Suitable packaging for pharmaceutical products is a must to ensure the integrity of the products is maintained, which includes making sure the product does not degrade, become contaminated, or get damaged when being transported, for example. The role packaging plays in protecting drug products is important irrespective of dosage form or administration route; however, as the drug molecules themselves become more complex, packaging has also needed to advance.

“With highly complex biologics and other specialty drugs representing an increasing proportion of the pharmaceutical market, demand for pre-sterilized and ready-to-use (RTU) drug packaging options has increased in recent years; valued at $8.42 billion in 2022 and predicted to reach $14.23 billion by 2031 (1),” says Carole Grassi-Mircich, chief commercial marketing and innovation officer at SGD Pharma. “As well as this, trends such as personalized treatments in place of blockbuster drugs, increasing regulatory quality and compliance and a move towards self-medication, are changing the way that drugs are administered and therefore manufactured.”

“As the drug pipeline becomes more complex with the rise of biologics and personalized medicine, sterile drug containment and delivery systems have emerged as a great solution,” explains Robert Lindner, global product manager for Bulk and Sterile Solutions at SCHOTT Pharma. “Both prefillable polymer syringes and RTU [ready-to-use] cartridges offer the versatility to handle a wide range of drug formulations. The ability to pre-fill syringes and cartridges in a sterile environment and their compatibility with various drug formulations make them indispensable for biologics and other complex therapies and reduce the risk of contamination.”

Made from either glass or advanced polymers, prefillable syringes are a convenient option for the end user and have become a cornerstone of modern drug packaging, asserts Nina Krautwurst, global product manager for Polymer Solutions at SCHOTT Pharma. “Polymer syringes offer the advantage of being shatterproof, significantly reducing the risk of breakage during handling. This is crucial for maintaining the integrity of sensitive biologics and high-value medications. The design of these syringes has evolved to ensure they are user-friendly and safe, making them ideal for both clinical and at-home use. Their compact and robust nature facilitates easy integration into secondary packaging solutions.”

Additionally, there have been advances made in secondary packaging for prefillable syringes to ensure safe transportation and storage, specifies Krautwurst. “Modern designs focus on maintaining the syringes in optimal condition and ready for use. This includes robust and compact packaging solutions that emphasize safety and compliance,” she says. “The secondary packaging is designed to be user-friendly, facilitating easy handling and reducing the risk of contamination.”

Pharmaceutical companies are moving toward RTU components as preferred solutions to meet the needs of the market and address challenges, concurs Grassi-Mircich. “And [pharmaceutical companies] are outsourcing their packaging to trusted experts who offer sterile and RTU options, [which,] in turn, has led pharmaceutical packaging manufacturers to invest in advanced packaging facilities to meet increased demand and ensure effective and timely product delivery,” he adds.

Grassi-Mircich also points out that for primary packaging of pharmaceuticals, glass provides significant benefits, including strong chemical and mechanical performance, and sustainability. “Based on the proven success of other RTU glass primary packaging solutions, RTU molded glass vials offer a new choice to pharmaceutical industries in aseptic manufacturing and processing,” she says.

“Molded glass brings its own improved chemical durability and greater mechanical strength, combined with proved industrial platforms for RTU primary packaging as well as state-of-the-art secondary packaging systems, such as trays and nest and tubs used in fill and finish,” Grassi-Mircich continues. “Secondary packaging removes glass-to-glass contact, improving the aseptic filling lines of pharmaceutical companies and reducing the risk of failure during drug manufacturing and development. The expansion of the pre-sterilized and RTU market has triggered renewed demand for secondary packaging systems that can easily incorporate RTU offerings.”

For RTU cartridges, particularly prior to the filling stage, secondary packaging developments have focused on sterility and protection, often incorporating sterile barrier systems such as nested tubs or trays, which maintain the integrity and cleanliness of the cartridges during transport and storage, confirms Lindner. “Modern secondary packaging solutions are optimized for automation, reducing manual handling and enhancing efficiency in high-throughput production lines. This [automation] minimizes contamination risks and streamlines the transition to the filling process, reflecting the industry’s focus on maintaining sterility while improving operational efficiency,” he says.

“Patient safety is paramount to pharmaceutical packaging manufacturers,” notes Grassi-Mircich. Additionally, it is important for packaging manufacturers, such as SGD Pharma, to ensure all products not only meet all relevant regulatory guidelines to ensure safety but also that any technological advances are also considered to improve the packaging for the patient, she states.

When looking at glass vials, for example, companies can use an internal siliconization treatment that provides advanced protection for drug products that are sensitive, aggressive, and viscous, Grassi-Mircich continues. “A micro-layer of silicone is highly bonded to the internal surface of the glass vials and acts as a barrier coating to provide dual protection: preventing ion leaching from the glass into the drug product as well as blocking drug molecules from penetrating the glass primary packaging. The internal coating enhances the functional performance of the glass vial while safeguarding the integrity of the sensitive therapeutic product to ensure it is preserved when it reaches the patient,” she adds.

“Patient safety has also been supported by the development of an external treatment on the sealing surface of glass vials that protect solid oral drug products from moisture and oxygen though a hermetic seal adhesion of the foil,” Grassi-Mircich specifies. “The vials are child-resistant senior-friendly (CRSF) compatible and have tamper-evident closures, both of which help prevent accidental ingestion.”

“Advances in drug packaging have played a crucial role in improving patient safety through several key innovations,” states Krautwurst. “Prefillable polymer syringes have significantly contributed to patient safety by offering features designed to reduce medication errors and improve the administration process. These syringes often come with tamper-evident closures, ensuring that the medication has not been compromised before use.”

Dosing errors are prevented through clear, easy-to-read labeling on the polymer syringes, which provides accurate information about the medication housed within, points out Krautwurst. “The design of these syringes allows for precise dosing, which is particularly important for administering potent biologics, ensuring that patients receive the correct amount of medication,” she says. “Additionally, using advanced polymer materials reduces the risk of contamination and particle generation, enhancing the overall safety profile of the drug.”

