Best Practices to Quantify and Identify Particulate Matter on the Interior Surfaces of Single-Use Systems.

The manufacturing of a wide range of biopharmaceuticals, from antibodies and vaccines to cell-based therapies, increasingly takes place in single-use processing equipment. Manufactured in clean rooms and sealed and sterilized, single-use systems (SUSs) are ready-to-use and easily scalable. Controls in the "clean-build" manufacturing of SUSs reduce the probability of occurrence of particulate matter in SUSs. However, the size, complexity, and limited transparency of SUSs clearly limit the detectability of particulate matter on the interior (fluid-contacting) surfaces of a SUS during a visual inspection, as demonstrated in a recent study. In applications downstream of final filters or in aseptic processing, particulate matter on the surfaces of a SUS could detach and contaminate the final drug product. A realistic assessment of this risk requires reliable test methods that quantify and identify particulate matter present on the interior surfaces of SUSs. Clearly problematic is the common certification of the cleanliness of a SUS via a force-fit adaptation of the pharmacopeial standard USP <788> entitled "Particulate Matter in Injections". USP <788> does not describe a procedure for extraction of particulate matter from the interior surfaces of SUSs. In addition, application of Method 1 Light Obscuration significantly limits the probability of detection for particles in the visible size range (≥ 100 µm). In this article, we describe best practices for extracting, counting, sizing, and chemically identifying particulate matter on the interior surfaces of SUSs. Highly effective procedures for the extraction of particulate matter result from application of the qualification methodology described in a recently published ASTM standard. Filtration of the liquid extract concentrates particulate matter onto the surface of a membrane filter, allowing rapid particle counting and sizing using automated membrane microscopy, along with detailed chemical identification using infrared microscopy and/or automated confocal Raman microscopy.

Effects of X-Rays, Electron Beam, and Gamma Irradiation on Chemical and Physical Properties of EVA Multilayer Films.

Gamma-ray irradiation, using the cobalt-60 isotope, is the most common radiation modality used for medical device and biopharmaceutical products sterilization. Although X-ray and electron-beam (e-beam) sterilization technologies are mature and have been in use for decades, impediments remain to switching to these sterilization modalities because of lack of data on the resulting radiation effects for the associated polymers, as well as a lack of education for manufacturers and regulators on the viability of these sterilization alternatives. For this study, the compatibility of ethylene vinyl acetate (EVA) multilayer films with different ionizing radiation sterilization (X-ray, e-beam, and gamma irradiation) is determined by measuring chemical and physical film properties using high performance liquid chromatography, differential scanning calorimetry, Fourier-Transform InfraRed spectroscopy (FTIR), surface energy measurement, and electron spin resonance techniques. The results indicate that the three irradiation modalities induce no differences in thermal properties in the investigated dose range. Gamma and X-Ray irradiations generate the same level of reactive species in the EVA multilayer film, whereas e-beam generates a reduced quantity of reactive species.

Effects of X-ray, electron beam and gamma irradiation on PE/EVOH/PE multilayer film properties.

To increase sterilization capacity, X-ray and e-beam irradiation modalities are more and more attractive for the indutrial sterilization of heathcare products (medical devices and biopharmaceutical goods). However, no study comparing these different techniques are available concerning multi-layer films. Thus, with the PE/EVOH/PE multilayer film as a model, we show that, whatever the modality of irradiation, the thermal properties are not significantly changed as shown by DSC, and, as such, the physical and mechanical properties of this material are also expected to behave similarly. On the other hand, chemical properties such as oxidation ability are strikingly modified, i.e., the same oxidation level for X-ray and γ-irradiation and twice weaker for e-beam irradiation.

Investigations at the Product, Macromolecular, and Molecular Level of the Physical and Chemical Properties of a γ-Irradiated Multilayer EVA/EVOH/EVA Film: Comprehensive Analysis and Mechanistic Insights.

Chemically and biologically safe storage of solutions for medical uses is a daily concern for industry since decades and it appeared even more dramatic during the last two years of pandemia. Biological safety is readily reached by sterilization using γ-irradiation process. However, such a type of irradiation induces the degradation and the release of chemicals able to spoil the biological solutions. Surprisingly, there are no investigations on multi-layer films combining multi-technique and multi-method approaches to unveil the events occurring during γ-irradiation. Furthermore, our investigations are focuses on properties/events occurring at product, macromolecular, and molecular levels.

Monitoring of Peroxide in Gamma Irradiated EVA Multilayer Film Using Methionine Probe.

In this study, the oxidation of methionine is used as a proxy to model the gamma radiation-induced changes in single-use bags; these changes lead to the formation of acids, radicals, and hydroperoxides. The mechanisms of formation of these reactive species and of methionine oxidation are discussed. With the help of reaction kinetics, the optimal conditions for the use of these single-use bags minimizing the impact of radical chemistry are highlighted. Biopharmaceutical bags gamma irradiated from 0 kGy to 260 kGy and aged from 0 to 36 months were filled with a methionine solution to follow the oxidation of the methionine. The methionine sulfoxide was measured with HPLC after different storage times (0, 3, 10, 14, 17, and 21 days). Three main results were analyzed through a design of experiments: the oxidative induction time, the methionine sulfoxide formation rate, and the maximum methionine sulfoxide concentration detected. A key aspect of the study is that it highlights that methionine is oxidized not necessarily directly by hydro(gen) peroxide but throughperacid, and likely peracetic acid. The answers to the design of experiments were considered to obtain the desirability domain for the optimization of the conditions of use for the single-use bags limiting the oxidation of methionine as well as the release of reactive species thereof.

Reconciliation of pH, conductivity, total organic carbon with carboxylic acids detected by ion chromatography in solution after contact with multilayer films after γ-irradiation.

The impact of γ-irradiation on polymers in multilayer films was studied by means of the study of the diffusion and release (spontaneous migration of the molecules from the container into the product) of chemical species in aqueous solution. A series of different measurements have been performed: pH, conductivity, total organic carbon (TOC) and ion chromatography (IC). Their evolution according to γ-irradiation dose was studied. More several rinsings made over several months allowed to quantify well the impact of the irradiation on these polymers. The samples are irradiated at several γ-doses, up to 270 kGy, and compared with a non-irradiated sample used as reference. It shows that quantity of generated carboxylic acids depends on the film material (PE/EVOH/PE and EVA/EVOH/EVA) and increases with γ-dose.

Impact of γ-irradiation, ageing and their interactions on multilayer films followed by AComDim.

To highlight the main factors involved in the degradation of polymers in multilayer films under γ-irradiation, the ANOVA Common Dimensions (AComDim, Analysis of Variance in Common Dimensions) method is applied on spectra recorded with ATR-FTIR (Attenuated Total Reflection-Fourier Transform Infrared). The present study focuses on the stability of γ-irradiated polymers used in single-use plastic bags made of multilayer films for the biopharmaceutical and biotechnological industries. The samples are irradiated at several γ-doses, up to 270 kGy, and compared with a non-irradiated sample used as reference. It shows that the γ-dose, the natural ageing up to six months and the γ-dose × ageing interaction are the most influential factors.