Filling Unit Operation for Biological Drug Products: Challenges and Considerations

One of the key unit operations during the aseptic fill-finish process of parenteral products, such as biologics, is the filling process of the formulated, sterile filtered drug substance into primary packaging containers. The applied filling technology as well as the process performance majorly impacts final drug product quality. The present review provides an overview of commonly used filling technologies during fill-finish operations of biologics including positive displacement pump systems such as radial peristaltic pump, rotary piston pump, rolling diaphragm pump, or innovative systems such as the linear peristaltic pump, as well as time-over-pressure filling technology. The article describes the operating principle of each pump system and reviews advantages and drawbacks. We highlight specific considerations for individual systems, such as the risk of protein particle formation and particle shedding from wear and tear of tubing, and discuss current literature about general challenges associated with the filling process, such as hydrogen peroxide uptake, adsorption phenomena to tubing material, and needle clogging. We suggest process development and process characterization studies to assess the impact of the filling process on product quality, and lastly provide an outlook about the use of disposable equipment during filling operations related to sustainability considerations.

Prospective comparison between a peristaltic pump and vacuum containers for paracentesis: Time, resources and safety

RATIONALE AND OBJECTIVES

To meet the increasing demand for radiology departments to perform paracenteses, this study was done to compare the operational, financial and clinical impact of draining ascites with a peristaltic pump versus conventional vacuum containers.

MATERIALS & METHODS

Prospective cohort study of 157 paracenteses (56 subjects) drained with ACCEL® evacuated drainage bottles (B. Braun Interventional Systems, Bethlehem, PA) and 159 paracenteses (53 subjects) drained with the RenovaRP® pump (Laborie Medical Technologies Corp., Portsmouth, NH). A short elective questionnaire was then distributed to the procedure staff and the subjects drained by both methods.

RESULTS

Mean volume drained with the pump (5 L) was comparable to that drained by vacuum containers (4.9 L, p = 0.77). Mean time to drain subjects with the pump (18.6 min) was 9.1 min shorter and 3.8 min less variable than subjects drained with vacuum containers (27.7 min). This difference was statistically significant (p < 0.01) and clinically important (effect size = 0.73). Flow rate with the pump (4 min/L) was significantly faster (p < 0.05) than vacuum containers flow rate (6.6 min/L). No adverse events occurred in either group. Use of the pump increased the average cost by 21% and reduced earnings by 3%. All assistants (n = 6) and patients (n = 10) that responded to the questionnaire recommended the use of the pump over vacuum containers.

CONCLUSION

The peristaltic pump safely drains ascites significantly faster and with less variability in time than vacuum containers. While use of the pump slightly increases cost per paracentesis, it was recommended by all paired subjects undergoing a paracentesis and all personnel assisting in the procedure.

Solid-Solid Interfacial Contact of Tubing Walls Drives Therapeutic Protein Aggregation During Peristaltic Pumping

Peristaltic pumping during bioprocessing can cause therapeutic protein loss and aggregation during use. Due to the complexity of this apparatus, root-cause mechanisms behind protein loss have been long sought. We have developed new methodologies isolating various peristaltic pump mechanisms to determine their effect on monomer loss. Closed-loops of peristaltic tubing were used to investigate the effects of peristaltic pump parameters on temperature and monomer loss, whilst two mechanism isolation methodologies are used to isolate occlusion and lateral expansion-relaxation of peristaltic tubing. Heat generated during peristaltic pumping can cause heat-induced monomer loss and the extent of heat gain is dependent on pump speed and tubing type. Peristaltic pump speed was inversely related to the rate of monomer loss whereby reducing speed 2.0-fold increased loss rates by 2.0- to 5.0-fold. Occlusion is a parameter that describes the amount of tubing compression during pumping. Varying this to start the contacting of inner tubing walls is a threshold that caused an immediate 20-30% additional monomer loss and turbidity increase. During occlusion, expansion-relaxation of solid-liquid interfaces and solid-solid interface contact of tubing walls can occur simultaneously. Using two mechanisms isolation methods, the latter mechanism was found to be most destructive and a function of solid-solid contact area, where increasing the contact area 2.0-fold increased monomer loss by 1.6-fold. We establish that a form of solid-solid contact mechanism whereby the contact solid interfaces disrupt adsorbed protein films is the root-cause behind monomer loss and protein aggregation during peristaltic pumping.

Impact of mechanical stress on flexible tubing used for biomedical applications: Characterization of the damages and impact on the patient's health

Flexible tubing is a key part of a lot of medical devices used in hospital, but may be subjected to a lot of various mechanical stresses that can led to the failure or to complications for the patients. The nature and causes of these mechanical stresses were listed for peristaltic pump tubing, infusion set tubing and catheters. Their consequences in term of tubing damages and particular contamination were reported. The impact of the chemical nature of the tubing, of its size and also the impact of various parameters of the clinical acts were reviewed. Last the consequences for the patient's health were discussed.