Another advancement in packaging, driven by the trend to large-volume subcutaneous injections, is that of specialized containers. These larger cartridges and prefilled syringes “have been developed to handle higher volumes of medication higher volumes of medication while maintaining drug stability and ensure patient comfort during administration,” remarks Lindner.

“Packaging often integrates with wearable devices, autoinjectors, or infusion pumps, enabling patients to self-administer larger doses safely and conveniently outside clinical settings,” adds Lindner. “This reduces the need for frequent hospital visits and allows for more consistent treatment adherence. Innovations in packaging have prioritized sterility and ease of use, essential for patient safety. Sterile packaging minimizes the risk of infection, while user-friendly designs help ensure patients can administer their medications correctly and comfortably. These advancements reflect a strong focus on improving patient outcomes and supporting the unique demands of complex therapies.”

Furthermore, leveraging innovative technologies to make packaging more interactive has the potential to improve overall health outcomes for patients, asserts Lindner. “These innovations can be incorporated into RTU containers’ packaging to give patients instant access to dosing instructions, reminders, and other critical information via their smartphones,” he says. “This enhanced connectivity fosters greater patient engagement and compliance, which is essential for effectively managing chronic conditions.”

While patient safety is obviously critical, other factors that can help make a product appealing to the patient must also not be overlooked. “During recent years, the demand for sustainability has accelerated throughout the packaging industry and has had a particular influence on the pharmaceutical industry,” notes Grassi-Mircich. “Consumers are now more environmentally conscious than ever before, and sustainability has become a key factor in their decision-making. In a recent survey (2), FEVE [The European Container Glass Federation] revealed that three out of four European consumers find that purchasing sustainable products makes a difference for our environment.”

Grassi-Mircich highlights that “glass is already a highly sustainable packaging material and is [now] 70% less energy intensive than 50 years ago (3). However, in response to growing consumer demand,” she continues, “the glass packaging industry is striving to improve this further, investing around €600 million [US$670 million] each year on updates to manufacturing facilities and steps in the supply chain to improve energy efficiency.”

“Sustainability has become a driving force in the evolution of drug packaging,” confirms Krautwurst. For syringes, polymer materials provide a lightweight option that require less energy to produce and transport than other materials, which can result in a lower carbon footprint, she remarks. Further, high durability of polymer syringes can lead to fewer breakages and hence less waste during handling and transportation, Krautwurst states.

“Drug packaging has also become more sustainable through efforts to reduce its ecological impact, such as using steam-sterilized RTU cartridges. Steam sterilization, which operates with ultrapure water and heat, requires lower energy levels for the same or better microbial kill rates than chemical or radiation-based sterilization techniques, reducing the overall carbon footprint,” says Lindner. “Additionally, steam sterilization does not produce harmful residues or by-products. Further innovations include using eco-friendly materials and designs that minimize waste and energy consumption.”

Along with an increased demand for greener practices from consumers, regulatory pressures and overall industry goals to lower carbon footprints are driving the shift towards sustainability, adds Lindner. “These advancements aim to balance effective sterilization with environmental responsibility, reflecting a broader commitment to sustainability in the pharmaceutical industry,” he concludes.

Pre-Sterilized/Ready to Use Pharmaceutical Packaging Market Size, Share and Trends Analysis Report by Type of Container (Sterile Cartridges, Sterile Syringes, and Sterile Vials), by Type of Closure (Caps, Plungers, Seals, Stoppers, Tip Caps/Needle Shields), by Material of Fabrication, Region, and Segment Forecasts, 2023-2031

FEVE. Sustainability and Climate-Neutral Production. 

feve.org/glass-industry-positions/sustainability-climate-neutral/

Glass Hallmark. Why Glass is Best for Pharmaceutical Packaging. 

Felicity Thomas is associate editorial director for 

®
Vol. 48, No. 10
October 2024
Pages: 10–14

When referring to this article, please cite it as Thomas, F. Out-of-the-Box Packaging Advancements. 

Articles

Cover Story

Pharmaceutical packaging must advance to adapt to new, complex modalities.

Out-of-the-Box Packaging Advancements

Submitted: April 14, 2024
Accepted: July 9, 2024

Previously, a silver-based disinfectant composed of a low concentration (approximately 0.015% by weight) of a suspension of silver was sporicidal with a one-minute wet-contact time. The proprietary technology, licensed by the Environmental Protection Agency, for producing the silver particles has been enhanced to produce more consistent numbers and sizes of silver particles in the active raw material. Confirmatory testing has been performed on three manufactured lots to verify the consistency of disinfectant efficacy in accordance with 

United States Pharmacopoeia (USP) 37–National Formulary

 32. Various microorganisms, including molds and bacterial spores, were tested on stainless-steel coupons and demonstrated 2–6 log reductions with one-minute wet-contact times. These evaluations were designed to demonstrate that the enhanced disinfectant had a similar disinfectant efficacy as the previously tested product. Sterility testing suitability on the disinfectant was demonstrated according to the 

. Sterility testing on all three lots of disinfectant was satisfactory.

It was previously reported that a silver-based disinfectant composed of a low concentration (approximately 0.015% by weight) of a suspension of silver was sporicidal with a one-minute wet-contact time (1). The proprietary technology for producing the silver particles has been enhanced to produce more consistent numbers and sizes of silver particles in the active raw material. The new product is licensed by the Environmental Protection Agency (EPA) (EPA Registration Number 96194-1, 10 March 2021). Confirmatory testing has been performed on three recently manufactured lots to verify the consistency of disinfectant efficacy in accordance with the 

 32 (2). Various microorganisms including molds and bacterial spores were tested on stainless-steel coupons and demonstrated 2-6 log reductions with one-minute wet-contact times. These evaluations were designed to demonstrate that the enhanced disinfectant had a similar disinfectant efficacy as the previously tested product. Sterility testing suitability on the disinfectant was demonstrated according to the 

 (3). Sterility testing on all three lots of disinfectant was satisfactory.

