QBD Approach To Dissolution Through Understanding of The Release Mechanisms and Critical in Vivo Parameters
QBD Approach To Dissolution Through Understanding of The Release Mechanisms and Critical in Vivo Parameters
QBD Approach To Dissolution Through Understanding of The Release Mechanisms and Critical in Vivo Parameters
Outline
Formulation development QC method BCS based understanding of dissolution methodology in the absence of IVIVC
Guide formulation design and assess product quality The only product test that truly measures the effect of formulation and physical properties of the API on the rate of drug solubilization The only test that can monitor if the rate of drug solubilization is impacted by product storage conditions It is the best surrogate for bio-performance if IVIVC cant be established Required by many regulatory authorities for solid oral dosage forms, transdermal patches and oral suspensions
Pre Phase 1 --- Phase 1 --- Preliminary and Final Market Image QbD execution QTPP RA tools Design space experiments Monitor process/ refine SUPAC
Early development:
Disso method with bio relevant media key in guiding formulation development in the absence of human in-vivo data: Little value having a QC method at this stage
Dissolution method gains much more importance as a bioperformance/ quality method: Drug Product Process and components are usually defined
Exploring the Design Space and process scale-up: critical to have the right method in place Important to ensure consistent quality (consistency in clinical trials)
Should allow ranking of potential range of drug product formulation types (i.e. DFC, LFC, simple tablets) to maximize drug substance exposure Typically not sensitive of small changes within one formulation type
% Claim
LFCC:I:T C:T
I:T WG:C WG:TPGS SA:TPGS
Tox formulation
60 70 80 90 100 110 120 time (min)
DFC
4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0
Conc (uM)
LFC
Tox formulation
4 8
DFC (10% Vit. E TPGS) Time (hr) LFC (Im:Tw) SA Vehicle (20% Vit. E TPGS)
DFC
12
16
20
24
Phase I formulation typically not the formulation going forward and process conditions, API, excipients selection, etc. evolve May test further formulations in Bio Comparison studies before making final PMF definition With the additional human pK-data and formulation information opportunity to look for in-vitro and in-vivo relationship
Guide formulation selection and fine-tuning Become more formulation specific Predictive of in-put variables that may impact bio-performance Builds on prior knowledge including BCS classification system
Case Study 2:
API properties: BCS Class IV with low aqueous solubility across pH 1.0-6.0
Formulation: Tablets (doses: 100 -400 mg potency) with 25-50% drug load; Standard pharmaceutical ingredients present in the formulation. Immediate release dosage form.
Process: Roller compaction process; API and excipients are roller compacted. The granules are lubricated with SSF and magnesium stearate followed by compression and film coating. Dissolution mechanism: Spans from fast disintegration of tablets to slow disintegration of tablets
% Dissolved
9000 8000
Formulation 1 Formulation 2
Plasma Concentration
Formulation Identified, Dose(s) Identified -- Initial Quality Risk assessment Evaluate the in-put variables on Drug Product Quality API, Excipients, Drug product manufacturing process Identify Critical Process Parameters Explore the process design space Design Space: where the process works Develop the Control Strategy Desired Dissolution Method requirements: Method should be sensitive to the process parameters/ in-put variables that may affect bio-performance Method should be stability indicating, i.e. pick-up changes that are biorelevant
Final Formulation going into pivotal clinical studies has been defined CQAs have been identified
Need to ensure adequate methods are in place to control CQAs In-vivo performance is usually always a CQA
Dissolution testing is at this stage often the only test that probes drug substance release
In general methods should assure the quality of the drug product Dissolution method (or surrogates) should assure consistent bio-performance of the drug product Should be sensitive to in-puts/ variables that have been identified to impact bio-performance How can this be done? 1. Establish IVIVC (or IVIVR) 2. Use prior knowledge and appropriate risk assessment 3. A combination of both
II
Low solubility
I
High solubility
1.0
High permeability
High permeability
0.1
IV
Low solubility Low permeability
III
High solubility Low permeability
0.01
High Low Low
kd
kp
kdd
kd
Drug Particle
kid
General Dissolution
Intrinsic Rate of API Solubilization
API Surface Area
Disintegration or Erosion
Porosity
Hardness
Specific
A Biopharmaceutical Classification System Approach to Dissolution: Mechanisms and Strategies W. E. Bowen, Q. Wang, W. P. Wuelfing, D. L. Thomas, E. Nelson, Y. Mao, B. Hill, M. Thompson, R. A. Reed In "Biopharmaceutics Applications in Drug Development" R. Krishna and Lawrence Yu, Ed.; Springer, 2008, 290.
