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Quality by Design (QbD) Solutions

for Analytical Method Development


A systematic approach to reducing
variability

Andreas Tei
Pharmaceutical Segment Manager
QbD Method Development & Method Transfer Workflow
From UHPLC to HPLC in a nutshell

1290 1260 1260


1290 Emulation
QA/QC
R&D R&D R&D
3
1 2
Method transfer

Target System
Method development Target Systems in
Emulation by ISET
System QA/QC labs
Use of 1.8 µ particles
Robustness study by
and QbD software
QbD software

2
Content
• Introduction
- Traditional approach of method development and transfer
- QbD approach for method development

• Agilent solutions for method development


-Agilent method development systems
-Intelligent system emulation technology (ISET)
-Method scouting wizard software
-Third party QbD software

• A practical approach of method development under QbD principles


- Screening
- Optimization
- Robustness study, Design of Experiments
- Transfer & Verification
Method Development & Transfer Workflows
A Classic Approach

Develop Validate Transfer


QA / QC
R&D

 Parameters determined by trial-and error.


 Robustness tests performed by the one
factor at the time approach (OFAT)

4
OFAT Approach: Method Transfer is a balancing act

Different results on different systems

Variability of critical method


attributes (resolution, tailing, etc)

Development Target QA/QC


Small changes in pH, temperature
System Systems or flow rate shows a large effect

Even buffer solutions from different


operators deliver different results

10% of analytical methods are discarded per year to avoid high revalidation costs
after the methdod showed instabilities on the QC system
Quality by Design - A systematic approach to obtain a
“consistent quality” output

System System
Variabilities Understand
variability Variabilities

Fixed Flexible
process Quality
by process
Design
Control Continuous
Variability improvement
Variable
Consistent
output
output
ICH Q8-Q11

 http://www.fda.gov/downloads/Drugs/Guidances/ucm073507.pdf

6
More Robustness by Applying QbD Principles

Risk assessment process

 Define Critical Method Attributes CMAs


(resolution, peak tailing, etc.)

 Define critical method parameters CMPs


(flow, temp) which affects the CMAs

Perform a Design of Experiment (DoE) study by


modifying multiple CMAs in simultaneously
and create a Design Space

7
QbD Approach for Method Development

 Key is the statistical „Design of Experiment“


(DoE) where multiple CMPs will be varied in
each experiment

 A method is robust, as long all changes of CMAs


are within the determined Design Space

8
Creating a Design Space
Optimizing through One Variable at a Time vs. DoE

0.6 Injection Volume (µl) 3.0


One Variable at a Time
20

% Organic mobile
phase (methanol)
Variable 2

1.6 10
Flow Rate (ml/min)
0.8
Variable 1 30 Column Temp. (oC) 40
Impact of variables 1 and 2 (e.g. % organic mobile phase and column temperature)
on Critical Method Attributes (CMAs) e.g. peak resolution or %recovery

9
What Are The Advantages ?

 The relationship between the different critical method


parameters (CMPs) will be described and visualized in surface
or contour plots

 Increase of efficiency by avoiding unnecessary experiments


during the method development process (no trial an error!)

 DoE is delivering robust methods compared to the classic


„one-factor-at-the-time“ (OFAT) robustness testing process

10
Content
• Introduction
- Traditional approach of method development and transfer
- QbD approach for method development

• Agilent solutions for method development


-Agilent method development systems
-Intelligent system emulation technology (ISET)
-Method scouting wizard software
-Third party QbD software

• A practical approach of method development under QbD principles


- Screening
- Optimization
- Robustness study, Design of Experiments
- Transfer & Verification
Agilent Solutions for QbD Method Development
Method Development
System & Method Scouting SW

ISET

Intelligent System Emulation Technology

Harmonized Qualification

ACE RA
Remote Advisor
Rapid Development of Robust New Methods
Agilent 1290 Infinity II Series Method Development Solution

Agilent 1290 Infinity II Method Development Solution


6100 Series MSD and 1290 ELSD are optional detectors to
ensure the most comprehensive compound detection

13
1290 Infinity II Series Method Development Solution
Schematics
1290 Infinity II
MCT 8

1290 Infinity II x = 1352


Flexible Pump

12 + 1
A1 A2 B1 B2
External Solvent
Selection Valves x = 169
SSV1 SSV2

12 + 1

Up to 12 solvents
per SSV!!!