The antimicrobial effects of silver (Ag) have been recognized for thousands of years. In ancient times, it was used in water containers (4) and to prevent putrefaction of liquids and foods. In 1884, silver nitrate drops were introduced as a prophylactic treatment for the eyes of newborns, to prevent infections caused by 

 transmitted from infected mothers during childbirth (5). In 1928, the “Katadyn Process” for water purification, based on the use of silver in water at low concentrations, was introduced (6).

The bactericidal efficacy of silver and its associated ions is through the strong binding with disulfide (S—S) and sulfhydryl (—SH) groups found in the proteins of microbial cell walls. Through that binding event, normal metabolic processes 

of the cell are disrupted, leading to cell death (7). There is also evidence that after entering a cell the silver ions displace the hydrogen bonds between adjacent nitrogen molecules of purine and pyrimidine bases which may stabilize the DNA helix and prevent replication of the DNA and, subsequently, division of the cell (8).

John M. Lindsay (SM) ACM, is president, Aseptic Solutions, Inc.

®
Vol. 48, No. 10
October 2024
Pages: 27–33

When referring to this article, please cite it as Lindsay, J. M. A Silver-Based Disinfectant—Non-Corrosive, Non-Toxic, Sporicidal: Disinfectant Efficacy Evaluations. 

Peer-Reviewed Research

Various microorganisms, including molds and bacterial spores, were tested on stainless-steel coupons and demonstrated 2–6 log reductions with one-minute wet-contact times.

A Silver-Based Disinfectant—Non-Corrosive, Non-Toxic, Sporicidal: Disinfectant Efficacy Evaluations

Improving the sustainability of small-molecule API manufacturing is essential to ensuring the continued success of the pharmaceutical industry. For most APIs, however, evaluating the global warming potential along the whole value chain or lifecycle is difficult. The greatest contributor to the carbon footprint of API manufacturing operations is the use of solvents, reagents, and precious metal catalysts, for which significant restrictions on recycling and reuse can exist. The major argument against reuse and recycling is based on product and application safety, according to Michael Nonnenmacher, director global business development differentiating technologies with Evonik.

The ability to recycle and/or reuse these materials, however, enables measurable resource savings and carbon footprint reduction. “For multi-step syntheses, it is likely that hundreds of kilos of raw materials are used to produce a single kilogram of final product. It is still common practice to incinerate most of the waste generated from these raw materials, oftentimes resulting in tons of carbon dioxide (CO2) per kilo product. The possibility to recover some of these materials or replace them with greener alternatives would enable a tremendous reduction of the process carbon footprint and improve the overall sustainability of these operations,” Nonnenmacher states.

Solvent and catalyst recycling offers several significant advantages. In contrast to incineration or other forms of disposal, which generate substantial amounts of CO

, catalyst and solvent recycling allow repurposing in the same process or in different applications with minimal energy expenditure, according to Niklaus Künzle, senior director, global head of process technology and innovation for small molecules at Lonza. In addition to the reduced direct CO

 emissions, this approach also necessitates less production of raw materials, resulting in further substantial savings in both energy and CO

Solvent recovery is the most practiced recycling solution in established large-scale processes. “For API manufacturing, the use of recycled solvent is mostly restricted to the same process and a limited number of cycles, and a thorough risk assessment to mitigate potential impurity formation and accumulation in the process is needed,” Nonnenmacher says. “Since the discovery of nitrosamine impurities, which are potent carcinogens, stemming from solvent degradation, recovery is under a lot of scrutiny, but it should still be considered in cases where it will result in no process risk,” he adds. In cases where it is not appropriate to use recycled solvent in the API production process, Nonnenmacher observes that it is possible to find other fine-chemical applications where they are suitable.

Recycling of expensive palladium, platinum, rhodium, and other precious metal catalysts helps not only to reduce costs, but the carbon footprint associated with the mining and refining operations necessary to obtain the metals, notes Nonnenmacher. While solvent recycling is often performed in-house, the transformation of used catalysts back into active species is typically performed externally by specialized companies, according to Künzle.

In addition, although filtration of heterogeneous catalysts from process wastes is typically easy, separation of dissolved homogeneous catalysts from oftentimes dilute solutions requires more specialized technologies, comments Nonnenmacher. “Evonik has established an efficient process for the concentration of precious metal-containing organic waste streams using membrane cross filtration. This approach enables the sustainable recovery of the metal at the refinery, and thus contributes to resource saving and carbon footprint reduction,” he says.

The best strategy for realizing the greatest benefits from recycling during API manufacturing is to, according to Nonnenmacher, apply the principles of green chemistry early on during process development. “In this manner, it is possible to implement eco-friendly and more sustainable raw material and API manufacturing processes,” he notes. Key considerations highlighted by Nonnenmacher include avoiding the use of large volumes of especially hazardous organic solvents that cannot be recycled, applying process intensification approaches, and controlling the atom economy for waste reduction.

“Beyond these approaches, the introduction of recycling concepts or reuse options into processes right from the beginning can facilitate acceptance by regulatory authorities,” Nonnenmacher contends. Performance of process and product life-cycle analyses to generate important sustainability metrics such as process mass intensity and E-factor values when a candidate is in clinical development can, he says, help pharmaceutical firms and API makers visualize and understand potential adverse steps in the synthesis early enough, allowing manufacturers to implement more sustainable solutions.

Of course, one of the best approaches to improving sustainability is to avoid the use of problematic processes and materials. “Ideally, the most elegant solution is to minimize or completely eliminate the use of solvents,” Künzle states. Lonza therefore strives to implement process improvements in collaboration with drug developers during the early development phase. “These process improvements aim to reduce the number of used solvents, decrease dilution, and enhance the process yield. Selection of process solvents is also optimized by considering solvents and mixtures that are feasible to recover from process waste streams,” he explains.

Recycling compounds from a complex mixture requires efficient separation techniques, such as rectification and membrane separation. Continuous liquid-liquid or liquid-solid separation may also be employed, according to Nonnenmacher. The adsorption to scavengers or filter aids can be efficient for catalysts as well. Immobilizing catalysts such as enzymes by attaching them to a solid substrate also facilitates recovery and reuse, he says.

