The search for novel proline analogs for viscosity reduction and stabilization of highly concentrated monoclonal antibody solutions.

Administration of monoclonal antibodies (mAbs) is currently focused on subcutaneous injection associated with increased patient adherence and reduced treatment cost, leading to sustainable healthcare. The main bottleneck is low volume that can be injected, requiring highly concentrated mAb solutions. The latter results in increased solution viscosity with pronounced mAb aggregation propensity because of intensive protein-protein interactions. Small molecule excipients have been proposed to restrict the protein-protein interactions, contributing to reduced viscosity. The aim of the study was to discover novel compounds that reduce the viscosity of highly concentrated mAb solution. First, the chemical space of proline analogs was explored and 35 compounds were determined. Viscosity measurements revealed that 18 proline analogs reduced the mAb solution viscosity similar to or more than proline. The compounds forming both electrostatic and hydrophobic interactions with mAb reduced the viscosity of the formulation more efficiently without detrimentally effecting mAb physical stability. A correlation between the level of interaction and viscosity-reducing effect was confirmed with molecular dynamic simulations. Structure rigidity of the compounds and aromaticity contributed to their viscosity-reducing effect, dependent on molecule size. The study results highlight the novel proline analogs as an effective approach in viscosity reduction in development of biopharmaceuticals for subcutaneous administration.

Freeze-dried nanocrystal dispersion of novel deuterated pyrazoloquinolinone ligand (DK-I-56-1): Process parameters and lyoprotectant selection through the stability study.

Recently, nanocrystal dispersions have been considered as a promising formulation strategy to improve the bioavailability of the deuterated pyrazoloquinolinone ligand DK-I-56-1 (7­methoxy-2-(4­methoxy-d3-phenyl)-2,5-dihydro-3H-pyrazolo[4,3-c]quinolin-3-one). In the current study, the freeze-drying process (formulation and process parameters) was investigated to improve the storage stability of the previously developed formulation. Different combinations of lyoprotectant (sucrose or trehalose) and bulking agent (mannitol) were varied while formulations were freeze-dried under two conditions (primary drying at -10 or -45 °C). The obtained lyophilizates were characterized in terms of particle size, solid state properties and morphology, while the interactions within the samples were analyzed by Fourier transform infrared spectroscopy. In the preliminary study, three formulations were selected based on the high redispersibility index values (around 95%). The temperature of primary drying had no significant effect on particle size, but stability during storage was impaired for samples dried at -10 °C. Samples dried at lower temperature were more homogeneous and remained stable for three months. It was found that the optimal ratio of sucrose or trehalose to mannitol was 3:2 at a total concentration of 10% to achieve the best stability (particle size < 1.0 µm, polydispersity index < 0.250). The amorphous state of lyoprotectants probably provided a high degree of interaction with nanocrystals, while the crystalline mannitol provided an elegant cake structure. Sucrose was superior to trehalose in maintaining particle size during freeze-drying, while trehalose was more effective in keeping particle size within limits during storage. In conclusion, results demonstrated that the appropriate combination of sucrose/trehalose and mannitol together with the appropriate selection of lyophilization process parameters could yield nanocrystals with satisfactory stability.

Application of Quality by Design Principles to the Development of Oral Lyophilizates Containing Olanzapine.

Oral lyophilizates are intended for application to the oral cavity or for dispersing in water. The purposes of this research were: (i) to set up the quality by design approach in the development of oral lyophilizates for drug incorporation; and (ii) to evaluate the established approach by comparing its outcomes with experimentally obtained results. Within the knowledge space, properties about drugs, excipients, and the lyophilization process were acquired, followed by the determination of critical quality attributes via risk identification. Risks were assessed by failure mode and effective analysis, which recognized critical material attributes, i.e., type, concentration, particle size, solubility of drug and excipients, while as main critical process parameters, cooling rate, shelf temperature, and chamber pressure during drying were pointed out. Additionally, design space was established using the Minitab® 17 software and valued with an 88.69% coefficient of determination. A detailed comparison between the model and experimental results revealed that the proposed optimal compositions match in the total concentration of excipients (6%, w/w) in the pre-lyophilized liquid formulation, among which mannitol predominates. On the other hand, a discrepancy regarding the presence of gelatin was detected. The conclusion was that the set model represents a suitable onset toward optimization of drug-based oral lyophilizates development, preventing unnecessary investment of time and resources.

Excipients in freeze-dried biopharmaceuticals: Contributions toward formulation stability and lyophilisation cycle optimisation.

Biopharmaceuticals are one of the fastest growing areas within the pharmaceutical industry. As protein drugs require parenteral administration, they are commonly formulated as aqueous solutions. However, this is not always feasible due to their general instability. In such cases, lyophilised powders for injection are the dosage form of choice, for the preparation of stable products. Lyophilisation is known to be highly time and energy consuming, and hence it is an expensive technological process. Thus, the pharmaceutical industry is increasingly focused on its optimisation. Implementation of aggressive conditions, together with optimisation of formulation parameters, represent the contemporary approach to reduction of the primary drying time. As such, incorporation of drug-specific excipients can contribute significantly to the stability of a biologically active ingredient, and indirectly they can also affect the time needed for lyophilisation. The addition of the most relevant protein stabilisers, surfactants, buffers and bulking agents is therefore crucial. The main aim of the present review is to define the most important groups of biopharmaceutical excipients, based on their roles in formulations and the mechanism(s) through which they support the lyophilisation process, to provide products with the required protein efficiency and product characteristics. The scope of the article is to critically discuss the suitability of novel stabilizers, with higher critical temperatures and bulking agents in terms of implementation of aggressive primary drying. For better assignment of the topic-related challenges, the stabilities of biopharmaceutical drugs and the fundamentals of the lyophilisation process are also briefly described.

