Method optimization for drug impurity profiling in supercritical fluid chromatography: Application to a pharmaceutical mixture.

A supercritical chromatographic method for the separation of a drug and its impurities has been developed and optimized applying an experimental design approach and chromatogram simulations. Stationary phase screening was followed by optimization of the modifier and injection solvent composition. A design-of-experiment (DoE) approach was then used to optimize column temperature, back-pressure and the gradient slope simultaneously. Regression models for the retention times and peak widths of all mixture components were built. The factor levels for different grid points were then used to predict the retention times and peak widths of the mixture components using the regression models and the best separation for the worst separated peak pair in the experimental domain was identified. A plot of the minimal resolutions was used to help identifying the factor levels leading to the highest resolution between consecutive peaks. The effects of the DoE factors were visualized in a way that is familiar to the analytical chemist, i.e. by simulating the resulting chromatogram. The mixture of an active ingredient and seven impurities was separated in less than eight minutes. The approach discussed in this paper demonstrates how SFC methods can be developed and optimized efficiently using simple concepts and tools.

Enhanced selectivity and search speed for method development using one-segment-per-component optimization strategies.

Linear gradient programs are very frequently used in reversed phase liquid chromatography to enhance the selectivity compared to isocratic separations. Multi-linear gradient programs on the other hand are only scarcely used, despite their intrinsically larger separation power. Because the gradient-conformity of the latest generation of instruments has greatly improved, a renewed interest in more complex multi-segment gradient liquid chromatography can be expected in the future, raising the need for better performing gradient design algorithms. We explored the possibilities of a new type of multi-segment gradient optimization algorithm, the so-called "one-segment-per-group-of-components" optimization strategy. In this gradient design strategy, the slope is adjusted after the elution of each individual component of the sample, letting the retention properties of the different analytes auto-guide the course of the gradient profile. Applying this method experimentally to four randomly selected test samples, the separation time could on average be reduced with about 40% compared to the best single linear gradient. Moreover, the newly proposed approach performed equally well or better than the multi-segment optimization mode of a commercial software package. Carrying out an extensive in silico study, the experimentally observed advantage could also be generalized over a statistically significant amount of different 10 and 20 component samples. In addition, the newly proposed gradient optimization approach enables much faster searches than the traditional multi-step gradient design methods.

A Process Analytical Technology (PAT) approach to control a new API manufacturing process: development, validation and implementation.

Pharmaceutical companies are progressively adopting and introducing Process Analytical Technology (PAT) and Quality-by-Design (QbD) concepts promoted by the regulatory agencies, aiming the building of the quality directly into the product by combining thorough scientific understanding and quality risk management. An analytical method based on near infrared (NIR) spectroscopy was developed as a PAT tool to control on-line an API (active pharmaceutical ingredient) manufacturing crystallization step during which the API and residual solvent contents need to be precisely determined to reach the predefined seeding point. An original methodology based on the QbD principles was designed to conduct the development and validation of the NIR method and to ensure that it is fitted for its intended use. On this basis, Partial least squares (PLS) models were developed and optimized using chemometrics methods. The method was fully validated according to the ICH Q2(R1) guideline and using the accuracy profile approach. The dosing ranges were evaluated to 9.0-12.0% w/w for the API and 0.18-1.50% w/w for the residual methanol. As by nature the variability of the sampling method and the reference method are included in the variability obtained for the NIR method during the validation phase, a real-time process monitoring exercise was performed to prove its fit for purpose. The implementation of this in-process control (IPC) method on the industrial plant from the launch of the new API synthesis process will enable automatic control of the final crystallization step in order to ensure a predefined quality level of the API. In addition, several valuable benefits are expected including reduction of the process time, suppression of a rather difficult sampling and tedious off-line analyses.

Predictive elution window stretching and shifting as a generic search strategy for automated method development for liquid chromatography.

