we’re seeing a lot of people exploring whether other biomolecules that are safe can chemically attach to proteins and therefore change their PK properties.”
A number of biomolecules are being investigated and used in this way, including polyglycine and, increasingly, several types of starches, Dr. Manning said.
The starch derivative hydroxyethyl starch has been used in this manner in a proprietary process called HESylation. HESylation allows targeted modification of drugs and their characteristics by site-specific coupling to HES molecules, according to Boehringer Ingelheim, of Ingelheim, Germany.4
In a collaboration between Fresenius Kabi, of Bad Homburg, Germany, and Boehringer Ingelheim, HES was coupled to a therapeutic protein, and the resulting HESylated pharmaceutical was produced at industrial scale with quality and yield comparable to product made in the laboratory, a press release from Boehringer Ingelheim stated. The press release did not name the compound, but it stated that the two companies will continue to pursue their collaboration.

References

  1. Payne RW, Murphy BM, Manning MC. Product development issues for PEGylated proteins. Pharm Dev Technol. 2011;16(5):423-440.
  2. Shechter Y, Mironchik M, Rubinraut S, et al. Reversible pegylation of insulin facilitates its prolonged action in vivo. Eur J Pharm Biopharm. 2008;70(1):19-28.
  3. Khondee S, Olsen CM, Zeng Y, Middaugh CR, Berkland C. Noncovalent PEGylation by polyanion complexation as a means to stabilize keratinocyte growth factor-2 (KGF-2). Biomacromolecules. 2011;12(11):3880-3894.
  4. Boehringer Ingelheim. Boehringer Ingelheim RCV and Fresenius Kabi successfully coupled HES to a therapeutic protein in an industrial scale applying Fresenius Kabi’s HESylation Technology [press release]. Boehringer Ingelheim website. November 11, 2010. Available at: www.boehringer-ingelheim.com/news/news_releases/press_releases/2010/11_november_2010fresenius.html. Accessed March 13, 2012.


Editor’s Choice

  1. Gokarn YR, McLean M, Laue TM. Effect of PEGylation on protein hydrodynamics [published online ahead of print Feb. 21, 2012]. Mol Pharm.
  2. Vasudev SS, Ahmad S, Parveen R, et al. Formulation of PEG-ylated L-asparaginase loaded poly (lactide-co-glycolide) nanoparticles: influence of pegylation on enzyme loading, activity and in vitro release. Pharmazie. 2011;66(12):956-960.
  3. Mehmet Saka O, Bozkir A. Formulation and in vitro characterization of PEGylated chitosan and polyethylene imine polymers with thrombospondin-I gene bearing pDNA [published online ahead of print Jan. 25, 2012]. J Biomed Mater Res B Appl Biomater.

The Landscape of Pharmaceutical Packaging



Daniel L. Norwood, MSPH, PhD

Containers critical to drug product safety and efficacy

The vast majority of patients take little or no notice of the containers their medicines arrive in from the pharmacy, except perhaps to complain about a tamper-resistant seal. Even patients required to treat chronic disease conditions using medications with relatively complex container closure/drug delivery systems like metered-dose inhalers might only be interested when the drug appears not to work as fast as they might like.
What the average patient does not know—what even many pharmaceutical development professionals fail to fully appreciate—is the importance of pharmaceutical packaging to the safety and efficacy of medicines, and the level of science and engineering incorporated into many container closure/delivery systems.
Governments and their regulatory authorities, however, have long recognized the importance of pharmaceutical packaging. The Federal Food, Drug, and Cosmetic Act addresses packaging directly, stating in section 501(a)(3) that a drug or device shall be deemed to be adulterated “if its container is composed, in whole or in part, of any poisonous or deleterious substance which may render the contents injurious to health.”1 Section 502 of the FD&C Act delineates packaging situations for drugs and devices that can lead to charges of “misbranding,” and section 505 mandates drug product approval by the Federal government and lists the information required to obtain such approval, including “a full description of the…packing of such drug.” With this and other legislative mandates, governmental regulatory authorities such as the FDA, the European Medicines Agency, and other standard-setting bodies such as the U.S. Pharmacopeia-National Formulary (USP-NF) have addressed packaging and packaging-related issues with various guidance documents, characterization and quality control methods, and standards.
In the past several decades of the 20th century, with the rapid increase in new pharmaceutical dosage forms and new medical devices (which are in many cases also container closure/drug delivery systems), along with the replacement of many glass containers with various types of plastic, interest and concern regarding pharmaceutical packaging has significantly increased. As a result, in May 1999 the FDA released a definitive guidance document titled Guidance for Industry – Container Closure Systems for Packaging Human Drugs and Biologics – Chemistry, Manufacturing, and Controls Documentation.1 This guidance, often called the “Packaging Guidance,” presents regulatory expectations for packaging of new drug products based on the concept of “suitability for intended use,” which includes the requirements of protection, compatibility, safety, and performance. These terms are defined as follows:
  • Protection: The ability of a packaging system to guard the dosage form from “factors that can cause degradation in the quality of that dosage form over its shelf life” (e.g., temperature, light, moisture, loss of solvent, reactive gases, microbial contamination).
  • Compatibility: The attribute(s) of a packaging system and its various components that prevent interactions that promote “unacceptable changes in the quality of either the dosage form or the packaging component.” Such interactions can result in loss of potency or reduction of an active ingredient or excipient through absorption, adsorption, or degradation; precipitation and particle formation; pH change; appearance changes in either the dosage form or packaging system; or physical changes in the packaging system, resulting in reduced protection and/or performance.
  • Safety: The property of a packaging system and its components not to leach potentially harmful substances into the dosage form that could be delivered to the patient.
  • Performance: The ability of a packaging system and its components to “function in the manner for which it was designed.” This includes the ability of the packaging system to deliver the dosage form to the patient in an appropriate manner.
TABLE 1
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The requirements for packaging systems and their components are risk based, taking into consideration factors such as route of administration and the likelihood of packaging component–dosage form interaction (see Table 1).1 Additional details, such as the dose of the particular drug and the frequency and mode of administration are also considered.2

Terminology, Nomenclature

Modern pharmaceutical packaging systems are enormously diverse, even within specific dosage form types such as those listed in Table 1. To begin to understand this diversity, it is useful to consider the following terms as defined in the “Packaging Guidance” and in the comprehensive books by Jenke and by Ball and colleagues.1,3,4:
  • Container closure system: The sum of packaging components that together contain and protect the dosage form. The term “packaging system” as used in this article is equivalent to container closure system. Note that the term “container closure/delivery system” is used because the packaging system can also serve to deliver the drug to patients.
  • Packaging component: Any single part of a container closure/delivery system. Packaging components can be either primary, a term that describes those that are or may be in direct contact with the dosage form, or secondary, those that are not or will not be in direct contact with the dosage form.
  • Materials of construction: Substances used to manufacture a packaging component.
A container closure system can be relatively simple, such as a bottle containing pills, or relatively complex, like a single-use syringe containing an injectable solution or a dry powder inhaler. In the former, the primary packaging components are the bottle (fabricated from materials such as glass or a plastic such as polyethylene) and the cap (likely also fabricated from a plastic material), while secondary packaging components might include the paper label on the bottle (don’t forget the ink and glue on the label), cardboard shipping containers, and wooden shipping pallets. For the single-use syringe, primary packaging components include the syringe barrel and plunger and the syringe needle. The barrel and plunger are likely fabricated from plastic materials, while the needle is metal, secured to the barrel with a glue of some type. Secondary packaging components include the carton containing the syringe.
The diversity of primary packaging components is significant, including bottles, vials, ampoules, canisters, intravenous bags, septa, overseals, gaskets, caps, liners, and mouthpieces.1,4 Secondary packaging components are also diverse, including labels (inks and glues), overwraps, and shipping containers. Materials of construction include elastomers (i.e., rubber of various types), plastic (many varieties), metal (aluminum and stainless steel), paper, and wood. Note that any and all of these packaging components, both primary and secondary, can affect protection, compatibility, safety, and performance.

