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Dissertation
Continuous freeze-drying of nanoparticles
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Year: 2020 Publisher: Leuven KU Leuven. Faculteit Farmaceutische Wetenschappen

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This project focused on lyophilization of PLGA nanoparticles, more specifically on finding an optimal formulation and optimal lyophilization conditions. Preliminary tests were performed to investigate the influence of several cryo/lyoprotectans on nanoparticle characteristics such as particle size and polydispersity index. Determinations of the glass transition temperature of freeze-concentrated solutions and a design of experiments were performed and mannitol-sucrose 5% (m/V) (1:1) was selected as an optimal formulation. Several freezing methods were evaluated and both batch freezing and continuous freezing resulted in satisfactory results regarding cake appearance, reconstitution time, particle size and polydispersity index. Optimization of the primary drying step could not be performed due to the early termination of the project. Since mannitol is a crystalline component that can be present in an anhydrous (α, β, and δ) or hemi-hydrate state, experiments were conducted to investigate the solid state of mannitol in the selected formulation (mannitol-sucrose 5% (m/V) (1:1)). Storage of a product containing mannitol hemi-hydrate could result in a transformation to anhydrous mannitol accompanied by release of lattice water, which will result in loss of stability (1). Off-line raman spectra revealed that in the selected formulation, mannitol was present in its hemi-hydrate state. Possible strategies to eliminate this mannitol hemi-hydrate, are addition of an annealing step or secondary drying at a temperature of approximately 40°C (1). However, the glass transition temperature of the formulation was determined to be 43,8°C indicating that secondary drying at a temperature of 40°C might risk cake collapse. Therefore, in-line raman spectroscopy was performed to determine the minimum annealing temperature needed to promote transition of mannitol hemi-hydrate to a more stable, anhydrous state. Analysis of these spectra was performed using principal component analysis. Results showed that a transition to β-mannitol occurred at a temperature of -12,5°C. Therefore, it can be concluded that an annealing step at a minimum temperature of -12,5°C should be included in the lyophilization cycle to promote the formation of β-mannitol.

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Dissertation
Selection and qualification of a new container closure integrity test method for sterile, liquid filled vials

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This master thesis focused on container closure integrity, more specifically on the container closure integrity of vials. Vials are closed using a rubber stopper and an aluminum flip-off cap. Closure integrity is essential to ensure the sterility of the product. An evaluation of Merck’s guidelines and an update of Annex 1 by the European Commission gave rise to this project. The guidelines state that during manufacturing, samples must be tested for container closure integrity by conducting a validated test. In this project, different methods to test the integrity were evaluated and two methods, namely headspace analysis and the currently performed vacuum test were studied in detail. Sensitivity of both methods was evaluated, and it was decided to optimize and qualify the currently used vacuum test. This qualification required positive control test vials. The creation of these positive control vials was attempted in two ways, namely using vials with laser-drilled pinholes in the neck or wall of the vial or by inserting a wire between the rubber stopper and the vial. The second method better represented the potential risk that can occur during manufacturing. However, it was observed that these leaks are more difficult to quantify and are not stable over time. Therefore, the qualification will be performed using laser-drilled vials, containing pinholes of approximately 10 μm. It was also decided to re-evaluate the entire container closure integrity dossier according to the current guidelines. The required documents were written, and the necessary tests were performed. Also, an end-to-end risk assessment was performed to evaluate the risks to which the container closure system is exposed over shelf life. Therefore, all possible hazardous situations were evaluated together with the possibility of occurrence and the chance of detection. These three scores were multiplied to obtain the risk prioritization number. Based on this risk prioritization number it was decided whether it was necessary to take risk reducing measures.

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