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Castañeda Ruiz AJ, Shetab Boushehri MA, Phan T, Carle S, Garidel P, Buske J, Lamprecht A. Alternative Excipients for Protein Stabilization in Protein Therapeutics: Overcoming the Limitations of Polysorbates. Pharmaceutics 2022; 14:pharmaceutics14122575. [PMID: 36559072 PMCID: PMC9781097 DOI: 10.3390/pharmaceutics14122575] [Citation(s) in RCA: 11] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/20/2022] [Revised: 11/11/2022] [Accepted: 11/15/2022] [Indexed: 11/25/2022] Open
Abstract
Given their safety and efficiency in protecting protein integrity, polysorbates (PSs) have been the most widely used excipients for the stabilization of protein therapeutics for years. In recent decades, however, there have been numerous reports about visible or sub-visible particles in PS-containing biotherapeutic products, which is a major quality concern for parenteral drugs. Alternative excipients that are safe for parenteral administration, efficient in protecting different protein drugs against various stress conditions, effective in protein stabilization in high-concentrated liquid formulations, stable under the storage conditions for the duration of the product's shelf-life, and compatible with other formulation components and the primary packaging are highly sought after. The aim of this paper is to review potential alternative excipients from different families, including surfactants, carbohydrate- and amino acid-based excipients, synthetic amphiphilic polymers, and ionic liquids that enable protein stabilization. For each category, important characteristics such as the ability to stabilize proteins against thermal and mechanical stresses, current knowledge related to the safety profile for parenteral administration, potential interactions with other formulation components, and primary packaging are debated. Based on the provided information and the detailed discussion thereof, this paper may pave the way for the identification or development of efficient excipients for biotherapeutic protein stabilization.
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Affiliation(s)
- Angel J. Castañeda Ruiz
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany
| | | | - Tamara Phan
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
| | - Stefan Carle
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
| | - Patrick Garidel
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
| | - Julia Buske
- Boehringer Ingelheim Pharma GmbH & Co. KG, Innovation Unit, PDB, Birkendorfer Straße 65, 88397 Biberach an der Riss, Germany
- Correspondence: (J.B.); (A.L.); Tel.: +49-7351-54-145-398 (J.B.); +49-228-735-243 (A.L.)
| | - Alf Lamprecht
- Department of Pharmaceutical Technology and Biopharmaceutics, University of Bonn, 53121 Bonn, Germany
- Correspondence: (J.B.); (A.L.); Tel.: +49-7351-54-145-398 (J.B.); +49-228-735-243 (A.L.)
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Thakral S, Sonje J, Munjal B, Suryanarayanan R. Stabilizers and their interaction with formulation components in frozen and freeze-dried protein formulations. Adv Drug Deliv Rev 2021; 173:1-19. [PMID: 33741437 DOI: 10.1016/j.addr.2021.03.003] [Citation(s) in RCA: 39] [Impact Index Per Article: 13.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/08/2020] [Revised: 02/06/2021] [Accepted: 03/03/2021] [Indexed: 02/06/2023]
Abstract
This review aims to provide an overview of the current knowledge on protein stabilization during freezing and freeze-drying in relation to stress conditions commonly encountered during these processes. The traditional as well as refined mechanisms by which excipients may stabilize proteins are presented. These stabilizers encompass a wide variety of compounds including sugars, sugar alcohols, amino acids, surfactants, buffers and polymers. The rational selection of excipients for use in frozen and freeze-dried protein formulations is presented. Lyophilized protein formulations are generally multicomponent systems, providing numerous possibilities of excipient-excipient and protein-excipient interactions. The interplay of different formulation components on the protein stability and excipient functionality in the frozen and freeze-dried systems are reviewed, with discussion of representative examples of such interactions.
