Best Practices and Guidelines (2022) for Scale-Up and Tech Transfer in Freeze-Drying Based on Case Studies. Part 1: Challenges during Scale Up and Transfer

Author:

Tchessalov Serguei,Shalaev Evgenyi,Bhatnagar Bakul,Nail Steven,Alexeenko Alina,Jameel Feroz,Srinivasan Jayasree,Dekner Michael,Sahni Ekneet,Schneid Stefan,Kazarin Petr,McGarvey Orla,Van Meervenne Bert,Kshirsagar Vaibhav,Pande Paritosh,Philipp Jens,Sacha Greg,Wu Ke,Azzarella Joseph,Shivkumar Gayathri,Bhatt Shreyas

Abstract

AbstractThe freeze-drying process scale-up and transfer remain a complicated and non-uniform practice. We summarized inefficient and good practices in these papers and provided some practical advice. It was demonstrated that using the same process set points/times in laboratory and commercial scale dryers may lead to loss of product quality (collapse or vial breakage). The emerging modeling approach demonstrated practical advantages. However, the upfront generation of some input parameters (vial heat transfer coefficient, minimum controllable pressure, and maximum sublimation rate) is essential for model utilization. While the primary drying step can be transferred with a high degree of confidence (e.g., using modeling), and secondary drying is usually fairly straightforward, predicting potential changes in product behavior during freezing remains challenging. Graphical Abstract

Publisher

Springer Science and Business Media LLC

Subject

Drug Discovery,Pharmaceutical Science,Agronomy and Crop Science,Ecology,Aquatic Science,General Medicine,Ecology, Evolution, Behavior and Systematics

Reference40 articles.

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2. Rambhatla S, Ramot R, Bhugra C, Pikal MJ. Heat and mass transfer scale-up issues during freeze drying: II. Control and characterization of the degree of supercooling. AAPS PharmSciTech. 2004;5(4):54–62.

3. Jennings TA. Transferring the lyophilization process from one freeze-dryer to another. Am Pharm Rev. 2002;5(1):34–42.

4. Jameel F, Paranandi M. Critical considerations in the transfer and validation of a lyophilization process. Am Pharm Rev. 2006;9(3):53–5.

5. Pikal MJ. Freeze drying. In: Swarbrick J, ed. Encyclopedia of Pharmaceutical Technology, 3rd edn. New York, NY: Informa Healthcare USA, Inc, 2006: 1807–33.

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