Highly-customizable 3D-printed peristaltic pump kit

Commercially available peristaltic pumps for microfluidics are usually bulky, expensive, and not customizable. Herein, we developed a cost-effective kit to build a micro-peristaltic pump (~ 50 USD) consisting of 3D-printed and off-the-shelf components. We demonstrated fabricating two variants of pumps with different sizes and operating flowrates using the developed kit. The assembled pumps offered a flowrate of 0.02 ~ 727.3 μL/min, and the smallest pump assembled with this kit was 20 × 50 × 28 mm. This kit was designed with modular components (i.e., each component followed a standardized unit) to achieve (1) customizability (users can easily reconfigure various components to comply with their experiments), (2) forward compatibility (new parts with the standardized unit can be designed and easily interfaced to the current kit), and (3) easy replacement of the parts experiencing wear and tear. To demonstrate the forward compatibility, we developed a flowrate calibration tool that was readily interfaced with the developed pump system. The pumps exhibited good repeatability in flowrates and functioned inside a cell incubator (at 37 °C and 95 % humidity) for seven days without noticeable issues in the performance. This cost-effective, highly customizable pump kit should find use in lab-on-a-chip, organs-on-a-chip, and point-of-care microfluidic applications.

Syringe Filling of High-Concentration mAb Products Using Peristaltic Pump-Based Mechanism: Challenges and Mitigation Strategies

Syringe filling of high-concentration mAb formulation during manufacturing of large-scale drug product batches may present challenges such as product deposition onto the area of the syringe barrel where the stopper is inserted, product splashing or dripping, droplets left after the fill cycle, filling needle clogging, product build-up inside the needle during line stoppages, variation in fill weight/volume, and potential impact on product quality attributes. In this article, a summary of these issues and approaches to overcome them are summarized. Potential failure modes of the syringe filling process and appropriate in-process controls are provided. In addition to developing the filling process or resolving manufacturing issues, the pharmaceutical company developing the product and associated drug product manufacturing process may want to implement long-term strategic approaches to support the portfolio progression. Potential long-term approaches such as use of a viscosity reducing formulation development approach, improving peristaltic filling technology performance, building small-scale filling capability and establishing a streamlined filling process management cycle are also summarized. The aspects summarized in this article may be used to develop a robust filling process and control strategy for high-concentration mAb products and implement long-term strategic approaches to support the portfolio progression.

Investigating the static or dynamic flexural and compressive stresses on flexible tubing: Comparison of clamp and peristaltic pump impact on surface damages and particles leaching during infusion acts

This paper deals with the impact of the mechanical stresses on plasticized PVC infusion tubing. Stresses due to clamping were compared to those due to the use of a peristaltic pump. The degradation of the inner surface of plastic tubing due to a dynamic load with repeated flexion and compression was extensively studied in the case of peristaltic pump stress during extracorporeal (EC) acts. Even if clamping results in a less repeated stress, we show it can also lead to damages on the inner lumen of the tubing, especially in static conditions. As these degradations were responsible of particle shedding in the case of EC processes, a first evaluation of particular contamination was performed on the stressed infusion tubes.

Utility of low-cost, miniaturized peristaltic and Venturi pumps in droplet microfluidics

Many laboratory applications utilizing droplet microfluidics rely on precision syringe pumps for flow generation. In this study, the use of an open-source peristaltic pump primarily composed of 3D printed parts and a low-cost commercial Venturi pump are explored for their use as an alternative to syringe pumps for droplet microfluidics. Both devices provided stable flow (<2% RSD) over a range of 1-7 μL/min and high reproducibility in signal intensity at a droplet generation rate around 0.25 Hz (<3% RSD), which are comparable in performance to similar measurements on standard syringe pumps. As a novel flow generation source for microfluidic applications, the use of the miniaturized Venturi pump was also applied to droplet signal monitoring studies used to measure changes in concentration over time, with average signal reproducibility <4% RSD for both single-stream fluorometric and reagent addition colorimetric applications. These low-cost flow methods provide stable flow sufficient for common droplet microfluidic approaches and can be implemented in a wide variety of simple, and potentially portable, analytical measurement devices.

Filling of High-Concentration Monoclonal Antibody Formulations: Investigating Underlying Mechanisms That Affect Precision of Low-Volume Fill by Peristaltic Pump

