Steven L. Nail

Controlled nucleation in freeze-drying: Effects on pore size in the dried product layer, mass transfer resistance, and primary drying rate

A novel and scalable method has been developed to enable control of the ice nucleation step for the freezing process during lyophilization. This method manipulates the chamber pressure of the freeze dryer to simultaneously induce nucleation in all product vials at a desired temperature. The effects of controlled nucleation on the drying rate of various formulations including 5% (w/w) mannitol, 5% (w/w) sucrose, and a mixture of 3% (w/w) mannitol and 2% (w/w) sucrose were studied. For a 5% (w/w) mannitol, uncontrolled ice nucleation occurred randomly at product temperatures between -8.0°C and -15.9°C as the vials were cooled to -40°C. Controlled ice nucleation was achieved at product temperatures between -2.3°C and -3.7°C. The effect of nucleation control on the effective pore radius (r(e) ) of the cake was determined from the product temperature profiles using a pore diffusion model in combination with a nonlinear parameter estimation approach reported earlier. Results show that the value of r(e) for 5% (w/w) mannitol was enlarged from 13 to 27 μm by uniformly inducing nucleation at higher temperatures. Applying the resistance parameters obtained from the pore diffusion model for 5% (w/w) mannitol, optimized cycles were theoretically generated and experimentally tested, resulting in a 41% reduction in primary drying time.

Rapid Determination of Vial Heat Transfer Parameters Using Tunable Diode Laser Absorption Spectroscopy (TDLAS) in Response to Step-Changes in Pressure Set-Point During Freeze-Drying

The purpose of this study was to perform a rapid determination of vial heat transfer parameters, that is, the contact parameter K(cs) and the separation distance l(v), using the sublimation rate profiles measured by tunable diode laser absorption spectroscopy (TDLAS). In this study, each size of vial was filled with pure water followed by a freeze-drying cycle using a LyoStar II dryer (FTS Systems) with step-changes of the chamber pressure set-point at to 25, 50, 100, 200, 300, and 400 mTorr. K(cs) was independently determined by nonlinear parameter estimation using the sublimation rates measured at the pressure set-point of 25 mTorr. After obtaining K(cs), the l(v) value for each vial size was determined by nonlinear parameter estimation using the pooled sublimation rate profiles obtained at 25 to 400 mTorr. The vial heat transfer coefficient K(v), as a function of the chamber pressure, was readily calculated, using the obtained K(cs) and l(v) values. It is interesting to note the significant difference in K(v) of two similar types of 10 mL Schott tubing vials, primary due to the geometry of the vial-bottom, as demonstrated by the images of the contact areas of the vial-bottom.

Computational Analysis of Fluid Dynamics in Pharmaceutical Freeze-Drying

Analysis of water vapor flows encountered in pharmaceutical freeze-drying systems, laboratory-scale and industrial, is presented based on the computational fluid dynamics (CFD) techniques. The flows under continuum gas conditions are analyzed using the solution of the Navier-Stokes equations whereas the rarefied flow solutions are obtained by the direct simulation Monte Carlo (DSMC) method for the Boltzmann equation. Examples of application of CFD techniques to laboratory-scale and industrial scale freeze-drying processes are discussed with an emphasis on the utility of CFD for improvement of design and experimental characterization of pharmaceutical freeze-drying hardware and processes. The current article presents a two-dimensional simulation of a laboratory scale dryer with an emphasis on the importance of drying conditions and hardware design on process control and a three-dimensional simulation of an industrial dryer containing a comparison of the obtained results with analytical viscous flow solutions. It was found that the presence of clean in place (CIP)/sterilize in place (SIP) piping in the duct lead to significant changes in the flow field characteristics. The simulation results for vapor flow rates in an industrial freeze-dryer have been compared to tunable diode laser absorption spectroscopy (TDLAS) and gravimetric measurements.

Quality by design in formulation and process development for a freeze-dried, small molecule parenteral product: a case study

A case study has been developed to illustrate one way of incorporating a Quality by Design approach into formulation and process development for a small molecule, freeze-dried parenteral product. Sodium ethacrynate was chosen as the model compound. Principal degradation products of sodium ethacrynate result from hydrolysis of the unsaturated ketone in aqueous solution, and dimer formation from a Diels–Alder condensation in the freeze-dried solid state. When the drug crystallizes in a frozen solution, the eutectic melting temperature is above −5°C. Crystallization in the frozen system is affected by pH in the range of pH 6–8 and buffer concentration in the range of 5–50 mM, where higher pH and lower buffer concentration favor crystallization. Physical state of the drug is critical to solid state stability, given the relative instability of amorphous drug. Stability was shown to vary considerably over the ranges of pH and buffer concentration examined, and vial-to-vial variability in degree of crystallinity is a potential concern. The formulation design space was constructed in terms of pH and drug concentration, and assuming a constant 5 mM concentration of buffer. The process design space is constructed to take into account limitations on the process imposed by the product and by equipment capability.

