1
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Glace M, Armstrong C, Puryear N, Bailey C, Moazeni-Pourasil RS, Scott D, Abdelwahed S, Roper TD. An Automated Continuous Synthesis and Isolation for the Scalable Production of Aryl Sulfonyl Chlorides. Molecules 2023; 28:molecules28104213. [PMID: 37241953 DOI: 10.3390/molecules28104213] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/24/2023] [Revised: 05/16/2023] [Accepted: 05/17/2023] [Indexed: 05/28/2023] Open
Abstract
In this work, a continuous system to produce multi-hundred-gram quantities of aryl sulfonyl chlorides is described. The scheme employs multiple continuous stirred-tank reactors (CSTRs) and a continuous filtration system and incorporates an automated process control scheme. The experimental process outlined is intended to safely produce the desired sulfonyl chloride at laboratory scale. Suitable reaction conditions were first determined using a batch-chemistry design of experiments (DOE) and several isolation methods. The hazards and incompatibilities of the heated chlorosulfonic acid reaction mixture were addressed by careful equipment selection, process monitoring, and automation. The approximations of the CSTR fill levels and pumping performance were measured by real-time data from gravimetric balances, ultimately leading to the incorporation of feedback controllers. The introduction of process automation demonstrated in this work resulted in significant improvements in process setpoint consistency, reliability, and spacetime yield, as demonstrated in medium- and large-scale continuous manufacturing runs.
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Affiliation(s)
- Matthew Glace
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Cameron Armstrong
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Nathan Puryear
- Department of Electrical and Computer Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Colin Bailey
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | | | - Drew Scott
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Sherif Abdelwahed
- Department of Electrical and Computer Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
| | - Thomas D Roper
- Department of Chemical and Life Sciences Engineering, Virginia Commonwealth University, Richmond, VA 23284, USA
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2
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Feng Báez JP, George De la Rosa MV, Alvarado-Hernández BB, Romañach RJ, Stelzer T. Evaluation of a compact composite sensor array for concentration monitoring of solutions and suspensions via multivariate analysis. J Pharm Biomed Anal 2023; 233:115451. [PMID: 37182364 DOI: 10.1016/j.jpba.2023.115451] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/25/2023] [Revised: 04/24/2023] [Accepted: 05/07/2023] [Indexed: 05/16/2023]
Abstract
Compact composite probes were identified as a priority to alleviate space constraints in miniaturized unit operations and pharmaceutical manufacturing platforms. Therefore, in this proof of principle study, a compact composite sensor array (CCSA) combining ultraviolet and near infrared features at four different wavelengths (280, 340, 600, 860 nm) in a 380 × 30 mm housing (length x diameter, 7 mm diameter at the probe head), was evaluated for its capabilities to monitor in situ concentration of solutions and suspensions via multivariate analysis using partial least squares (PLS) regression models. Four model active pharmaceutical ingredients (APIs): warfarin sodium isopropanol solvate (WS), lidocaine hydrochloride monohydrate (LID), 6-mercaptopurine monohydrate (6-MP), and acetaminophen (ACM) in their aqueous solution and suspension formulation were used for the assessment. The results demonstrate that PLS models can be applied for the CCSA prototype to measure the API concentrations with similar accuracy (validation samples within the United States Pharmacopeia (USP) limits), compared to univariate CCSA models and multivariate models for an established Raman spectrometer. Specifically, the multivariate CCSA models applied to the suspensions of 6-MP and ACM demonstrate improved accuracy of 63% and 31%, respectively, compared to the univariate CCSA models [1]. On the other hand, the PLS models for the solutions WS and LID showed a reduced accuracy compared to the univariate models [1].
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Affiliation(s)
- Jean P Feng Báez
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Puerto Rico, Medical Sciences Campus, San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA
| | - Mery Vet George De la Rosa
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Puerto Rico, Medical Sciences Campus, San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA
| | | | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico, Mayagüez Campus, Mayagüez, PR 00681, USA
| | - Torsten Stelzer
- Department of Pharmaceutical Sciences, School of Pharmacy, University of Puerto Rico, Medical Sciences Campus, San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA.
