Potent Active Pharmaceutical Ingredients Research Articles

A Universal, Continuous Assay for SAM-dependent Methyltransferases.

Enzyme-catalyzed late-stage functionalization (LSF), such as methylation of drug molecules and lead structures, enables direct access to more potent active pharmaceutical ingredients (API). S-adenosyl-l-methionine-dependent methyltransferases (MTs) can play a key role in the development of new APIs, as they catalyze the chemo- and regioselective methylation of O-, N-, S- and C-atoms, being superior to traditional chemical routes. To identify suitable MTs, we developed a continuous fluorescence-based, high-throughput assay for SAM-dependent methyltransferases, which facilitates screening using E. coli cell lysates. This assay involves two enzymatic steps for the conversion of S-adenosyl-l-homocysteine into H2 S to result in a selective fluorescence readout via reduction of an azidocoumarin sulfide probe. Investigation of two O-MTs and an N-MT confirmed that this assay is suitable for the determination of methyltransferase activity in E. coli cell lysates.

Ein universeller, kontinuierlicher Assay für SAM‐abhängige Methyltransferasen

AbstractDie enzymkatalysierte Funktionalisierung (engl.: late‐stage functionalization (LSF)), wie z. B. die Methylierung von Arzneimittelmolekülen und Leitstrukturen, ermöglicht den direkten Zugang zu wirksameren pharmazeutischen Wirkstoffen (API). S‐Adenosyl‐l‐Methionin‐abhängige Methyltransferasen (MTs) können eine Schlüsselrolle bei der Entwicklung neuer Wirkstoffe spielen, da sie die chemo‐ und regioselektive Methylierung von O‐, N‐, S‐ und C‐Atomen katalysieren und damit den herkömmlichen chemischen Wegen überlegen sind. Um geeignete MTs zu identifizieren, haben wir einen kontinuierlichen fluoreszenzbasierten Hochdurchsatzassay für SAM‐abhängige Methyltransferasen entwickelt, der das Screening unter Verwendung von E. coli Zelllysaten erleichtert. Dieser Assay besteht aus zwei enzymatischen Schritten für die Umwandlung von S‐Adenosyl‐l‐Homocystein zu H2S, was zu einer selektiven Fluoreszenzmessung durch Reduktion eines Azidocoumarin‐Sulfidsensors führt. Die Untersuchung von zwei O‐MTs und einer N‐MT bestätigte, dass dieser Assay für die Bestimmung der Methyltransferase‐Aktivität in E. coli Zelllysaten geeignet ist.

Micro-dosing of powders into capsules using a new automated micro-dosing system: effect of powder characteristics and operating conditions on the filling of 0.5 mg–100 mg weights

Objective To demonstrate the applicability of a novel micro-dosing system for precisely filling low powder doses (down to a few mg) into capsules along with weighing the filled powder mass accurately. Methods Ten commonly used pharmaceutical powders, ranging from cohesive to free-flowing, were selected and filled at three target fill weights (0.5, 1, and 10 mg), to investigate the effect of distinct powder properties on the filling performance. The fill weight and variability, filling speed and yield (% and number of conforming capsules out of all capsules collected), as well as the system’s long-term performance were assessed. Results The filling accuracy was found to be good for all investigated powders. In particular, the results demonstrate that the tested powders, including the challenging cohesive ones, could be dosed at standard deviations within 0.23 mg at a 10 mg target weight, within 0.07 mg at a 1 mg target weight, and within 0.05 mg at a 0.5 mg target weight. In all cases, free-flowing powders showed lower standard deviations. Intermediate and cohesive powders had slightly higher standard deviations but were still within an acceptable range. Conclusion The study shows the suitability of the tested micro-dosing system for filling low powder doses into capsules, which is of particular importance for dosing active pharmaceutical ingredients (APIs) directly in capsules, i.e. an API-in-capsule (AIC) approach for clinical trials (often in conjunction with highly potent APIs), and for low-dose powder filling for inhalation applications.

Flamma launches investment campaign

Flamma , a pharmaceutical contract development and manufacturing firm based in Bergamo, Italy, has announced a three-year, $200 million investment program. The company says it will improve a manufacturing site it acquired in Bulciago, Italy, and expand manufacturing of active pharmaceutical ingredients (APIs) at its China location from 200 m 3 to 400 m 3 . It will also add highly potent API manufacturing at its plant in Malvern, Pennsylvania, and technologies including flow chemistry at its headquarters. The company says the expansion supports a strategy of securing domestic supply chains with the ability to transfer projects in China to Europe while pursuing API production for the Chinese market in China.