 1352 different combinations of column chemistries and eluents


 A nearly infinite number of separation conditions is created by including
different temperature and flow rates as variable parameters

14
Agilent ChemStation Method Scouting Wizard
There is no easier way to set up even complex screening campaigns

• Define project
Choose scouting combinations and
base method.
• Select columns
All installed columns are shown
automatically.
• Select solvents
Pump types and valves are
automatically detected.
• Define gradients
Select between different gradients and
temperatures.
• Review and select screening
methods
Check for incompatible combinations.
• Set up samples
Define injection volumes and number of
repetitions. Easy and fast
setup of sequences !

15
Agilent ChemStation Method Scouting Wizard
Ease of Use: Screening Report
Fast screening of mobile and stationary phases with 1290 Infinity II LC –
Analysis of Degradation Products of Metoprolol

Max. Retention Time

Injections

Bubble size represents the number of integrated peaks and,


consequently, best mobile and stationary phase
combination.
https://www.agilent.com/cs/library/applications/5991-0989EN.pdf

16
Intelligent System Emulation Technology (ISET)
- Seamless transfer of methods between LCs, regardless of the brand

PO-Nr. G2197AA
Method Transfer Between Different LC Instruments
Method transfer from a UHPLC system with a minimized dwell
volume and optimized mixing behavior to any other LC system is
often challenging and affects rentention time and resolution

Example: Method Transfer from a 1290 UHPLC to a 1100 HPLC system


mAU

175

150

125

100 1290 Infinity LC


75

50

25 1100 Series Binary System

0
3 4 5 6 7 8 9 10 11 min
Practical aspects how to measure dwell volumes, transfer & optimize methods

19
How To Measure Dwell Volumes
 Add a UV active tracer to solvent B (often acetone)
 Remove the column, fit a restriction capillary
 Run a step gradient from 10%B to 90%B
 Calculate the dwell volume by the delay between
UV response and the step with respect to the flow rate

20
Method Transfer Between Different LC Instruments

Gradient differences due to different dwell


mAU volumes and different mixing behavior
600
1290 Infinity LC
500

400 1100 Series Quaternary LC

300

200

100

Results from a tracer experiment


0
0 1 2 3 4 5 6 7 8 9 min

21
Method Transfer Between Different LC Instruments
Approach # 1: Isocratic holding step to synchronize

1290 Infinity LC
mAU
Still gradient differences due to 1 min isocratic hold
different mixing behavior

400
1100 Series Quaternary LC

300

200

100

Results from a tracer experiment


0

0 1 2 3 4 5 6 7 8 9 min

22
Approach # 1: Applying Isocratic Holding Steps
Results

1260 Infinity LC

1290 Infinity LC
+ 900 µl hold

• Results shows a low consitency


• Requires manual determination of the dwell volume/ isocratic hold
(in solvent delivery systems equipped with dampeners the dwell volume is pressure
dependent and variable)
• Requires modification of the methods
(should be avoided in validated environment,
but doesn’t require revalidation USP Chapter <621>)

23
Method Transfer Between Different LC Instruments
Approach # 2: Adding a physical void volume

1290 Infinity LC

mAU
Almost consistency of both 1 mL loop installed

gradient curves

400
1100 Series Quaternary LC

300

200

100

Results from a tracer experiment


0

0 1 2 3 4 5 6 7 8 9 min

24
Approach # 2: Adding a Physical Void Volume
Results

1290 + 1000 µL dwell vol.

