Surface denaturation at solid-void interface--a possible pathway by which opalescent particulates form during the storage of lyophilized tissue-type plasminogen activator at high temperatures.

During protein lyophilization, it is common practice to complete the freezing step as fast as possible in order to avoid protein denaturation, as well as to obtain a final product of uniform quality. We report a contradictory observation made during lyophilization of recombinant tissue-type plasminogen activator (t-PA) formulated in arginine. Fast cooling during lyophilization resulted in a lyophilized product that yielded more opalescent particulates upon long term storage at 50 degrees C, under a 150 mTorr nitrogen seal gas environment. Fast cooling also resulted in a lyophilized cake with a large internal surface area. Studies on lyophilized products containing 1% (w/w) residual moisture and varying cake surface areas (0.22-1.78 m2/gm) revealed that all lyophilized cakes were in an amorphous state with similar glass transition temperatures (103-105 degrees C). However, during storage the rate of opalescent particulate formation in the lyophilized product (as determined by UV optical density measurement in the 360 to 340 nm range for the reconstituted solution) was proportional to the cake surface area. We suggest that this is a surface-related phenomenon in which the protein at the solid-void interface of the lyophilized cake denatures during storage at elevated temperatures. Irreversible denaturation at the ice-liquid interface during freezing in lyophilization is unlikely to occur, since repeated freezing/thawing did not show any adverse effect on the protein. Infrared spectroscopic analysis could not determine whether protein, upon lyophilization, at the solid-void interface would still be in a native form.

A turbidimetric method to determine visual appearance of protein solutions.

An instrumental method to analyze protein solutions for visual appearance is described which is based on spectrophotometric comparison to reference suspensions with varying degrees of turbidity. This method provides a useful substitute for visual inspection of uniform opalescent suspensions in that it is more convenient and less time-consuming and has the potential to be more reproducible, accurate and objective. Established categories of opalescence based on European Pharmacopoeial reference suspensions were determined using turbidity measured as optical density in the 340-360 nm range. A comparison of the mean optical density of a protein sample to those of the reference suspensions allowed a more reproducible assignment of the sample's category of opalescence than that of visual inspection.

Determining the optimum residual moisture in lyophilized protein pharmaceuticals.

A general concern in the lyophilization of protein pharmaceuticals is how dry a product should be in order to maintain its stability during storage. This paper presents our exploratory studies on determining if there is an optimal residual moisture content for lyophilized recombinant protein products. The proteins used in this study were methionyl human growth hormone (met-hGH) and tissue type plasminogen activator (tPA). The amount of water adsorbed on each protein can be determined and approximated as a monolayer by the Brunauer-Emmett-Teller method. The result was in good agreement with the theoretical value calculated from the total number of strong polar groups in the molecule without regard to the conformation of the protein. This approach suggests that each protein may have a minimum moisture content that is necessary to shield the polar groups, and that over-drying will lead to exposure of these groups. The effect of residual moisture content on the stability of tPA in lyophilized excipient-free powder was studied. Samples that were dried to a water content below the calculated monolayer exhibited opalescence upon reconstitution, while those that were dried to either monolayer or multilayer water content tended to show a greater loss in biological stability upon storage under temperature stress conditions. The results of our studies reveal that the generally accepted concept "the drier the better" may not be appropriate for tPA. An optimum residual moisture content is required to balance the physical stability and the biological stability. These observations may apply to other protein products as well.