1. 2006.01.09. Pogány - Guilin 1/57 WHO Training Workshop on Pharmaceutical Quality, G MP and Bioequivalence with a focus on artemisinines János Pogány, pharmacist, Ph.D. consultant to WHO Guilin, China, 10 January 2006 E-mail: pogany@t-online.hupogany@t-online.hu Pharmaceutical quality by design and development

2. 2006.01.09. Pogány - Guilin 2/57 Abbreviations APIActive Pharmaceutical Ingredient BPBritish Pharmacopoeia FDCFixed-Dose Combination FPPFinished Pharmaceutical Product ICHInternational Conference on Harmonization PhEurEuropean Pharmacopoeia PhIntInternational Pharmacopoeia USPUnited States Pharmacopeia

3. 2006.01.09. Pogány - Guilin 3/57 Subjects for discussion 1. DESIGN (product-specific research )  Desk research  API (specifications, stress stability testing, etc.)  FPP (pre-formulation, stability studies, etc.) 2. DEVELOPMENT (m anufacturing process)  Laboratory  Pilot plant  Production plant 3. Main points again

4. Guideline on Submission of Documentation for Prequalification of Multi-source (Generic) Finished Pharmaceutical Products (FPPs) Used in the Treatment of HIV/AIDS, Malaria and Tuberculosis 3.2.2 Information from literature (Desk research)

5. 2006.01.09. Pogány - Guilin 5/57 EOI – Oral Preparations  Artesunate* + Amodiaquine  Artemether* + Lumefantrine*  Artesunate* + Mefloquine  Artesunate* + SP (sulphadoxine / pyrimethamine) * No comparator at the beginning * High-risk API +... FDC or co-blistered (co-packaged) FPPs All oral FPPs include paediatric formulations. (EOI is included in the Notes Page of this and the subsequent slides)

6. 2006.01.09. Pogány - Guilin 6/57 EOI – Other dosage forms  Artemether Injection and rectal FPPs  Artemotil (arteether) Injection  Artesunate Injection and rectal FPPs Only FPPs listed in the EOI are discussed.

7. 2006.01.09. Pogány - Guilin 7/57 Artemisinin  Active antimalarial constituent of the traditional Chinese medicinal herb 青蒿素 Artemisia annua L., Compositae  Artemisinin has seven (7) centers of assymetry but Artemisia annua makes only one configuration (Identification)  Practically insoluble in water  The bond energy of the O-O bond is ~30 kcal/mol  When the peroxide comes into contact with high iron concentrations, the molecule becomes unstable and "explodes" into free radicals.  The API, the capsules and the tablets are official in the Ph. Int. Not included in the current EOI.

8. 2006.01.09. Pogány - Guilin 8/57 Artemether  Practically insoluble in water  Artemether injection is an oily soulution  The API, the capsules, the tablets and the injection are official in the Ph. Int.

9. 2006.01.09. Pogány - Guilin 9/57 Artenimol  Practically insoluble in water. Slightly soluble in ethanols and dichloromethane.  Both the API and the tablets are official in the Ph. Int.  Not included in the current EOI

10. 2006.01.09. Pogány - Guilin 10/57 Artesunate  Very slightly soluble in water  The ester linkage is in alpha configuration.  Both the API and the tablets are official in the Ph. Int.  Two functional groups are liable to decomposition

11. 2006.01.09. Pogány - Guilin 11/57 Metabolism of Artemether and Artesunate

12. 2006.01.09. Pogány - Guilin 12/57 Amodiaquine Amodiaquine Hydrochloride USP, C 20 H 22 ClN 3 O.2HCl.2H 2 O. Merck Index: pH of 1% aqeous solution is from 4.0 to 4.8.