Filling of high-concentration/viscosity monoclonal antibody formulations into vials or syringes by peristaltic pumps is an industrial standard. Control of the peristaltic pump on fill weight/volume accuracy/precision over time, however, has not been fully disclosed in the literature. This study systematically evaluated the impact of a broad range of system/pump parameters, from tubing setup to pump parameter settings to the filling nozzle, on filling precision using a bench-top system with fill weight readings from a high-precision balance. A low fill volume of 0.3 mL was targeted to fill liquids of various viscosities (including a high-concentration monoclonal antibody formulation). Fill weight precision was reported via percent of fill weight data points (at least 100 consecutive points) falling within 3% of the target fill weight (e.g., within 0.009 g for a 0.3 g target fill weight). Experimental results suggested that the 3% precision target is challenging for filling high-viscosity liquids due to run-to-run and day-to-day variability. More importantly, none of the system/pump parameters seemed to directly correlate with fill weight precision. Photograph analysis revealed liquid suck-back height variations during fill, which correlated well with fill weight variability. Suck-back height variation was attributed to two possible root causes: (1) inconsistent liquid stream separation point at the end of fill and (2) pressure-induced variations upon suck-back. Liquid stream break-up was influenced by liquid properties as well as liquid/nozzle interactions, and pressure variations might be associated with tubing and overall mechanism of the peristaltic pump. A custom nozzle tip design featuring a hydrophobic tip and a pressure-resistance barrier enabled consistent suck-back heights for each fill and approximately 90% of fill weight data within 3% precision for a high-concentration monoclonal antibody formulation.

LAY ABSTRACT

Vial and syringe filling by peristaltic pump is considered a well-established manufacturing process and has been implemented by numerous contract manufacturing organizations and biopharmaceutical companies. However, its technical details and associated critical process parameters on fill weight precision are rarely published. Such information on high-concentration/viscosity formulation filling is particularly lacking. This study aimed to identify critical filling parameters that dictate a tight control on fill weight precision. The findings of this study indicate that mitigating suck-back height variation is the key to achieving improved fill weight precision. Liquid properties, the influence of liquid/nozzle interactions, and pressure variations during suck-back are inherent to fill weight variations. Optimizing fill weight precision by manipulating pump system parameters is not a root-cause solution. The outcomes of this study will benefit scientists and engineers who develop pre-filled syringe/vial products by providing a better understanding of high-concentration formulation filling principles and challenges.

Filling of high-concentration monoclonal antibody formulations into pre-filled syringes: filling parameter investigation and optimization

Syringe filling, especially the filling of high-concentration/viscosity monoclonal antibody formulations, is a complex process that has not been widely published in literature. This study sought to increase the body of knowledge for syringe filling by analyzing and optimizing the filling process from the perspective of a fluid's physical properties (e.g., viscosity, concentration, surface tension). A bench-top filling unit, comprising a peristaltic pump unit and a filling nozzle integrated with a linear actuator, was utilized; glass nozzles were employed to visualize liquid flow inside the nozzle with a high-speed camera. The desired outcome of process optimization was to establish a clean filling cycle (e.g., absence of splashes, bubbles, and foaming during filling and absence of dripping from the fill nozzle post-fill) and minimize the risk of nozzle clogging during nozzle idle time due to formulation drying at or near the nozzle tip. The key process variables were determined to be nozzle size, airflow around the nozzle tip, pump suck-back (SB)/reversing, fluid viscosity, and protein concentration, while pump velocity, acceleration, and fluid/nozzle interphase properties were determined to be relatively weak parameters. The SB parameter played an especially critical role in nozzle clogging. This study shows that an appropriate combination of optimal SB setting, nozzle size, and airflow conditions could effectively extend nozzle idle time in a large-scale filling facility and environment.

LAY ABSTRACT

Syringe filling can be considered a well-established manufacturing process and has been implemented by numerous contract manufacturing organizations and biopharmaceutical companies. However, its technical details and associated critical process parameters are rarely published. The information on high-concentration/viscosity formulation filling is particularly lacking. The purpose of this study is three-fold: (1) to reveal design details of a bench-top syringe filling unit; (2) to identify and optimize critical process parameters; (3) to apply the learning to practical filling operation. The outcomes of this study will benefit scientists and engineers who develop pre-filled syringe products by providing a better understanding of HC formulation filling principles and challenges.

A self-priming, roller-free, miniature, peristaltic pump operable with a single, reciprocating actuator

We present a design for a miniature self-priming peristaltic pump actuated with a single linear actuator, and which can be manufactured using conventional materials and methods. The pump is tolerant of bubbles and particles and can pump liquids, foams, and gases. We explore designs actuated by a motor (in depth) and a shape memory alloy (briefly); and briefly present a manually actuated version. The pump consists of a Delrin acetal plastic body with two integrated valves, a flexible silicone tube, and an actuator. Pumping is achieved as the forward motion of the actuator first closes the upstream valve, and then compresses a section of the tube. The increased internal pressure opens a downstream burst valve to expel the fluid. Reduced pressure in the pump tube allows the downstream valve to close, and removal of actuator force allows the upstream valve and pump tube to open, refilling the pump. The motor actuated design offers a linear dependence of flow rate on voltage in the range of 1.75-3 V. Flow rate decreases from 780 μl/min with increasing back pressure up to the maximum back pressure of 48 kPa. At 3 V and minimum back pressure, the pump consumes 90 mW. The shape memory alloy actuated design offers a 5-fold size and 4-fold weight reduction over the motor design, higher maximum back pressure, and substantial insensitivity of flow rate to back pressure at the cost of lower power efficiency and flow rate. The manually actuated version is simpler and appropriate for applications unconstrained by actuation distance.