Papp(x10 )
0.1
IV
1e+8 1e+7 1e+6 1e+5 1e+4 1e+3 1e+2 1e+1 1e+0 1e-1 1e-2
III
1e-3
(N = 15)
Yes
Case 3
CQA Tablet disintegration capsule rupture
(N = 13)
API properties: Borderline BCS Class I/III permeability with high aqueous solubility (>40 mg/mL) at pH 1-7.5 Formulation: tablets (doses: 25 - 200 mg) with 32% drug load; Standard pharmaceutical ingredients present in the formulation Process: Direct compression process; API & excipients are blended and then lubricated with magnesium stearate and sodium stearyl fumarate, followed by compression. Dissolution mechanism: tablet disintegration followed by rapid solubilization of drug particles Critical Quality Attribute: tablet disintegration
% Dissolved
90
80
70 0 15 30 45 60
Time, min
Disintegration
160 140 120 100 80 60 40 20 0 10 15 20 25
95 90 85 80 75 10 15 20 25 Hardness, kP
Hardness, kP
Disintegration is the more sensitive method and serves as a better indicator for product quality than a dissolution test
(N = 15)
No
Yes No Yes Disintegration/erosion control? Characterization of dissolution mechanism Perform Dissolution of dosage form and granules.
Case 3
CQA Tablet disintegration capsule rupture
Yes
Case 4 (N = 1)
(N = 13)
API properties: API 1: Borderline BCS I/III permeability with high aqueous solubility (>40 mg/mL) at pH 1-7.5; API 2: BCS III with high aqueous solubility (~200 mg/mL) at pH 1-7.5 Formulation: Combination tablets. Standard pharmaceutical ingredients present in the formulation Process: Wet granulation process; Fluid-bed wet granulation of API 1 and API 2. The granules are dried and blended with microcrystalline cellulose and magnesium stearate followed by compression and film coating Dissolution mechanism: Tablet erosion followed by rapid solubilization of drug particles; controlled by tablet erosion
% Dissolved @ 15-minutes
95
90
y = -1.6531x + 121.7 2 R = 0.9968
85
60 40 20 0 0 15 30
80
75
45
60
70 15
31
Time (min)
Strong correlation between dissolution and disintegration Both methods monitor critical quality attributes sufficiently Disintegration is recommended for simplicity
(N = 15)
No
Yes No Yes Disintegration/erosion control? Characterization of dissolution mechanism Perform Dissolution of dosage form and granules. No
Case 3
CQA Tablet disintegration capsule rupture
Yes
Case 4 (N = 1)
Case 5
CQA Granule properties or others
(N = 13)
(N = 1)
API properties: BCS Class I with high aqueous solubility (0.1 mg/mL) at pH 1-7.5. Formulation: Tablets (dose: 4 mg); Standard pharmaceutical ingredients present in the formulation Process: Wet granulation process; Granulated in water. The granules were dried, blended with starch and magnesium stearate followed by compression Dissolution mechanism: Fast tablet disintegration followed by drug release from granules and rapid solubilization of drug particles; Controlled by drug release from granules Critical Quality Attribute: Granule particle size
% Release
80 60 40 20 0 0 15 30 45 60 75 Time (minutes)
Test conditions Media Water Apparatus USP II Agitation 50 rpm
Overall dissolution profile is dependent on the granule size distribution Dissolution profile is monitored for quality control
Overall Design Principle: Rapid dissolution so like dosing an oral solution Formulation: Tablets, Capsules or Oral Disintegrating Tablets Process: Direct compression, Wet Granulation, Roller Compaction, Encapsulation or Freeze Drying Dissolution mechanism: tablet or capsules disintegration followed by rapid solubilization of drug particles, i.e. kdd << kid Critical Quality Attribute: Design for Disintegration (i.e. to make it like dosing an oral solution) Merck Biopharmaceutical Experience: In 3 out of 3 cases examined, the solid oral dosage form has been bio-equivalent to an oral solution
Papp(x106)
10
L000222628
L000854384
0.1
IV
III