13. 2006.01.09. Pogány - Guilin 13/57 Mefloquine hydrochloride  Has an optically active carbon  Very slightly soluble in water  Has no reactive functional groups under general environmental conditions

14. 2006.01.09. Pogány - Guilin 14/57 Lumefantrin

15. 2006.01.09. Pogány - Guilin 15/57 Pharmaceutical information  Artemisinin derivatives may have α- or β-configuration and each of them can exist in two conformations. The literature does not reveal any impact of the geometric isomerism on efficacy, safety or quality of artemisinins.  The internal peroxide bound is the most reactive part of the molecule. When the peroxide comes into contact with high iron concentrations, the molecule becomes unstable and "explodes" into free radicals.  The ester bound of artesunate is liable to hydrolysis.  The non-artemisinin APIs in the EoI are chemically stable.

16. 2006.01.09. Pogány - Guilin 16/57 Biopharmaceutical information  The internal peroxide bound is fundamental for antimalarial activity.  Artemisinin has a  poor solubility in both water and oil,  short pharmacological half life,  high first-pass metabolism, and  poor oral bioavailability.  Its lactol ethers –artemether and arteether– are soluble in oils.  The lactol hemiester –artesunate– is slightly soluble in water and soluble at a basic pH.

17. Guideline on Submission of Documentation for Prequalification of Multi-source (Generic) Finished Pharmaceutical Products (FPPs) Used in the Treatment of HIV/AIDS, Malaria and Tuberculosis 3.2 Pharmaceutical development

18. 2006.01.09. Pogány - Guilin 18/57 3.2.1 Company research and development The Pharmaceutical Development section should contain information on the development studies conducted to establish that the dosage form, the formulation, manufacturing process, container closure system, microbiological attributes and usage instructions are appropriate for the purpose specified in the application. The studies described here are distinguished from routine control tests conducted according to specifications. The summary should highlight the evolution of the formulation design from initial concept up to the final design and it should also take into consideration the choice of drug product components (e.g., the properties of the drug substance, excipients, container closure system, the manufacturing process, and, if appropriate, knowledge gained from the development of similar drug product(s).

19. 2006.01.09. Pogány - Guilin 19/57

20. 2006.01.09. Pogány - Guilin 20/57 Product-specific physical API properties Introduction of the API starting material(s) into process Production of intermediate(s) Isolation and purification Physical processing and packaging Product-specific physical properties depend on crystallization and subsequent physical processing.

21. 2006.01.09. Pogány - Guilin 21/57 Potentially critical attributes of API Key physicochemical characteristics: 1. Solubility over the physiological pH range (e.g., BCS, dissolution testing, cleaning validation ) 2. Octanol-water partition ( BCS ) 3. Particle size ( pharmaceutical and bioequivalence, processability ) 4. Polymorphic or solid state form ( if relevant) 5. Bulk density, untapped and tapped (processability) 6. Flowability (processability) 7. Color, olor, taste, consistency ( choice of dosage form ) should be discussed and supported by experimental data.

22. 2006.01.09. Pogány - Guilin 22/57 Solubility of artesunate pHDissolved material (mg/ml) 11,9 51,5 63,5 710,2 812,2

23. 2006.01.09. Pogány - Guilin 23/57 Degradation of artesunate in aqueous solution ConditionsTime (h)Degradation (%) Water20 0.1N HCl274 0.1N NaOH2100

24. 2006.01.09. Pogány - Guilin 24/57 Relationship between permeability coefficient and octanol-water partition 1 Prednisolone... 3 Dexamethazone... 9 Dexamethazone-acetate... 11 Progesterone

25. 2006.01.09. Pogány - Guilin 25/57 Particle size When the solubility of an API is less than 0.1 mg/ml and does not change with pH in the physiological range, then the optimisation of the particle size during preformulation may be critical to efficacy or pharmaceutical equivalence. Other researchers believe that particle size may be critical at a solubility of 1 mg/ml or less.