Influence of ethanol on physical state of freeze-dried mannitol.

PurposeThe purpose of this study is to characterize freeze-dried mannitol prepared from an ethanol-containing solution as a function of the ethanol ratio, mannitol concentration, and annealing in the freeze-drying cycle.MethodsThe characteristics of the freeze-dried mannitol were evaluated by X-ray diffractometry (XRD) and differential scanning calorimetry (DSC). The reconstitution time was measured for the freeze-dried solids as well as the residual moisture and ethanol by Karl–Fischer titration and gas chromatography, respectively.ResultsThe XRD pattern of 5% (w/v) mannitol freeze-dried from aqueous solution with no annealing cycle showed all the five characteristic peaks at 13.6° and 17.2° 2θ for the α polymorph, at 14.6° and 23.4° 2θ for the β polymorph and at 9.7°2θ for the δ polymorph. The addition of ethanol to the initial solutions resulted in only a peak at 9.7° 2θ, indicating the presence of only the δ polymorph, regardless of the ethanol ratio in the initial solutions used [10, 20, 30, and 40% (v/v)]. However, annealing during freeze-drying influenced the XRD pattern; in particular, for the solid prepared from the 10% ethanol solution. Annealing of the 10% ethanol solution promoted the formation of the α polymorph and produced a different peak that might be attributable to another polymorph. In DSC thermograms, an endotherm and a subsequent exotherm were found in the temperature range of 150°C to 160°C, which corresponded to the transition of the δ form to α or β forms. The magnitude of this transition was smaller as the ethanol ratio increased for the solids from ethanol-containing solutions with an annealing cycle. In other words, annealing of the ethanol-containing solutions promoted δ polymorph formation in the lyophiles. In addition, the mannitol concentration affected the polymorphism in freeze-dried solids prepared from aqueous and 10% ethanol solutions. Addition of ethanol in the initial solution, in particular, at a lower ethanol level (10% v/v), and a higher concentration of mannitol could also promote the generation of lumps in freeze-dried solids during reconstitution, and result in longer reconstitution time. The residual moisture levels were less than 0.5%, and residual ethanol levels were less than 0.1%, irrespective of the formulation used.ConclusionsThe physical state and reconstitution time of the freeze-dried mannitol appears to be a complex function of the ethanol and mannitol concentrations in the initial solution before freeze-drying and of annealing during the freeze-drying process.

Rapid freeze-drying cycle optimization using computer programs developed based on heat and mass transfer models and facilitated by tunable diode laser absorption spectroscopy (TDLAS)

Computer programs in FORTRAN were developed to rapidly determine the optimal shelf temperature, T(f), and chamber pressure, P(c), to achieve the shortest primary drying time. The constraint for the optimization is to ensure that the product temperature profile, T(b), is below the target temperature, T(target). Five percent mannitol was chosen as the model formulation. After obtaining the optimal sets of T(f) and P(c), each cycle was assigned with a cycle rank number in terms of the length of drying time. Further optimization was achieved by dividing the drying time into a series of ramping steps for T(f), in a cascading manner (termed the cascading T(f) cycle), to further shorten the cycle time. For the purpose of demonstrating the validity of the optimized T(f) and P(c), four cycles with different predicted lengths of drying time, along with the cascading T(f) cycle, were chosen for experimental cycle runs. Tunable diode laser absorption spectroscopy (TDLAS) was used to continuously measure the sublimation rate. As predicted, maximum product temperatures were controlled slightly below the target temperature of -25 degrees C, and the cascading T(f)-ramping cycle is the most efficient cycle design. In addition, the experimental cycle rank order closely matches with that determined by modeling.

