Comprehensive Quality by Design for Pharmaceutical Product Development and Manufacture

List of Contributors xiii Preface xix 1 Introduction 1 Christine Seymour and Gintaras V. Reklaitis 1.1 Quality by Design Overview 1 1.2 Pharmaceutical Industry 2 1.3 Quality by Design Details 3 1.4 Chapter Summaries 4 References 7 2 An Overview of the Role of Mathematical Models in Implementation of Quality by Design Paradigm for Drug Development and Manufacture 9 Sharmista Chatterjee, Christine M. V. Moore, and Moheb M. Nasr 2.1 Introduction 9 2.2 Overview of Models 9 2.3 Role of Models in QbD 12 2.4 General Scientific Considerations for Model Development 20 2.5 Scientific Considerations for Maintenance of Models 22 2.6 Conclusion 23 References 23 3 Role of Automatic Process Control in Quality by Design 25 Mo Jiang, Nicholas C. S. Kee, Xing Yi Woo, Li May Goh, Joshua D. Tice, Lifang Zhou, Reginald B. H. Tan, Charles F. Zukoski, Mitsuko Fujiwara, Zoltan K. Nagy, Paul J. A. Kenis, and Richard D. Braatz 3.1 Introduction 25 3.2 Design of Robust Control Strategies 31 3.3 Some Example Applications of Automatic Feedback Control 35 3.4 The Role of Kinetics Modeling 40 3.5 Ideas for a Deeper QbD Approach 42 3.6 Summary 44 Acknowledgments 46 References 47 4 Predictive Distributions for Constructing the ICH Q8 Design Space 55 John J. Peterson, Mohammad Yahyah, Kevin Lief, and Neil Hodnett 4.1 Introduction 55 4.2 Overlapping Means Approach 56 4.3 Predictive Distribution Approach 59 4.4 Examples 61 4.5 Summary and Discussion 68 Acknowledgments 69 References 69 5 Design of Novel Integrated Pharmaceutical Processes: A Model?]Based Approach 71 Alicia Román?]Martínez, John M. Woodley, and Rafiqul Gani 5.1 Introduction 71 5.2 Problem Description 73 5.3 Methodology 76 5.4 Application: Case Study 80 5.5 Conclusions 91 References 91 6 Methods and Tools for Design Space Identification in Pharmaceutical Development 95 Fani Boukouvala, Fernando J. Muzzio, and Marianthi G. Ierapetritou 6.1 Introduction 95 6.2 Design Space: A Multidisciplinary Concept 98 6.3 Integration of Design Space and Control Strategy 102 6.4 Case Studies 102 6.5 Conclusions 119 Acknowledgment 120 References 120 7 Using Quality by Design Principles as a Guide for Designing a Process Control Strategy 125 Christopher L. Burcham, Mark LaPack, Joseph R. Martinelli, and Neil McCracken 7.1 Introduction 125 7.2 Chemical Sequence, Impurity Formation, and Control Strategy 130 7.3 Mass Transfer and Reaction Kinetics 140 7.4 Optimal Processing Conditions 165 7.5 Predicted Product Quality under Varied Processing Conditions 174 7.6 Conclusions 186 Acknowledgments 187 Notation 187 Acronyms 187 Symbols 187 Notes 189 References 189 8 A Strategy for Tablet Active Film Coating Formulation Development Using a Content Uniformity Model and Quality by Design Principles 193 Wei Chen, Jennifer Wang, Divyakant Desai, Shih?]Ying Chang, San Kiang, and Olav Lyngberg 8.1 Introduction 193 8.2 Content Uniformity Model Development 197 8.3 RSD Model Validation and Sensitivity Analysis for Model Parameters 212 8.4 Model?]Based Design Space Establishment for Tablet Active Film Coating 219 8.5 Summary 229 Notations 230 References 230 9 Quality by Design: Process Trajectory Development for a Dynamic Pharmaceutical Coprecipitation Process Based on an Integrated Real?]Time Process Monitoring Strategy 235 Huiquan Wu and Mansoor A. Khan 9.1 Introduction 235 9.2 Experimental 237 9.3 Data Analysis Methods 239 9.4 Results and Discussion 240 9.5 Challenges and Opportunities for PCA?]Based Data Analysis and Modeling in Pharmaceutical PAT and QbD Development 250 9.6 Conclusions 252 Acknowledgments 252 References 253 10 Application of Advanced Simulation Tools for Establishing Process Design Spaces Within the Quality by Design Framework 257 Siegfried Adam, Daniele Suzzi, Gregor Toschkoff, and Johannes G. Khinast 10.1 Introduction 257 10.2 Computer Simulation?]Based Process Characterization of a Pharmaceutical Blending Process 261 10.3 Characterization of a Tablet Coating Process via CFD Simulations 276 10.4 Overall Conclusions 294 References 295 11 Design Space Definition: A Case Study--Small Molecule Lyophilized Parenteral 301 Linas Mockus, David LeBlond, Gintaras V. Reklaitis, Prabir K. Basu, Tim Paul, Nathan Pease, Steven L. Nail, and Mansoor A. Khan 11.1 Introduction 301 11.2 Case Study: Bayesian Treatment of Design Space for a Lyophilized Small Molecule Parenteral 302 11.3 Results 307 11.4 Conclusions 311 Appendix 11.A Implementation Using WinBUGS and R 311 Shelf Life 315 Notation 316 Acknowledgments 317 References 317 12 Enhanced Process Design and Control of a Multiple?]Input Multiple?]Output Granulation Process 319 Rohit Ramachandran 12.1 Introduction and Objectives 319 12.2 Population Balance Model 320 12.3 Simulation and Controllability Studies 323 12.4 Identification of Existing "Optimal" Control?]Loop Pairings 327 12.5 Novel Process Design 330 12.6 Conclusions 335 References 336 13 A Perspective on the Implementation of QbD on Manufacturing through Control System: The Fluidized Bed Dryer Control with MPC and NIR Spectroscopy Case 339 Leonel Quiñones, Luis Obregón, and Carlos Velázquez 13.1 Introduction 339 13.2 Theory 340 13.3 Materials and Methods 344 13.4 Results and Discussion 348 13.5 Continuous Fluidized Bed Drying 355 13.6 Control Limitations 356 13.7 Conclusions 357 Acknowledgment 357 References 357 14 Knowledge Management in Support of QbD 361 G. Joglekar, Gintaras V. Reklaitis, A. Giridhar, and Linas Mockus 14.1 Introduction 361 14.2 Knowledge Hierarchy 363 14.3 Review of Existing Software 364 14.4 Workflow?]Based Framework 365 14.5 Drug Substance Case Study 368 14.6 Design Space 374 14.7 Technical Challenges 382 14.8 Conclusions 384 References 385 Index 387