26. 2006.01.09. Pogány - Guilin 26/57 Potentially critical attributes of API Cross reference to stress testing ( forced degradation ): 1. Sensitivity to temperature ( wet granulation, sterilization ) 2. Sensitivity to moisture ( wet granulation, hygroscopicity ) 3. Sensitivity to light ( packing materials ) 4. Sensitivity to oxidation ( inert gas atmosphere in ampoules ) 5. Sensitivity to pH ( FDC with HCL salts of weak bases ) 6. Sensitivity to metal ions ( internal peroxide bond ) Expected degradants, manufacturing conditions, etc.

27. 2006.01.09. Pogány - Guilin 27/57 Rate of water absorption as a function of RH

28. 2006.01.09. Pogány - Guilin 28/57 Overages in the formulation Information should be provided on the 1. amount of overage, 2. reason for the overage (e.g., to compensate for expected and documented manufacturing losses), and 3. justification for the amount of overage (API but not EXCIPIENT). The overage should be included in the amount of drug substance listed in the batch formula.

29. 2006.01.09. Pogány - Guilin 29/57 Compatibility of APIs in FDCs  Artemether + Lumefantrine  Artesunate + Amodiaquine.2HCl  Artesunate + Mefloquine.HCl  Artesunate + Sulphadoxine/Pyrimethamine (SP)

30. 2006.01.09. Pogány - Guilin 30/57 Compatibility of the API with excipients and diluents  Magnesium stearate is incompatible with salts of weak bases and strong acids (e.g. Amodiaquine.2HCl) because the formed MgCl 2 is highly hygroscopic and, as a result, its lubricant properties also change.  The compatibility of the drug product with reconstitution diluents should be addressed, e.g. in Artesunate injection.

31. 2006.01.09. Pogány - Guilin 31/57 Selection of excipients - Talc Time (week)Talc ATalc B Salicylic acid, % 00.10 40.325.85 80.4113.00 120.8028.50

32. 2006.01.09. Pogány - Guilin 32/57 Selection of tablet mass CompositionABC API (mg)500 Excipients (mg)200125 56 Tablet mass (mg):700625556 Granules, LOD (%)0,90,8 Median diameter (μm)194186189 Tablets, hardness (kp)12.813.312.4 Friability (%)0.70.5 Disintegration time6’30’’7’40’’10’50’’ Dissolution (%, 15’)96.695.696.7

33. 2006.01.09. Pogány - Guilin 33/57 Selection of binder and solvent Povidone, water (W), ethanol (E)W-EWE Granules LOD(%)0.80.90.8 Median diameter (μm)186179184 Tablets Average weight (mg)626624628 Hardness (kp)13.311.212.9 Friability (%)0.5 0.4 Disintegration time7’4’’2’10’’6’35’’ Dissolution (%, 15’)95.696.375.7

34. 2006.01.09. Pogány - Guilin 34/57 Special requirements In case of tablets designed with a score line, information should be given whether or not reproducible dividing of the tablets has been shown. e.g. „the scoreline is only to facilitate breaking for ease of swallowing and not to divide into equal doses”, „the tablet can be divided into equal halves”.

35. 2006.01.09. Pogány - Guilin 35/57 Dissolution testing*  Dissolution testing is used for the selection of the formulation and comparison of the dissolution profiles with that of the innovator product and clinical batches. This should be a basic strategy in pharmaceutical development to maximize the chances of bioequivalence.  Limits should be set for each API in fixed-dose FPPs.  The dissolution method should be incorporated into the stability and quality control programs.  Multipoint dissolution profiles of both the test and the reference FPPs should be compared. * Supplement 1 to the Generic Guideline.

