Tolerance Interval Approach for the Determination of Overfill of Liquid Parenteral Drug Products.

Liquid parenteral products contain an overfill to ensure withdrawal of the declared volume. The overfill must be sufficiently high to compensate for the expected loss during product preparation and administration, but it should also be minimized to prevent accidental overdosing and unforeseen dose splitting of single-dose products. Finding the right balance between too much and too little overfill with an acceptable risk of product failure is challenging and requires consideration of the relevant sources of variability of the extractable volume. This article provides a novel approach for the calculation of the required overfill based on tolerance interval methodology. In a first step, a tolerance interval multiplier from the literature is proposed, and a simulation study is conducted to assess the appropriateness of its use for overfill determination. In a second step, this multiplier is adapted to cover operator-to-operator variability in the loss data and compared with other multipliers via a second simulation study. Use of a tolerance interval multiplier enables adaptation of the overfill such that the risk of not reaching the minimum extractable volume fulfills predefined acceptance criteria. By this, the scientific justification of the selected overfill is strengthened and control over a critical quality attribute is improved.

Reductive alkylation of active methylene compounds with carbonyl derivatives, calcium hydride and a heterogeneous catalyst.

A one-pot two-step reaction (Knoevenagel condensation - reduction of the double bond) has been developed using calcium hydride as a reductant in the presence of a supported noble metal catalyst. The reaction between carbonyl compounds and active methylene compounds such as methylcyanoacetate, 1,3-dimethylbarbituric acid, dimedone and the more challenging dimethylmalonate, affords the corresponding monoalkylated products in moderate to good yields (up to 83%) with minimal reduction of the starting carbonyl compounds.

Selective synthesis of 1-O-alkyl(poly)glycerol ethers by catalytic reductive alkylation of carboxylic acids with a recyclable catalytic system.

(Poly)glycerol monoethers were synthesized in good yield and selectivity by the catalytic reductive alkylation of glycerol, diglycerol, and triglycerol with readily available, cheap and/or bio-sourced carboxylic acids. The reaction was catalyzed by 1 mol % of Pd/C under 50 bar H(2) using an acid ion-exchange resin as a recyclable cocatalyst. The catalytic system was recycled several times, and a mechanism is proposed for this transformation.

Online fluorescent dye detection method for the characterization of immunoglobulin G aggregation by size exclusion chromatography and asymmetrical flow field flow fractionation.

The aim of this study was to develop an online fluorescent dye detection method suitable for high-pressure size exclusion chromatography (HP-SEC) and asymmetrical flow field flow fractionation (AF4). The noncovalent extrinsic fluorescent dye 4,4'-dianilino-1,1'-binaphthyl-5,5'-disulfonic acid (Bis-ANS) was added to the mobile phase or the sample, and the fluorescence emission at 488nm was recorded on excitation at 385nm. By combining HP-SEC and AF4 with online dye detection, it was possible to simultaneously detect heat-induced aggregation and structural changes of monomeric and aggregated immunoglobulin G (IgG); an increase in Bis-ANS fluorescence was observed in both the aggregate and monomer fractions. These structural changes of individual fractions, which were not detectable by online UV and multiangle laser light scattering (MALLS) or by stand-alone dynamic light scattering (DLS), intrinsic IgG fluorescence, and far-UV circular dichroism (CD), resulted in progressive aggregation on storage. The developed online fluorescent dye detection for HP-SEC or AF4 with Bis-ANS is a powerful method to detect both aggregation and structural changes of both monomeric and aggregated IgG in heat-stressed formulations.

Extrinsic fluorescent dyes as tools for protein characterization.

Noncovalent, extrinsic fluorescent dyes are applied in various fields of protein analysis, e.g. to characterize folding intermediates, measure surface hydrophobicity, and detect aggregation or fibrillation. The main underlying mechanisms, which explain the fluorescence properties of many extrinsic dyes, are solvent relaxation processes and (twisted) intramolecular charge transfer reactions, which are affected by the environment and by interactions of the dyes with proteins. In recent time, the use of extrinsic fluorescent dyes such as ANS, Bis-ANS, Nile Red, Thioflavin T and others has increased, because of their versatility, sensitivity and suitability for high-throughput screening. The intention of this review is to give an overview of available extrinsic dyes, explain their spectral properties, and show illustrative examples of their various applications in protein characterization.