Inhalation Products

Among all dosage form types, none connects packaging systems more intimately with safety and performance than inhalation drug products—also referred to as orally inhaled and nasal drug products or OINDP—including inhalation aerosols, inhalation solutions/sprays, nasal sprays, and inhalation powders. Table 1 clearly shows that the regulatory authorities consider these dosage form types to be of high concern because of their route of administration and the likelihood of packaging component-dosage form interaction. This is true because 1) inhalation drug products are typically administered over many years directly to the diseased organs of sensitive patient populations with chronic conditions such as asthma and chronic obstructive pulmonary diseases, and 2) the packaging system is typically a true container closure/delivery system, with primary packaging components intimately associated with proper administration of the drug formulation.
FIGURE 1. Schematic diagram of a metered dose inhaler drug product. (Image provided by Bespak, a division of Consort Medical; www.bespak.com.)
FIGURE 1. Schematic diagram of a metered dose inhaler drug product. (Image provided by Bespak, a division of Consort Medical; www.bespak.com.)
Consider the metered dose inhaler drug product shown in Figure 1. MDIs contain active ingredients either in solution or suspended in an organic propellant, such as chlorofluorocarbons, hydrofluorocarbons, along with cosolvents and excipients like ethanol, soy lecithin, or oleic acid. Primary packaging components, also referred to as critical components, include the dose metering valve with its rubber gaskets and seals, plastic valve components, the metal canister, and a plastic actuator/mouthpiece.4
These components are designed and carefully controlled with respect to dimensions and physical properties so that appropriate doses of drug are delivered to the patient over the shelf life of the drug product unit (a typical MDI might contain 200 actuations of drug formulation). For example, the orifice shape and dimensions of the actuator/mouthpiece affect the geometry of the aerosol “plume” of actuated drug formulation dose, which in turn affects the delivery of active ingredient to the patient’s lung.
Also, the physical properties of the rubber gaskets and seals—for example, their elasticity—can affect the performance of the dose metering valve during actuation of a dose, which can in turn affect the delivered dose. Therefore, control of primary packaging components is critical to the performance of an MDI. Other inhalation drug product container closure/delivery systems, such as dry powder inhalers and inhalation sprays, can be even more complex and also require rigorous primary packaging component controls to ensure adequate dosage form performance.
The term “likelihood of packaging component-dosage form interaction” attempts to quantify the probability that a container closure/delivery system will leach chemical entities with possible safety concerns for patients into a drug formulation. This concept is easily conceptualized with reference to the MDI schematic in Figure 1. As noted above, in an MDI the formulation includes an organic solvent propellant and other ingredients such as organic solvents.
These solvents can interact with primary packaging components, such as the rubber gaskets and seals, as well as plastic valve components, to leach organic and inorganic chemical entities into the formulation. These chemical entities are then referred to as leachables and are considered by regulatory authorities to be a separate class of drug product impurity. (For a more detailed summary of leachables in MDIs, see case study, “Leachables and the MDI CFC Transition.”)
FIGURE 2. Chemical structures of some common chemical antioxidants used as additives in rubber and plastic: A) Irganox 1010; B) Diphenylamine; C) Irganox 1076; D) Irgafos 168.
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FIGURE 2. Chemical structures of some common chemical antioxidants used as additives in rubber and plastic: A) Irganox 1010; B) Diphenylamine; C) Irganox 1076; D) Irgafos 168.
Rubber and plastic are particularly good sources of potential leachables because these materials require chemical additives to achieve and maintain various physical properties of the finished components. Functional categories of chemical additives include antioxidants, UV light stabilizers, cross-linking agents, polymerization agents, plasticizers, lubricants, anti-static agents, anti-slip agents, and mold release agents.4 Each functional category also contains significant chemical diversity; for example, note the various chemical types of antioxidant in Figure 2. Along with chemical additives to rubber and plastic components, potential leachables also include byproducts of incomplete polymerization such as monomers and oligomers, organic and inorganic residues on component surfaces, and chemical entities added to component surfaces by processing equipment.
Obviously, liquid-based drug formulations are at highest risk for potential leachables. These include the aforementioned inhalation drug products, as well as injectables and parenterals, ophthalmic solutions, and suspensions. Oral and topical solutions and suspensions, while still considered to be at the highest risk for potential leachables, are considered low risk with respect to route of administration. Aqueous drug formulations also have a lower risk for potential leachables than those that are organic solvent based like MDIs. Although direct contact with primary packaging components is the main source of drug product leachables, indirect contact with secondary packaging components is also a potential source. Notable case studies include the following:
  • Vanillin, a chemical entity associated with lignin (a primary structural polymer in wood), detected at significant levels in aqueous inhalation solution drug products contained in low-density polyethylene containers. It was determined that the source of vanillin was the cardboard shipping containers used as secondary packaging for the LDPE containers, and that aluminum foil overwrap of the containers prevented migration of vanillin through the LDPE into the aqueous drug product.5
  • Photoinitiators, including 1-benzoylcyclohexanol and 2-hydroxy-2-methylpropiophenone, detected above regulatory thresholds in a solid oral dosage form contained in a high-density polyethylene bottle. These photoinitiators were found to derive from the paper label (with ink and coating) used on the plastic bottle. The semi-volatile organic compounds were able to migrate through the HPDE bottle material and into the drug product.6
  • Recalls of drugs such as Risperdal and Tylenol due to odor problems linked to the migration of organic compounds such as 2,4,6-tribromoanisole from treated wooden shipping pallets.7,8
Although safety and performance are emphasized for the container/closure systems of inhalation drug products, protection and compatibility are also significant. For example, the rubber gaskets and seals in an MDI also serve to protect the MDI formulation from moisture ingress, which can reduce the shelf life of certain MDI drug products. Also, as noted above, secondary packaging of inhalation solution plastic containers with foil overwrap prevents migration of volatile organic chemical entities from the environment into the drug formulation. Some MDI metal canisters have an organic coating on their interior surfaces to reduce to possibility of active ingredient particles sticking to the surfaces and affecting the delivered dose, making the canisters more compatible with the drug formulation.

Biological Protein Products

A packaging system or packaging component can be considered incompatible with a drug product formulation if it interacts with that formulation in ways that negatively affect the quality attributes of the formulation, like potency or delivered dose, or the quality attributes of the packaging system or component such as the ability to protect the formulation from the external environment. All dosage form types have potential compatibility issues with packaging systems; however, biological active ingredients such as therapeutic biological proteins may be particularly susceptible to compatibility issues associated with leachables from packaging components, for reasons listed and described by Markovic.2 These include:
  • The very large sizes and complex molecular structures of protein molecules compared with other active ingredient molecules. In addition to amino acid sequences (i.e., primary structure), protein molecules can include secondary structures such as α-helices, tertiary structures such as three-dimensional folding, and quaternary oligomeric structures. Each of these structural elements can be critical to the potency and efficacy of the therapeutic protein;
  • The large surface areas of protein molecules, resulting from their large molecular sizes and complex molecular structures, which include many sites of potential interaction and chemical reactivity with leachables; and
  • The relative complexity of manufacturing processes for therapeutic biological proteins, which allows for contact between active ingredients and numerous materials and components, with the accompanying increased possibilities for leaching.
In addition, therapeutic biological proteins are typically administered with relatively high frequency as sterile injectables of relatively high volume.
In other reports, Markovic has presented various case studies related to compatibility issues with therapeutic biological proteins and leachables, including the following:
  • Chemical degradation (N-terminal) of a therapeutic protein due to the presence of a leached divalent metal cation from a rubber stopper included in a new liquid formulation of the drug product;
  • Foreign particle formation due to barium leaching from glass vials into a drug formulation and reacting with sodium sulfate excipient, forming insoluble barium sulfate crystals; and
  • Protein oxidation followed by aggregation resulting from reaction with leached tungsten oxide salts in a pre-filled syringe container closure/delivery system. 9,10
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CASE STUDY: Leachables and the MDI CFC Transition