1100/1200 Quat Pump

• Results shows a good consitency


• Manual determination of dwell volumes required (issues of a variable
dwell volume with systems containing damperners)
• All mechanical changes are laboriously not flexible

25
Agilent Solution:
Intelligent System Emulation Technology (ISET)
mAU
400

350

Injection
300
Software controlled compensation
250
of dwell volume differences and
synchronization of mixing
200 behaviors

150

100 Programmed gradient


1290 gradient
50
1200 gradient
0
0 0.5 1 1.5 2 2.5 3 3.5 min

26
Agilent Solution: Method Transfer by ISET
Results: 1260 Infinity Binary LC to 1290 Infinity LC

Paracetamol
mAU
• Consistency of results
40

Imp J
Imp H
30
Imp K

Imp F
20

Imp A
Imp B

10

1290 Infinity LC with ISET

1260 Infinity Binary LC

1 2 3 4 5 6 7 8 9 min

27
Agilent Application Notes
Method Transfer by ISET
• Fast screening of mobile and stationary phases with the Agilent 1290 Infinity LC
and seamless method transfer to an Agilent 1200 Series LC using ISET

Agilent Application Note 5991-0989EN

• Developing faster methods for generic drugs within USP <621>allowed limits

Agilent Application Note 5991-0278EN

• Effective use of pharmacopeia guidelines to reduce cost of


chromatographic analysis

Agilent Application Note 5991-1053EN

• Developing faster methods for generic drugs within EP 2.2.46E allowed limits

Agilent Application Note 5991-0394EN

28
3rd Party Add-On QbD Software
Turn your LC into an automated
QbD method development system!

AutoChrom

ChromSwordAuto
Chemstation

Fusion QbD
Only Agilent‘s Method Development Solution is supported by all
three big manufactures of automated method optimization software!

29
Fusion QbD Software (S-Matrix)
Statistical approach identifying the best separation conditions

A graphic plot illustrates the position of the best conditions

15.0

Initial %
Organic 4.5

3.5
pH
5.0

2.5
30.0 60.0
Oven Temp

Sequence of Experiments 3 Dimensional Results Plot

30
Creating a Design Space
Simple DoE Example for HPLC Method

CMPs: Impact on Selectivity, Five Variables Two Levels


Run # % Org.Phase pH Col. Temp Column Flow Rate
1 -1 -1 +1 +1 +1
2 -1 +1 +1 -1 +1
3 -1 +1 -1 +1 +1
4 +1 -1 +1 -1 -1
5 +1 -1 -1 +1 -1
6 +1 +1 -1 -1 -1

40 % ACN
Level -1 = 4.0 25 ºC 10 cm 2.0 ml/min
-
60% ACN
Level +1 = 6.0 40 ºC 20 cm 2.5 ml/min
40% Water

FDA: Need sufficient statistical power to support analytical “Design Space”

31
Creating a Design Space (Fusion QbD Software)
Robustness Testing & Establishing a Design Space (MODR)

Design Space
List of CMPs and CMAs for robustness
testing

* The coded names are used in robustness model displays

32
Chromsword Software
• Method scouting • Interactive
• User defined • Find workable
• Statistical DOE method ASAP

Rapid
Screening
optimization

Robustness Fine
Studies Optimization

• Full factorial • Interactive


• Statistical DOE • Sample profiling
• Impurities search

33
Details of Chromsword Software

• Method development and optimization based on


the solvatic model of RP-LC

• Building retention models after processing results


by applying different variables as listed below
• Organic modifier concentration (C)
• Gradient time (Grad)
• Temperature (T)
• pH
• Multi variables: C+pH; Grad +T; C1 +C2

34
Details of Chromsword Software

• Automated resolution optimization of critical peak pairs

3.232

Norm.
Norm.

3.070
100 600
80 500

60 400
300
40
1.136
1.384

200
20

1.970

2.820
2.049
100
0
0
1 2 3 4 5 6 7 8 9 min 0.5 1 1.5 2 2.5 3 3.5 4 4.5 min

35
Details of Chromsword Software
Design space creation after robustness study is fundamental to the
Quality by Design approach