1e-3
1e-1
1e-2
Papp(x106)
10
0.1
IV
1e-1
III
1e-2 1e-3
Case 6
Yes
API properties: BCS Class IV with low aqueous solubility at pH 1.0-7.0. Formulation: Liquid Filled Capsules (LFC). Dose: 0.1 50 mg. The drug is fully dissolved in the liquid core of the LFC Process: API was dissolved in liquid vehicle, which is then filtered, and filled into hard (or soft) gelatin capsules Dissolution mechanism: capsule disintegration followed by dispersion of liquid content Product Design Target: API is solubilized in formulation
No
Dissolution mechanism characterization Perform Dissolution of dosage form, API (different PSD) and/or granules
No
Yes
Case 6
Yes
Yes Design Target API remains in solution CQA API Particle size, etc
Case 7
API properties: BCS Class IV with low aqueous solubility across pH 1.0-7.5. Formulation: Capsules (dose: 100 mg) with 67% drug load; Standard pharmaceutical ingredients present in the formulation Process: API and excipients are dry blended, then lubricated with magnesium stearate. The powder blend is then filled in hard gelatin capsules. Dissolution mechanism: Rupture of capsule shell followed by API dissolution. Controlled by API solubilization Critical Quality Attribute: Physical properties of API
Average % Dissolved
80.0
60.0
40.0
20.0
Sieve Cut < 75 microns Sieve Cut 180-250 microns Sieve Cut > 355 microns
0 20 40 60 80 100
0.0
Time, minutes
No
Dissolution mechanism characterization Perform Dissolution of dosage form, API (different PSD) and/or granules
No
Yes
Case 6
Yes
No
Case 8
Yes CQA API Particle size, etc
Case 7
API properties: API 1: BCS II with low solubility across pH 1-7.5; API 2: BCS Class IV with low aqueous solubility across pH 3.0-7.5 Formulation: Combination drugs in capsules (strength: 200/100 mg); Standard pharmaceutical ingredients present in the formulation Process: Roller compaction process; APIs and excipients granulated via roller-compaction. Granules are milled, lubricated with magnesium stearate and encapsulated in hard gelatin capsules. Dissolution mechanism: Rapid rupture of capsule shell followed disintegration of capsule plug and drug release from granules. Controlled by plug disintegration and release from granules. Critical Quality Attribute: granule density
% Dissolved
60 40 20 0 0 15 30 45 60 75
Clinical Batch, 18 mm Disk, Loose Plug Reference Batch 131-B: 60 bar Roll Pressure, Hand-filled Capsule 131-2: 90 bar Roll Pressure, Hand-filled Capsule 131-3: 120 bar Roll Pressure, Hand-filled Capsule
Time (minutes)
No
Dissolution mechanism characterization Perform Dissolution of dosage form, API (different PSD) and/or granules
No
Yes
Case 6
Yes
Case 9
CQA API remains in solution
No
Case 8
Yes CQA API Particle size, etc
Case 7
API properties: BCS Class IV with low solubility across pH 3.0-7.5. Highly soluble at gastric pH (>200 mg/mL) Formulation: Capsules (doses: 200 - 400 mg) with 65% drug load. Standard pharmaceutical ingredients present in the formulation Process: Roller compaction process; API and excipients granulated via roller-compaction. Granules are milled, lubricated with magnesium stearate, and encapsulated in hard gelatin capsules Dissolution mechanism: Capsule rupture followed by rapid release from granules. Controlled by capsule rupture Critical Quality Attribute: Capsule rupture (cross-linking)
% Dissolved
80 60
Unstressed Capsules
40 20 0 0 10 20 30 40 50
Time (Minutes)
Overall Design Principle: Solubilization enhancement e.g. LFCs, API physical properties reduce particle size, increase surface area add solubilizing agents, etc. Formulation: Capsules, Tablets, ODTs Process: Direct compression, Wet Granulation, Roller Compaction, Freeze Drying, liquid filled gel caps Dissolution mechanism: varied, i.e. kid << kdd, kdd << kid , kdd ~ kid Critical Quality Attribute: Disintegration, API physical properties, dissolution