For solvents specifically, distillation, extraction, adsorption, and membrane separation techniques, according to Künzle. “Often,” he notes, “multiple technologies must be combined to ensure the purity required for recycling these materials back into API processes.”

Nonnenmacher also emphasizes that both increasing cost constraints and sustainability ambitions are driving the development of more efficient processing techniques for separation, as well as more selective processes that result in waste mixtures that are less difficult to separate.

Recycling, whether of solvents or catalysts, is often not an easy task given the complex solutions used in API manufacturing. “Extracting valuable materials from complex process mixtures can be a significant challenge, especially when aiming to restore them to a high-purity starting quality with minimal energy consumption and at minimal cost,” says Künzle.

Another major challenge for implementing recycling solutions at both clinical and commercial scale is that recycling is usually not attractive enough for small campaigns, according to Nonnenmacher. “It is considered a given that waste is sent to incineration and, therefore, oftentimes from a cost and effort perspective, recycling strategies are not a priority,” he adds. In addition, especially for smaller API manufacturing sites that are not fully self-sustained, there are significant logistical constraints given that recycling requires significant site infrastructure. “Even if waste streams are shipped offsite for recovery, a minimum buffer capacity separate from other wastes needs to be available,” Nonnenmacher observes.

Another factor that impacts recycling opportunities is regulatory considerations. The recycling of solvents in API manufacturing may come with potential impurity accumulation and is therefore scrutinized by regulating authorities, especially when considering environmental- and health-critical solvents, according to Nonnenmacher.

For example, Nonnenmacher points to the decomposition of dimethyl formamide (DMF) to dimethylamine and the potential for subsequent formation and accumulation of the carcinogen N-nitrosodimethylamine, which makes DMF recycling almost prohibitive.

When developing a solvent recycling process, notes Künzle, it is therefore crucial to ensure that no by-products accumulate in the solvents, which involves extensive laboratory and pilot testing and continuous analysis. In addition, whenever recycling of less critical solvents is possible from a risk perspective, Nonnemacher once again emphasizes the importance of establishing any recycling concepts during early development and into validation and using a defined, limited number of cycles before final disposal. “As part of the process, the recycling concept needs to be filed and accepted by the authorities,” he notes.

A risk-based approach to recycling is also required for materials other than solvents. “In most cases, waste streams from API manufacturing must be incinerated due to the potential risk of pharmaceuticals or other contaminants leaking into the environment,” observes Nonnenmacher. However, he does comment that recycling of metals that in principle undergo complete reset to their original state is handled outside of the process and not questioned by regulatory agencies.

Regardless of the material or technology, the best strategy is to integrate recycling considerations into regulatory filing activities from the very beginning, Künzle concludes.

Recognition of the importance of increasing the sustainability of pharmaceutical manufacturing operations is driving investment in many new technologies and solutions, including those for recycling. “Current and future innovation in many fields will contribute to the sustainability of API manufacturing and recycling of process components. Those innovations may come from established fields like from physical separations, or from research areas less obviously related, such as more in-depth process development supported by artificial intelligence resulting in more efficient production methods and cleaner off-streams, which would be easier to recycle,” Nonnenmacher comments.

Lonza, for instance, is working to enhance its entire infrastructure to enable the realization of additional recycling solutions, according to Künzle. One example is the expansion of pervaporation capacities in Switzerland, which allow the company to process challenging mixtures with minimal energy expenditure. Lonza is also applying new oxidation and enzymatic technologies for wastewater treatment that involve significantly reduced energy consumption.

Evonik, meanwhile, is leveraging fundamentally different approaches to how pharmaceutical chemistry is performed. One example is the Chemistry in Water platform the company is developing and using for the manufacture of active ingredients. “This technology allows significant reduction of organic solvent consumption, oftentimes combined with offering superior reaction performance, such as in the field of cross-coupling reactions,” Nonnenmacher says.

Cynthia A. Challener, PhD, is a contributing editor to 

®
Vol. 48, No. 10
October 2024
Pages: 18–20, 33

When referring to this article, please cite it as Challener, C.A. Improving the Sustainability of API Manufacturing with Recycling Technologies. 

Development

Sustainability of small-molecule API manufacturing ensures continued success.

Improving the Sustainability of API Manufacturing with Recycling Technologies

Advances in equipment and control systems for three-dimensional printing (3DP) are creating new opportunities to use this alternative manufacturing method for solid dosage drugs. Printers—which are available in good manufacturing practice (GMP) versions—use various additive manufacturing methods to build layer upon layer, which allows precise placement of multiple ingredients within a dose. This customization offers advantages for modified and controlled release, personalized medicine, and point-of-care manufacturing, such as in hospital pharmacies.

“3DP’s material placement turns geometry into a dosing parameter,” explains Sharon Flank, CEO of technology company InfraTrac. “It can use layer thickness, shape, and differential material properties to create complex versions of controlled-release particles.” For example, 3DP can create “upstairs and downstairs layers for a polypill of two or more APIs, or an outer layer and multiple inner layers for precision control of release. Shape manipulation can control release in a way no tablet will ever do,” Flank says. Although 3DP is not as fast as conventional tableting, it can be used to meet the needs of a smaller target patient population that was previously underserved. Custom modifications can be quickly performed via software that controls material placement, compared to conventional tableting that would require tooling changes, Flank explains.

Using 3DP, dosage shapes can go beyond tablets, Flank adds. InfraTrac is working with Stephen Hoag’s Applied Pharmaceutics Lab at the University of Maryland School of Pharmacy on extrusion-based 3DP techniques to create orodispersible films, such as a pediatric rifapentine dose to treat tuberculosis. Outside of oral dosage, the researchers are designing long-acting implants with internal compartments for subdoses.

One example of using 3DP to meet a patient need is Aprecia’s levetiracetam, a high-drug load, rapidly disintegrating design for patients with difficulty swallowing that was approved by FDA in 2015. Made using the company’s 3D-printed ZipDose technology, it was the first drug to be approved using 3DP. It is made with an open-bed, binder-jetting method. More recently, Aprecia has developed its Z-Form 3DP platform integrated with process analytical technology (PAT) that prints doses directly in their primary packaging. The company worked with Battelle to develop the new technology platform for the development and production of dosage forms with a range of functionalities, including the ability to 3D print customized tablets or those with multiple APIs (1).