In the 1970s, scientific investigations and theories came together to confirm that when chlorofluorocarbons get into the upper regions of the earth's atmosphere, they deplete the amount of ozone in the ozone layer that surrounds the Earth, thus increasing the risk of potentially serious health problems such as skin cancer and cataracts, as well as other health and environmental problems.1,2
The chemistry of ozone depletion involves CFCs drifting from the lower atmosphere, where they are relatively stable, into the upper atmosphere, where they are degraded when solar radiation releases chlorine radicals, which in turn reacts with ozone. At that time, CFCs were used in many ways, two of the more common uses being as refrigerants and as propellants in many types of aerosol products.
In order to lower the risk of health and environmental problems caused by ozone depletion and to help restore the earth’s ozone layer, the Montreal Protocol was adopted in 1987. This agreement restricted the production of CFCs by nations that were party to the agreement. In 1992, the Protocol signatories further agreed that CFC production would be phased out except for so-called “essential uses,” which included their use as propellants in metered dose inhaler drug products. The International Pharmaceutical Aerosol Consortium was formed in 1989 to help address the regulatory consequences of the Montreal Protocol for MDIs and to help manage the CFC transition to alternative propellants such as hydrofluorocarbons, HFAs, and other innovative inhalation dosage forms such as dry powder inhalers.
The timing of the Montreal Protocol and the formation of IPAC coincided with a period of heightened concern by regulatory authorities regarding leachables in MDIs.3 Rubber gaskets and seals that contacted the MDI drug formulation were identified as sources of potential leachables. In 2001, the International Pharmaceutical Aerosol Consortium on Regulation and Science was officially formed as a pharmaceutical industry consortium separate from IPAC. The mission of IPAC-RS was, and continues to be, to advance consensus-based and scientifically driven standards and regulations for inhaled and nasal drug products.4
Responses to the leachables concern and the CFC transition, led by IPAC-RS and individual innovator pharmaceutical manufacturers, in collaboration with packaging component suppliers, included:
  • Initiation of research programs to characterize, and determine the sources of, leachables related to MDIs under development;
  • Consideration of strategies to create “cleaner” MDI container closure system components (e.g., use of peroxide cured rubber, pre-washing rubber components, customized and optimized rubber curing processes, and chemical additive packages); and
  • Development of innovative dosage forms, such as DPIs and aqueous based inhalation sprays, to minimize leachables and replace MDIs.
In addition, beginning in 2001, IPAC-RS led an initiative within the Product Quality Research Institute in which representatives of academia, the pharmaceutical industry, and the FDA worked cooperatively on the leachables issue. This collaboration resulted in a recommendation document titled “Safety Thresholds and Best Practices for Leachables and Extractables Testing in Orally Inhaled and Nasal Drug Products,” which was submitted to the FDA in 2006.5 The document included science and data-based recommendations and best practices for leachables characterization and control in MDIs, as well as other inhalation dosage forms. A new book, titled “Leachables and Extractables Handbook – Safety Evaluation, Qualification, and Best Practices Applied to Inhalation Drug Products,” written and edited by pharmaceutical development scientists involved in IPAC-RS and PQRI, has also recently become available.6
This case study demonstrates that, in many instances, regulation fosters and promotes innovation in both dosage form and packaging system development, to the ultimate benefit of patients and all humanity.—DN

References

  1. International Pharmaceutical Aerosol Consortium. A message about IPAC. Available at: www.ipacmdi.com. Accessed March 25, 2012.
  2. International Pharmaceutical Aerosol Consortium. Ensuring patient care: the role of the HFC MDI. 2nd edition. Available at: www.ipacmdi.com/Ensuring.html. Accessed March 25, 2012.
  3. Schroeder AC. Leachables and extractables in OINDP: An FDA perspective. Paper presented at: The PQRI Leachables and Extractables Workshop; Dec. 5-6, 2005; Bethesda, Md.
  4. International Pharmaceutical Aerosol Consortium on Regulation and Science. IPAC-RS website home page. Available at: www.ipacrs.com. Accessed March 25, 2012.
  5. PQRI Leachables and Extractables Working Group. Safety thresholds and best practices for extractables and leachables in orally inhaled and nasal drug products. Product Quality Research Institute. Sept. 8, 2006. Available at: www.pqri.org/pdfs/LE_Recommendations_to_FDA_09-29-06.pdf. Accessed March 25, 2012.
  6. Ball DJ, Norwood DL, Stults CLM, Nagao LM, eds. Leachables and Extractables Handbook. Hoboken, N.J.: John Wiley and Sons; 2012.

Counterfeit Drugs

The meaning of protection can be taken in a broader context than simple protection of the drug product formulation from environmental or other factors that could potentially reduce shelf life and potency. This broader context might include, for example, protecting patients from safety and efficacy risks associated with counterfeit drug products.
The term “counterfeit” refers to “the theft of a product or brand by reproducing and substituting a similar product.”11 Unlike the legitimate product, however, counterfeit products can contain a reduced amount, or even none, of the active ingredient, as well as potentially higher levels of impurities or a very different impurity profile than the approved product. These issues pose significant potential safety risks for patients who unknowingly take counterfeit drug products. The World Health Organization has reported that the worldwide pharmaceutical market includes approximately 10% counterfeits and up to 50% of branded products in certain countries. It has also been reported that the annual cost to consumers in the United States is around $200 billion. Counterfeit drug products have become a source of funding for both international organized crime and terrorist groups.
Packaging systems and their components can be employed in anti-counterfeiting strategies for drug products. Tamper-evident designs for packaging systems and authentication technologies—both overt and covert—are well established and relatively simple anti-counterfeiting strategies.11,12 Overt authentication technologies are apparent to human senses and are therefore easily detected by patients and pharmacists. These include holograms, microtext, and line-screen printing. Covert technologies, which require instrumentation for detection, include elements that are sensitive to invisible light such as ultraviolet or infrared, nanotext, and hidden images.
A novel covert authentication strategy is potentially available from the leachables profile of the drug product, assuming that the drug product contains a significant and unique leachables profile throughout its shelf life. In principle, the leachables profile is unique to the branded drug product’s primary packaging components.
The future holds the promise of being able to establish a drug product’s “e-pedigree” through use of two-dimensional bar coding or the inclusion of radio frequency identification tags within the packaging system. The reader should be aware that at the time of this writing, the USP-NF has proposed a new General Chapter <1083> entitled “Good Distribution Practices¬ – Supply Chain Integrity,” which addresses counterfeit drug products and the important relationship of packaging systems.

Quality Control

FIGURE 3. Schematic representation of a pharmaceutical packaging system supply chain. (Images provided by Bespak, a division of Consort Medical; www.bespak.com.)
click for larger view
FIGURE 3. Schematic representation of a pharmaceutical packaging system supply chain. (Images provided by Bespak, a division of Consort Medical; www.bespak.com.)
Maintaining quality in the packaging component supply chain first involves understanding the supply chain. Figure 3 shows a schematic of the supply chain for an MDI dose metering valve critical component—for example, a valve stem constructed from polybutyleneterephthalate, or PBT plastic. Packaging component supply chains are typically viewed in reverse, with the drug product manufacturer designated as N.4 Working backward in the chain, the valve assembler would be N-1, the component fabricator or molder N-2, and the synthesizer of the base polymer resin N-3.
In some supply chains for this type of packaging component, the component fabricator and valve assembler are the same, making the resin synthesizer N-2. The pharmaceutical manufacturer has the approved drug product and is responsible for supply chain quality and integrity. Formal quality systems are always in place at the N level and also typically at the N-1 and N-2 levels, with supply and quality agreements established between the N level and the N-1/N-2 levels. Supply agreements cover issues such as security of supply, change management, availability of compliance statements and other supplier information, and material/component testing.13
Security of supply, and the problems associated with both anticipated and unanticipated changes at all levels less than N, are an ever-present challenge in the pharmaceutical industry. A typical scenario might involve an N-3 supplier being required to close an environmentally unfriendly chemical plant and change to a new polymerization process. Even though the new process might produce a superior material of construction for the valve stem, the N-1 supplier would be required to perform various studies on the resulting finished components as well as on assembled valves to ensure physical performance of components molded from the new material of construction.
Further, the drug product manufacturer would be required to ensure that drug product made with valves, including the new stems, performed according to approved specifications and acceptance criteria throughout the approved shelf life of the product. Formal approval of appropriate regulatory authorities after review of submitted documentation is required. Such a “change-control” process often requires years to complete. In order to avoid potential problems with drug product supply, the International Pharmaceutical Aerosol Consortium on Regulation and Science recommends that supply agreements include a 36-month rolling availability of unchanged material.13
IMAGE_CAPTION
FIGURE 4. The quality-by-design “universe.”
The potential supply problems inherent in any change-control situation, along with release testing requirements for individual batches of certain high-risk dosage form components, can be partly ameliorated with a quality-by-design process. In QbD (see Figure 4), a “design space” is created within the sum total of knowledge, or the so-called “knowledge space,” of a process. Design space is the multi-dimensional combination and interaction of design input variables—for example material critical quality attributes, such as elasticity for rubber—and process parameters, like molding temperature for a plastic, that have been demonstrated to provide assurance of quality in a finished product.14 In principle, as long as the process is controlled within an approved design space, then changes could be made within the design space without prior regulatory approval. In addition, release testing of finished products manufactured within the approved design space might not be required. QbD remains a goal rather than a reality in the pharmaceutical packaging industry.

