excipient variability sources, importance and potential impact chris moreton, ph.d past chair...
TRANSCRIPT
Excipient VariabilitySources, Importance and Potential
Impact
Chris Moreton, Ph.DPast Chair IPEC-Americas
Partner – FinnBrit [email protected]
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Presentation Outline
• Background• Why excipient variability is important• How excipient variability can arise• Options for addressing excipient
variability
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The Objective• To manufacture robust medicines that deliver
the drug to the patient:– In the required amount (content and assay).– At the optimum rate necessary to achieve the
desired therapeutic benefit (in vivo dissolution).– Consistently:
• Within lots (blend uniformity for all components).• Between lots (validated manufacturing process).
– For the shelf life of the product (stability).• At the same time, the development process
has to be efficient.
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Components of a medicinal product
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Why is excipient variability important?
• Excipients are important components of drug products.
• Excipient variability may impact drug product variability.– But excipients are not the only sources
of drug product variability• API and process parameters may also be
sources of product variability.
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Excipient Variability
• There is inherent variability in everything:– Excipients are no exception.
• Why is it important?– It can contribute to product variability.
• But it is not the only potential source of product variability!
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Excipient Variability
• We can sometimes see the effect of excipient variability in failed batches, but
• We cannot always control excipient variability adequately
• Why?– How does excipient variability arise?
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Sources of Excipient Variability
• Many excipients are natural products, or derived from natural products.
– Source of feedstock (crop)• Species/varietal• Soil composition• Use of fertilizer
– Weather is changeable• Conditions during the growing season• Conditions during harvesting• Conditions during transportation to the processing site• Conditions during storage of the crude feedstock• Conditions during processing• Conditions during packaging, storage and distribution
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Sources of Excipient Variability
• Even for synthetic materials:– There is a misconception that synthetic or
semi-synthetic materials are less variable than natural products• It depends on the chemical processing
– Single phase or multiphase, etc.
– Most synthetic materials are derived from crude oil or gas which varies with location of the well:• Content of sulfur• Content and range of heavy metals• Distribution of the different organic components
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Sources of Excipient Variability
• Manufacturing process– Scale of manufacture
• Excipients frequently manufactured using continuous processing.
– Location of manufacturing site• Different scale of manufacture at different sites.
– Alternate processes used by different manufacturers.• Anti-oxidant vs. inert gas blanket
– Normal wear and tear of the equipment train• Supply chain
– Type of transportation– Duration– Storage conditions en route
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Excipient Variability
• We have to accept that there will be variability.
• We need to come to terms with it.• Options may include:– Designing more robust formulations to
cope with variability• QbD will help
– Using processing end-points to compensate for materials variability.
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What is a Robust Formulation?
• A formulation that is able to accommodate the typical variability seen in:– API– Excipients– Processes
Without compromising the manufacture, stability, performance or any other attribute of the product critical to the patient’s care or well being.
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Formulation variability– a Simplistic View
σσσσ 2Process
2Excipients
2Active
2Product
BulkActiveDrug
Variability
ExcipientsVariability
ProcessVariability
ProductVariability
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Formulation variability– a Wrong View
σσσσ 2Process
2Excipients
2Active
2Product
BulkActiveDrug
Variability
ExcipientsVariability
ProcessVariability
ProductVariability
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In reality!
BulkActiveDrug
Variability
ExcipientsVariability
ProcessVariability
ProductVariability
σσσσσ2
nsInteractio
2
Process
2
Excipients
2
Active
2
Product
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Interactions in Product Manufacture
• Interactions include:– Powder – Powder– Powder – Liquid– Powder – Equipment– Liquid – Equipment
• For each unit process
– Powder – Operator– Liquid – Operator– Equipment – Operator– etc.
• For each component
σσσσ
σσσσσ
2(n)n Interactio
2(2)n Interactio
2(1)n Interactio
2nsInteractio
2nsInteractio
2Process
2Excipients
2API
2Product
.......
:Where
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Which type of variability applies to our application?
Batch number/Time of output
Raw materialparameter
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Raw Material Variability
Raw materialParameter
Raw material batches
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Raw Material Variability: Acceptable
Raw materialParameter
Raw material batches
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Raw Material Variability:Possibly acceptable
Raw materialParameter
Raw material batches
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Raw Material Variability:Impossible limits
Raw materialParameter
Raw material batches
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Conclusions
• Excipient variability is important.• There is inherent variability in
excipients arising from a variety of possible sources.
• Designing product formulations and setting excipient specifications that do not allow for the inherent variability of the excipient is a recipe for disaster.
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Thank you!
We will now answer Questions.
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