We report on the possibilities of a new method development (MD) algorithm that searches the chromatographic parameter space by systematically shifting and stretching the elution window over different parts of the time-axis. In this way, the search automatically focuses on the most promising areas of the solution space. Since only the retention properties of the first and last eluting compounds of the sample need to be (approximately) known, the algorithm can be directly applied to samples with unknown composition, and the proposed solutions are not sensitive to any modeling errors. The search efficiency of the algorithm has been evaluated on an extensive set of random-generated in silico samples covering a broad range of different retention properties. Compared to a pure grid-based search, the algorithm could reduce the number of missed components by 50% and more. The algorithm has also been applied to solve three different real-world separation problems from the pharmaceutical industry. All problems could be successfully solved in a very short time (order of 12 h of instrument time).

Combined use of isopropylamine and trifluoroacetic acid in methanol-containing mobile phases for chiral supercritical fluid chromatography.

In chiral supercritical fluid chromatography (SFC), mobile-phase additives are often used to improve enantioseparations and peak shapes. An acidic or basic additive is chosen, depending on the nature of the compound. This work highlights the simultaneous use of the acidic additive trifluoroacetic acid (TFA) and the basic additive isopropylamine (IPA) in supercritical fluid chromatography for enantioseparations. To evaluate the combination of TFA and IPA, 59 chiral pharmaceutical compounds were analyzed on four polysaccharide-based chiral stationary phases (CSPs): Lux® Cellulose-1, Lux® Cellulose-2, Lux® Cellulose-4 and Lux® Amylose-2. The results show that an important increase in enantioselectivity of the chromatographic system can occur when combining trifluoroacetic acid and isopropylamine in the mobile phase (MP), compared to the individual use of these additives. However, the combination of isopropylamine and trifluoroacetic acid in a supercritical methanol-containing mobile phase can also lead to problems as a result of the formation of salt complexes between the two additives. Combining the additives trifluoroacetic acid and isopropylamine and taking the appropriate measures to avoid salt formation, i.e. reducing the additives' concentrations, can lead to simpler chiral SFC screening conditions that display even broader enantioselectivity.

A variable column length strategy to expedite method development.

A variable length method development (or VL-MD)strategy, exploiting the potential of an automatic column coupling system, is proposed and has been applied to a number of different pharmaceutical and environmental samples with a varying degree of complexity. The proposed strategy consistently produced separation methods that had at least an equally good critical pair resolution and an equally short run time to those of methods produced using commercially available MD assistance software. In some cases, the VL-MD strategy allowed the MD time to be drastically shortened from >30 h to an overnight run of only 12 h. The developed strategy has the potential to become fully automated provided that reliable chromatogram read-out software becomes available. The advantage of combining different stationary phase types to improve the available selectivity and the integration into the general VL-MD strategy was also demonstrated.

Kinetic plot equations for evaluating the real performance of the combined use of high temperature and ultra-high pressure in liquid chromatography. Application to commercial instruments and 2.1 and 1 mm I.D. columns.

The use of ultra-high pressure liquid chromatography (UHPLC) with pressures up to 1000 bar and columns packed with sub-2-microm particles combined with high-temperature mobile phase conditions (up to 90 degrees C) is assessed according to the current available instrumentation via constrained kinetic plot equations. It is shown that the gain in separation speed, theoretically expected from high-temperature UHPLC (HT-UHPLC), is significantly reduced when taking into account the existing instrumental constraints (extra-column band broadening, flow-rate and column length limitations). This study also shows that significant improvements could be expected on the current commercial instruments by increasing the flow-rate limit and/or using packing columns with particle size in the range 2.5-3.5 microm instead of the current sub-2 microm. These particles should obviously withstand very high pressure.

Use of 120-nm deep channels for liquid chromatographic separations.

The present study reports on the exploration of the separation speed limits of RPLC chromatography in open-tubular channels. Applying the shear-driven chromatography principle in a 120-nm deep open channel, and using an improved detection set-up, the separation of three coumarin dyes was detectable 8mm downstream of the injection point. At this distance, separation efficiencies of N = 17,900 - 24,100 plates were obtained at a velocity of 10 mm s(-1), corresponding to a plate generation velocity of 21,100 to 28,300 plates per second for the most and least retained component, respectively.