36. 2006.01.09. Pogány - Guilin 36/57 Dissolution testing  Three media - 900 ml or less - all at 37°C  Buffer pH 1.2, SGF without enzymes or 0.1M HCl  Buffer pH 4.5  Buffer pH 6.8 or SIF without enzymes  Water may be used additionally (not instead of) 2. Paddle at 50 or basket at 100 rpm 3. Twelve units of each product in all 3 media 4. Dissolution samples collected at short intervals, e.g.  10, 15, 20, 30, 45 and 60 minutes  Analyse samples for all APIs, when applicable

37. 2006.01.09. Pogány - Guilin 37/57 Hypothetical dissolution profile of a 2-FDC FPP

38. 2006.01.09. Pogány - Guilin 38/57 Artemether injection Possible design and development issues:  Selection of oil.  Heat stability of the oil and the oily solution of artemether (standard conditions for dry heat sterilization: NLT 160 o C, two hours)  Alternatively, sterile filtration under aseptic conditions.

39. 2006.01.09. Pogány - Guilin 39/57 Artesunate injection  In the treatment of severe malaria, intravenous artesunate is more rapidly acting than intravenous quinine in terms of parasite clearance, is safer, and is simpler to administer, but whether it can reduce mortality is uncertain.  „ Every 60mg vial contained anhydrous artesunic acid, which we dissolved in 1mL 5% sodium bicarbonate and then mixed with 5mL of 5% dextrose before injecting as a bolus into an indwelling intravenous cannula”. www.thelancet.comwww.thelancet.comVol366August 27, 2005

40. 2006.01.09. Pogány - Guilin 40/57 4-FDC antituberculosis FPP Originator FPP in ICH region  None FPP in current Essential Drug List  Rifampicin150 mg  Isoniazid 75 mg  Pyrazinamide400 mg  Ethambutol275 mg

41. 2006.01.09. Pogány - Guilin 41/57 4FDC-TB tablets exposed to 40°C/75%RH for one week Two different products. “Bleeding” may start after more exposure to stress testing without packing material. (North- West University, South Africa) Control on left

42. 2006.01.09. Pogány - Guilin 42/57 Critical quality variables 1. The formulation is hygroscopic, sensitive to light and unstable. 2. Moisture content of FPP and intermediates. 3. Ethambutol.2HCl provides acidic conditions to accelerate decomposition between rifampicin and isoniazid. 4. Packing materials are critical for stability.

43. 2006.01.09. Pogány - Guilin 43/57 Special attention in assessment  Compatibility of APIs with each other and with excipients.  Stress stability of the final formulation.  Equilibrium moisture content of granules and uncoated tablets.  Control of temperature and RH during the manufacturing process.

44. 2006.01.09. Pogány - Guilin 44/57 Special attention in assessment  Specifications and sampling of the primary packing materials.  Heavy-duty compression machine.  Validation batches and annual product review reports.  Stability testing of the FPP to include visual inspection, assay, impurities and degradants (in particular isonicotinyl hydrazone), water, hardness, and other attributes.

45. 2006.01.09. Pogány - Guilin 45/57 Container closure system  The choice and rationale for selection of the container closure system for the commercial product [described in 3.10 Container/closure system(s) and other packaging] should be discussed.  The data should include details on:  tightness of closure.  protection of the contents against external factors.  container/contents interaction (e.g. sorption, leaching).  influence of the manufacturing process on the container (e.g. sterilisation conditions).

46. 2006.01.09. Pogány - Guilin 46/57 Microbiological attributes  The microbiological attributes of the FPP should be discussed in this section. The discussion should include, for example :  The rationale for performing or not performing microbial limits testing for non-sterile FPPs (e.g., Decision Tree #8 in ICH Q6A Specifications).  Antimicrobial preservative effectiveness should be demonstrated during development.

47. 2006.01.09. Pogány - Guilin 47/57 Pivotal batches A tabulated summary of the compositions of the clinical, bioequivalence, stability and validation FPP batches together with documentation (batch number, batch size, manufacturing date and certificate of analysis at batch release) and a presentation of dissolution profiles must be provided. Results from comparative in vitro studies (e.g., dissolution) or comparative in vivo studies (e.g., bioequivalence) should be discussed when appropriate.