Stable sugar-based protein formulations by supercritical fluid drying.

The aim of this work was to produce stable, sugar-containing protein formulations by supercritical fluid (SCF) drying. Lysozyme solutions with and without added sucrose or trehalose were dried by spraying them in an SCF composed of CO(2) and ethanol or CO(2) only. The protein-to-sugar ratio was varied between 1:0 and 1:10 (w/w). Dried formulations were stored at 4 degrees C for three months and analyzed by Karl Fischer titration, scanning electron microscopy, X-ray powder diffraction, differential scanning calorimetry and Fourier transform infrared spectroscopy. Lysozyme stability after reconstitution was determined by an enzymatic activity assay, UV/Vis spectroscopy, and SDS-PAGE. Smooth, spherical particles of 1-25 microm size were obtained. All formulations were initially amorphous. Crystallization during storage only occurred with a protein-to-sugar ratio of 1:10 and could be avoided by performing SCF drying without ethanol. Absence of residual ethanol in dried trehalose formulations increased the glass transition temperature up to 120 degrees C. Lysozyme in dried formulations was structurally stable, with exception of the 1:0 and 1:1 protein-to-sugar ratios, where reversible protein aggregation occurred. The results show that by avoiding ethanol, which up to now has been considered mandatory for efficient drying of aqueous solutions, and by choosing the proper protein-to-sugar ratio, it is possible to obtain stable, sugar-based protein formulations through SCF drying.

Self-assembly of recombinant amphiphilic oligopeptides into vesicles.

The aim of the present study was to design amphiphilic oligopeptides that can self-assemble into vesicular structures. The ratio of hydrophilic to hydrophobic block length was varied, and peptides were designed to have a hydrophobic tail in which the bulkiness of the amino acid side groups increases toward the hydrophilic domain (Ac-Ala-Ala-Val-Val-Leu-Leu-Leu-Trp-Glu(2/7)-COOH). These peptides were recombinantly produced in bacteria as an alternative to solid-phase synthesis. We demonstrate with different complementary techniques (dynamic and static light scattering, tryptophan fluorescence anisotropy, and electron microscopy) that these amphiphilic peptides spontaneously form vesicles with a radius of approximately 60 nm and a low polydispersity when dispersed in aqueous solution at neutral pH. Morphology and size of the vesicles were relatively insensitive to the variations in hydrophilic block length. Exposure to acidic pH resulted in formation of visible aggregates, which could be fully reversed to vesicles upon pH neutralization. In addition, it was demonstrated that water-soluble molecules can be entrapped inside these peptide vesicles. Such peptide vesicles may find applications as biodegradable drug delivery systems with a pH-dependent release profile.

Characterization of a cyclosporine solid dispersion for inhalation.

For lung transplant patients, a respirable, inulin-based solid dispersion containing cyclosporine A (CsA) has been developed. The solid dispersions were prepared by spray freeze-drying. The solid dispersion was characterized by water vapor uptake, specific surface area analysis, and particle size analysis. Furthermore, the mode of inclusion of CsA in the dispersion was investigated with Fourier transform infrared spectroscopy. Finally, the dissolution behavior was determined and the aerosol that was formed by the powder was characterized. The powder had large specific surface areas (~ 160 m(2)). The water vapor uptake was dependant linearly on the drug load. The type of solid dispersion was a combination of a solid solution and solid suspension. At a 10% drug load, 55% of the CsA in the powder was in the form of a solid solution and 45% as solid suspension. At 50% drug load, the powder contained 90% of CsA as solid suspension. The powder showed excellent dispersion characteristics as shown by the high emitted fraction (95%), respirable fraction (75%), and fine-particle fraction (50%). The solid dispersions consisted of relatively large (x(50) approximately 7 mum), but low-density particles (rho approximately 0.2 g/cm(3)). The solid dispersions dissolved faster than the physical mixture, and inulin dissolved faster than CsA. The spray freeze-drying with inulin increased the specific surface area and wettability of CsA. In conclusion, the developed powder seems suitable for inhalation in the local treatment of lung transplant patients.

Recombinant gelatin hydrogels for the sustained release of proteins.