Breakage Assessment of Lath-Like Crystals in a Novel Laboratory-Scale Agitated Filter Bed Dryer

Agitated filter bed dryer is often the equipment of choice in the pharmaceutical industry for the isolation of potent active pharmaceutical ingredients (API) from the mother liquor and subsequent drying through intermittent agitation. The use of an impeller to promote homogeneous drying could lead to undesirable size reduction of the crystal product due to shear deformation induced by the impeller blades during agitation, potentially causing off-specification product and further downstream processing issues. An evaluation of the breakage propensity of crystals during the initial development stage is therefore critical. A new versatile scale-down agitated filter bed dryer (AFBD) has been developed for this purpose. Carbamazepine dihydrate crystals that are prone to breakage have been used as model particles. The extent of particle breakage as a function of impeller rotational speed, size of clearance between the impeller and containing walls and base, and solvent content has been evaluated. A transition of breakage behaviour is observed, where carbamazepine dihydrate crystals undergo fragmentation first along the crystallographic plane [00l]. As the crystals become smaller and more equant, the breakage pattern switches to chipping. Unbound solvent content has a strong influence on the breakage, as particles break more readily at high solvent contents. The laboratory-scale instrument developed here provides a tool for comparative assessment of the propensity of particle attrition under agitated filter bed drying conditions.

Compression Vehicle: A Technical Review

The compressed dosage forms such as tablets are the most preferred and widely accepted due to their dosing accuracy, compactness, manufacturing efficiency, stability and better patient compliance. Pharmaceutical Diluents or filler binders, usually referred to as Compression vehicles, contribute significantly to the formulation blend, especially in compressed solid dosage forms containing potent active pharmaceutical ingredients. The functionality of these filler binders mainly depends on their physicochemical and mechanical properties. They provide performance characteristics and quality attributes of the compressed solid dosage forms. Understanding the effect of compression vehicles'bulk and particle level properties is of prime importance in optimising various process parameters and unit operations. The mechanical properties of a compression blend viz plasticity, elasticity, viscoelasticity, brittleness, and bonding index play an essential role in the effective compaction of compressed solid dosage forms. In addition to this, the porosity, volume, density or void-volume ratio of compact with applied pressure is required to understand the compaction behaviour of solid to form a compact with well-defined geometry.

A Novel Computational Approach Coupled with Machine Learning to Predict the Extent of Agglomeration in Particulate Processes.

Solid particle agglomeration is a prevalent phenomenon in various processes across the chemical, food, and pharmaceutical industries. In pharmaceutical manufacturing, agglomeration is both desired in unit operations like wet granulation and undesired in unit operations such as agitated filter drying of highly potent active pharmaceutical ingredients (API). Agglomeration needs to be controlled for optimal physical properties of the API powder. Even after decades of work in the field, there is still very limited understanding of how to quantify, predict, and control the extent of agglomeration, owing to the complex interaction between the solvent and the solid particles and stochasticity imparted by mixing. Furthermore, a large size of industrial scale particulate process systems makes it computationally intractable. To overcome these challenges, we present a novel theory and computational methodology to predict the agglomeration extent by coupling the experimental measurements of agglomeration risk zone or "sticky zone" with discrete element method. The proposed model shows good agreement with experiments. Further, a machine learning model was built to predict agglomeration extent as a function of input variables, such as material properties and processing conditions, in order to build a digital twin of the unit operation. While the focus of the present study is the agglomeration of particles during industrial drying processes, the proposed methodology can be readily applied to numerous other particulate processes where agglomeration is either desired or undesired.

Curia to expand Rensselaer facility

Curia plans to spend $35 million to expand the capacity of its facility in Rensselaer, New York. The contract development and manufacturing organization, known until recently as AMRI, aims to more than double the site’s batch production capability for small-molecule active pharmaceutical ingredients (APIs), allowing it to meet growing demand for highly potent APIs. The expansion is expected to be completed in 18 months. Curia has several facilities in the US, as well as plants in France, Spain, Italy, and India.