Integration of porous layers in ordered pillar arrays for liquid chromatography.

The present paper describes a method for the production of partly porous micro-pillars in columns suitable for use in liquid chromatography. These layers increase the available surface at least two orders of magnitude without destroying the huge benefits of the ordered nature of the system. A process flow was developed that enabled us to create a 550 nm thick porous layer on the pillar array in a sealed channel configuration, withstanding pressures up to at least 70 bar. Measuring band broadening under non-retained conditions, only a modest increase in plate height was observed in the porous pillar array as compared to that in a non-porous pillar array. The homogeneity of the layers was demonstrated using an optical microscope and SEM pictures and by monitoring peak velocities at constant pressures. The internal porosity was determined using particles with a diameter larger than the mesopores in combination with a dye that could penetrate into the pores.

Pressure-driven reverse-phase liquid chromatography separations in ordered nonporous pillar array columns.

Building upon the micromachined column idea proposed by the group of Regnier in 1998, we report on the first high-resolution reversed-phase separations in micromachined pillar array columns under pressure-driven LC conditions. A three component mixture could be separated in 3 s using arrays of nonporous silicon pillars with a diameter of approximately 4.3 microm and an external porosity of 55%. Under slightly retained component conditions (retention factor k' = 0.65-1.2), plate heights of about H = 4 microm were obtained at a mobile phase velocity around u = 0.5 mm/s. In reduced terms, such plate heights are as low as hmin = 1. Also, since the flow resistance of the column is much smaller than in a packed column (mainly because of the higher external porosity of the pillar array), the separation impedance of the array was as small as E = 150, i.e., of the same order as the best currently existing monolithic columns. At pH = 3, yielding very low retention factors (k' = 0.13 and 0.23), plate heights as low as H = 2 microm were realized, yielding a separation of the three component mixture with an efficiency of N = 4000-5000 plates over a column length of 1 cm. At higher retention factors, significantly larger plate heights were obtained. More experimental work is needed to investigate this more in depth. The study is completed with a discussion of the performance limits of the pillar array column concept in the frame of the current state-of-the-art in microfabrication precision.

State of the art of shear driven chromatography. Advantages and limitations.

The present paper reports on the experimental difficulties encountered when trying to realize the full potential of shear-driven chromatography in nanochannels. While it theoretically offers the possibility to yield over 10,000 plates per centimetre in a few seconds, the practical realization of this potential requires a detector miniaturisation that is carried to the extreme combined with very high sampling rates. In the present study, a charge coupled device camera and a photomultiplier tube combined with pinhole were tested as detector. Despite the fact that the photomultiplier tube could offer a higher sampling rate and a better sensitivity, the charge coupled device turned out to be better suited for the current set-up because of inevitable problems with the stray-light transported through the glass channel wall. The chemistry of the separation surface was additionally studied getting more homogenous coating, thus higher separation efficiency. Having also carried out a number of mechanical improvements, it is now possible to measure separations at a distance of 8mm downstream from the injection point. This is four times further downstream than ever before while realizing a four components mixture separation in less than 1.5s, with a plate generation velocity of about 2000-7000 plates per second depending on the sample.

Method to predict and compare the influence of the particle size on the isocratic peak capacity of high-performance liquid chromatography columns.

A kinetic plot based method has been used to experimentally predict the optimal particle size yielding the maximal isocratic peak capacity in a given analysis time. Applying the method to columns of three different manufacturers and characterizing them by separating a 4-component paraben mixture at 30 degrees C, it was consistently found that the classical 3 and 3.5 microm particles provide the highest peak capacity for typical isocratic separation run times between 30 and 60 min when operating the columns at a conventional pressure of 400 bar. Even at 1000 bar, the sub-2 microm particles only have a distinct advantage for runs lasting 30 min or less, while for runs lasting 45 min or longer the 3 and 3.5 microm again are to be preferred. This finding points at the advantage for high-resolution separations that could be obtained by producing 3 and 3.5 microm particle columns that can be operated at elevated pressures.