36
ACD/AutoChrom Software

1. Data Collection

Start
5. Next
Experiment Column, Buffer &
2. Peak Tracking
Solvent Screening

Select Best

Optimize Gradient
& Temperature

End
4. Modeling

3. Interpretation
Gradient

Temperature

Report

37
Content
•Introduction
– Traditional approach of method development and transfer
– QbD approach for method development

• Agilent solutions for method development


–Agilent method development systems
–Intelligent system emulation technology (ISET)
–Method scouting wizard software
–Third party QbD software

• A practical approach of method development under QbD


principles
– Screening
– Optimization
– Robustness study, Design of Experiments
– Transfer & Verification
QbD Method Development & Method Transfer Workflow
From UHPLC to HPLC in a nutshell

1290 1260 1260


1290 Emulation
QA/QC
R&D R&D R&D
3
1 2
Method transfer

Target System
Method development Target Systems in
Emulation by ISET
System QA/QC labs
Use of 1.8 µ particles
Robustness study by
and QbD software
QbD software

39
QbD Based Method Development Workflow

Overall workflow which


consists of four main steps Screening
namely • Column Chemistry
Agilent Method • pH conditions
• Organic Solvent Selection
Scouting
• Gradients, temperatures
• Step # 1: Screening Wizard
Optimization
• Step # 2: Optimization • Optimize Gradient Profiles
• pH conditions
QbD Software • Flow rates, temperatures

40
Optimization
Results: peak purity and separation after optimization 99.8%

| |
| ' ' ' ' ' |
| |
| ' ' ' ' ' |
Set by User
998
Set by User 998

10.543
mAU
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
350 ++++++++++++++------+++++++++----------+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++ 10 10.2 10.4 min
300 10.5 10.55 10.6 10.65 10.7 min

250
200 Purity< 90%
150 Before
100
50
Optimization
0
2.5 5 7.5 10 12.5 15 17.5 20 min
10.007

mAU
350
300
250 99.8 % purity After
200
150 Optimization
100
50
0
2.5 5 7.5 10 12.5 15 17.5 20 min

41
QbD Based Method Development Workflow

Overall workflow which Screening


consists of four main steps •

Column Chemistry
pH conditions
Agilent Method
namely Scouting •

Organic Solvent Selection
Gradients, temperatures
Wizard
Optimization
• Step #1: Screening •

Optimize Gradient Profiles
pH conditions
• Step #2: Optimization QbD Software • Flow rates, temperatures
Design of Experiments
• Step #3: DOE & Emulate
• Multivariate study
• Robust region
QbD Software • Design Space

42
Method Transfer & Verification
From UHPLC to HPLC

1290 Emulation 1260


R&D R&D
2
Method transfer

Target System
Emulation by ISET

Robustness study by
QbD software

43
Method Transfer From UHPLC To HPLC

HPLC Calculator University of Geneva

http://www.unige.ch/sciences/pharm/fanal/lcap/telechargement.htm

Crawford Scientific Calculator


http://www.crawfordscientific.com/
HPLC_Method_Transfer_On-line.htm

44
Robustness Study
Modeling a HPLC design space on an emulated 1260 system
HPLC design space parameters HPLC design space with new CMA
Critical Method Proven Critical Method
Parameters (CMPs) Acceptable Attributes (CMAs)
Range (PARs)
Column: Agilent ZORBAX No. of peaks (>40)
Eclipse Plus C8 4.6X150 API resolution (>4)
mm, 3.5 µm Peak purity (≥ 98%)
Peak tailing (<1.3)

Strong solvent: Methanol

% Strong solvent: 87.5.% ± 1.5%

Aqueous solvent pH: 7.7 ± 0.1

Gradient range: 5% to
87.5%
Oven Temperature: 37°C

Gradient time: 45 min

Flow rate: 1.4 mL/min


Wavelength: 292 nm

45
Proof Of Robustness
Conditions applied from center point and the four corner points of the Design Space

Critical Method Attributes remain within the limits

mAU
350
A
250 API Rs> 4 and API tailing = 1.2 for all runs
150 % B max: 86 %; pH: 7.6
50
0
10 20 30 40 50 min
mAU B
350
250
% B max: 89 %; pH: 7.6
150
50
0
10 20 30 40 50 min
mAU T
350
250
% B max: 87.5 %; pH: 7.7
150
50
0
10 20 30 40 50 min
mAU D
350
250 % B max: 89 %; pH: 7.8
150
50
0
10 20 30 40 50 min
mAU C
350 % B max: 86 %; pH: 7.8
250
150
50
0
10 20 30 40 50 min