Current Environment

The landscape of pharmaceutical packaging is both broad and diverse. At the center are the drug product manufacturers, whose business it is to produce innovative, safe, and effective medicines to treat disease. Critical to this business are drug product packaging systems, and critical to these packaging systems are the supply chains with all their various levels of individual suppliers. Effective partnerships between drug product manufacturers and packaging component/material suppliers are required to maintain the quality and integrity of the supply chain, particularly related to high-risk dosage forms. Additional partnerships with regulatory authorities, who should provide the most guidance both possible and practical, are also required.
The landscape also includes:
  • Industry consortia, such as the previously mentioned IPAC-RS and the Extractables and Leachables Safety Information Exchange;
  • Scientific organizations such as the Parenteral Drug Association; and
  • Non-governmental standard-setting bodies, such as the U.S. Pharmacopeia/National Formulary.
These groups provide best practice guidances, set standards, create and validate test methods, and provide training in all areas related to pharmaceutical packaging systems. The future suggests even greater width and diversity for the landscape of pharmaceutical packaging, and it is hoped that this brief overview has provided the reader with some appreciation for the current reality and future possibilities.
Dr. Norwood is a distinguished research fellow with Boehringer Ingelheim Pharmaceuticals.

References

  1. U.S. Food and Drug Administration. Center for Drug Evaluation and Research. Center for Biologics Evaluation and Research. Guidance for Industry: Container closure systems for packaging human drugs and biologics: chemistry, manufacturing, and controls documentation. May 1999. Available at: www.fda.gov/downloads/Drugs/GuidanceComplianceRegulatoryInformation/Guidances/ucm070551.pdf. Accessed March 25, 2012.
  2. Markovic I. Evaluation of safety and quality impact of extractable and leachable substances in therapeutic biologic protein products: a risk-based perspective. Expert Opin Drug Saf. 2007;6(5):487-491.
  3. Jenke D. Compatibility of Pharmaceutical Products and Contact Materials: Safety Considerations Associated with Extractables and Leachables. Hoboken, N.J.: John Wiley and Sons; 2009.
  4. Ball DJ, Norwood DL, Stults CLM, Nagao LM, eds. Leachables and Extractables Handbook. Hoboken, N.J.: John Wiley and Sons; 2012.
  5. Conkins D, Economou JE, Boersma JA, Dedhiya MG, Hansen G. Reversed phase-high performance liquid chromatographic (RP-HPLC) method to measure migration of semi-volatile compound, vanillin, in ipratropium bromide inhalation solution. AAPS PharmSci. 1999;1(3):E15.
  6. Fang X, Cherico N, Barbacci D, Harmon AM, Piserchio M, Perpall H. Leachable study on solid dosage form. Am Pharm Rev. 2006;9(7):58, 60-63.
  7. Cerra A. J&J subsidiary recalls one lot of Risperdal, risperidone tablets. DSN Drugstore News online. June 20, 2011. Available at: http://drugstorenews.com/article/jj-subsidiary-recalls-one-lot-risperdal-risperidone-tablets. Accessed March 25, 2012.
  8. PR Newswire. TYLENOL recall confirms Congress, FDA must regulate wood pallets to prevent threats to U.S. food, drug supply. PR Newswire online. Dec. 31, 2009. Available at: www.prnewswire.com/news-releases/tylenol-recall-confirms-congress-fda-must-regulate-wood-pallets-to-prevent-threats-to-us-food-drug-supply-80407777.html. Accessed March 25, 2012.
  9. Markovic I. Challenges associated with extractables and/or leachable substances in therapeutic biological protein products. Am Pharm Rev. 2006;9(6):20-27.
  10. Markovic I. Risk management strategies for safety qualification of extractable and leachable substances in therapeutic biological protein products. Am Pharm Rev. 2009;12(4):96-101.
  11. Forcinio H. Technology advances anticounterfeiting options. PharmTech. 2002:26-34.
  12. U.S. Pharmacopeia/National Formulary. Proposed General Chapter 1083: Good distribution practices¬ – supply chain integrity. Available at: www.usp.org/USPNF/notices/generalChapter1083.html. Accessed March 25, 2012.
  13. International Pharmaceutical Aerosol Consortium on Regulation and Science. Baseline requirements for materials used in orally inhaled and nasal drug products (OINDP). June 22, 2011. Available at: www.ipacrs.com/PDFs/Baseline.pdf. Accessed March 25, 2012.
  14. International Conference on Harmonisation of Technical Requirements for Registration of Pharmaceuticals for Human Use. ICH harmonised tripartite guideline. Pharmaceutical Development Q8(R2). Current Step 4 version. August 2009. Available at: www.ich.org/fileadmin/Public_Web_Site/ICH_Products/Guidelines/Quality/Q8_R1/Step4/Q8_R2_Guideline.pdf. Accessed March 25, 2012.

Editor’s Choice

  1. Jenke D, Odufu A. Utilization of internal standard response factors to estimate the concentration of organic compounds leached from pharmaceutical packaging systems and application of such estimated concentrations to safety assessment. J Chromatogr Sci. 2012;50(3):206-212.
  2. Chan EK, Hubbard A, Hsu CC, Vedrine L, Maa YF. Root cause investigation of rubber seal cracking in pre-filled cartridges: ozone and packaging effects. PDA J Pharm Sci Technol. 2011;65(5):445-456.
  3. Butschli J. Pharmaceutical packaging growth forecast in emerging economies. Healthcare Packaging online. Feb. 22, 2010. Available at: www.healthcarepackaging.com/archives/2010/02/pharmaceutical_packaging_growt.php. Accessed March 25, 2012.