An automated injection system for sub-micron sized channels used in shear-driven-chromatography.

This paper describes a method to automatically and reproducibly inject sharply delimited sample plugs in the shallow (i.e., sub-micron) channels typically used in shear driven chromatography. The formation of asymmetric plugs, which typically occurs during loading of the sample in wide channels, is circumvented by etching a slit in the middle of the channel that is connected to a micro-well and a vacuum system with syringes for the supply of both the analyte and the mobile phase. The design of the injection slit was supported by a series of CFD simulations to optimize its shape and that of the corresponding injection well. The system was intensively tested experimentally and showed good reproducibility, both for the width and the area of the injected peaks (relative standard deviations are max. 4 and 6%, respectively). The concentration of the injected plug was found to be approximately 80% of the original sample concentration. It was also observed that with the current setup the lower limit of the peak width was about 120 microm. This is a consequence of the fact that the peak width originating from the convection filling step becomes negligible to the contribution of diffusion during the filling and flushing time. Being fully automated and perfectly closed, the presently proposed injection system also paves the way to integrate other functionalities in shear driven chromatography, i.e. gradient elution and parallelization.

Future of high pressure liquid chromatography: do we need porosity or do we need pressure?

Making a theoretical study supported by experiments of the kinetic advantages of increased inlet pressures versus increased external porosity using impedance plots of analysis time versus required plate number, it is found that both approaches more or less have the same effect on the kinetic performance. The need to change a given system to one with an increased inlet pressure or with an increased external porosity can best be assessed from the optimal plate number (N(opt)) of the system. When the pursued application requires a plate number that is larger than N(opt), any increase in inlet pressure and external porosity is beneficial. When the required plate number is smaller than N(opt), any increase in inlet pressure and external porosity should preferentially be accompanied by an overall reduction of the feature sizes of the support. The degree to which this feature size reduction can be realized in practice will to a large extent determine which of the two approaches will be the dominant system of the future.

Detection enhancement in nano-channels using micro-machined silicon groove.

The present paper reports on an experimental study of the possibility to use a micro-machined detection groove to enhance the detection sensitivity in flat-rectangular nano-channels for ultra-rapid liquid chromatography separations. Transversally running detection grooves with three different axial widths (respectively, 2, 4 and 6 microm) and one depth (4.75 microm) were tested in glass and silicon channels for the whole range of detectable fluorescein isothiocyanate isomer I, FITC, concentrations. The groove with the most square-like cross-section (i.e., 4 microm wide and 4.75 microm deep) yielded the best combination of detection gain and minimal additional band broadening. In a 1cm long channel, the effective plate loss caused by the 4 microm wide groove would only be of the order of 20%, while the gain in S/N-ratio was of the order of a factor of 5. The detection groove concept yields larger gains in silicon channel substrates than in glass channel substrates, due to the larger stray light losses occurring in the latter.

Practical constraints in the kinetic plot representation of chromatographic performance data: theory and application to experimental data.

It is demonstrated that the kinetic plot representation of experimental plate height data can also account for practical constraints on the column length, the peak width, the viscous heating, and the mobile-phase velocity without needing any iterative solution routine. This implies that the best possible kinetic performance to be expected from a given tested support under any possible set of practical optimization constraints can always be found using a directly responding calculation spreadsheet template. To show how the resulting constrained kinetic plots can be used as a powerful design and selection tool, the method has been applied to a series of plate height measurements performed on a number of different commercial columns for the same component (butyl-parabene) and mobile-phase composition. The method, for example, allows one to account for the fact that the advantageous solutions displayed by the silica monolith and 5 microm particle columns in the large plate number range of the free kinetic plot are no longer accessible if applying a maximal column length constraint of Lmax = 30 cm. In the plate number range that remains accessible, the investigated sub-2 mum particle columns in any case perform (at least for the presently considered parabene separation) better than the 3.5 mum particle columns or silica monolith, especially if considering the use of system pressures exceeding 400 bar. The constrained kinetic plot method can also be used to select the best-suited column length from an available product gamma to perform a separation with a preset number of plates. One of the optimization results that is obtained in this case is that sometimes a significant gain in analysis time can be obtained by selecting a longer column, yielding the desired plate number at a larger velocity than that for a shorter column.