46
QbD Based Method Development Workflow
Screening
• Column Chemistry
Overall workflow which has Agilent Method • pH conditions
• Organic Solvent Selection
four main steps namely Scouting
Wizard
• Gradients, temperatures
Optimization & DOE
• Optimize Gradient Profiles
•Step #1: Screening • DOE
QbD Software • Creating a Design Space
•Step #2: Optimization Emulate Target System
•Step #3: DOE & Emulate • Transfer gradient profile
•Step #4: Verify ISET •

Emulate target system
DOE
QbD Software
• Creating a Design Space
Verify on Target System
• Apply Method
Target System • Verify Results
• Validate Results

47
Verification Of The Final Method With The Target System
Results: 1260 Infinity data compared to 1290 Infinity data in emulation mode
Final gradient
Time %B

24.115
mAU
1260 target system 0.3 5
45.6 87.5
400
49.2 87.5
300 49.5 95
49.8 95
200
API Rs = 4.1

23.347
50.1 5
API tailing = 1.2 53.1 5
100

10 20 30 40 50 min

24.091
mAU

400 1290 emulated as 1260


300

200 API Rs = 4.2


23.344

100 API tailing = 1.2


0

10 20 30 40 50 min

Critical Method Attributes are within the defined limits

48
Conclusions
Agilent Method Scouting Wizard Software supports
automated method development workflows

Significant time saving has been achieved by using sub-2-


micron columns for method development workflows

ISET supports seamless method transfer processes to other


LC-systems

Additional 3rd Party QbD software is used to create more


reliable and robust methods

49
Agilent Application Note

Title: QbD Based Method Development on an


Agilent 1290 Infinity UHPLC system Combined
with a Seamless Method Transfer to HPLC
Using Intelligent System Emulation Technology
Type: Application Note
Publication Number: 5991-5701EN
Pages: 8
Target segments: Pharmaceutical QA/QC
Language: English
Author: Vinayak A.K.
LitStation Availability: May 5, 2015, CPOD

50
Agilent Application Notes
QbD based Method Development

• Quality-by-Design Approach to Stability Indicating Method


Development for Linagliptin Drug Product
– Agilent Application Note 5991-3834EN

• Automated QbD Based Method Development and Validation of


Oxidative Degraded Atorvastatin
– Agilent Application Note 5991-4944EN

• Development of an UHPLC Method for Azithromycin Tablets Using


ChromSword Auto Software
– Agilent Application Note 5991-5428EN

• QbD Based Method Development on an Agilent 1290 Infinity UHPLC


system Combined with a Seamless Method Transfer to HPLC Using
Intelligent System Emulation Technology
- Agilent Application Note 5991-5701EN

51
Agilent Instrument Control Framework (ICF)
Seamless Integration Of Innovative Technology
WATERS THERMO AB SCIEX SHIMADZU
Empower Chromeleon Analyst LabSolution

ICS/OIP Adapter DDK Adapter AB SCIEX I/F Shimadzu I/F

ICF

RC.NET
API

Driver

Agilent
Instrument

• One consistent driver set developed by Agilent


• Developer support provided by Agilent
• Significantly less effort / faster time to market
Waters Empower 3: Ready for Agilent 1290 Infinity II
Agilent LC and ICF Releases

1290 Multisampler 1290 Infinity II LC


LC Drivers 2.10 LC Drivers 2.11

Agilent LC Hardware
Time A ICF A.02.03 Time B ICF A.02.03 DU1
LC Drivers 2.10 LC Drivers 2.11

Agilent ICF Software


Time A Time B
+ 6 weeks + 6 weeks
Waters ICS 2.1 HF1 71600xxx
ICF A.02.03 DU1
LC Drivers 2.11