Leachables and Extractables Affect Single-Use and Disposable Systems



Nigel J Smart, PhD

Take steps to limit undesirable effects

Leachables and extractables have become a significant driver in the potential application of single-use and disposable systems. The increase in industry activity associated with these systems and products reflects their perceived relevance and importance for biopharmaceutical drug manufacturing.
Issues connected with the use of leachables and extractables with various plastics and polymers have been discussed for more than 25 years in the pharmaceutical industry, where products have been in widespread use and have been associated with a variety of applications. Many applications have included use in water-based systems such as syringes and various other sealing components, so there is a long history with regulatory authorities such as the FDA.
However, in the past 10 years there has been an explosion in the use of disposable bags, wave bags, disposable plastic bioreactor inserts, and a myriad of associated tubing parts, samplers, and other components.
Some of this growth has been catalyzed by the need for rapid, inexpensive mechanisms for production as well as for prompt deployment of countermeasure products in the case of pandemic disease situations or terrorist attacks in which biological agents are required in significant quantities at very short notice.
The most notable application of disposable systems is in the area of clinical trial material supply, in which relatively small quantities of active drug substance are often required. Producing these materials using disposable systems in openly designed standardized production facilities provides for significant flexibility in the supply of multiple drug agents without the high cost of dedicated-purpose “machine in place” facilities.
This increase in the application of disposable systems for the production of biological drug substances is driving the application of new standards and methodologies.
There is a regulatory requirement to assure that the drug substance and drug products are in no way contaminated or adulterated by materials that could be either leaching from the various polymers used in the construction and fabrication of these new bioreactor systems or, conversely, extracted from these same polymer materials as a result of some elution process occurring due to solvent action.
The relevance of this increased activity related to materials use translates into a potential increase in the probability of, for example, some elastomer eluting from the components or a breakdown product washing off the material into the product stream.
So why is this important?
It is now well recognized in the modern biopharmaceutical industry that disposables and single-use systems can potentially offer significant advantages over conventional production systems. One important advantage includes the probability of rapid product changeovers, reduced or eliminated validation, cleaning validation, and a higher degree of process flexibility. These all propel the possibility of driving lean manufacturing principles into bioprocessing and biopharmaceutical processes, which ultimately leads to more efficient use of resources. Because the potential for driving efficiency and the effective use of resources is high on the agenda of manufacturers, the use of these systems is highly desirable. That said, nothing in life comes without a cost.
The real issue, as previously mentioned, is that if the disposable processing adds something to the product stream, there might be a safety issue for the patient taking the drug. From a regulatory compliance perspective, any unwanted contaminants would render the product adulterated and unsafe for use.

Addressing the Issue

Although the potential for issues with leachables and extractables has been known for decades due to the pharmaceutical industry’s experience with various polymers, this involved their characterization using selected USP tests. Using these tests for extractables profiles, subsequent leachables profiles have been developed based upon these and additional tests.
These generally recognized as safe (GRAS) limits were developed with the assumption that there was no drug interaction; however, with biopharmaceutical products, there have been some examples where an interaction of the leachable with the products has given rise to an increase in immunogenicity. This occurred in the case of EPREX, as reported by Sharma and colleagues as well as Schellekens and Jiskoot.1,2
In cases like this, new pathways of degradation will likely result. If this occurs, existing USP tests may well be ineffective due to interference; new, more specific testing methodologies may need to be developed.
Due to the importance of this issue for the whole biopharmaceutical industry, companies and user groups have pooled their resources to address the issues. Both have a vested interest in making sure that these highly flexible and lean solutions don't become derailed through unaddressed regulatory questions.
At the forefront of these initiatives are several industry associations, including:
  • The Bio-Process Systems Alliance (BPSA), which generally reflects the input and opinions of component suppliers;3-5
  • The Extractables and Leachables Safety Information Exchange (ELSIE), which represents pharmaceutical manufacturers’ experiences with leachables and extractables; and
  • The Product Quality Research Initiative (PQRI), which publishes data connected with extractables and leachables for a variety of pharmaceutical product types.
In particular, the BPSA published a 2010 series of recommendations for testing and evaluating extractables from single-use process equipment, providing a very helpful starting point for biopharmaceutical companies that use this type of technology to manufacture their products.6
Another overview of this area, which opens an interesting window on what the FDA’s Center for Drug Evaluation and Research believes are important issues related to leachables and extractables for single-use systems, was also recently provided by the FDA. This is a must review.7
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Categories of Leachables and Extractables

Although leachables and extractables often have differing mechanisms of interaction, they frequently have well-defined breakdown patterns that can be characteristic of the material degrading. This is very helpful for new materials that degrade by somewhat regular reactions, producing related subsets of breakdown products even when the endpoint is new. Listed here are some common leachables and extractables:
Organics:
  • Polyethylene
  • Polypropylene
  • Polyvinyl chloride
  • Elastomeric materials
Inorganics
These include the following metal ions:
  • Tungsten
  • Iron
  • Aluminum
  • Calcium
  • Barium
  • Boron
  • Silicon
  • Nickel
  • Magnesium

Regulation

As referenced earlier, a plethora of regulations and guidances provide instruction for the assessment of leachables and extractables in pharmaceutical systems. Some useful regulations include the following:
  • 21CFR600.11(b), which references guidance for equipment;
  • 21CFR600.11(h), which refers to containers and closures;
  • 21CFR211.65(a), which refers to equipment construction;
  • ICH Q9 5.1, covering equipment connected to the manufacture of APIs and intermediates; and
  • ICH Q5C, which refers to the stability of biotechnology and biopharmaceutical products.
Navigating these various regulations successfully enables the development of a useful strategy to address potential issues before they can have a detrimental effect on the product.

Useful Definitions

Several characteristics have been identified to help distinguish extractables from leachables. Some of these are listed below:
  • Extractables have been characterized as entities extracted from the component material;
  • Extractables have been characterized as entities occurring as a result of the exaggerated conditions of use;
  • Extractables are produced in organic, water/aqueous, or dried products vehicles; and
  • Extractables have been identified as being useful in predicting leachables.
The following lists some useful characteristics of leachables:
  • Leachables have been described as migrants from the component material;
  • Leachables often occur within the specifications connected with the recommended conditions of use and storage;
  • Leachables occur in the drug product’s vehicle; and
  • Leachables are often, but not always, a subset of extractables.
All this presents some challenges for biopharmaceutical products. Several issues are relevant:
  • Accurate processing and storage conditions must be derived to help reduce and manage the potential for leachable and extractable issues to arise;
  • Suitable limits and ranges for detection analysis and product stability must be defined;
  • Better standards are needed for toxicological characterization to quantify risks; and
  • Appropriate risk management, risk analysis, and risk mitigation strategies are needed to deal with any problems that are detected.
Important considerations that may influence these limits and ranges include those relative to the specific toxicity of the product in question and the intended therapeutic dose of the drug being evaluated. Information about the patient treatment population might also be important. For example, immunocompromised, elderly, or infant patients might be more susceptible to any potential contaminants than mainstream adult populations.

Are They a Problem?

For all new biopharmaceutical products, the FDA will require a comprehensive risk assessment for biologics license application submissions. This includes an analysis of the overall production process for the products, with a plan for data collection from early clinical trials material production through to the BLA submission and new drug application approvals. That plan should include a study that incorporates both accelerated and real-time data studies.
If there is a problem, suppliers and users have a role to play. Suppliers address this by being supportive and providing extractables information about their materials.
Typically, they develop a profile of extractables and identify individual chemical species. Often these are done using alcohol on water-based systems, because these are often the systems in use in biopharmaceutical manufacturing processes. The following points are particularly important to record during this process:
  • Quantitate all extractables using quantitative tests. These should have sufficient sensitivity and specificity to provide accurate results.
  • Provide this data to drug sponsors as an approved statement of the material’s suitability to be used in their processes to produce biopharmaceutical products.
Sponsor companies use this data to develop strategies to look at leachables, which are often a subset of chemical species seen during extraction processes performed by the suppliers.
Leaching processes may occur in a variety of situations, including the following:
  • In upstream systems, which includes media preparation and buffer preparation operations;
  • In midstream process operations, which includes cell culture and fermentation operations;
  • In downstream process operations, which includes concentration of the product and exchange and purification operations;
  • In bulk storage operations, which includes API and formulated bulk; and
  • In drug products storage, which includes final product containers such as vials and pre-filled syringes.

Assess, Mitigate Risk

From the user’s point of view, there is a need to be proactive and characterize the chemical species to assure safety. This involves developing appropriate solutions to potential problems before they arise. The risk assessment required by the FDA needs to be data-driven and will involve the construction of a dossier that will be a compilation of all the relevant information to support the use of the material connected with the manufacture of the product.
Typical components examined during the risk assessment process will include insert liners, filters, bags, containers closures, multiuse assembly components, and other product contacting component surfaces.
Now, using a decision tree-type chart to rank situations that may require action and mitigation, it becomes possible to create an action strategy to deal with these issues.
A series of compendial tests can be used as part of this risk analysis process, including USP 381, which deals with elastomer closures, USP 661 covering containers, USP 87 covering in vitro biological testing, and USP 88 covering in vivo biological testing. By using these, integrated with other information, it is possible to decide which situations probably require mitigation and which involve low risk.
However, it should be noted that compendial methods may not always be adequate for identifying extractables or leachables in the system under consideration, and in situations like this, other methods may be required to identify degradation species. Depending upon the nature of the species being produced during a leachables study, a variety of analysis techniques may be required to accurately identify them. Some techniques that may be used in the identification of these compounds are high performance liquid chromatography, gas chromatography HPLC/mass spectrometry, GC MS, ion chromatography, infrared, and inductively coupled plasma.