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Thorat AA, Munjal B, Geders TW, Suryanarayanan R. Freezing-induced protein aggregation - Role of pH shift and potential mitigation strategies. J Control Release 2020; 323:591-599. [DOI: 10.1016/j.jconrel.2020.04.033] [Citation(s) in RCA: 28] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/11/2020] [Revised: 04/15/2020] [Accepted: 04/22/2020] [Indexed: 12/25/2022]
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Simon N, Sperber C, Voigtländer C, Born J, Gilbert DF, Seyferth S, Lee G, Kappes B, Friedrich O. Improved stability of polyclonal antibodies: A case study with lyophilization-conserved antibodies raised against epitopes from the malaria parasite Plasmodium falciparum. Eur J Pharm Sci 2020; 142:105086. [PMID: 31626961 DOI: 10.1016/j.ejps.2019.105086] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2019] [Revised: 09/18/2019] [Accepted: 09/19/2019] [Indexed: 11/29/2022]
Abstract
Antibodies can be produced as polyclonal (pAb) or monoclonal (mAb) liquid formulations with limited shelf-life. For pAbs, unlike mAbs, only little is known about excipients and lyophilization affecting antibody stability upon reconstitution. We used a model pAb directed against Plasmodium falciparum (Pf) pyridoxal 5'-phosphate synthase 2 (Pdx2) to systemically study effects of bulking agents (amino acids, phosphate buffers, salt solutions), sugar(alcohols), surfactants and protein additions (bovine serum albumin, BSA) in liquid pAb formulations (isolated or in combinations) on the activity to detect the antigen in Pf extracts by Western blots. Repeated freeze-thaw cycles (20x) and extended room temperature storage markedly compromised pAb stability, the former being ameliorated by addition of cryoprotectants (glycerol, sucrose). Lyophilization of pure liquid pAb formulation markedly decreased antibody reactivity upon reconstitution which was not preserved by most bulking agents tested (e.g., histidine, arginine, acetate). Among the tested salt solutions (NaCl, Ringer, PBS), phosphate buffered saline had the largest lyoprotective potential, alongside sucrose, but not trehalose or maltitol. Among combinations of excipients, PBS, sucrose, low concentration BSA and Tween potently preserved PfPdx2 stability. Results for PBS were transferable to PfEnolase pAb, indicating that some of the formulations investigated here might be a low-cost solution for more general applicability to pAbs.
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Affiliation(s)
- Nina Simon
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany.
| | - Christine Sperber
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany; Division of Pharmaceutics, Friedrich-Alexander University Erlangen-Nürnberg, Cauerstrasse 4, Erlangen 91058, Germany
| | - Cornelia Voigtländer
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany
| | - Julia Born
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany
| | - Daniel F Gilbert
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany
| | - Stefan Seyferth
- Division of Pharmaceutics, Friedrich-Alexander University Erlangen-Nürnberg, Cauerstrasse 4, Erlangen 91058, Germany
| | - Geoffrey Lee
- Division of Pharmaceutics, Friedrich-Alexander University Erlangen-Nürnberg, Cauerstrasse 4, Erlangen 91058, Germany
| | - Barbara Kappes
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany
| | - Oliver Friedrich
- Institute of Medical Biotechnology, Friedrich-Alexander University Erlangen-Nürnberg, Paul-Gordan-Str. 3, Erlangen 91052, Germany.
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Faschinger AM, Sessler N. Development of a Lyophilized Formulation of Pegaspargase and Comparability Versus Liquid Pegaspargase. Adv Ther 2019; 36:2106-2121. [PMID: 31140125 PMCID: PMC6822849 DOI: 10.1007/s12325-019-00988-5] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/01/2019] [Indexed: 10/27/2022]
Abstract
INTRODUCTION Pegaspargase, a pegylated asparaginase, is a core component in the treatment of acute lymphoblastic leukemia. Pegaspargase in liquid form has a limited shelf life of 8 months due to depegylation, leading to changes in purity and potency over time. Lyophilization is an approach that can improve the stability of biological drug conjugates. METHODS Here we describe the development of a lyophilized formulation of pegaspargase and present results of a series of tests demonstrating that the lyophilized form has comparable physicochemical properties to the liquid form. RESULTS Stability tests of critical quality attributes, including purity, potency, aggregates and total free polyethylene glycol, demonstrate that lyophilized pegaspargase remains stable for at least 3 years, with optimum stability achieved with storage under refrigerated conditions (2-8 °C). CONCLUSIONS Lyophilization improved the stability of pegaspargase without altering other physicochemical properties, permitting a prolonged shelf life of at least 2 years when stored at 2-8 °C. This may enable greater storage flexibility and allow for better management of pegaspargase. FUNDING Study Sponsor: Baxalta (now part of Takeda). Publication Sponsor: Servier Affaires Médicales.