Recommended Best Practices for Process Monitoring Instrumentation in Pharmaceutical Freeze Drying—2017

Recommended best practices in monitoring of product status during pharmaceutical freeze drying are presented, focusing on methods that apply to both laboratory and production scale. With respect to product temperature measurement, sources of uncertainty associated with any type of measurement probe are discussed, as well as important differences between the two most common types of temperature-measuring instruments—thermocouples and resistance temperature detectors (RTD). Two types of pressure transducers are discussed—thermal conductivity-type gauges and capacitance manometers, with the Pirani gauge being the thermal conductivity-type gauge of choice. It is recommended that both types of pressure gauge be used on both the product chamber and the condenser for freeze dryers with an external condenser, and the reasoning for this recommendation is discussed. Developing technology for process monitoring worthy of further investigation is also briefly reviewed, including wireless product temperature monitoring, tunable diode laser absorption spectroscopy at manufacturing scale, heat flux measurement, and mass spectrometry as process monitoring tools.

Determination of shelf heat transfer coefficients along the shelf flow path of a freeze dryer using the shelf fluid temperature perturbation approach.

The spatial distribution of local shelf heat transfer coefficients, Ks, was determined by mapping the transient temperature response of the shelf surface along the serpentine internal channels of the shelf while the temperature of the heat transfer fluid was ramped from −40° to 40°C. The solution of a first-order non-steady-state differential equation resulted in a predicted shelf surface temperature as a function of the shelf fluid temperature at any point along the flow path. During the study, the shelf surfaces were maintained under a thermally insulated condition so that the heat transfers by gas conduction and radiation were negligible. To minimize heat conduction by gas, the chamber was evacuated to a low pressure, such as 100 mTorr. To minimize heat transfers between shelves, shelves were moved close together, with a gap of approximately 3 mm between any two shelves, because the shelf surface temperatures at corresponding vertical locations of two shelves are virtually equal. In addition, this also provides a shielding from radiation heat transfer from shelf to walls. Local heat transfer coefficients at the probed locations hx (≈Ks) were calculated by fitting the experimental shelf temperature response to the theoretical value. While the resulting values of Ks are in general agreement with previously reported values, the values of Ks close to the inlet are significantly higher than those of other locations of the shelf channel. This observation is most likely attributed to the variation of the flow pattern of heat transfer fluid within the channels.

Subambient Behavior of Mannitol in Ethanol-Water Co-solvent System

PurposeThe purpose of this study is to characterize the freezing behavior of mannitol in ethanol–water co-solvent systems in comparison with the corresponding aqueous solution.MethodsSubambient differential scanning calorimetry (DSC) and microscopy techniques were used to investigate the freezing behavior of mannitol in aqueous solutions and in ethanol–water co-solvent systems.ResultsThe DSC thermogram of the frozen aqueous solution, which was warmed after cooling at 5.0°C/min, consisted of a glass transition, an endothermic transition, and a crystallization exotherm from mannitol, respectively. The thermograms of ethanol-containing solutions were different in view of including some thermal events attributable to ethanol hydrates. The glass transition of amorphous mannitol was also observed in the thermograms, but became unclear with increasing ethanol in the co-solvent system. The microscopy experiments enabled understanding of the subambient behavior of mannitol. Ethanol was largely removed by vacuum drying rather than freeze-drying. In addition, such manipulations as annealing during the freezing process and slower cooling (0.5°C/min) enhanced the crystallization of mannitol in the frozen system.ConclusionsIn the presence of ethanol, crystallization of mannitol was inhibited under subambient conditions. Annealing or slower cooling promoted the crystallization of mannitol during the freezing process.

A proposed rationale and test methodology for establishment of acceptance criteria for vacuum integrity testing of pharmaceutical freeze dryers.

A scientific rationale is proposed for the establishment of acceptance criteria for leak rates in pharmaceutical freeze dryers. A method was developed to determine the quantity of air that could leak into any lyophilizer from the outside while still maintaining Class 100/Grade A microbial conditions. A lyophilizing product is assumed most vulnerable to microbial contamination during secondary drying, when mass transfer of water vapor from product to condenser is minimal. Using the void volume of the dryer, calculated from change in internal pressure when a known volume of air is introduced, and the potential maximum bioburden of the leaked air (based on measured values), calculations can determine the allowable leaked volume of air, the flow rate required to admit that volume in a given time frame, and the pressure rise that would result from the leak over a given testing period. For the dryers in this study, using worst-case air quality conditions, it was determined that a leak resulting in a pressure rise of 0.027 mbar over a 30 min period would allow the dryers to remain in secondary drying conditions for 62 h before the established action level of one colony forming unit for each cubic meter of air space would be reached.