Triastek is using its Melt Extrusion Deposition (MED) 3DP process for microstructured drug delivery platforms that it has designed for modified release, colon targeting, gastric retention, solubility enhancement, and for improving oral bioavailability of peptides. The company has five drug products in clinical development (in the United States, China, or both) that use these platforms, including its most recent, a 3D-printed drug product designed for extended release and absorption of drugs in the upper gastrointestinal tract that received investigational new drug (IND) clearance from FDA in early 2024 (2).

In July 2024, Triastek announced a collaboration with BioNTech to develop oral delivery forms of RNA therapeutics using 3DP. The researchers aim to use multilayer and multi-compartment tablet designs to minimize degradation in the gastrointestinal tract and deliver the dose to where it can be absorbed optimally (3).

In addition to serving smaller patient populations, the flexible, small volumes enabled by 3D printing are useful in formulation development and clinical manufacturing.

“In clinical and preclinical trial supply, a nimble, small-scale production system could save a lot of time and therefore money,” says Flank. “Whether the final doses are produced via 3DP or conventionally, it is clearly helpful to be able to test several different formulations in a single day or even hour.”

Triastek is working with Boehringer Ingelheim to quickly create multiple prototypes of a new chemical entity and examine dose designs and drug release behavior using its 3DP technology (4). The company says its formulation-by-design approach can accelerate early drug development.

Small 3D printers can be useful for point-of-care manufacturing in a hospital pharmacy or potentially for remote locations, such as battlefields or space travel. A GMP-ready printer from FABRX, the M3DIMAKER, is now available with either one or three printheads and with printhead attachments for different extrusion printing methods—fused deposition modeling, semi-solid extrusion, and direct powder extrusion (DPE).

“We are working with hospitals and healthcare providers to implement our 3D-printing solutions directly into clinical settings, allowing for on-site production of personalized medications,” says Alvaro Goyanes, director and co-founder of FABRX. The United Kingdom-based company also launched a US-based company, FABRX US, in 2024, and is working with InfraTrac and Hoag’s lab on PAT for quality control.

The researchers, funded by the National Institute of Standards and Technology (NIST) through a Small Business Innovation Research program, are working on a predictive model that uses a near infrared (NIR) spectrometer incorporated into the drug printer, in this case the FABRX M3DIMAKER2, says Flank. The lab initially used a Viavi MicroNIR spectrometer and is also testing a Sentronic instrument. “Preliminary results show how NIR can validate and even quantitate API, detect out-of-specification moisture, and reject certain mis-printed doses,” reports Flank. “A robust model should facilitate point-of-care customization by creating pass/fail quality parameters that allow the pharmacist to manage doses and flavorings while delivering GMP product.”

“Integrating PAT and advanced testing capabilities into our machines addresses a critical need for real-time quality control and assurance in 3D-printed pharmaceuticals,” adds Goyanes. “This integration ensures that every product meets stringent quality standards, enhancing the reliability and safety of the medications produced.”

Goyanes points out that the development of effective cleaning protocols for printheads is essential to maintain equipment performance and prevent cross-contamination. FABRX introduced a new DPE printhead cleaner in July 2024 to improve the cleaning process. The company continues to work on technologies to meet other user needs it has identified, including development of modular and scalable 3D printing systems that can be easily adapted to different production volumes and requirements, Goyanes says.

Another technology designed for 3D-printing of personalized medicine in compounding pharmacies is the Pharma Kit from CurifyLabs. The platform includes GMP-manufactured excipient bases (called Pharma Inks); a desktop-sized automated Pharma Printer; software containing a library of validated formulae of Pharma Inks with APIs that guides the user; and integrated, automated quality control tools.

“Our goal was to modernize and bring automation to compounding and hospital pharmacies to make safer products and save time,” says Niklas Sandler, founder and CTO at CurifyLabs.

The developers automated as much of the workflow as possible, including weighing, mixing, dispensing, and packaging, explains Sandler. The built-in quality control tools include NIR to test blend homogeneity and a weigh scale to measure every tablet. The library of premanufactured excipient bases that have been optimized for the printing process and the formulations that have been validated are crucial to the system, says Sandler.

“We did all the validation work up front so that it would be easy and quick for pharmacists to follow the validated process. The technology can be used to produce a wide range of dosage forms, such as tablets and suppositories, and to dispense liquids accurately. The Pharma Kit is used in several markets in Europe,” Sandler adds.

“Both Europe and North America are witnessing a growing adoption of 3D printing in the pharmaceutical industry,” Goyanes suggests. In 2023, Goyanes and others launched the Pharmaceutical 3D Printing Initiative, an international consortium to facilitate collaboration between academic institutions, healthcare providers, regulatory agencies, and industry players. Other partnerships with universities and hospitals aim to train the next generation of scientists and engineers in 3D printing technologies. “These collaborations are crucial for advancing the field and ensuring that our solutions are continually evolving to meet the dynamic needs of the healthcare industry,” Goyanes concludes.

Aprecia. Aprecia and Battelle Are Impacting the Pharmaceutical Industry Through 3D Printing Innovation. Press Release, Nov. 15, 2023.

Triastek. Triastek’s 3D Printed Gastric Retention Product T22 Receives FDA Clearance of IND Application. Press Release, Jan. 31, 2024.

Triastek. Triastek Announces Research Collaboration and Platform Technology License Agreement with BioNTech to Advance 3D Printed Oral RNA Therapeutics. Press Release, July 23, 2024.

Triastek. Triastek Announces Collaboration with Boehringer Ingelheim to Advance and Accelerate Research and Development of Innovative Pharmaceutical Products with MED 3D Printing Technology. Press Release, March 17, 2023.

Jennifer Markarian is a contributing editor to 


Vol. 48, No. 10
October 2024
Pages: 22–23

When referring to this article, please cite it as Markarian, J. Exploring 3D Printing for Solid Dosage Drugs. 

