Skip to main content

Application of QbD Elements in the Development and Manufacturing of a Lyophilized Product

  • Chapter
  • First Online:
Principles and Practices of Lyophilization in Product Development and Manufacturing

Part of the book series: AAPS Advances in the Pharmaceutical Sciences Series ((AAPS,volume 59))

  • 875 Accesses

Abstract

Since the roll out of ICH Q8, Q9, and Q10 documents and FDA drafted a QbD CMC review MaPP (MAPP 5016.1), the regulatory agencies expect and encourage the pharmaceutical/biopharmaceutical industry the use of QbD in drug applications as implementation of QbD will enhance the assurance of pharmaceutical quality in the market and improve the quality of CMC information submitted. It is believed to be a win-win situation for both industry and regulators as it ensures less IRs (information request) during the review, speeds up approval process, and provides flexibility to make changes within the design spaces while providing a quality product with a better design with fewer problems in manufacturing resulting in reduction in overall costs of manufacturing, and creates less waste. This chapter describes how QbD elements—risk assessment, process characterization, and design space—can be applied to design, develop, and scale-up and control the lyophilization process.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 139.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 179.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 179.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. US Food and Drug Administration, Center for Drug Evaluation and Research, Office of New Drug Quality Assessment. Quality by design implementation: significant accomplishments to date. www.fda.gov/aboutfda/transparency/track/ucm238167.htm.

  2. ICH harmonised tripartite guideline Q8(R2): pharmaceutical development (Step 4). International conference on harmonisation of technical requirements for registration of pharmaceuticals for human use. Geneva, Switzerland, August 2009.

    Google Scholar 

  3. Pikal M. Freeze drying. In: Swarbrick J, editor. Encyclopedia of pharmaceutical technology, vol. 1. New York: Informa Healthcare USA, Inc; 2007. p. 1807–73.

    Google Scholar 

  4. Pikal MJ, Rigsbee D, Roy ML, Galreath D, Kovach KJ, Wang W, Carpenter JF, Cicerone MT. Solid state chemistry of proteins: II. The correlation of storage stability of freeze-dried human growth hormone (hGH) with structure and dynamics in the glassy solid. J Pharm Sci. 2008;97(12):5106–21.

    Article  CAS  PubMed  Google Scholar 

  5. Pikal MJ, Rigsbee DR. The stability of insulin in crystalline and amorphous solids: observation of greater stability for the amorphous form. Pharm Res. 1997;14:1379–87.

    Article  CAS  PubMed  Google Scholar 

  6. Yoshioka S, Aso Y, Kojima S. Usefulness of the Kohlrausch-Williams-Watts stretched exponential function to describe protein aggregation in lyophilized formulations and the temperature dependence near the glass transition temperature. Pharm Res. 2001;18:256–60.

    Article  CAS  PubMed  Google Scholar 

  7. Searles JA, Carpenter JF, Randolph TW. Annealing to optimize the primary drying rate, reduce freezing-induced drying rate heterogeneity, and determine T’g in pharmaceutical lyophilization. J Pharm Sci. 2001;90(7):872–87.

    Article  CAS  PubMed  Google Scholar 

  8. Zhu T, Moussa EM, Witting M, Zhou D, Sinha K, Hirth M, Gastens M, Shang S, Nere N, Somashekar SC, Alexeenko A, Jameel F. Predictive models of lyophilization process for development, scale-up/tech transfer and manufacturing. Eur J Pharm Biopharm. 2018;128:363–78.

    Article  CAS  PubMed  Google Scholar 

  9. Pikal MJ, Shah S. Intravial distribution of moisture during the secondary drying stage of freeze drying. PDA J Pharm Sci Technol. 1997;51:17–24.

    CAS  PubMed  Google Scholar 

  10. ICH harmonised tripartite guideline Q9: quality risk management (Step 4). International conference on harmonisation of technical requirements for registration of pharmaceuticals for human use. Geneva, Switzerland, November 2005.

    Google Scholar 

  11. Zheng JY, Janis LJ. Influence of pH, buffer species, and storage temperature on physicochemical stability of a humanized monoclonal antibody LA298. Int J Pharm. 2006;308(1–2):46–51.