Investigating hesperetin nanocrystals with tailor-made sizes for the prevention and treatment of Alzheimer\u2019s disease

Poor aqueous solubility of drug substances is associated with poor bioavailability and thus hampers the effective use of many potent active pharmaceutical ingredients. Various strategies to overcome poor solubility are available, whereby drug nanocrystals represent one of the most powerful formulation strategies to enhance the kinetic solubility and dissolution rate of poorly soluble drugs. Nanocrystals are simply obtained by milling large-sized drug powders to sizes < 1 µm. The so obtained nanocrystals possess an increased dissolution rate and kinetic solubility when compared with larger-sized bulk material. The aim of this study was to produce differently sized hesperetin nanocrystals and to investigate the influence of nanocrystal size on the bioefficacy of the natural antioxidant hesperetin in two cell culture models for the prevention and treatment of Alzheimer’s disease. Results showed that the testing of poorly soluble compounds is challenging and requires incredibly careful characterization. Reasons for this are possible changes of the formulations in cell culture media which can occur due to various reasons. If the changes are not considered, results obtained can be misleading and even lead to a false interpretation of the results obtained. Besides, results demonstrate the increase in dissolution rate with decreasing particle size that is especially pronounced with particle sizes < 200 nm. Data also provide clear evidence that smaller nanocrystals with higher kinetic solubility possess higher antioxidant capacity. This results in lower amounts of free radicals in the cell culture models, suggesting that hesperetin nanocrystals, that improve the poor aqueous solubility of hesperetin, are promising for the prevention and treatment of Alzheimer’s disease.Graphical abstract

Direct derivation of the crystalline fraction of highly potent active pharmaceutical ingredients by X-ray powder diffraction

Direct derivation (DD) is a novel Powder X-ray diffraction quantification method based on intensity–composition equation, which can determine the weight fraction of individual phases in a mixture of components by chemical formulas . The DD method was applied to determine crystallinity degree of binary mixtures containing amorphous hydroxypropyl methylcellulose and crystalline monohydrate α-lactose in weight percentage ≤ 15% w/w. Three different scenarios were considered: a) the unit cell parameters of the crystalline phases are available b) the unit cell parameters are unknown but the patterns of pure crystalline and amorphous references are available and c) only the mixtures’ patterns are available. Relative errors in scenarios a and b were comparable and reasonable (<20%), while in c, the crystalline degree was clearly underestimated evidencing the importance of determining the maximum number of crystalline reflections This can be easily achieved when the unit cell parameters and/or the patterns of pure references are available. To simulate the quantification of high potent API, the method was evaluated considering the scenario b, in samples covered by Kapton® film as containment system. In this case, an accurate quantification was achieved by subtracting the film signal from the observed pattern.

Performance Evaluation of a High-Precision Low-Dose Powder Feeder

Highly potent active pharmaceutical ingredients (APIs) and low-dose excipients, or excipients with very low density, are notoriously hard to feed with currently available commercial technology. The micro-feeder system presented in this work is capable of feeding low-dose rates of powders with different particle sizes and flow properties. Two different grades of lactose, di-calcium phosphate, croscarmellose sodium, silicon dioxide, a spray-dried intermediate, and an active ingredient were studied to vary material properties to test performance of the system. The current micro-feeder system is a volumetric feeder combined with a weighing balance at the outlet that measures feeder output rates. Feeding results are shown as a so-called “displacement-feed factor” curve for each material. Since the powder mass and volume are known in the micro-feeder system, in this work, we characterized an observed density variation during processing via a “displacement-feed factor” profile for each of the fed powders. This curve can be later used for calibrating the system to ensure an accurate, constant feed rate and in addition predicting feeding performance for that material at any feed rate. There is a relation between powder properties and feeding performance. Powders with finer particles and higher compressibility show densification during their feeding process. However, powders with larger particles and lower compressibility show both “densification” and “powder bed expansion,” which is the manifestation of dilation and elastic recovery of particles during the micro-feeding process. Through the application of the displacement-feed factor, it is possible to provide precise feeding accuracy of low-dose materials.Graphical abstract

A solution for low-dose feeding in continuous pharmaceutical processes.

Continuous feeding of small quantities of powder is increasingly applied in pharmaceutical manufacturing. With that regard, what is crucial is not only the feasibility, but also the accuracy and stability. To enable stable processing, low amounts of various agents, e.g., lubricants, can be used. Even more important is the exact dosage of highly potent active pharmaceutical ingredients (APIs), which require feed rates within the range of grams per hour. Conventional feeders cannot supply powder at such rates, especially when the material properties are challenging. In this work, a novel micro-feeder was integrated into a continuous manufacturing line and its capability to supply API at feed rates down to one gram per hour was tested. The micro-feeder system is based on the principle of active volumetric displacement: a piston pushes the powder out of the cartridge upwards to the end of a plate, where a scraper places it into the process inlet. In this study, a hot melt extrusion process was used, during which the API was dissolved in a polymer matrix. Samples of the strand were analysed with regard to their content by means of HPLC. The results showed that the novel micro-feeder system can feed powder with good accuracy and reproducibility, indicating its high potential for continuous process implementation.