Manufacturing

As a GMP manufacturing method, 3D printing offers benefits for modified release and personalized dosages. 

Exploring 3D Printing for Solid Dosage Drugs

It’s an election year in the United States, and it’s not just the cost of groceries that Americans are concerned with. The cost of medications has been a long-standing debate in the US government. How the Republican and Democrat presidential candidates might appeal to voters on this topic is starting to be seen. But will pharmaceutical companies take a hit?

In the past, according to Allison Gatlin of 

, the previous administration under Donald Trump proposed an approach whereby the Medicare prices for drugs given in doctor’s offices are linked to an international pricing index. There was also a plan to pass rebates to Medicare enrollees that would go to insurers and pharmacy benefit managers (1). If Trump is elected for a second term, it is possible that he could seek to implement the use of international price referencing for prescription drug costs, which had failed to get approval during his first term in office (2).

The current Administration, which includes Democrat presidential nominee, Vice President Kamala Harris, is jumping into the ring by announcing lower prices for the first 10 drugs selected for Medicare price negotiation (3). Medicare can negotiate prescription drug prices as part of the power given to it by the Inflation Reduction Act, which was signed into law by President Biden in August 2022.

Harris has also backed a draft guidance to allow federal agencies to exercise “march-in rights” (4). This guidance, if approved, would mean that federal contractors could retain the rights to patents for innovations developed with federal financial backing. Essentially, this is aimed at enabling greater competition within a specified market, such as healthcare.

However, this is not the first time that market competition has been assessed in the US. In fact, this year sees the 40th anniversary of the Drug Price Competition and Patent Term Restoration Act of 1984, which was created to increase market competition between generic-drug companies and pharmaceutical companies. This Act, according to Darby Kozak, PhD, deputy director for the Center for Drug Evaluation and Research, Office of Generic Drugs, in FDA, resulted in a growth in the generic-drug market, with generic drugs increasing from 19% of the market in 1984 to 90% in 2024 (5).

Whichever way the pendulum swings in November 2024, the bio/pharma industry should probably brace itself for an impact.

1. Gatlin, A. 2024 Election: Drug Prices Remain a ‘Hot Topic’. Can Pharma Stocks Withstand the Pressure? 

2. Cohen, J.P. Trump Plans to Rescind Funds for IRA Law’s Climate Provisions, but May Keep Drug Price Measures. 

FACT SHEET: Biden-Harris Administration Announces New, Lower Prices for First Ten Drugs Selected for Medicare Price Negotiation to Lower Costs for Millions of Americans. 

March-In Rights Under the Bayh-Dole Act: Draft Guidance. 

5. FDA. 40th Anniversary of the Generic Drug Approval Pathway. CDER Conversations. 

, Sept. 23, 2024 (accessed Sept. 25, 2024). 

Mike Hennessy Jr is President and CEO of MJH Life Sciences®.

When referring to this article, please cite it as Hennessy, M. Drug Prices on Debate. 

From the CEO

How the Republican and Democrat presidential candidates might appeal to voters on this topic is starting to be seen. 

Drug Prices on Debate

Q: I work for a 503B compounding organization. A customer has asked us to manufacture a drug product that includes a food-grade component because it is less expensive than the compendial-grade material. Is this an acceptable substitution?

A: No. Substituting a food-grade material when a compendial material is available is not acceptable. US 21 United States Code (USC) 351 states that a drug is considered adulterated if it “purports to be or is represented as a drug the name of which is recognized in an official compendium, and its strength differs from, or its quality or purity falls below, the standard set forth in such compendium” (1). This section of the USC goes on to state, “No drug defined in an official compendium shall be deemed to be adulterated under this paragraph because it differs from the standard of strength, quality, or purity therefore set forth in such compendium, if its difference in strength, quality, or purity from such standard is plainly stated on its label.”

This is supported in the language contained in the General Notices of the 

] are recognized in the laws and regulations of many countries throughout the world.” It also states, “In the United States under the Federal Food, Drug, and Cosmetic Act (FDCA), both 

 are recognized as official compendia. A drug with a name recognized in 

 must comply with compendial identity standards or be deemed adulterated, misbranded, or both. See, e.g., FDCA § 501(b) and 502(e)(3)(b); also US Food and Drug Administration (FDA) regulations, 21 

] § 299.5(a&b). To avoid being deemed adulterated, such drugs must also comply with compendial standards for strength, quality, and purity, unless labeled to show all respects in which the drug differs. See, e.g., FDCA § 501(b) and 21 

 § 299.5(c).”The General Notices goes on to state, “Compounded preparations, including drug products compounded by outsourcing facilities, may also be subject to applicable monographs” (2).

However, there may be situations where there is no compendial standard for the material you are being asked to use in the formulation. In that case, you need to perform an assessment that would allow you to introduce the material. However, before you go through the activity of introducing a non-compendial material into your facility, it is advisable to check to see if the material in question is supported by monograph requirements contained in either the European or Japanese pharmacopoeias. If neither of those compendia contain a monograph, the following questions may help you determine if the material in question is safe to bring into your facility:

How are you going to accept this material and bring it into your facility?

Because it is food grade, are there additional specifications you need to have based on the intended use of the finished drug product?

Are there additional tests you need to conduct? If so, then talk to the supplier. You must work with supplier to establish the conditions, criteria, specifications, under which you will accept this material and make sure the additional criteria are included on the Certificate of Analysis.

Determine what type of additional training needs to be conducted so you are assured you can perform the test methods for the new material.

Determine if the cleaning procedures are effective. Is there cross-contamination to consider for the new component?

Having a robust quality management system will help you to answer these questions. You should be able to understand the risks and how to obtain information on how to sample/store the material. All of this will be in your quality management system which will allow you to have a risk management plan.

21 USC 351: Adulterated Drugs and Devices. Title 21 Food and Drugs. Updated Sept. 16, 2024.

Susan J. Schniepp is a distinguished fellow at Regulatory Compliance Associates.