Waters Empower Software


Oct 16th 2015
Chromeleon 7.2 SRx
ICF A.02.02/3
Agilent LC 2.10/2.11

Work in Progress: Thermo Chromeleon Software


Agilent LC Instrument Control in Empower 3
Required software modules to support Agilent 1290 Infinity II

Waters Empower 3
CDS and CDS specific
adapter from Waters
Adapter: Waters ICS 2.1 HF1 (ICS= Instrument Control Software)

Agilent ICF A.02.03 DU 1 HF2

Agilent ICF Adapter


RC.NET
API

Core
Driver
A.02.11SP1
Agilent RC.Net Drivers
Agilent
1290 LC
Agilent 1290 Infinity II under Empower 3
How does it look like?
LC Status Interface

Method Interface
Agilent’s ICF Concept
Please download our Technical Notes
ICF website: www.agilent.com/chem/icf

ICF Release Notes on agilent.com ICF Publications / Technical Notes

• ICF Technical Overview, Pub. No.: 5990-6504EN


• Using the Agilent Instrument Control Framework to control the Agilent 1220 Infinity LC system through
Waters Empower software, Pub. No. 5990-9399EN
• Using the Agilent Instrument Control Framework to control the Agilent 1260 Infinity LC through Waters
Empower software, Pub. No 5990-9092EN
• Using the Agilent Instrument Control Framework to control the Agilent 1290 Infinity LC through Waters
Empower software, Pub. No 5990-9093EN
• Using the Agilent Instrument Control Framework to control the Agilent 1260 Infinity Bio-inert Quaternary LC
through Waters Empower software, Pub. No 5990-9354EN.pdf
• Agilent 1290 Infinity LC with ISET under Waters Empower Control - Emulation of Agilent 1100 Series LC
5991-2275EN
• Operating the Agilent 1260 Infinity LC with Dionex Chromeleon software using Instrument Control
Framework, Instrument control and performance, Pub. No 5990-7232EN
• Operating the Agilent 1290 Infinity LC with Dionex Chromeleon software using Instrument Control
Framework, Instrument set up and performance Pub. No 5990-7215EN
*SPRS: Skills & Resources Planning System
THANK YOU

57
QbD terminology in Method Development
Appendix
Analytical QbD Terminology

QbD process terminology Analytical QbD Examples


terminology
Analytical Target Profile Accurate quantitation of API
without interferences from
(ATP) degradants

Quality Target Product Quality Target Method Profile pKa, Log P, Solubility
Profile (QTPP) (QTMP)
Critical Process Parameters Critical Method Parameters Flow rate,
(CPP) (CMP) Temperature, pH
Critical Quality Attributes Critical Method Attributes Resolution, Peak
(CQA) (CMA) Tailing, Peak Capacity
Control Strategy pH ± 0.1; Wavelength
± 2 nm
Appendix: Agilent Application Notes
Method Transfer by ISET
• Fast screening of mobile and stationary phases with the Agilent 1290 Infinity LC
and seamless method transfer to an Agilent 1200 Series LC using ISET

Agilent Application Note 5991-0989EN

• Developing faster methods for generic drugs within USP <621>allowed limits

Agilent Application Note 5991-0278EN

• Effective use of pharmacopeia guidelines to reduce cost of


chromatographic analysis

Agilent Application Note 5991-1053EN

• Developing faster methods for generic drugs within EP 2.2.46E allowed limits

Agilent Application Note 5991-0394EN

59
Appendix : Agilent Application Notes
QbD based Method Development

• Quality-by-Design Approach to Stability Indicating Method


Development for Linagliptin Drug Product
– Agilent Application Note 5991-3834EN

• Automated QbD Based Method Development and Validation of


Oxidative Degraded Atorvastatin
– Agilent Application Note 5991-4944EN

• Development of an UHPLC Method for Azithromycin Tablets Using


ChromSword Auto Software
– Agilent Application Note 5991-5428EN

• QbD Based Method Development on an Agilent 1290 Infinity UHPLC


system Combined with a Seamless Method Transfer to HPLC Using
Intelligent System Emulation Technology
- Agilent Application Note 5991-5701EN

60

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