Conclusions
BCS based drug release testing leads to: Focus on value added specifications in alignment with QbD principles and approaches Removal of non-value added specifications BCS Class I/III IR products ability to eliminate dissolution testing and replace with disintegration testing BCS Class II/IV IR products ability to drill down to key quality attributes and replace dissolution testing consistent with the design of the product some dissolution testing still adds value
Part B
IVIVC/R approach
IVIVC/IVIVR approach
In-vitro Dissolution In-vivo human PK
IVIVC/R
Patients
IVIVC/ IVIVR
Consistent with existing SUPAC guidance, this provides highest degree of regulatory flexibility Disso in BCS I and III formulations often too fast
Absorption and metabolism may also make it difficult to deconvolute the data Remember dissolution driven by drug solubility Often no relationship between dissolution rate and pK achievable
BCS IV
0 -10 -20
Case A no IVIVC/R
Case A
No changes in pK-parameters observed within the tested batches Dissolution method is sensitive to process parameters and other in-put variables
Would suggest using % release/ time Q value(s) to provide process control if required
In-put variable changes are justifiable as long as within the above experience range
Assessment should be based on FMEAC analysis Changes that result in disso profiles outside the experience/ spec range likely require in-vivo justification
-20
-40
Case B - IVIVC
-60
Case B
IVIVC is achievable! In-vitro Method can directly assess the magnitude of in-vivo changes due to process or other in-put variable changes As existing SUPAC already suggests, this method can be used to justify scale-up and post approval changes in lieu of BE studies
-20
Case C
-40
-60
Case C
setting the disso spec to the slowest acceptable profile. Any result above appears to provide adequate in-vivo performance Any dissolution result below the proposed spec may indicate non-acceptable change Since IVIVC possible one can directly assess the extent of the pK-changes
Conclusion
Part A of this presentation highlights the use of prior knowledge, QbD tools and good science to assure consistent product quality Establishing IVIVC/R provides most direct link to bioperformance
Stronger link between in-vivo and in-vitro performance as compared to using empirical approaches (F2) Might be costly up-front investment
QbD frame-work allows for regulatory flexibility this should be a strong incentive
But remember- achieving IVIVC/R might not always be possible at least with the current in-vitro and in-silico tools available
Acknowledgements
Bill Bowen Steve Biffar Kim Gallagher John Higgins Brian Hill Craig Ikeda Kiki Luna Yun Mao Eric Nelson Robert Reed Denise Thomas Mark Thompson Qingxi Wang Conrad Winters Pete Wuelfing
Thank you!
References
W. E. Bowen, Q. Wang, W. P. Wuelfing, D. L. Thomas, E. Nelson, Y. Mao, B. Hill, M. Thompson, R. A. Reed, A Biopharmaceutical Classification System Approach to Dissolution: Mechanisms and Strategies, in Biopharmaceutics Applications in Drug Development" by R. Krishna and Lawrence Yu (Editor); Springer, 2008, 290 P.A Dickinson, Wang Wang Lee, Paul W. Stott, Andy Townsend, John Smart, Parviz Ghaharamani, Tracey Hammett, Linda Billet, Sheena Behn, Ryan C. Gibb, Bertil Abrahamsson, AAPS Journal, Vol. 10, No. 2, June 2008, p.380-390 Paul Dickinson et al. (2009), Applied Biopharmaceutics and QbD for Dissolution/ Release Specification setting: Product Quality for Patient Benefit Amidon, G.L., H. Lennerns, V.P. Shah, and J. R. Crison, "A theoretical basis for a biopharmaceutics Drug Classification: The correlation of in vitro drug product dissolution and in vivo bioavailability." Pharmaceutical Research 12 (3, March), 413-420, 1995