A recombinant gelatin (HU4) containing part of the amino acid sequence of the alpha1-chain of human type I collagen was used for preparing hydrogels for the sustained release of proteins. HU4 gelatin was modified with methacrylate residues for chemical crosslinking and gel formation. Methacrylated gelatins with degrees of substitution (DS; defined as fraction of methacrylate residues with respect to the total number of primary amines) of 0.24, 0.67, 0.82, and 0.97 were synthesized, and hydrogels with polymer volume fractions in the swollen state (upsilon(2,s)) between 0.01 and 0.14 were formed by radical polymerization. Mesh size (xi) was > or =26 nm, as determined by dynamic mechanical analysis. Release of the incorporated model proteins lysozyme and trypsin inhibitor occurred by diffusion and was nearly complete. Protein diffusion coefficients in the gel were between 5.0 x 10(-7) and 4.0 x 10(-8) cm(2) s(-1), up to 100 fold lower than in water. Release under physiological conditions was effectively controlled by varying hydrogel mesh size and protein-gelatin charge interactions, which demonstrates that recombinant gelatins are a versatile class of biopolymers for the preparation of hydrogels for protein delivery. HU4 hydrogels were enzymatically degradable by human matrix metalloproteinase 1, which is an indication of their in vivo biodegradability.

Sensitive spectroscopic detection of large and denatured protein aggregates in solution by use of the fluorescent dye Nile red.

The fluorescent dye Nile red was used as a probe for the sensitive detection of large, denatured aggregates of the model protein beta-galactosidase (E. coli) in solution. Aggregates were formed by irreversible heat denaturation of beta-galactosidase below and above the protein's unfolding temperature of 57.4 degrees C, and the presence of aggregates in heated solutions was confirmed by static light scattering. Interaction of Nile red with beta-galactosidase aggregates led to a shift of the emission maximum (lambda (max)) from 660 to 611 nm, and to an increase of fluorescence intensity. Time-resolved fluorescence and fluorescence correlation spectroscopy (FCS) measurements showed that Nile red detected large aggregates with hydrodynamic radii around 130 nm. By steady-state fluorescence measurements, it was possible to detect 1 nM of denatured and aggregated beta-galactosidase in solution. The comparison with size exclusion chromatography (SEC) showed that native beta-galactosidase and small aggregates thereof had no substantial effect on the fluorescence of Nile red. Large aggregates were not detected by SEC, because they were excluded from the column. The results with beta-galactosidase demonstrate the potential of Nile red for developing complementary analytical methods that overcome the size limitations of SEC, and can detect the formation of large protein aggregates at early stages.

Correlation of membrane order and dynamics derived from time-resolved fluorescence measurements with solute permeability.

The relevance of order and dynamics of phospholipid bilayer membranes as detected with fluorescent probe molecules embedded in the membranes for describing their permeability properties was studied. Order parameters (S) and rotational diffusion coefficients (Dperpendicular) of 1,6-diphenyl-1,3,5-hexatriene (DPH) and 1-(4-trimethylammoniumphenyl)-6-phenyl-1,3,5-hexatriene (TMA-DPH) in unilamellar vesicles were determined by time-resolved fluorescence spectroscopy. Vesicles consisting of combinations of 1-palmitoyl-2-oleoyl-sn-glycero-3-phosphatidylcholine, 1,2-dimyristoyl-sn-glycero-3-phosphatidylcholine, egg sphingomyelin and cholesterol were studied at 288, 298, and 308 degrees K. Permeability coefficients (P) of the model permeant D-[14C]mannitol were determined. A model was proposed for correlating P with both S and Dperpendicular, where S is linked to the average free surface area per lipid molecule and Dperpendicular reflects lipid thermal motion and, thus, redistribution rate of free surface area of the bilayer. P values ranging from 0.9 to 12.4 x 10(-11) cm/s were well described by the model. This supports the notion that permeation depends on membrane structural and dynamic properties. While changes in both S and Dperpendicular, at relative significance varying with the situation, appeared responsible for the effect of lipid composition on permeability, the effect of temperature on P was related primarily to Dperpendicular. P correlated better with S and Dperpendicular obtained with TMA-DPH rather than DPH. The location of the fluorescent probe molecules within the membranes is discussed as the cause for this difference.