Risk and the Process Stream


FIGURE 1: Example of a Risk Assessment Chart for Leachables
In shaping risk assessment practices that are helpful in the development of protein therapeutics, it is important to first quantify the extent of the potential risk and then subsequently ameliorate any possible negative outcomes that are identified.
Figure 1 illustrates a typical risk assessment tool that may be employed in the evaluation of potential issues associated with leachables.
In terms of the process stream, risk is increased when the disposable contact surface is in contact with the product process stream toward the end of the manufacturing process.
This higher risk is highlighted in red in the chart, where there is substantially higher risk associated with any function late in the manufacturing process.
In other circumstances, systems failing existing USP testing regimes will also fall into a higher risk category and will require additional mitigation measures to assure safety and meet prevailing regulatory requirements.
One factor of special note is that excipients and other materials that may be added to the final formulation can increase the potential for leaching and should be monitored carefully. Supplementary decision trees, which deliver a multifactorial analysis that requires individual ranking of factors in terms of their importance on the final outcome, can help with this consideration.
This type of approach should always produce a low-risk outcome. Any other result requires a comprehensive and detailed mitigation strategy that would support the components’ use. Inevitably, this would involve additional extraction of the components and further identification of any resulting chemical species that are produced, using reliable analytical methods.

A Check List

It is important to make sure you develop a complete and accurate dossier of the risk analysis and data package for each component unit or component type to be used in your single-use /disposable manufacturing system.
Remember that toxicity studies do not measure chronic response to potential long-term leachable exposure, so this should be factored into data collection programs. Product end-of-shelf life dating is rarely evaluated clinically, which could be an issue for some systems. As a result, studying the leachables profiles over the life of the product is an important consideration.
Because new supplier information may become available, it is imperative to update the product dossier to keep it current and relevant to your product system. Revisit your system periodically to make sure that nothing has changed over time. Remember that these dossiers are living documents and will require periodic attention to remain accurate, especially if parts of the process are changed or new equipment substituted. Make sure that the team conducting the risk assessment is multidisciplinary so that all aspects of the study are appropriately covered.
Finally, do not overthink the methodology used to analyze whether there is a significant risk. There are many existing methodologies available and documented for this purpose, and it is important that you choose one that fits well with your system needs. Experience teaches us that the best approaches are often the simplest.


References

  1. Sharma B, Ryan MH, Boven K. Reactions to Eprex’s adverse reactions. Nat Biotechnol. 2006;24:1199-1200.
  2. Schellekens H, Jiskoot W. Eprex-associated pure red cell aplasia and leachates. Nat Biotechnol. 2006;24(6):613-614.
  3. Ding W, Martin J. Implementation of single-use technology in biopharmaceutical manufacturing: an approach to extractables and leachables studies, part one–connectors and filters. BioProcess Int; 2008;6(9):34-42.
  4. Ding W, Martin J. Implementation of single-use technology in biopharmaceutical manufacturing: an approach to extractables and leachables studies, part two–tubing and biocontainers. BioProcess Int; 2009;7(5):46-51.
  5. Ding W, Martin J. Implementation of single-use technology in biopharmaceutical manufacturing: an approach to extractables and leachables studies, part three–single-use systems. BioProcess Int; 2010;8(10):52-61.
  6. Bio-Process Systems Alliance. BPSA guides to extractables and leachables from single-use systems. Available at: www.bpsalliance.org/guides.html. Accessed January 28, 2012.
  7. Markovic I. Considerations for extractables and leachables in single-use systems. A risk-based approach. Paper presented at: Parentarel Drug Association Single Use Systems Workshop; June 22-23, 2011; Bethesda, Md.

Editor’s Choice

  1. Sauerborn M, Brinks V, Jiskoot W, Schellekens H. Immunological mechanism underlying the immune response to recombinant human protein therapeutics. Trends Pharmacol Sci. 2010;31(2):53-59.
  2. Rathore N, Rajan RS. Current perspectives on stability of protein drug products during formulation, fill and finish operations. Biotechnol Prog. 2008;24(3):504-514.
  3. Mueller R, Karle A, Vogt A, et al. Evaluation of the immuno-stimulatory potential of stopper extractables and leachables by using dendritic cells as readout. J Pharm Sci. 2009;98(10):3548–3561.
  4. Yu X, Wood D, Ding X. Extractables and leachables study approach for disposable materials used in bioprocessing. BioPharm Int website. Feb. 1, 2008. Available at: www.biopharminternational.com/biopharm/article/articleDetail.jsp?id=490803. Accessed Jan. 23, 2012.
  5. MacDonald JS, Robertson RT. Toxicity testing in the 21st century: a view from the pharmaceutical industry. Toxicol Sci. 2009;110(1):40-46.

Keep Formulations Clean

 Keep Formulations Clean

Testing for leachables and extractables is an absolute necessity for drug manufacturers

In an era of increasing regulation of products, devices, and ingredients, the testing for and identification of leachables and extractables in the drug-manufacturing process is more vital than ever.
Extractables are chemical entities released from a single-use manufacturing or storage component under harsh conditions such as high temperature, strong solvents, or other conditions such as a long exposure time. Leachables are chemical compounds that can be released from, or leached off, a single-use component such as a filter or a storage container into a final drug product when that product has been processed or stored under normal conditions.
The identity of the leachable or extractable depends on the raw materials used in the manufacture of the single-use component and the raw materials used in the pharmaceutical processing of the drug formulation. For example, in polycarbonate bottles, there is a concern about the presence of the leachable Bisphenol A (BPA) leaching into the final drug product.
Extractables derive from any of the plastic components used in the workflow. In general, extractable species fall into three main groups: unreacted or partially reacted monomer, resin additives, and film-processing aids. According to Richard Bhella, product manager for ATMI LifeSciences in Bloomington, Minn., an unreacted monomer is a function of the polymer material and its manufacturing process, so selecting a resin for its ultimate molecular weight range uniformity and low levels of unreacted monomer is important.
Resin additives are typically present to stabilize the base resin against degradation from environmental exposure (antioxidants, UV stabilizers, etc.) and generally do more good than harm. These additives represent the bulk of the leachable and extractable (L&E) species encountered in a typical bioprocess film, but normally at extremely low levels (in parts per billion) and are thus generally tolerable. Lastly, film processing aids—added to allow faster or more efficient film extrusion—are the most common L&E risk present in disposables and thus their use should be minimized.
“The type and quantity of chemicals that can become leached or extracted from a polymer film depend substantially on the type and purity of the resin used to make the contact film,” says Bhella. For example, folder films with ethylene vinyl acetate contact layer produces significantly higher levels of L&E than the newer polyethylene films.