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3
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Leveraging first-principles and empirical models for disturbance detection in continuous pharmaceutical syntheses. J Flow Chem 2023. [DOI: 10.1007/s41981-023-00266-0] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/17/2023]
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4
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Comito M, Monguzzi R, Tagliapietra S, Palmisano G, Cravotto G. Towards Antibiotic Synthesis in Continuous-Flow Processes. Molecules 2023; 28:molecules28031421. [PMID: 36771086 PMCID: PMC9919330 DOI: 10.3390/molecules28031421] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/24/2022] [Revised: 01/20/2023] [Accepted: 01/23/2023] [Indexed: 02/05/2023] Open
Abstract
Continuous-flow chemistry has become a mainstream process and a notable trend among emerging technologies for drug synthesis. It is routinely used in academic and industrial laboratories to generate a wide variety of molecules and building blocks. The advantages it provides, in terms of safety, speed, cost efficiency and small-equipment footprint compared to analog batch processes, have been known for some time. What has become even more important in recent years is its compliance with the quality objectives that are required by drug-development protocols that integrate inline analysis and purification tools. There can be no doubt that worldwide government agencies have strongly encouraged the study and implementation of this innovative, sustainable and environmentally friendly technology. In this brief review, we list and evaluate the development and applications of continuous-flow processes for antibiotic synthesis. This work spans the period of 2012-2022 and highlights the main cases in which either active ingredients or their intermediates were produced under continuous flow. We hope that this manuscript will provide an overview of the field and a starting point for a deeper understanding of the impact of flow chemistry on the broad panorama of antibiotic synthesis.
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Affiliation(s)
- Marziale Comito
- Dipartimento di Scienza e Tecnologia del Farmaco, University of Turin, Via Pietro Giuria 9, 10125 Turin, Italy
- Research and Development, ACS Dobfar SpA, Via Paullo 9, 20067 Tribiano, Italy
| | - Riccardo Monguzzi
- Research and Development, ACS Dobfar SpA, Via Paullo 9, 20067 Tribiano, Italy
| | - Silvia Tagliapietra
- Dipartimento di Scienza e Tecnologia del Farmaco, University of Turin, Via Pietro Giuria 9, 10125 Turin, Italy
| | - Giovanni Palmisano
- Dipartimento di Scienza e Alta Tecnologia, University of Insubria, Via Valleggio 9, 22100 Como, Italy
| | - Giancarlo Cravotto
- Dipartimento di Scienza e Tecnologia del Farmaco, University of Turin, Via Pietro Giuria 9, 10125 Turin, Italy
- Correspondence: ; Tel.: +39-011-670-7183
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5
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Scott D, Briggs NEB, Formosa A, Burnett A, Desai B, Hammersmith G, Rapp K, Capellades G, Myerson AS, Roper TD. Impurity Purging through Systematic Process Development of a Continuous Two-Stage Crystallization. Org Process Res Dev 2023. [DOI: 10.1021/acs.oprd.2c00317] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/05/2023]
Affiliation(s)
- Drew Scott
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia23284, United States
| | - Naomi E. B. Briggs
- On Demand Pharmaceuticals, 1550 E Gude Drive, Rockville, Maryland20850, United States
| | - Anna Formosa
- On Demand Pharmaceuticals, 1550 E Gude Drive, Rockville, Maryland20850, United States
| | - Annessa Burnett
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia23284, United States
| | - Bimbisar Desai
- TCG GreenChem, Inc., 701 Charles Ewing Boulevard, Ewing, New Jersey08628, United States
| | - Greg Hammersmith
- On Demand Pharmaceuticals, 1550 E Gude Drive, Rockville, Maryland20850, United States
| | - Kersten Rapp
- On Demand Pharmaceuticals, 1550 E Gude Drive, Rockville, Maryland20850, United States
| | - Gerard Capellades
- Henry M. Rowan College of Engineering, Rowan University, Glassboro, New Jersey08028, United States
| | - Allan S. Myerson
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts02139, United States
| | - Thomas D. Roper
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia23284, United States
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6
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Burange AS, Osman SM, Luque R. Understanding flow chemistry for the production of active pharmaceutical ingredients. iScience 2022; 25:103892. [PMID: 35243250 PMCID: PMC8867129 DOI: 10.1016/j.isci.2022.103892] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022] Open
Abstract
Multi-step organic syntheses of various drugs, active pharmaceutical ingredients, and other pharmaceutically and agriculturally important compounds have already been reported using flow synthesis. Compared to batch, hazardous and reactive reagents can be handled safely in flow. This review discusses the pros and cons of flow chemistry in today’s scenario and recent developments in flow devices. The review majorly emphasizes on the recent developments in the flow synthesis of pharmaceutically important products in last five years including flibanserin, imatinib, buclizine, cinnarizine, cyclizine, meclizine, ribociclib, celecoxib, SC-560 and mavacoxib, efavirenz, fluconazole, melitracen HCl, rasagiline, tamsulosin, valsartan, and hydroxychloroquine. Critical steps and new development in the flow synthesis of selected compounds are also discussed.
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Affiliation(s)
- Anand S. Burange
- Department of Chemistry, Wilson College, Chowpatty, Mumbai 400007, India
- Corresponding author
| | - Sameh M. Osman
- Chemistry Department, College of Science, King Saud University, P.O. Box 2455, Riyadh 11451, Saudi Arabia
| | - Rafael Luque
- Departamento de Quimica Organica, Universidad de Cordoba, Edificio Marie Curie (C-3), Ctra Nnal IV-A, Km 396, E14014 Cordoba, Spain
- Peoples Friendship University of Russia (RUDN University), 6 Miklukho Maklaya str., 107198 Moscow, Russian Federation
- Corresponding author
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7
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Capellades G, Bonsu JO, Myerson AS. Impurity incorporation in solution crystallization: diagnosis, prevention, and control. CrystEngComm 2022. [DOI: 10.1039/d1ce01721g] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/14/2023]
Abstract
This work highlights recent advances in the diagnosis, prevention, and control of impurity incorporation during solution crystallization.