Ultra-rapid separation of an angiotensin mixture in nanochannels using shear-driven chromatography.

The present paper reports on the separation of a mixture of fluorescein isothiocyanate-labeled angiotensin I and II peptides in a shear-driven nanochannel with a C18-coating and using an eluent consisting of 5% acetonitrile in 0.02 M aqueous phosphate buffer at pH 6.5. The flat-rectangular nanochannel in fused silica consisted of an etched structure in combination with a flat moving wall. The very fast separation kinetics that can be achieved in a nanochannel allowed to separate the angiotensin peptides in less then 0.2 s in a distance of only 1.8 mm. Plate heights as small as 0.4 microm were calculated after substraction of the injection effect.

Measurements of diffusion coefficients in 1-D micro- and nanochannels using shear-driven flows.

The present paper describes a method for measuring the molecular diffusion coefficient of fluorescent molecules in microfluidic systems. The proposed static shear-driven flow method allows one to perform diffusion measurements in a fast and accurate manner. The method also allows one to work in very thin (i.e. submicron) channels, hence allowing the investigation of diffusion in highly confined spaces. In the deepest investigated channels, the obtained results were comparable to the existing literature values, but when the channel size dropped below the micrometer range, a significant decrease (more than 30%) in molecular diffusivity was observed. The reduction of the diffusivity was most significant for the largest considered molecules (ssDNA oligomers with a size ranging between 25 to 100 bases), but the decrease was also observed for smaller tracer molecules (FITC). This decrease can be attributed to the interactions of the analyte molecules with the channel walls, which can no longer be neglected when the depth of the channel reaches a critical value. The change in diffusivity seems to become more explicit as the molecular weight of the analytes increases.

Geometry-independent plate height representation methods for the direct comparison of the kinetic performance of LC supports with a different size or morphology.

The advantages of representing experimental plate height data as a plot of Kv/u0(2) or H2/Kv versus Kv/(Hu0) instead of as H versus u0 are discussed (Kv=column permeability). Multiplying the values on both axes by the ratio of a reference pressure drop and mobile-phase viscosity, the obtained plots directly yield the kinetic performance limits of the tested support structure, without any need for further numerical optimization. Directly showing the range of plate numbers or analysis times wherein the tested support geometry can yield faster separations or produce more plates than another support type, such kinetic plots are ideally suited to compare the performance of differently shaped or sized LC supports. The approach hence obviates the need for a common reference length, which is a clear problem if it is attempted to compare differently shaped supports on the basis of their flow resistance phi and reduced plate height h. It is also shown how an MS Excel template file, only requiring the user to paste the column permeability Kv and a series of experimental (u0, H) data, can be used to automatically establish a series of so-called kinetic performance (KP) numbers, which can be used to completely describe the performance characteristics of the considered support. The advantages of the proposed data representation methods are demonstrated by applying them to several recent literature plate height data sets, showing that the obtained kinetic plots directly visualize the range of plate numbers where new approaches such as ultra-high-pressure HPLC or the use of open-porous silica monoliths can be expected to provide a substantial gain and where not. The data analysis also showed that the most generally relevant KP numbers are N(opt) (the plate number for which the support achieves its best analysis time/pressure cost ratio), t(opt) (the time needed to obtain N(opt) plates), and t(1K) (the time needed to generate 1000 or 1 kilo of theoretical plates). These KP numbers are much more informative than the H(min), u(0,opt), and Kv data traditionally employed to quantify the performance of LC supports.