    Article  CAS  PubMed  Google Scholar 

  12. Thompson RW Jr, Latypov RF, Wang Y, Lomakin A, Meyer JA, Vunnum S, Benedek GB. Evaluation of effects of pH and ionic strength on colloidal stability of IgG solutions by PEG-induced liquid-liquid phase separation. J Chem Phys. 2016;145(18):185101.

    Article  PubMed  Google Scholar 

  13. Shah A, Patel SM, Jameel F. Application of QbD principles for lyophilized formulation development. In: Jameel F, Hershenson S, Khan M, Martin-Moe S, editors. Quality by design for biopharmaceutical drug product development, AAPS advances in the pharmaceutical sciences series, vol. 18. New York: Springer; 2015. https://doi.org/10.1007/978-1-4939-2316-8_14.

    Chapter  Google Scholar 

  14. Al-Hussein A, Gieseler H. The effect of mannitol crystallization in mannitol–sucrose systems on LDH stability during freeze-drying. J Pharm Sci. 2012;101(7):2534–44.

    Article  CAS  PubMed  Google Scholar 

  15. Liao X, Krishnamurthy R, Suryanarayanan R. Influence of the active pharmaceutical ingredient concentration on the physical state of mannitol—implications in freeze-drying. Pharm Res. 2005;22(11):1978–85.

    Article  CAS  PubMed  Google Scholar 

  16. Colandene JD, Maldonado LM, Creagh AT, Vrettos JS, Goad KG, Spitznagel TM. Lyophilization cycle development for a high-concentration monoclonal antibody formulation lacking a crystalline bulking agent. J Pharm Sci. 2007;96:1598–608.

    Article  CAS  PubMed  Google Scholar 

  17. Moussa EM, Zhu T, Jameel F. Chapter 16: Development of robust lyophilization process for therapeutic proteins: a case study. In: Jameel F, Skoug J, Nesbitt R, editors. Development of biopharmaceutical drug-device products, AAPS advances in the pharmaceutical sciences series, vol. 35. Springer; 2020.

    Chapter  Google Scholar 

  18. Vargo KB, Stahl P, Hwang B, Hwang E, Giordano D, Randolph P, Celentano C, Hepler R, Amin K. Surfactant impact on interfacial protein aggregation and utilization of surface tension to predict surfactant requirements for biological formulations. Mol Pharm. 2021;18(1):148–57.

    Article  CAS  PubMed  Google Scholar 

  19. Patapoff TW, Overcashier DE. The importance of freezing on lyophilization cycle development. BioPharm. 2002;15(3):16–21+72.

    Google Scholar 

  20. Rambhatla S, Pikal MJ. Heat and mass transfer scale-up issues during freeze-drying, I: atypical radiation and the edge vial effect. AAPS PharmSciTech. 2003;4(2):22.

    Article  PubMed Central  Google Scholar 

  21. Liu L, Qi W, Schwartz DK, Randolph TW, Carpenter JF. The effects of excipients on protein aggregation during agitation: an interfacial shear rheology study. J Pharm Sci. 2013;102(8):2460–70.

    Article  CAS  PubMed  PubMed Central  Google Scholar 

  22. Patel S, Jameel F, Sane S, Kamat M. Lyophilization process design and development using QbD principles. In: Jameel F, Hershenson S, Khan M, Martin-Moe S, editors. Quality by design for biopharmaceutical drug product development, AAPS advances in the pharmaceutical sciences series, vol. 18. New York: Springer; 2015. https://doi.org/10.1007/978-1-4939-2316-8_14.

    Chapter  Google Scholar 

Download references

Acknowledgment

We would like to acknowledge Abe Germansderfer for his valuable insights and contributions.

Author information

Authors and Affiliations

Authors

Editor information

Editors and Affiliations

Appendix (Table 18)

Appendix (Table 18)

Table 18 Model definition

Rights and permissions

Reprints and permissions

Copyright information

© 2023 America Association of Pharmaceutical Scientists

About this chapter

Check for updates. Verify currency and authenticity via CrossMark

Cite this chapter

Jameel, F. (2023). Application of QbD Elements in the Development and Manufacturing of a Lyophilized Product. In: Jameel, F. (eds) Principles and Practices of Lyophilization in Product Development and Manufacturing . AAPS Advances in the Pharmaceutical Sciences Series, vol 59. Springer, Cham. https://doi.org/10.1007/978-3-031-12634-5_23

Download citation

Publish with us

Policies and ethics