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PAT in Freeze Drying
PAT in Freeze Drying
PAT in Freeze Drying
Disclaimer: The views expressed in this presentation are the personal opinions of the speaker and do not necessarily represent the views of FDA
Overview
Process Analytical Technology (PAT) Freeze-drying Application of PAT in freeze drying Case study Conclusion
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Process
Process Variability
Process Controls/PAT
4 Nasr, FDA
Freeze-Drying
Low-temperature drying process Convert solutions of heat-labile materials into solids Heat and mass transfer
Steps in freeze-drying:
i. Freezing: water converted to ice and the solutes are crystallized or transformed into solid
ii. Primary drying: ice crystals removed by sublimation under vacuum iii. Secondary drying: drying under vacuum where most of the unfrozen water is removed by desorption.
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TEMPRISTM
positioned bottomcenter in the vial -less robust, difficult to handle, sterility problems -Used mainly in laboratory scale wireless battery-free temperature sensors sterilizable and can be used in both laboratory and manufacturing scale optimal comparability of temperature profiles for scale up
+ Reliable, easy to sterilize - size, accurate positioning is difficult, limited validity due to measurement of temperature average primarily in manufacturing scale
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Pikal et al., 2002; Scheind & Giessler, 2008; Chouvene et al., 2005; Schneid, SP Industries Webinar, 2009
Determines the loss of weight of a sample vial during freeze drying by intermittent or continuous weighing information about sublimation rate and process step endpoints for research and development
Mayeresse & Veillon, 2006; Schneid, SP Industries Webinar, 2009 7
Pressure Measurements
Capacitance Manometer Thermal conductivity sensor (Pirani) Dew point sensor
Roy and Pikal, 1989; Jennings and Duan, 1995; Schneid, SP Industries Webinar, 2009
Pressure Measurements
Mass Spectrometer Plasma emission spectroscopy Manometric Temperature Measurement (MTM)
Measures water vapor, N2 also any additional residual solvents, volatiles, etc
LyotrackTM: Spectroscopic measurement of water concentration in the chamber atmosphere using a cold plasma source connected to the chamber
Pressure Rise Tests are performed periodically by rapid closing (<0.1 s) of the isolation valve between chamber and condenser (laboratory scale)
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Milton et al., 1997; Tang et al., 2006a; Tang et al., 2006b; Schneid, SP Industries Webinar, 2009
Pressure Measurements
Tunable Diode Laser Absorption Spectroscopy
NIR-spectroscopic method for the determination of trace concentrations of a gas No contact to the product Use in sterile processes (manufacturing) and in all scales of freeze dryers Eg: SMARTTM freeze dryer
www.tdlas.com; Schneid, SP Industries Webinar, 2009 10
Spectroscopic Techniques
Near infra red/Raman Spectroscopy
Near infra-red: for residual moisture measurements in vials through continuous measurements during secondary drying Raman: for determination of physical product characteristics Only one vial monitored for research and development
Brulls et al., 2003;Liu; Bai et al., 2005; Lin & Hsu, 2005, Schneid, SP Industries Webinar, 2009 De Beer et al., 2007; Romero-Torres et al., 2007 11
LyostatTM
Determination of crystallineDetermination of crtical temperatures amorphous transitions (Collapse/Eutectic) for optimized 13 process Taylor and Zhai, , ;Hatley and Franks, 1991; Pyne and Suryanarayanan, 2001
A Case Study
Use of Near Infra-Red (NIR) to determine moisture content for Freeze-Drying Unit Operation
Design
Analyze
Control
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Design
Noncontact probes built into the chamber through gaps made in the door of the freeze dryer chamber Placement of sensor depends upon measurement attribute: NIR for residual moisture content and cake quality placed at the bottom of the vial Calibration is set up with various levels of moisture content of the product analyzed with NIR. Calibration can be performed on-line or off-line and validation test samples are also run on the NIR instrument.
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Analyze
Principal Component Analysis (PCA) to characterize raw materials and process variables
Partial Least Square (PLS) regression to investigate the linkages between spectral information and other sources of data. Sometimes done after pretreatment (2nd derivative or normalization of spectral data)
Y = f{x}+error
Build robust prediction model. Determine accuracy, precision, errors of calibration and prediction 16
Control
Feed incoming data into the computer
If obtained Y is on target, no need to change operating parameters If outside the range, operating parameters are adjusted
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Drying Curve
Knowledge space
% water
Drying time
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Summary
Improve process control and deliver more consistent product quality and achieve higher operational efficiency by use of PAT in biotech Freeze-drying process
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Questions?
Rakhi.shah@fda.hhs.gov
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