The use of single-use systems has been getting more popular in biologics manufacturing. Utilization of this novel technology enables the efficient manufacturing, including prevention of cross contamination, flexibility to manufacture multiple products, and elimination of the need for cleaning and steam sterilization including those validations. In order to ensure the quality and stable supply of biologics, appropriate risk management considering the characteristics of the system is necessary. However, there is no regulatory document describing the examples or recommendations on it. In 2015, we published the White paper of “Approaches to Quality Risk Management When Using Single-Use Systems in the Manufacture of Biologics” in AAPS PharmSciTech, which was a fruit of discussion in the research group consisting of Japanese pharmaceutical manufacturers, single-use suppliers, academia and regulatory agencies. This review introduces the contents of the White paper with some revision reflecting the comments on it as well as the discussion in our research group after publishing the paper. The basic concept is consistent with ICH guideline on quality risk management. Here we describe the points to consider in risk assessment as well as in risk control when single-use systems are used in biologics manufacturing.
On the development of subcutaneous injection form of antibody drugs, small injection volume (i.e. 1mL) is the key achievement for enabling subcutaneous injection. Therefore, stable formulation and manufacturing process of highly concentrated/viscous antibody solution should be established for reducing injection volume. For the treatment of chronic diseases, pre-filled syringe or autoinjector is expected to improve the quality of life of patients. Considering these requirements and circumstances, we have established the drug product of ACTEMRA® 162mg Syringe and Auto-Injector for SC Injection. This paper describes the approach for establishing ACTEMRA® SC injection. The contents in this paper is mainly disclosed in Pre-filled Syringe Seminar 2016 Tokyo (May 17-18, 2016) by PDA Japan Chapter and includes the additional information of formulation and manufacturing process investigation.
Chronic diseases management lead to very specific and challenging set of requirements for the prefillable syringe (PFS) used. Glass PFS based solutions still remains the gold standard that offers a large range of options for injectable biopharmaceuticals. A complete overhaul and redesign of the Glass PFS manufacturing process, through a quality by design approach and the introduction of innovative and best in class technologies (have increased significantly the syringe performances until the level required to meet the best in class product specifications with BD NeopakTM BD Neopak XsiTM coating, as an inert & immobilized cross-linked silicone for an optimized interfacial contact with biologics, has been developed to maximize the compatibility of the container with the drug product and increase the performance of BD NeopakTM by eliminating the contribution of the container to the Subvisible particles. BD Neopak DuraShieldTM, results from a specific treatment in a molten bath of neat potassium nitrate (KNO3 molten salt), that enables ions exchange at an atomic level putting the glass under compression. Such treatment increases significantly the BD NeopakTM breakage resistance and durability (that presents already high level of performance for these criteria) opening the way to overcoming none controlled challenging situations, but at a much higher acquisition cost.
Aseptic processing or manufacturing is a method of manufacture in which microorganisms are excluded from the production environment and thereby prevented from entering the product. It has been recognized for decades and humans working in aseptic environments were the only significant source of contamination and therefore posed the greatest risk to both successful production of heat labile products and to the patient. Over the last two decades, there has been a technological evolution in aseptic processing which has greatly increased patient safety by dramatically reducing the risk of microbial contamination in aseptic processing. The improvements that have occurred in aseptic processing arise from two principal technological features. The first of these is the use of isolator technology and the second is the introduction of effective machine automation and robotics. Isolators have reduced contamination risk by effectively separating the human technician from the aseptic environment. Because isolators are an unmanned environment, which is much smaller in volume than a conventional manned clean room, they can be decontaminated in a manner that effectively eliminates microbial contamination of all kinds. The isolator after sporicidal decontamination is effectively a microorganism free environment. The capabilities of the isolator have been further enhanced by the application of robots and other forms of automation. An important recent innovation is the introduction of robotics that could be built into isolator systems and decontaminated in place. These specialized robots along with machine automation have further reduced contamination risk and at the same time eliminated the possibility of technician error. The modern isolator system is very well suited to meeting the cell culture requirements necessary for the production of cytotherapeutics, and as a result cell culture isolators are proving to be the best option for the production of many regenerative medicine products.