The formation and effect of mannitol hemihydrate on the stability of monoclonal antibody in the lyophilized state.

Crystalline bulking agent in lyophilized biopharmaceutical formulations provides an elegant lyophilized cake structure and allows aggressive primary drying conditions. The interplay between amorphous and crystalline state of excipients heavily influence the stability of lyophilized biological products and should be carefully evaluated in the formulation and process development phase. This study focuses on: (1) elucidating the influence of formulation and lyophilization process variables on the formation of different states of mannitol and (2) its impact on model monoclonal antibody stability when compared to sucrose. The main aim of the present research work was to study the influence of different mannitol to sucrose ratios and monoclonal antibody concentrations on mannitol physical form established during lyophilization. In addition, also the effect of process variables on mannitol hemihydrate (MHH) formation was under investigation. Thermal analysis and powder X-ray diffraction results revealed that the ratio between sucrose and mannitol and mAb concentration have a decisive impact on mannitol crystallization. Namely, increasing amount of mannitol and monoclonal antibody resulted in decreasing formation of MHH. From the process parameters investigated, a higher secondary drying temperature has the biggest impact on the complete dehydration of MHH. Specifically, higher secondary drying temperature reflected in complete dehydration of MHH. Annealing temperature was shown to affect the MHH content in the final product, wherein the higher annealing temperature was preferential for formation of anhydrous mannitol. Temperature stress stability study revealed that the most important parameter influencing monoclonal antibody stability is the ratio of protein to sucrose. Contrary to widespread assumption, we did not detect any impact of MHH on the stability of the investigated monoclonal antibody.

Aggressive conditions during primary drying as a contemporary approach to optimise freeze-drying cycles of biopharmaceuticals.

Freeze-drying is the method of choice to dry formulations with biopharmaceutical drugs, to enhance protein stability. This is usually done below the glass transition temperature of maximally freeze-concentrated solutions (Tg'), to avoid protein aggregation, preserve protein activity, and obtain pharmaceutically 'elegant' cakes. Unfortunately, this is a lengthy and energy-consuming process. However, it was recently shown that drying above Tg' or even above the collapse temperature (Tc) is not necessarily detrimental for stability of biopharmaceuticals, and hence provides an attractive option for freeze-drying cycle optimisation. The goal of the present study was to optimise the freeze-drying cycle for a model IgG monoclonal antibody (20 mg/mL) in sucrose and sucrose/glycine formulations, by reducing primary drying time. To study the impact of shelf temperature (Ts) and chamber pressure on product temperature (Tp), one conventional and five aggressive cycles were tested. Aggressive conditions during primary drying were achieved by increasing Ts from -20 °C (conventional cycle) to 30 °C, with chamber pressure set to 0.1 mbar, 0.2 mbar or 0.3 mbar. These combinations of Ts and chamber pressure resulted in Tp well above Tg', and in some cases, even above Tc, without causing macrocollapse. Other critical quality attributes of the products were also within the expected ranges, such as reconstitution time and residual water content. Physical stability was tested using size exclusion chromatography, dynamic light scattering, and micro-flow imaging. All of the lyophilised samples were exposed to stress and the intended storage conditions, with no impacts on the product seen. These data show that implementation of aggressive conditions for the investigated formulations is possible and can significantly contribute to the reduction of primary drying times by up to 54% (from 48 to 22 h) in comparison to conventional freeze-drying.

Thermoreversible in situ gelling poloxamer-based systems with chitosan nanocomplexes for prolonged subcutaneous delivery of heparin: design and in vitro evaluation.

In situ forming systems including thermoreversible hydrogels, which undergo sol-gel transition upon an increase in temperature have been used for various biomedical applications. Heparins are the standard of anticoagulation in the prophylaxis and treatment of deep vein thrombosis and pulmonary embolism. Both conditions require long-lasting treatment with frequent subcutaneous administrations of heparin. The objective of this study was to prepare and evaluate in situ forming gel systems designed by combination of two poloxamers (P407 and P188) and hydroxypropylmethylcellulose (HPMC) for prolonged release of heparin. Thermoreversible hydrogels were prepared with heparin solution and dispersion of heparin/chitosan nanocomplexes. Nanocomplexes formed by self-assembly of heparin with chitosan at various mass ratios were thoroughly characterized. A heparin/chitosan mass ratio of 1:1 with pH 5.20 was the most appropriate for preparation of small, homogenous and stable nanocomplexes (mean diameter 123 nm; polydispersity index 0.22 and zeta potential+35.5 mV). Thermoreversible hydrogels were evaluated by gelation temperature, viscosity over the temperature range 20-40 °C, rate of hydrogel dissolution, and heparin release in vitro. The addition of P188 to P407 gel formulations resulted in an increase in gelation temperature, decrease in viscosity at room temperature and faster gel dissolution. The opposite effects were observed with formulations containing HPMC which demonstrated 18-day-long gel dissolution and complete heparin release in 9days from gels containing heparin solution. Considerable prolongation of heparin release was achieved with incorporation of heparin/chitosan nanocomplexes into the gelling systems. It may be concluded that with poloxamer mixtures at specific concentrations, addition of HPMC and use of heparin/chitosan nanocomplexes dispersions, thermoreversible formulations for prolonged subcutaneous release of heparin are feasible.