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ROADMAP
Introduction Overview of stability studies Zone concept Stability of drug substances (physical, chemical and microbiological) Stability of specialized products Stability protocol Stability data handling Regulatory requirements Conclusion
INTRODUCTION
Pharmaceutical product development involves in development of safe, efficacies and quality product Pharmaceutical analysis and stability studies play a key role in successful product development Stability studies involved in determination and assurance of identification, potency and integrality of active substances as well as formulation
INTRODUCTION
Stability of products is defined as the extent of period retains its initial properties and characteristics within the specified limit Specific limits to be retained duting storage and usage Product characteristics and properties at the time of packaging to be maintained through put the shelf life
INTRODUCTION
Product properties and characteristics are Physical properties Chemical properties Microbial load Therapeutic properties Toxic characteristics All the above mentioned properties to be maintained with in the specification throughout the shelf life
INTRODUCTION
Stability studies provide evidence of impact of temperature, humidity and light on quality of products Purpose of stability studies Shelf life determination Assigning proper storage conditions Suitable packaging development
INTRODUCTION
Focus of stability testing Chemical (integrity, potency and degradation) Physical (solubility, hardness, sedimentation etc) Microbiological (resistance for microbial growth) Analytical methodologies Chromatography (LC, GC, TLC, LCMS) Thermal analysis (DSC, TGA, DTA) Particle size (CC, PCS, LD)
INTRODUCTION
OBJECTIVE OF STABILITY STUDIES
OBJECTIVE
Select the formulation and packaging
USE
Development of the product
TYPE
Accelerated
Shelf life determination Development of the product and Accelerated and and storage condition preparation of registration real time assessment dossier
Claiming shelf life SUPAC Registration of dossier QA and QC Real time Accelerated and real time
STABILITY PROTOCOL
Properly well designed protocol is the prerequisite for stability studies Stability protocol should be designed for both formulation development as well as registration batches Key elements should be constant in both the protocols Whereas the extent of stability studies should be lengthy incase of registration batches
STABILITY PROTOCOL
Content of stability protocol Type, size and number of batches Type, size and source of containers and closures Container storage orientation Test time points Sampling plan Plan for storage conditions Test parameters Test methods Acceptable criteria
THERMAL CYCLING
1. 2. 3. 4. Thermal cycling is carried out establish the influence of temperature variation during distribution Thermal cycling is advisable for the products, which has Phase separation Loss of viscosity Precipitation Aggregation Drug products under go temperature variation below sub freezing (-10 to -20C, followed by 40C, two days, three cycles, for twelve days) Drug products under go temperature variation above freezing (2-8C, followed by 40C, two days, three cycles, for twelve days)
CAUSE OF INSTABILITY
Physical stability of drug substances Chemical stability of drug substances Microbial stability of dosage forms Stability of dosage forms in general
PHYSICAL STABILITY
Most studies focused on chemical stability of drug products However, physical stability of the formulation is also equally important for safety, efficacy and quality of drug products In general DSC and PXRD is widely useful techniques to assess the physical stability Physical changes in crystalline form of API in dosage form affect the drug dissolution and drug release subsequently, bioavailability and therapeutic efficacy In Parenterals, crystallization may cause serious problems
PHYSICAL STABILITY
In case of pharmaceutical suspension, sedimentation may be the problem which affect the content uniformity and hence safety and efficacy Moisture up take and hardening and softening of tablets and capsules results with potential bioavailability problem due altered dissolution Incase of solid oral dosage forms, moisture uptake potentiate the hydrolysis of active ingredients and hence alter the chemical stability There are different kind of physical de-formality that could directly affect the quality, safety and efficacy of the drug products.
