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Pharma Tech Outlook | Wednesday, February 01, 2023
Chemical process engineers know that even if you follow the steps exactly, the wrong temperature - too high or too low - can have an adverse impact on the product.
Fremont, CA: Developing a safe and robust process that will allow pharmaceutical firms and Contract Manufacturing Organizations (CMOs) to bring the API to market safely and effectively is the number-one goal of their business.
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It is the research scientist's job to identify the process, or development route that is robust, safe, scalable, while also providing a path leading to the best yield and purity. Route selection is crucial.
Six issues that can arise during API manufacturing – and how to resolve them:
Unexpected impurities
As a result of scaling up, unknown impurities or a greater yield of impurities can be produced. Impurities can emerge during scaling up that weren’t present in smaller-scale production or their amounts can increase dramatically. As a result, the R&D team needs to examine each step to determine whether an impurity can be eliminated or reduced.
Problems with starting materials
The team may need to evaluate the grade or supplier of a key starting material if it does not work as intended. Occasionally, it is necessary for the CMO to re-do the process if the work was performed in a different facility or the other provider took shortcuts that were not documented.
The initial process may not be scalable
There would be a need to reevaluate the process, including determining if the master batch records are sloppy. Another option is to determine if there are larger machines available that will mimic R&D.
Time needed in production
Stability of the material should be an important consideration. It is sometimes difficult for teams to ask whether a product is stable enough to be held, or if it is likely to degrade, in the quest to progress to the next step.
Wrong temperature
Chemical process engineers know that even if you follow the steps exactly, the wrong temperature - too high or too low - can have an adverse impact on the product.
Poorly defined Critical Process Parameters (CPPs)
In the FDA's definition, a critical process parameter (CPP) is one whose variability affects a critical quality attribute (CQA). The order of addition, particle size, moisture content, filtration method, and many other factors must be considered. Scaling up could pose major issues if they are not clearly defined ahead of time.
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