Seqens adds capacity in France

At an event attended by French president Emmanuel Macron, Seqens inaugurated a facility in Villeneuve-la-Garenne, France, that produces highly potent active pharmaceutical ingredients. Built at a c...

Freeze-drying in protective bags: Characterization of heat and mass transfer

During lyophilisation of highly potent Active Pharmaceutical Ingredients (APIs) potential contamination of the freeze-drier is an important safety issue. Since the stoppers are in semistoppered position during the lyophilization process, API may contaminate the chamber and cross-contamination may occur as well. In this study two protective bags, which enclose each tray and their influence on heat and mass transfer during freeze-drying were investigated. Sublimation tests were performed using either purified water or solutions containing trehalose as well as hydroxypropyl-β-cyclodextrin (HPbCD) as bulking agents. During sublimation tests with purified water both bags clearly influenced heat and mass transfer compared to unpacked reference vials. The bag, which was originally designed to be used for steam sterilization, had a massive impact on drying characteristics. The bag membrane becomes the rate limiting factor, generating a separate compartment within the bag. In this compartment vapor pressure is much higher compared to the chamber pressure during primary drying, leading to altered drying conditions. However, drying was still possible. The other bag, which was specifically designed for lyophilization, also had an impact on drying behavior which could be assigned to the foil between shelf and bottom of the vials. This was detectable as differences in Kv values. Membrane resistance, however, becomes negligible when 10% (w/w) trehalose or HPbCD solutions were dried using the later bag as containment. The data reported in this work demonstrate the relevance and value of sublimation tests to understand the lyophilization process, especially when new components are implemented. The data should be considered, when freeze-drying shall be performed using such bags.

Development of an automated and High throughput UHPLC/MS based workflow for cleaning verification of potent compounds in the pharmaceutical manufacturing environment

Cleaning verification (CV) is a critical step in the pharmaceutical manufacturing process to eliminate or reduce unacceptable contamination of a product as a result of insufficiently cleaned equipment surfaces. The main concern is cross contamination with active pharmaceutical ingredients (APIs) from previous runs that may impact patient safety. Current conventional approaches involve rather tedious sample preparation and analytical methods with relative lengthy analysis time. Potent APIs possessing low acceptable daily intake (ADI) values require analytical methods for CV with very low detection limits to confirm that these APIs are below their acceptance limits prior to the next manufacturing process. In this work, a novel end to end CV workflow was developed, which includes the automated sample and calibration solution preparation as well as high throughput analysis by ultra-high-performance liquid chromatography (UHPLC) coupled with single quadrupole mass spectrometry in multiple injection chromatography and selected ion monitoring mode (MIC-MS-SIM). The method was validated using ten model compounds. Acceptable specificity, linearity (R2 > 0.997) and single digit ng/mL LOQ and LOD were achieved for all model compounds. This approach was also successfully applied to the analysis of 22 internal CV samples from an internal program.

Lonza to boost highly potent drug actives

Lonza plans to increase capacity for highly potent active pharmaceutical ingredients (HPAPIs) by adding two 4 m3 multipurpose production lines at its main site in Visp, Switzerland, by July 2020. The expansion will support a long-term manufacturing agreement with AstraZeneca as well as overall increased HPAPI demand for cancer therapies. “Oncology continues as the leading indication in biopharma,” says Lee Newton, head of Lonza’s API business.

Site-Specific Conjugation of Thiol-Reactive Cytotoxic Agents to Nonnative Cysteines of Engineered Monoclonal Antibodies.

Antibody-drug conjugates (ADCs) have been proven to be a successful therapeutic concept, allowing targeted delivery of highly potent active pharmaceutical ingredients (HPAPIs) selectively to tumor tissue. So far, HPAPIs have been mainly attached to the antibody via a chemical reaction of the payload with lysine or cysteine side chains of the antibody backbone. However, these conventional conjugation technologies result in formation of rather heterogeneous products with undesired properties. To overcome the limitations of heterogeneous ADC mixtures, several site-specific conjugation technologies have been developed over the last years. Originally pioneered by scientist from Genentech with their work on THIOMABs, several engineered cysteine mAb ADCs (ECM-ADCs) are now investigated in clinical trials. Here, we describe in detail how to engineer additional cysteines into antibodies and efficiently use them as highly site-specific conjugation sites for HPAPIs.

Preventing Cross-Contamination during Lyophilization: GMP and Occupational Cleaning Requirements for Nonproduct and Indirect Product-Contact Parts.