Testing for L&E

Testing can be performed by either the disposables manufacturer or the end user. “When we talk to customers that purchased disposable components from a vendor without receiving extractables or leachables data from that vendor, we always recommend that they, the customer, gets the testing done,” says Laura Okhio, director of validation services for Sartorius Stedim North America in Atlanta, Ga. Most users prefer to have a company such as Sartorius Stedim perform the testing.
Sartorius Stedim performs testing for leachables in the following way: Each study is conducted with a negative (or “blank”) control exposed to the same extraction conditions as the sample and provides the basis of comparison for the study. The blank is the drug formulation that has not been in contact with the single-use component. Sartorius Stedim performs an extraction for leachables under controlled time and temperature conditions. Then they perform the analysis to make the comparison between the extract and the blank.
“Identification and quantification of L&E species is not particularly challenging, but it does involve the use of a variety of complex and expensive analytical instrumentation; gas and liquid chromatography, mass spectrometry etc. Thus, for most end-users, testing will be outsourced,” says Bhella.
According to Sartorius Stedim’s E&L Strategy Guide, the analytical tools to detect, quantify, and identify extractables and leachables are HPLC-UV and GC-MS. When using HPLC-UV, the detectable compounds are UV active, non/semi-volatiles, hydrophobic, and hydrophilic (unknowns). When GC-MS is used for analysis, they are semi-volatile, volatile, UV, and non-UV active compounds (unknowns). “Other analytical techniques which are non-specific can be applied such as a measurement of the Non-Volatile Residue (NVR) or Total Organic Carbon (TOC). These techniques can provide an overall mass of extractables/leachables, but do not provide specific compound information,” says Okhio.
In their strategy guide, Sartorius Stedim also outlines the procedures for their extractables and leachables studies. For their extractables study, solvents are chosen that mimic those used throughout a customers’ bioprocessing protocol or their product formulation. From the guide, “the test extraction is conducted using exaggerated conditions of time and temperature. For example, an aqueous process/product formulation could be bracketed using water and ethanol at the exaggerated extraction conditions of 72 hours at 50 degrees C. Overall, extractables are conducted with simple extraction media such as low molecular weight alcohol, high pH buffers, low pH buffers, or pure organic solvents.” For the leachables study, the actual process stream solution or final product formulation is used to detect and identify leachables. Again, according to the guide, “the test extraction is conducted using conditions that mimic and target worst-case process/actual parameters.”
According to Sartorius Stedim, leachables studies should be conducted when one or more of the following conditions are met:
  • The extractables testing does not sufficiently bracket the process conditions.
  • The formulation is unusually complex.
  • Liposomes capture organic extractables.
  • Any formulation with more than 10% to 20% organic content, such as polyethylene glycol.
  • When detected extractables have the known potential to cause safety or efficacy issues (e.g., BPA)
  • When the test article is not used in the same configuration as was used for the extractables test.
  • When there is a real or perceived need for direct data or there is high regulatory concern.
“The types of L&E also depend on the solvent being used,” says Bhella, who adds that a polar inorganic solvent like water will extract very different species compared with a non-polar organic solvent like hexane. So the disposables user must assess all liquids that will come in contact with the film’s surface.
Once the results of analysis are received, “if we find [mass spectrometric] peaks that are in the extract but not in the blank, we call that a leachable,” says Okhio. The extractable or leachable to be identified depends on the location of the suspect component relative to the position of the final formulation. The idea here is to ensure that the final product, after coming in contact with all the components (stoppers, stirrers, bottles, et cetera) in the workflow, is free of extractables and leachables that could negatively impact the formulation. “Most of our customers do not perform testing for extractables and leachables at the laboratory scale. They wait until phase two or phase three,” says Okhio.

Why Testing is Necessary

Testing for leachables in the final drug formulation is necessary to ensure that the interaction between the single-use component and the drug formulation does not result in any toxic chemical entities, i.e., it is necessary to ensure that the drug formulation is safe for humans, especially in regards to drugs that are inhaled or injected.
“Whether or not a leachable or extractable is toxic depends on the structure of the materials. It depends on the solution in contact with the components,” says Okhio. Like most disposables manufacturers, Sartorius Stedim does not make the assessment of toxicity but it does give the identity of the leachable or extractable. It is then the end-users’ job to consult with a toxicologist to determine if the amount of that chemical is toxic in their drug formulation. And although there are no specific FDA guidelines for extractables and leachables there are organizations such as the PDA and the BPSA that provide recommendations on how to test for them.
“The guidance from the regulatory authorities can sometimes be maddeningly vague and typically relates to the likely levels in the final drug product dose,” says Bhella. “Thus, a risk-based assessment protocol is more appropriate than a blanket threshold concentration.”
One of the leading advisers on L&E industry standards is BioProcess Systems Alliance, an industry body representing manufacturers and users of bioprocess single-use technologies. “Fortunately, the industry and regulators are starting to realize that the L&E profile of medical-grade polyethylene resins is relatively comparable. As the body of data on these films continues to grow, the trend will be towards more and more comfort with their interchangeability,” says Bhella.
Finally, Bhella notes that ATMI LifeSciences, in response to the industry’s concern with L&E, now offers all their single-use bags made from ATMI’s “universal” TK8 bioprocess film. The goal of the new offering is to use the same contact material in all applications, streamlining the film validation process as much as possible.


Editor’s Choice

  1. Wakankar AA, Wang YJ, Canova-Davis E, set al. On developing a process for conducting extractable–leachable assessment of components used for storage of biopharmaceuticals. J Pharm Sci. 2010 May;99(5):2209–2218.
  2. Rathore N, Rajan, RS. Current perspectives on stability of protein drug products during formulation, fill and finish operations. Biotechnology Progress. 2008 May/June;24(3):504–514.
  3. Kauffman JS. Identification and risk-assessment of extractables and leachables. Pharmaceutical Technology, 2006. Available at http://pharmtech.findpharma.com/pharmtech/Validation+and+compliance/Identification-and-Risk-Assessment-of-Extractables/ArticleStandard/Article/detail/309314. Accessed Dec. 3, 2011.
  4. Yu X, Wood D, Ding X. Extractables and leachables study approach for disposable materials used in bioprocessing. BioPharm International. 2008 Feb;21(2):42-51.
  5. Qiu F, Norwood DL. Identificatio

Sunday, April 22, 2012

The Perfect Pediatric Pill?



Maybelle Cowan-Lincoln

Oral Disintegrating Tablets Make Dosing Challenges for Children Disappear

Pediatric patients present unique challenges when it comes to administering medications. Solid oral dosing forms are particularly difficult for this population; children under four cannot swallow tablets, and capsules are often not an option until after 12 years of age. Many young patients also experience a fear of choking that can make taking any kind of pill nearly impossible.1
To overcome these issues, liquid formulations have been the standard dosing form for children. However, liquids have shortcomings of their own. Solubility can be an obstacle for both the excipients and the active ingredients, and stability may present a problem when a drug requires taste-masking additives or preservatives.
In addition, liquid medications are particularly vulnerable to dosing errors. A study conducted by Regions Hospital in St. Paul, Minn., illustrated how prevalent these mistakes can be. In this study, the most commonly used dosing device was the household teaspoon. However, this tool is hardly accurate, as teaspoons can vary in volume from 2 mL to 10 mL. Even using the same spoon, different users can deliver doses ranging from 3 mL to 7 mL. Consequently, since 1975, the American Academy of Pediatrics has strongly recommended against using household teaspoons for measuring liquid medications.2
Specially designed dosing devices such as dosing cups and cylindrical spoons appear promising but do not solve the problem. In the Minnesota study, some participants confused the markings on a dosing cup for teaspoons and tablespoons, and the cylindrical spoon increased the risk of spillage.
Similar to the action of a cotton candy machine, centrifugal action creates a floss which is then cooled, partially recrystallized, and finally compressed into ODTs.
Another potential dosing error can result from misinterpreting the dosing chart on the liquid medication package. If a child’s weight is discordant with his/her age, the weight should be used to determine the correct dose. However, parents or caregivers may use the child’s age, resulting in either an overdose or a therapeutically inadequate amount.
Beyond dosing accuracy, another challenge presented by liquids is taste masking. When drug developers are choosing medication flavors to cover the taste of an active ingredient, they must consider the fact that the pediatric palate responds to flavors very differently than that of an adult. Choosing tastes is made more complicated by cultural factors—different flavors are favored by the populations of different countries, and medications incorporating flavors that are regionally popular are considered more palatable in those regions. But, while a pleasant taste can help with compliance, manufacturers must be careful to avoid encouraging overconsumption by making medicine taste too much like a sweet treat.3
Newer dosing forms have emerged to meet the challenges posed by pediatric patients. One technology is the oral disintegrating tablet, a solid dosing form that disintegrates in the mouth within five to 30 seconds without chewing or liquids. Because this type of formulation does not require swallowing, it offers a significant advantage for children. In addition, the drug can be absorbed in multiple places in the gastrointestinal tract, from the pharynx down, resulting in greater bioavailability than traditional oral dosing technologies.4-6
continues below...