48. 2006.01.09. Pogány - Guilin 48/57 Manufacturing Process Development The progress from pre-formulation (size:1x) → formulation (10x) → pilot manufacture (100x but not less than 100,000 capsules or tablets) → production scale (approved batch size) manufacture should be shown in the dossier submitted for prequalification to be logical, reasoned and continuous. A pilot batch is manufactured by a procedure fully representative of and simulating that to be applied to a full production scale batch.

49. 2006.01.09. Pogány - Guilin 49/57 Manufacturing Process Development  Significant differences between the manufacturing processes used to produce batches for pivotal clinical trials (safety, efficacy, bioavailability, bioequivalence) or primary stability studies and the process described in 3.5 Manufacturing process should be discussed.  The information should include, for example,  the identity (e.g., batch number) and use of the batches produced (e.g., bioequivalence study batch number),  the manufacturing site,  the batch size, and  significant equipment differences (e.g., different design, operating principle, size).

50. 2006.01.09. Pogány - Guilin 50/57 Manufacturing Process Development  The selection, the control, and any improvement of the manufacturing process described in 3.5 Manufacturing process should be explained.  Appropriateness of the equipment used for the intended product(s) should be discussed.  Process development studies should provide the basis for process improvement, process validation, continuous process verification (where applicable), and any process control requirements.

51. 2006.01.09. Pogány - Guilin 51/57 Manufacturing Process Development  An assessment of the ability of the process to reliably produce a product of the intended quality e.g., the performance of the manufacturing process under  different operating conditions,  at different scales, or  with different equipment can be provided.  Unsatisfactory processes must be modified and improved until a validation exercise proves them to be satisfactory.  An understanding of process robustness can be useful in risk assessment and risk reduction.

52. 2006.01.09. Pogány - Guilin 52/57 Compression Tabletting machine BB3 β-Press Granules, (Mg-stearate %)0.250. 50 LOD (%)1.5 Median diameter (μm)341 Tablets Average weight (mg)605607599 Hardness (kp)10.99.77.3 Friability (%)0.30.50.8 Disintegration time6’48’’14’19’’8’14’’ Dissolution (%, 15’)99.576.792.0

53. 2006.01.09. Pogány - Guilin 53/57 Film-coating conditions Spraying conditionsPilot batch 1Pilot batch 2 Film-coaterManesty Nozzle (mm)0.8 Spraying pressure (psi)40/25 Inlet temperature ( o C)8171 Outlet temperature ( o C)4544 Spray rate (g/min)3626 Drum speed (rpm)810

54. 2006.01.09. Pogány - Guilin 54/57 Film-coating results Quality parameter Pilot batch 1Pilot batch 2 CoreCoatedCoreCoated Weight increase (%)2.122.04 Appearancegood Mean thickness (mm)4.254.284.344.37 Hardness (kp)9.214.78.710.8 Friability (%)0.300.440 Disintegration time3’40’’5’32’’1’44’’2’46’’ Dissolution (15’, %)-93-98

55. 2006.01.09. Pogány - Guilin 55/57 Main points again  Development pharmaceutics is an essential part of applications for prequalification.  Desk research gives valuable design and development information.  The specifications of an API are finalized during pharmaceutical development studies.  FPP design, characterization and selection should follow a scientific methodology.  Manufacturing process design and optimization identifies the critical attributes whose control leads to the batch-to- batch consistency of quality.

56. 2006.01.09. Pogány - Guilin 56/57 Literature 1. Monographs from the Merck Index ®, 13 th edition (2001). 2. Xuan-De Luo and Chia-Chiang Shen : The Chemistry, Pharmacology and Clinical Applications of Qinghaosu (Artemisinin) and its Derivatives (Med. Research Reviews, Vol. 7, No.1, 29-52 (1987). 3. The International Pharmacopoeia, 3rd ed., Volume 5, 185-233, WHO, Geneva (2003).

57. 2006.01.09. Pogány - Guilin 57/57 THANK YOU 谢谢 !