A detailed overview is provided for the possible patient exposure to highly potent active pharmaceutical ingredients (HPAPIs) from potential cross-contamination through the lyophilization process. The intent of this paper is to raise awareness of the risk(s) to patients and stimulate the implementation of adequate risk-based controls, such as containment process(es), use of adequate surrogates in cleaning validation/verification, and test method-sensitivity-based cleaning validation acceptance conditions. Although lyophilizers are considered to be nonproduct-contact surfaces because their surfaces and fixtures do not usually come into direct contact with the product, product contamination can occur at critical locations within a lyophilizer and/or during the unloading process. Contamination of the air because of released product particles can also create a risk. Therefore, special attention should be paid to HPAPIs, as the permitted daily exposures (PDEs) for patients are particularly low. During a lyophilizer cycle, areas of concern are spreading of the lyophilizer HPAPI powder because of air turbulence, contaminated plates, mechanical transfer systems, and spreading because of damaged vials or contaminated stainless steel or plastic surfaces. Specific considerations for contamination containment for the lyophilizer unloading process are presented. Suggestions are provided for the prevention of patient exposure through cross-contamination via direct-contact areas and prevention of manufacturing personnel exposure via non-direct-contact areas. A surface limit(s) of 1 PDE per square decimeter for nonproduct-contact surfaces inside a lyophilizer is proposed. Risk-based cleaning validation/verification strategies are discussed, with specific consideration of the quality control test method sensitivity expectations and use of suitable surrogates for lyophilized products in the cleaning verification studies.LAY ABSTRACT: This paper provides an overview of important points to consider during the manufacture of highly potent active pharmaceutical ingredients (HPAPI) with the intention to limit patient exposure and/or manufacturing personnel exposure to these highly toxic HPAPIs. HPAPI can potentially be spread during the freeze-drying process (lyophilization) and may cross-contaminate products. Manufacturing personnel and patients taking other freeze-dried products made in the same lyophilizer could be contaminated. It is therefore necessary to implement rigorous contamination controls. Within the lyophilizer, areas of concern are spreading of the lyophilizer HPAPI powder because of air turbulence, contaminated plates, mechanical transfer systems, and spreading because of damaged vials or contaminated stainless steel or plastic surfaces. Cleaning validation/verification studies, intended to demonstrate sufficient cleanability of the freeze-drying process as well as the recommended test method sensitivity to detect these highly toxic HPAPIs, are reviewed. Limits for the relevant production surface areas where cross-contamination and/or personnel exposure (through direct contact) could occur are proposed in this paper.

An investigation into the effects of excipient particle size, blending techniques and processing parameters on the homogeneity and content uniformity of a blend containing low-dose model drug.

Powder blend homogeneity is a critical attribute in formulation development of low dose and potent active pharmaceutical ingredients (API) yet a complex process with multiple contributing factors. Excipient characteristics play key role in efficient blending process and final product quality. In this work the effect of excipient type and properties, blending technique and processing time on content uniformity was investigated. Powder characteristics for three commonly used excipients (starch, pregelatinised starch and microcrystalline cellulose) were initially explored using laser diffraction particle size analyser, angle of repose for flowability, followed by thorough evaluations of surface topography employing scanning electron microscopy and interferometry. Blend homogeneity was evaluated based on content uniformity analysis of the model API, ergocalciferol, using a validated analytical technique. Flowability of powders were directly related to particle size and shape, while surface topography results revealed the relationship between surface roughness and ability of excipient with high surface roughness to lodge fine API particles within surface groves resulting in superior uniformity of content. Of the two blending techniques, geometric blending confirmed the ability to produce homogeneous blends at low dilution when processed for longer durations, whereas manual ordered blending failed to achieve compendial requirement for content uniformity despite mixing for 32 minutes. Employing the novel dry powder hybrid mixer device, developed at Aston University laboratory, results revealed the superiority of the device and enabled the production of homogenous blend irrespective of excipient type and particle size. Lower dilutions of the API (1% and 0.5% w/w) were examined using non-sieved excipients and the dry powder hybrid mixing device enabled the development of successful blends within compendial requirements and low relative standard deviation.

Cerbios opens Swiss R&amp;D center

The pharmaceutical services firm Cerbios-Pharma has opened an R&D center at its headquarters in Lugano, Switzerland, for the development of highly potent active pharmaceutical ingredients and monoclonal antibodies. The four-story, 1,120-m2 facility will house separate laboratories dedicated to biologics and small-molecule APIs manufactured to FDA’s current Good Manufacturing Practice quality standard.