Case Study: Fast-Acting Oral Thin Films Show Promise

Another oral delivery system that can effectively meet the challenges of the pediatric population is the oral thin film. These fast-dissolving, mucoadhesive films are composed of the active ingredient, polymers, plasticizers, and surfactants, along with colors and flavorings to make the experience palatable. OTFs usually measure between 2 and 8 cm2 and are placed on or under the tongue, where they rapidly dissolve and release the drug at the application site.1,2
In addition to overcoming the pediatric swallowing challenge, OTFs offer several advantages over ODTs and conventional oral delivery systems. They can provide increased bioavailability for some drugs, potentially improve the onset of action, decrease dosing, and enhance a drug’s efficacy and safety profile. They can also be produced at a cost competitive with that of conventional tableting.
There are numerous methods used to manufacture these minty-flavored wafers. The preferred method is solvent casting, because it employs equipment already common throughout the pharmaceutical manufacturing world. Water-soluble ingredients are dissolved to form a viscous solution; then the active ingredient is dissolved in a small amount of the solution. The solution containing the drug is then mixed with the viscous solution, and any entrapped air is vacuumed out. The final solution is cast as a film, dried, and cut into pieces.3
There are several challenges to achieving commercial scale production of OTFs. A key factor in the process is reaching sufficiently rapid speeds in the coating and drying operations. This can be facilitated by employing enough dryers of the correct type, either horizontal-nozzle, bow, or hot-flue.
Another important consideration for production is taking the proper measures to prevent air and moisture from becoming entrapped in the film. Air in the OTFs would produce an uneven surface, and water would affect properties such as tensile strength, flexibility, and folding endurance.
OTFs offer the pharmaceutical industry an attractive alternative to oral dosing form. They are portable, easy to use, and convenient, and they can be manufactured on equipment already used by drug manufacturers. —MCL

References

  1. Malke S, Shidhaye S, Desai J, Kadam V. Oral films – patient compliant dosage form for pediatrics. The Internet Journal of Pediatrics and Neonatology. Available at: www.ispub.com/journal/the-internet-journal-of-pediatrics-and-neonatology/volume-11-number-2/oral-films-patient-compliant-dosage-form-for-pediatrics.html. Accessed March 13, 2012.
  2. Arya A, Chandra A, Sharma V, Pathak K. Fast dissolving oral films: an innovative drug delivery system and dosage form. Int J ChemTech Res. 2010;2(1):576-583.
  3. Greb E. Are orally dissolving strips easy for manufacturers to swallow? PharmTech.com. Jan. 21, 2009. Available at: http://license.icopyright.net/user/viewFreeUse.act?fuid=MTU0OTgxMTg%3D. Accessed March 13, 2012.
The ODT dosing form is a viable option for numerous active ingredients. As long as a drug is water soluble, is permeable, and can be dosed at less than 20 mg, it is a candidate for delivery as an ODT. Taste is an important factor as well—because the tablet is dissolving in the mouth, it must be possible to mask the drug’s taste.7
Several widely prescribed pediatric medications are currently marketed as ODTs: Prevacid, an antiulcerative; Zofran, an antiemetic indicated to prevent the nausea and vomiting associated with chemotherapy; and Clarinex RediTabs, an antihistamine. In addition to these prescription brands, OTC products include Claritin RediTabs, Alavert, and Triaminic.
There are two main types of ODT formulations. The first is a loosely compressed tablet manufactured using conventional tableting technology with lesser degrees of compaction, combined with water-soluble excipients and/or powerful disintegrants. The second type is a very porous, lyophilized (freeze-dried) formulation. Both categories exploit the rapid uptake of saliva to achieve fast disintegration.
There are numerous processes used to manufacture the loosely compressed ODTs. One popular method is called the cotton candy process. The active ingredient is combined with sugar alcohols such as mannitol or sorbitol and melted. Similar to the action of a cotton candy machine, centrifugal action creates a floss which is then cooled, partially recrystallized, and finally compressed into ODTs.
The lyophilization process involves trapping a drug in a matrix of fast-dissolving excipients including saccharides, gums and collapse protectants.
Another method combines super disintegrants with highly volatile ingredients such as camphor or menthol. Once the active ingredient is added, the mixture is compressed into tablets and the volatile substances are removed by sublimation, leaving a very porous and easily disintegrating ODT. A simpler technique involves blending sugar alcohols with active ingredients and excipients, including solidifying agents, and then melting them together. The molten mixture is then poured into blister packaging wells and dried.
Alternatively, the lyophilization process involves trapping a drug in a matrix of fast-dissolving excipients including:
  • Saccharides to add hardness and pleasant texture;
  • Gums to impart stability; and
  • Collapse protectants to prevent long-term shrinkage.
The ingredients are dissolved in water and the solution is poured into blister packs—or another unit dosing form—and freeze dried. This process avoids heating, making it suitable for drugs that would be adversely affected by elevated temperatures.

References

  1. U.S. Department of Health and Human Services. Development of appropriate pediatric formulations and drug delivery systems SBIR (R43) application. Available at: http://grants.nih.gov/grants/guide/pa-files/PAR-11-304.html. Accessed March 13, 2012.
  2. Madlon-Kay DJ, Mosch FS. Liquid medication dosing errors. The Journal of Family Practice online. Available at: www.jfponline.com/Pages.asp?AID=2582. Accessed March 13, 2012.
  3. Gauthier P, Cardot JM. Developing drugs for children and the adjustment of medication – is it a new challenge or an adaptation of past ideas? Journal of Personalized Medicine online. Available at: www.mdpi.com/2075-4426/1/1/5/. Accessed March 13, 2012.
  4. Banbury S, MacGregor K. Fast-dispersing dosage forms for the pediatric market. Drug Deliv Technol. 2011;11(2):32-35.
  5. Stoltenberg I, Winzenburg G, Breitkreutz J. Solid oral dosage forms for children – formulations, excipients and acceptance issues. Journal of Applied Therapeutic Research. Available at: www.euromedcommunications.com/files/products/Stoltenberg%20Winzenburg%20Breitkreutz.pdf. Accessed March 13, 2012.
  6. Goel H, Rai P, Rana V, Tiwary A. Orally disintegrating systems: innovations in formulation and technology. Recent Pat Drug Deliv Formul. 2008;2(3):258-274.
  7. Strickley RG, Iwata Q, Wu S, Dahl TC. Pediatric drugs – a review of commercially available oral formulations. J Pharm Sci. 2008;97(5):1731-1774.

Editor's Coice

  1. Parkash V, Maan S, Yadav SK, et al. Fast disintegrating tablets: Opportunity in drug delivery system. J Adv Pharm Technol Res. 2011;2(4):223-235.
  2. Ascher-Svanum H, Furiak NM, Lawson AH, et al. Cost-effectiveness of several atypical anti-psychotics in orally disintegrating tablets compared with standard oral tablets in the treatment of schizophrenia in the United States [published online ahead of print Feb. 21, 2012]. J Med Econ.
  3. Solanki SS, Dahima R. Formulation and evaluation of aceclofenac mouth-dissolving tablet. J Adv Pharm Technol Res. 2011;2(2):128-131.
  4. Kondo K, Niwa T, Ozeki Y, Ando M, Danjo K. Preparation and evaluation of orally rapidly disintegrating tablets containing taste-masked particles using one-step dry-coated tablets technology. Chem Pharm Bull (Tokyo). 2011;59(10):1214-1220.
  5. Gryczke A, Schminke S, Maniruzzaman M, Beck J, Douroumis D. Development and evaluation of orally disintegrating tablets (ODTs) containing ibuprofen granules prepared by hot melt extrusion. Colloids Surf B Biointerfaces. 2011;86(2):275-284.