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Affiliation(s)
- Gerard Capellades
- Department of Chemical Engineering, Henry M. Rowan College of Engineering, Rowan University, Glassboro, New Jersey 08028, USA
| | - Jacob O. Bonsu
- Department of Chemical Engineering, Henry M. Rowan College of Engineering, Rowan University, Glassboro, New Jersey 08028, USA
| | - Allan S. Myerson
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, USA
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8
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Miyai Y, Formosa A, Armstrong C, Marquardt B, Rogers L, Roper T. PAT Implementation on a Mobile Continuous Pharmaceutical Manufacturing System: Real-Time Process Monitoring with In-Line FTIR and Raman Spectroscopy. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00299] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
Affiliation(s)
- Yuma Miyai
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia 23284-2512, United States
| | - Anna Formosa
- OnDemand Pharmaceuticals, Rockville, Maryland 20850, United States
| | - Cameron Armstrong
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia 23284-2512, United States
| | | | - Luke Rogers
- OnDemand Pharmaceuticals, Rockville, Maryland 20850, United States
| | - Thomas Roper
- Department of Chemical and Life Science Engineering, Virginia Commonwealth University, Richmond, Virginia 23284-2512, United States
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De la Rosa MVG, Báez JPF, Romañach RJ, López-Mejías V, Stelzer T. Real-time concentration monitoring using a compact composite sensor array for in situ quality control of aqueous formulations. J Pharm Biomed Anal 2021; 206:114386. [PMID: 34607202 DOI: 10.1016/j.jpba.2021.114386] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/14/2021] [Revised: 08/29/2021] [Accepted: 09/15/2021] [Indexed: 11/25/2022]
Abstract
Recent advancements have demonstrated the feasibility of refrigerator-sized pharmaceutical manufacturing platforms (PMPs) for integrated end-to-end manufacturing of active pharmaceutical ingredients (APIs) into formulated drug products. Unlike typical laboratory- or industrial-scale setups, PMPs present unique requirements for process analytical technology (PAT) with respect to versatility, flexibility, and physical size to fit into the PMP space constraints. In this proof of principle study, a novel compact composite sensor array (CCSA) combining ultraviolet (UV) and near infrared (NIR) features at four different wavelengths (280, 340, 600, 860 nm) with temperature measuring capability in a 380 × 30 mm housing (length x diameter, 7 mm diameter at the probe head), were evaluated. The results indicate that the CCSA prototype is capable of measuring the solution and suspension concentrations in aqueous formulations of four model APIs (warfarin sodium isopropanol solvate, lidocaine hydrochloride monohydrate, 6-mercaptopurine monohydrate, acetaminophen) in situ and in real-time with similar accuracy as an established Raman spectrometer commonly applied for method development.
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Affiliation(s)
- Mery Vet George De la Rosa
- Department of Pharmaceutical Sciences, University of Puerto Rico, Medical Sciences Campus San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA
| | - Jean P Feng Báez
- Department of Pharmaceutical Sciences, University of Puerto Rico, Medical Sciences Campus San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA
| | - Rodolfo J Romañach
- Department of Chemistry, University of Puerto Rico, Mayagüez Campus,. Mayagüez, PR, 00681, USA
| | - Vilmalí López-Mejías
- Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA; Department of Chemistry, University of Puerto Rico, Río Piedras Campus, San Juan, PR 00931, USA.
| | - Torsten Stelzer
- Department of Pharmaceutical Sciences, University of Puerto Rico, Medical Sciences Campus San Juan, PR 00936, USA; Crystallization Design Institute, Molecular Sciences Research Center, University of Puerto Rico, San Juan, PR 00926, USA.
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10
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Capellades G, Neurohr C, Briggs N, Rapp K, Hammersmith G, Brancazio D, Derksen B, Myerson AS. On-Demand Continuous Manufacturing of Ciprofloxacin in Portable Plug-and-Play Factories: Implementation and In Situ Control of Downstream Production. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00117] [Citation(s) in RCA: 10] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
Affiliation(s)
- Gerard Capellades
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - Clemence Neurohr
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - Naomi Briggs
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - Kersten Rapp
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - Gregory Hammersmith
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - David Brancazio
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - Bridget Derksen
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
| | - Allan S. Myerson
- Department of Chemical Engineering, Massachusetts Institute of Technology, E19-502D, 77 Massachusetts Avenue, Cambridge, Massachusetts 02139-4307, United States
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