The study presents an integrated approach to characterizing Desethynyl Erlotinib, a process impurity in the synthesis of Erlotinib, a potent EGFR tyrosine kinase (EGFR TK) inhibitor used in lung cancer treatment. A normal phase high-performance thin-layer chromatography (NP-HPTLC) method was developed and validated for the simultaneous profiling of Erlotinib and its Desethynyl Erlotinib impurity. The optimized method utilized ethyl acetate, methanol, and glacial acetic acid (9: 0.5: 0.5 v/v/v) as the mobile phase for effective separation and quantification. The method demonstrated excellent linearity for Erlotinib and its impurity over a concentration range of 200-1200 ng/spot, with R2 values of 0.9979 and 0.9998, respectively. Validation confirmed precision with intra-day and inter-day % RSD values of less than 2% and robustness. The “limits of detection (LOD) and quantification (LOQ)” were 5.18 ng/spot and 15.70 ng/spot for Erlotinib and 7.07 ng/spot and 21.43 ng/spot for the impurity. In-vitro assays against the A549 lung cancer cell line expressing wild-type EGFR tyrosine kinase (WT EGFR TK) showed that the Desethynyl Erlotinib impurity exhibits significant inhibition compared to Erlotinib, suggesting the potential toxicity of the Desethynyl Erlotinib impurity and causing side effects such as diarrhea, skin rashes and interstitial lung disease due to WT EGFR tyrosine kinase (WT EGFR TK) inhibition. Molecular docking and molecular dynamics simulations further corroborated greater stability in the Desethynyl Erlotinib impurity with WT EGFR tyrosine kinase (WT EGFR TK). Clinically, these findings highlight the importance of monitoring and minimizing impurities like Desethynyl Erlotinib to prevent adverse effects and maintain the therapeutic safety of Erlotinib in lung cancer treatment. This research underscores the necessity for rigorous quality control in Erlotinib production to ensure purity and therapeutic effectiveness.
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