PHYSICAL STABILITY
Causes of physical degradation Crystallization of amorphous form Transition of crystalline state Formation and growth of crystals Vapor phase transfer including sublimation Moisture adsorption and uptake
PHYSICAL STABILITY
Crystallization of amorphous form Amorphous forms are used to enhance the solubility, dissolution and bioavailability of dosage forms Crystalline substances having low surface free energy and hence thermodynamically stable Amorphous forms possess high free energy and hence thermodynamically unstable Therefore crystallization occurs during storage
PHYSICAL STABILITY
Crystallization of amorphous form
Example is Nifedipine amorphous form are partially crystalized during storage at high RH and resulted with lower in dissolution during storage period
PHYSICAL STABILITY
Crystallization of amorphous form
Another classical example is oxyphenbutazone, relative humidity at variuos level leads different crystals
PHYSICAL STABILITY
Crystallization of amorphous form
Non ionic and cellulosic polymers have been used to reduce the crystallinity This is due polymer matrix reduce the mobility of molecules and prevent the crystal seed formation in both solid as well as liquid state (e.g Haloperidol with different cellulosic polymers)
PHYSICAL STABILITY
Crystallization of amorphous form
Preparation of amorphous formulations have profound effect on stability Spray drying at higher temperature will provide amorphous forms with higher stability High stability of amorphous form is identified with high glass transition temperature Crystallization of amorphous excipients for example sucrose at higher humidity
PHYSICAL STABILITY
PHYSICAL STABILITY
CRYSTAL GROWTH
Definition High array of molecules in lattice is called as crystals
Insulin crystals
PHYSICAL STABILITY
CRYSTAL GROWTH
Crystals are even though considered as thermodynamically stable Crystals should not be considered as static one Crystals may grow or reduce in their size depends on the free energy and environment Sublimation of growth of crystals may occur in liquid or gas matrix Crystal growth or sublimation in tablet surface may results whiskering effect Crystallization is favored in high porous tablet matrix at high temperature
PHYSICAL STABILITY
CRYSTAL GROWTH
The extent formation of whisker at 30 C for caffeine and ethezamide
PHYSICAL STABILITY
CRYSTAL GROWTH
Carbamazepine tablets are another classical example for crystal growth Carbamazepine tablets stored at high RH, results with formation of CBZ dihydrate crystals CBZ tablets containing stearic acid, if stored at higher temperature, forms columnar crystals The suggested reason is that stearic acid melt at higher temperature, CBZ gets dissolved in melted steraic acid and recrystallized in different form
PHYSICAL STABILITY
PHYSICAL STABILITY
PHYSICAL STABILITY
MOISTURE ADSORPTION
Moisture adsorption is generally observed with solid pharmaceutical substances Hydrophilic substances adsorbs more moisture Moisture adsorption reduces the chemical stability of drug substances Drug substance prone to hydrolysis are worst affected with moisture adsorption Moisture adsorption affects the pharmaceutical properties such as dissolution, disintegration and hardness Hydrophilic excipients accelerates the rate and extent of moisture adsorption Moisture adsorption is based on RH of the environment
PHYSICAL STABILITY
MOISTURE ADSORPTION
PHYSICAL STABILITY
PHYSICAL STABILITY
PHYSICAL STABILITY
PHYSICAL STABILITY
PREFORMULATION
Preformulation studies are designed To deliver the physicochemical data Of drug substances, excipients and packaging material either alone or in combinations To guide the formulator to select the right active and inactive ingredients to achieve a stable and desirable formulations
PREFORMULATION
I. Physicochemical properties of the drug substance
Solubility studies Salt screening pKa determination Partition coefficient Crystallization studies Polymorphism studies II. Stability data Chemical stability (accelerated and stress studies) Thermal properties Hygroscopicity (storage conditions) Excipients and packaging compatibility studies III. Early stage formulation Design composition and form according to specifications, dose and bioavailability
PREFORMULATION STUDIES
Preformulation studies are initiated to select Choice of crystalline form (usually stable form, but not always) Choice of particle size (degradation with finer particles but gives better dissolution profile) Choice of vendor (many cases vendor specific impurities) Choice of excipients (some of excipients beneficially or adversely affect the quality of product)
PREFORMULATION STUDIES
Choice of dosage forms (e.g voriconazole, rabeprazole etc) Choice of storage conditions Choice of manufacturing process Choice of packaging material Two important prerequisite for preformulation studies are Analytical method for detecting physical and chemical degradation Factorial analysis of data
PREFORMULATION STUDIES
Preformulation studies Method for quantification of active and inactive ingredients Method for solid state characterization of drug substances and drug products Method for characterization of physical properties of dosage forms such as pH, zeta potential, sedimentation, hardness, redesipersibility, friability, moisture up take, clarity and so on Selection of route of administration Selection of dosage form (solid, liquid etc) Selection of special drug delivery system (solubility enhancement, permeability enhancement, enteric dosage forms etc) Data analysis
