| Literature DB >> 26288941 |
Akiko Ishii-Watabe1, Akihiko Hirose2, Noriko Katori2, Norikata Hashii2, Susumu Arai3, Hirotoshi Awatsu4, Akira Eiza5, Yoshiaki Hara6, Hideshi Hattori7, Tomomi Inoue8, Tetsuya Isono9, Masahiro Iwakura10, Daisuke Kajihara11, Nobuo Kasahara12, Hiroyuki Matsuda13, Sei Murakami14, Taishiro Nakagawa15, Takehiro Okumura16, Takeshi Omasa17, Shinya Takuma9, Iyo Terashima18, Masayoshi Tsukahara15, Maiko Tsutsui19, Takahiro Yano20, Nana Kawasaki21.
Abstract
Biologics manufacturing technology has made great progress in the last decade. One of the most promising new technologies is the single-use system, which has improved the efficiency of biologics manufacturing processes. To ensure safety of biologics when employing such single-use systems in the manufacturing process, various issues need to be considered including possible extractables/leachables and particles arising from the components used in single-use systems. Japanese pharmaceutical manufacturers, together with single-use suppliers, members of the academia and regulatory authorities have discussed the risks of using single-use systems and established control strategies for the quality assurance of biologics. In this study, we describe approaches for quality risk management when employing single-use systems in the manufacturing of biologics. We consider the potential impact of impurities related to single-use components on drug safety and the potential impact of the single-use system on other critical quality attributes as well as the stable supply of biologics. We also suggest a risk-mitigating strategy combining multiple control methods which includes the selection of appropriate single-use components, their inspections upon receipt and before releasing for use and qualification of single-use systems. Communication between suppliers of single-use systems and the users, as well as change controls in the facilities both of suppliers and users, are also important in risk-mitigating strategies. Implementing these control strategies can mitigate the risks attributed to the use of single-use systems. This study will be useful in promoting the development of biologics as well as in ensuring their safety, quality and stable supply.Entities:
Keywords: biologics; manufacturing technology; quality risk management; regulatory science; single-use system
Mesh:
Substances:
Year: 2015 PMID: 26288941 PMCID: PMC4674654 DOI: 10.1208/s12249-015-0368-z
Source DB: PubMed Journal: AAPS PharmSciTech ISSN: 1530-9932 Impact factor: 3.246
Fig. 1Pharmacopoeia specifications of insoluble particulate matter and insoluble visible matter for injections
Examples of Points to Consider When Introducing Single-Use Components
| Examples of lists to be assessed | Examples of issues to be assessed |
|---|---|
| Structure design | Shape, layered structure for preventing leachables, compatibility with other components, structure for preventing misuse, strength |
| Raw materials control | Monomers, polymerization initiators, metal catalysts, additives (antioxidants, lubricants, anti-adhesives, antistatics), adhesives, printing inks, solvents, and biological ingredients |
| Manufacturing environment control | Air cleanliness, airborne microorganisms |
| Manufacturing process control | Inspections upon receipt of materials and components, shape-forming, film-forming, bag-making, assembly, integrity test |
| Sterilization process control | Radiation dosage (gamma- and beta-rays), level of ethylene oxide gas |
| Quality control | Reliability of test procedure and analytical methods for extractables, test procedure and acceptance criteria for insoluble particulate matter |
| Release test | Appearance, integrity test, consistency with the drawings, endotoxin test, inspection of foreign matters, sterility assurance |
| Packaging and delivery control | Primary packaging, wrapping, transport |
Examples of Information Normally Disclosed to Users by Suppliers
| Organization, equipment, quality control system of the single-use component supplier |
| • General quality system |
| • Manufacturing facilities and environment (including manufacturing area, layout of facilities such as warehouses, grade, environmental management) |
| • Manufacturing supply capacity, delivery time, and supply system |
| • Procedure to develop or change specifications |
| • System to qualify the outsourcing contractors such as irradiation sterilization vendors |
| • Staff education |
| • Business continuity plan |
| Methods for manufacturing and quality control |
| • Prevention measures of operational error |
| • Control methods for foreign material |
| • List of foreign materials possessed by the supplier |
| • Control methods of foreign insoluble matter attached to or embedded in single-use components |
| • Control methods of insoluble particulate matter |
| • Control methods for endotoxins |
| • Sterilization procedures and validation |
| • Qualification of each part of the single-use component |
| • Compatibility assessment of each part of the single-use component |
| • Procedure and recording of line clearance (prevention of contamination and wrong assembling, |
| • Process control, recording, operator education and qualification of assembly |
| • Release tests (list of tests, methods, acceptance criteria, |
| • Validation methods for shipping |
| Test results of single-use component |
| • Extractables test (test methods including preparation condition of extractables, analytical equipment used, results of analytical method validation, |
| • Insoluble particulate matter test |
| • Mechanical strength test |
| • Gamma-ray irradiation resistance test |
| • Shelf time test |
| • Biological safety test |
| • Oxygen permeability test |
| • CO2 permeability test |
| • Vapour permeability test |
| • Solution drainage test |
| • Test methods for aseptic connection |
| • Other test required for an assessment of the performance of single-use components |
| Others |
| • Storage methods of materials (temperature, humidity, necessity of shielding, |
| • Contract testing of leachables |
Examples of Information Normally Disclosed to Suppliers by Users
| 1) Information about solutions that contact single-use components |
| • General composition |
| • pH |
| • Protein concentration |
| • Volume |
| • Temperature |
| • Viscosity |
| 2) Conditions of use of single-use components |
| • Maximum temperature |
| • Minimum temperature |
| • Contact duration |
| • Use of peristaltic pump |
| • Maximum pressure |
| • Use of autoclave sterilization |
| • Flushing prior to use |
| • Stirring |
| • Filter integrity test (sterilization filter) |