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Denaturation and Aggregation of Interferon-τ in Aqueous Solution. Pharm Res 2018; 35:137. [DOI: 10.1007/s11095-018-2418-1] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/24/2018] [Accepted: 04/22/2018] [Indexed: 10/16/2022]
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Reduced Subvisible Particle Formation in Lyophilized Intravenous Immunoglobulin Formulations Containing Polysorbate 20. J Pharm Sci 2016; 105:2302-9. [DOI: 10.1016/j.xphs.2016.05.013] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/06/2016] [Revised: 04/25/2016] [Accepted: 05/03/2016] [Indexed: 12/27/2022]
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Zhou C, Cleland D, Snell J, Qi W, Randolph TW, Carpenter JF. Formation of Stable Nanobubbles on Reconstituting Lyophilized Formulations Containing Trehalose. J Pharm Sci 2016; 105:2249-53. [DOI: 10.1016/j.xphs.2016.04.035] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2016] [Accepted: 04/29/2016] [Indexed: 12/31/2022]
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Merutka G, Murphy BM, Payne RW, Wilson GA, Matsuura JE, Henry CS, Manning MC. Stability of lyophilized teriparatide, PTH(1-34), after reconstitution. Eur J Pharm Biopharm 2016; 99:84-93. [DOI: 10.1016/j.ejpb.2015.11.012] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/18/2015] [Revised: 11/17/2015] [Accepted: 11/18/2015] [Indexed: 01/01/2023]
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Telikepalli S, Kumru OS, Kim JH, Joshi SB, O'Berry KB, Blake-Haskins AW, Perkins MD, Middaugh CR, Volkin DB. Characterization of the physical stability of a lyophilized IgG1 mAb after accelerated shipping-like stress. J Pharm Sci 2014; 104:495-507. [PMID: 25522000 DOI: 10.1002/jps.24242] [Citation(s) in RCA: 42] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/26/2014] [Revised: 10/04/2014] [Accepted: 10/13/2014] [Indexed: 12/29/2022]
Abstract
Upon exposure to shaking stress, an IgG1 mAb formulation in both the liquid and lyophilized state formed subvisible particles. Because freeze-drying was expected to minimize protein physical instability under these conditions, the extent and nature of aggregate formation in the lyophilized preparation were examined using a variety of particle characterization techniques. The effects of formulation variables such as residual moisture content, reconstitution rate, and reconstitution medium were also examined. Upon reconstitution of shake-stressed lyophilized mAb, differences in protein particle size and number were observed by microflow digital imaging, with the reconstitution medium having the largest impact. Shake stress had minor effects on the structure of protein within the particles as shown by SDS-PAGE and FTIR analysis. The lyophilized mAb was shake stressed to different extents and stored for 3 months at different temperatures. Both extent of cake collapse and storage temperature affected the physical stability of the shake-stressed lyophilized mAb upon subsequent storage. These findings demonstrate that physical degradation upon shaking of a lyophilized IgG1 mAb formulation includes not only cake breakage, but also results in an increase in subvisible particles and turbidity upon reconstitution. The shake-induced cake breakage of the lyophilized IgG1 mAb formulation also resulted in decreased physical stability upon storage.
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Affiliation(s)
- Srivalli Telikepalli
- Department of Pharmaceutical Chemistry, Macromolecule and Vaccine Stabilization Center, University of Kansas, Lawrence, Kansas, 66047
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