PREFORMULATION STUDIES
Analytical methodologies for estimation of drugs and RS some time inactive HPLC method stability indicating method Use PDA detector for rapid method development LC MS incase of structural elucidation of impurities Stability indicating method should be developed Non interference of any inactive ingredients as well un known or new impurities Prior to develop stability indicating method, forced state degradation studies with API alone and in combination with inactive ingredients
CHARACTERIZATION OF POLYMORPHS
Techniques in solid state characterization X ray diffraction - Single crystal XRD - Powder XRD Microscopic techniques - Optical microscopy - Scanning Electron Microscopy - Atomic Force Microscopy Thermal analysis (DSC, TGA, HSM) Spectroscopic studies (FTRI, Raman, ssNMR)
CHARACTERIZATION OF POLYMORPHS
X ray diffraction X rays fall on crystalline phase, there will be diffraction pattern X ray pattern of pure substance is unique and constant and hence it is nothing but finger printing of crystals Mixture of substances, gives its diffraction patent individually
CHARACTERIZATION OF POLYMORPHS
Single Crystal XRD Very difficult to isolate single crystals Precision is very difficult Determination of atomic structure Used to study the Molecule structure, bond angle, type, length PXRD Easy Powder sample is sufficient Non destructive method Identification of drug substances Quantification is possible Identification of impurities in substances
CHARACTERIZATION OF POLYMORPHS
PHARMACEUTICAL APPLICCATION
PXRD Identification of polymorphs Quantification of polymorphs and mixtures Process optimization Detection of impurities
PROCESS OPTIMIZATION
API batch to batch uniformity in crystalinty Granulation parameter optimization
Effect of temperature on polymorphism of theophylline granules
Theophylline anhydrous
Propylphenazone: enatiotropic
2
D SC mW /mg 0.00
Peak
4
-2.00
File N ame: PU R E D R U G 2008-01-08.tad D etec tor: D SC -60 Ac quis ition D ate 08/01/08 Ac quis ition Time 14:01:21(+0530) Sample N ame: PU R E D R U G Sample W eight:2.670[mg] Annotation:
-4.00
6
-6.00
[Temp Program] Start Temp30.0 Temp R ateH old TempH old Time Gas [C /min ] [C ] [ min ] 10.00 210.0 0 N itrogen
50.00
100.00 Temp [C ]
150.00
200.00
For the anhydrous hydrochloride salt (2) on an open pan without purging with N2, (3) in a pan closed by crimping (4) in a hermetically sealed pan For the monohydrate hydrochloride salt (5) on an open pan without purging with N2 (6) on an open pan with purging with N2 (7) in a pan closed by crimping (8) hermetically sealed pan
IR SPECTROSCOPY
In addition to chemical identification IR is used to differentiate the solid state structures Different arrangement of molecules in different crystals will lead different molecular environment This phenomenon can be used distinguish polymorphic form
IR SPECTROSCOPY
Polymorphs IR peaks
CM-1
FACTORIAL DESIGN
In formulation development, all the factors are affecting he stability of dosage form Stability of final dosage form is dependent on many complex factors Quantitative role of each factor on stability to be explored It causes very large and complex series of experiment During evaluation of one factor other must be in constant in order to explore the effect
FACTORIAL DESIGN
Factorial analysis usually called as factorial design is a statistical technique to minimize the number of experiment to get a meaningful results Factorial analysis not only results meaningful results but also provide cost effective stable formulation It reduces the developmental time
FACTORIAL DESIGN
Factorial design involves two parameters such as Level of factor Number of factor e.g 2n factorial design, here 2 is the level and n is the number of factor Minimum two levels are required and one can go any number of factors As number of factor and level increases with complexity of experiment
FACTORIAL DESIGN
21 factorial design (two experiments) 22 factorial design (four experiments) 23 factorial design (eight experiments) 31 factorial design (three experiments) 32 factorial design (nine experiments) 33 factorial design (twenty seven experiments) 43 factorial design (sixty four experiments)
FACTORIAL DESIGN
21 factorial design (two experiments) Level is 2 Number of factor is 1 For example effect of HPMC on drug release in CR tablets Here, HPMC is the number of factor, which influence drug release Two levels of 10% and 30% are considered with two different experiment
FACTORIAL DESIGN
22 factorial design (four experiments) Level is 2 Number of factor is 2 For example effect of HPMC and lactose on drug release in CR tablets Here, HPMC and lactose are the number of factors, which influence drug release Level of HPMC is 10% and 30% and level of lactose is 10% and 50% Experiments are 10/10, 10/50, 30/10, 30/50
FACTORIAL DESIGN
23 factorial design (six experiments) Level is 2 Number of factor is 3 For example effect of HPMC, sodium alginate and lactose on drug release in CR tablets Here, HPMC and lactose are the number of factors, which influence drug release Level of HPMC and HEC is 10% and 30% and level of lactose is 10% and 50% Experiments are 10/10/10, 10/10/50, 30/10/10, 30/10/50, 10/30/10, 10/30/50, 30/30/10, 30/30/50