When referring to this article, please cite it as Schniepp, S.J. Using Compendial-Grade Materials for 503B Compounding Facilities.Pharmaceutical Technology 

Ask the Expert

Substituting a compendial-grade material with a food-grade material is not acceptable, says Susan J. Schniepp, distinguished fellow at Regulatory Compliance Associates. 

Using Compendial-Grade Materials for 503B Compounding Facilities

Materials used in the formulation and manufacture of drug products must meet certain qualifications, as do the companies that manufacture these materials. Contract development and manufacturing organizations (CDMOs), contract testing laboratories (CTLs), and contract manufacturing organizations (CMOs) can assist sponsor companies with the testing of these crucial drug components. Testing may include analytical testing, impurities testing, and qualification services.

According to Iain McGhee, vice-president of Quality at Ascend Advanced Therapies, contract organizations can provide proprietary and sourced analytics and assays as standalone services or included in a complete program. “Regardless of who you work with, CMO/CDMOs should be able to provide suggestions on a range of testing depending on the customer program,” says McGhee. “If they do not offer this in house, they should have validated partners to do this with.”

Contractors can either do the testing or work with other, outside testing facilities to perform testing on raw materials to ensure compliance with specifications and standards. At Andelyn, according to Rajiv Vaidya, head of MS&T, the company uses a two-phased approach to raw material testing. The process is performed in-house as much as possible to keep everything streamlined. “We have a program in place to continuously evaluate and in-source as much material testing as possible,” says Vaidya. “There is a sweet spot to understanding the balance between what should and should not be done in house—it depends not only on speed and cost but what is the best or most excellent provider for any given test, whether outsourced or in-house. We will only in-source a testing method after we’ve confirmed definitively that the methodology and result will be at least equivalent to the CTLs.”

Determining how to test bio/pharmaceutical materials depends on the API, the dosage form, and the stage of the material, according to Mayank Nagar, vice-president and head–Tech Services and New Product Launches, North Americas at Dr. Reddy’s Laboratories, and Himanshu Joshi, director, New Product Launches, North Americas at Dr. Reddy’s Laboratories. Testing may be performed from pre-formulation through packaging and life-cycle management, say Nagar and Joshi.

Contract organizations can provide custom material testing services for a sponsor company’s needs, including identity tests, purity tests, assays, polymorph testing, and compatibility testing, say Nagar and Joshi. “Various physicochemical testing [such as] dissolution, particle size, description, density, LOD are routinely being serviced by CMOs. Additionally, safety, sterility testing, microbiology, and confirmatory testing are other services provided to sponsor companies,” they say.

CDMOs can also provide final product release testing, according to Kim Arsenault, Quality Compliance manager, BIOVECTRA, such as the following:

using high-performance liquid chromatography (HPLC) to provide assay and impurity content utilizing ultraviolet (UV), charged aerosol (CAD), or mass spectrometry (MS) detectors

testing for residual solvents by using gas chromatography (GC)

performing Karl Fischer (KF) titration to test water content

detecting elemental impurities by using inductively coupled plasma with mass spectrometry (ICP–MS) or optical emission spectroscopy (ICP–OES)

microbial limits and bacterial endotoxins testing

performing identity testing using chemical techniques or infrared (IR) spectroscopy

performing enzyme-linked immunosorbent assay and sodium dodecyl sulfate-polyacrylamide gel electrophoresis biochemical methods

testing for compendial compliance of pH, optical rotation, and loss on drying

performing gravimetry, titrimetry, and colorimetry bench techniques.

Production stage and the grade of materials used matters, according to McGhee. “Ironically, a lower grade of material with impurities can sometimes makes results look better. However, these results will not scale as the grade tightens—we need to know this early on,” he cautions.

Utilizing CMOs and CDMOs to perform the necessary analytical and quality testing of raw materials used in the production of bio/pharmaceutical products can ensure that these medicines are safe and effective for patients. Contract organizations typically have the knowledge, expertise, and equipment to perform the necessary testing.

“Generally, CMOs/CDMOs should be able to perform the tests outlined for characterizing APIs as listed in ICH [International Council for Harmonisation] Q6A, including characterization of physicochemical properties (e.g., pH, melting point/range, IR), particle size determination, polymorphic form, assay and impurity testing (including tests for chirality, identification tests, residual water content, residual solvents, inorganic impurities), and microbial limits (if applicable),” says Joshua Hoerner, general manager and executive vice president, Purisys (part of the Noramco Group). “It is also important to have hyphenated or specialized techniques [such as] LC–MS, GC–MS, LC–CAD/LC–ELSD, and NMR [nuclear magnetic resonance] for investigative or characterization purposes, should a sponsor’s product experience unexpected results during release or stability testing,” he concludes


Vol. 36, No. 9
October 2024
Pages: 31–33

When referring to this article, please cite it as Haigney, S. Contractors Support Material Testing. 

Outsourcing

Contract organizations offer assistance for testing raw materials obtained from outside suppliers.

Contractors Support Material Testing

Glycan modifications of recombinant proteins and antibodies can impact their function and stability and thus the safety and efficacy of drug products based on these molecules. Understanding these important critical quality attributes (CQAs) is essential, and therefore, regulatory bodies expect a comprehensive understanding of glycans for submission.

Comprehension necessitates overcoming inherent challenges such as positional isomers and heterogeneity, as well as method-induced artifacts that influence sensitivity and specificity, according to Paula Orens, senior global market development manager, Biopharma, at SCIEX.

Multispecifics, including bi-, tri-, and tetraspecific antibodies, present additional challenges to glycan analysis beyond those of traditional monoclonal antibodies (mAbs) because the complexity of these molecules is much greater.

“Site-specific and intact mass analysis may become more challenging for increasingly complex molecules, particularly when the number of N-glycosylation sites, post translational modifications, and potential degradation products increases,” observes Oscar Potter, biological chemistries R&D manager in the Chemistries and Supplies Division at Agilent.

Structurally, multispecific antibodies are a combination of different antibody domains that allow the multispecific to bind at multiple sites. “The various domains will have their own glycosylation patterns (integral to efficacy, safety, and stability) and their own impurities, all of which need to be characterized comprehensively, effectively multiplying the glycosylation analysis complexity by the number of binding sites,” Orens explains. She adds that as the number of binding sites increases, so too does the risk of intra-protein cross talk.

Multispecifics can also include candidates in which an antibody-portion is combined with some other protein-based component. Chimeric proteins, where the domains are not only antibody in origin, are complicated to analyze due to the individual properties of each component, according to Orens. “For example,” she says, “fusion proteins are typically heavily glycosylated with N- and O-linked glycans to improve biological activity, properly stabilize the structure, or improve solubility.”

“Overall,” Orens concludes, “while the complexity of analysis is dependent on the types of domains used in a multispecific, it is certain that the analysis of these molecules will be more complicated than that of a mAb.”

Consequences of incorrect glycosylation analysis

The greater complexity of multispecifics raises the stakes for achieving correct glycan analysis. “Not only can the glycosylation patterns in multispecifics impact the stability, pharmacokinetics, off-target effects, and effector functions such as complement activation and antibody-dependent cellular cytotoxicity, conceivably the additional functions that multispecific antibodies are capable of might result in unique biological consequences from incorrect glycosylation,” Potter comments.

In addition, because glycosylation is a critical and highly regulated quality attribute of all antibodies, misunderstanding or incorrectly characterizing glycosylation patterns could lead to a variety of consequences, depending on the development stage of the candidate, notes Orens. She highlights a couple of examples. “At the hit-identification stage, a mis-characterized but suitable candidate could be eliminated due to poor efficacy or stability. At later development stages, meanwhile, a drug metabolism and pharmacokinetics study could exhibit faster-than-expected clearance or undesired concentration in the target tissue. An incorrect analysis could also result in promotion of a misunderstood candidate through to late-stage toxicology studies, causing unnecessary investment in time and resources for the project only to be shut down later than expected.”

There are several different techniques used for the glycan analysis of antibody-based candidates. “Fundamentally, the same glycan analysis approaches are used for multispecific antibodies as mAbs, most commonly liquid chromatography (LC), capillary electrophoresis (CE), and mass spectrometry (MS). Each analytical approach offers a plethora of techniques which provide complementary or alternative details about the glycosylation profiles,” Orens observes. She does note, though, that the inherent complexity of the molecule will impart different challenges on each approach.

Typical analytical methods for glycosylation analysis of multispecifics are similar to those used for more traditional therapeutic mAbs, agrees Potter. “Released glycan analysis methods generate a glycan profile, usually based on separation by CE or LC. Intact LC/MS analysis can provide limited information about the major glycoforms, while LC/MS of protease-digested samples can give site-specific information for molecules with more than one glycosylation site,” he outlines.

Released glycan analysis relies on high-resolution separation of fluorescently labeled glycans by hydrophilic interaction liquid chromatography (HILIC) or CE. HILIC is used in conjunction with fluorescence or mass detection to separate and quantify individual glycan species over long gradients, according to Orens. Similarly, CE systems can offer comparable quantitation details with an alternative separation mode, often with faster separation. “These approaches are often used as monitoring techniques to ensure batch consistency during manufacturing,” she says.

Released glycan analysis once suffered from tedious sample prep, according to Potter, but protocols have been greatly simplified in recent years through rapid-release and instant fluorescent labeling sample prep kits. He observes that HILIC methods enable the most exact assignment of glycan structures, either using retention time reference standards or retention libraries, or by hyphenating with MS detection. “HILIC separations can often distinguish between isomeric structures, including potentially harmful alpha-galactose (α-Gal) structures masquerading as beneficial galactosylated complex glycans,” he says.

Measuring the intact mass of multispecific antibodies via LC/MS does not require any sample prep, which can be advantageous. A well-optimized method run on a high-resolution instrument such as a time-of-flight (TOF)-based system is needed, however, Potter observes.

Orens adds that TOF systems can be used as the detection method for several techniques to help identify and localize glycans, as well as quantify, resolve isomers, and structurally elucidate the different species.

Potter cautions, though, that while very convenient, measuring the intact mass may only reveal the sum of masses of the two or more glycans on each molecule, which may confound assignment of exact glycan structures. Distinguishing between isomers is also not possible.

The most information can be obtained by first digesting the multispecific with a protease such as IdeS (immunoglobulin G-degrading enzyme of 

) or trypsin into smaller peptides, according to Potter. “Digestion allows for site-specific glycosylation analysis by LC/MS, which may be particularly useful when distinguishing between glycosylation in the fragment antigen-binding (Fab) and fragment crystallizable (Fc) regions, the latter of which greatly impacts the Fc effector functions of the antibody,” Potter contends.

Orens further notes that when peptide mapping is performed using a MS system with specialized fragmentation capabilities such as electron activated dissociation (EAD), it is possible to identify unknown modifications or impurities, then localize the species to a specific domain or amino acid of the protein. “EAD,” she says, “is integral to this process, as it differentiates between isomers and maps specific amino acids, and thus provides a comprehensive understanding of the protein with its modifications.”

Ultimately, Orens emphasizes, the appropriate analytical approach is entirely dependent on the purpose of the analysis.

Given the importance of accurate glycan analysis for multispecifics, the best strategy for ensuring success according to both Orens and Potter is to use a combination of available methods.

“While using top down, sub-unit, or peptide mapping methods and state-of-the-art MS systems enables comprehensive glycan analysis of multispecifics since it provides the most information in a single step, including molecular weight, domain/site localization, species identity, and species quantity, most organizations employ multiple analytical approaches to support their characterization efforts and obtain secondary, confirmatory evidence,” says Orens.

“The best way to ensure accurate and comprehensive characterization,” agrees Potter, “is to use more than one orthogonal method. Released glycan analysis, intact mass LC/MS, and LC/MS after protease digestion needn’t be mutually exclusive—they can be complementary,” he concludes.


October 2024
Vol. 36, No. 9
Pages: 28-30

When referring to this article, please cite it as Challener, C.A. Glycosylation Analysis for Multispecifics. 

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