FACTORIAL DESIGN
31 factorial design (three experiments) level 3 Factor 1 Factor is HPMC and effect of three lecl on drug release such as 10, 20 and 30 % on drug release
FACTORIAL DESIGN
32 factorial design (six experiments) Level 3 Factor 2 Two factors such as sodium alginate and HPMC on drug release Level of HPMC is 10, 15 and 20 % and sodium alginate is 5, 10 and 15% Nine different experiment provides optimal composition for best release profiles 10/5, 10/10, 10/15, 15/5, 15/10, 15/15, 20/5, 20/10, 20/15,
FUNCTIONAL CHANGES OF DOSAGE FORM WITH TIME Mechanical strength Drug dissolution from tablets and capsules Melting point of suppositories Drug release from polymeric matrix Drug leaking from liposomes Aggregation of emulsion Moisture adsorption Discoloration Effect of packaging
Physical changes in formulation may affect the in vitro drug release Many of these changes are occurred during the storage period Ideal formulation should be stable, and all the physical parameters should be within the limit throughout the shelf life Changes in physical parameters not only affect the invitro drug release but also in vivo release and clinical efficacy
Mechanical strength
Mechanical strength of the solid dosage forms are dependent on humidity and temperature Hydrophobic lubricants such as wax and vegetable oil melt at elevated temperature and causes softening of the tablets Moreover, this waxes, reduce the porosity of the tablet, once it melts, waxes diffuses tablet matrix and fill in the pores of the tablet This leads to pit forming in the surface of the tablets Chances for reduction in drug dissolution time
MECHANICAL STRENGTH
In contrast to hydrophobic low melting excipients, hydrophilic excipients are prone to moisture associated deformalities in mechanical strength Packaging material play an important role in moisture permeability of dosage forms PVP is more permeable, PVdC blisters should be used to pack the moisture sensitive dosage form Highly moisture sensitive drug, HDP bottles with desiccant or glass bottles are highly suitable for moisture sensitive dosage forms A close correlation has been observed with moisture and mechanical strength of the tablets
MECHANICAL STRENGTH
AGGREGATION OF EMULSION
Aggregation is normal physical phenomenon Oxygen-transporting emulsions of perfluorodecalin needed stabilizing additives to prevent aggregation. Increased droplet size is one of the properties of total parental nutrient emulsion during storage Emulsion stability is based on zeta potential of the emulsion Increasing the storage temperature from 25 to 40C markedly reduced the stability of a clofibride emulsion for oral administration, Whereas storage at 4C caused rapid phase separation owing to decreased solubility
AGGREGATION OF EMULSION
AGGREGATION OF EMULSION
Physical stress state stability studies are performed to evaluate the stability of emulsion Ultra-centrifugation, freez thaw cycling, sonication and stress state shaking are used to evaluate the physical stability
DISCOLORATION
Although the discoloration of dosage forms may result from chemical degradation, Mechanisms are usually unclear Discoloration is generally considered to be a physical degradation (degradation of appearance) The changes in discoloration is based on Arrhenius behavior and hence possible to predict the release kinetics
DISCOLORATION
DISCOLORATION
Although the discoloration of dosage forms may result from chemical degradation, Mechanisms are usually unclear Discoloration is generally considered to be a physical degradation (degradation of appearance) The changes in discoloration is based on Arrhenius behavior and hence possible to predict the release kinetics
A log-log plot of sorption number ( Sn ) into a PVC container versus octanol-water partition coefficient (Poctanol ) for a number of drugs. Drugs were stored at 15-20C for 1, and 24 h
Shelf life is referred to as t90(T1) when the lower specification limit of content is 90%. Shelf life exhibits a log-linear relationship versus 1/T in a given temperature range when the activation energy is constant The latter condition usually is only met when the degradation mechanism is the same across the temperature range of exposure. For example, a shelf life of 6 months at 40C corresponds to a shelf life of 3 years at 25C when an activation energy of 22.1 kcal/mol is assumed
Degradation may affect the aesthetic look of the formulation Degradation may change the color, odor and taste of the formulation Example ephedrine to adrenochrome causes intense red color
The extent to which D rearranges to P will depend on the free-energy differences between D and P. If P is of much lower free energy than D, then the reaction is better defined by
P will be formed if D and A collide with sufficient energy (and an appropriate orientation) to result in a molecular rearrangement to form P. In this simple case, the rate of loss of D, -d[D]/dt, is said to be proportional to the activity (or, more simply, the concentration) of both D and A, as indicated by Eq.
Effect of changes in solvent dielectric constant on the degradation rate of chloramphenicol in the presence of perchloric acid