Escolar Documentos
Profissional Documentos
Cultura Documentos
Dr Dave Elder and Dr Simon Mills, GSK Cape Town, South Africa 16-21st April, 2007
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 1
Introduction
Blister Packs Container/Closures Bottles Blister Packs Injectables Tubes Inhalation/IntraNasal products US, EU, Pharmacopoeial Extractable/Leachables
General Overview
Regulatory
Packaging Development
Commercial image market requirements/trends dosing/patient compliance security/tamper evidence manufacturing economics - COG Corporate Global Quality Policies
Moisture sensitive drugs increasing barrier requirements Novel delivery systems Emphasis on speed to market Control of R&D Expenditure/resource - number of stability studies Global - Regional - Local packs Anti-counterfeiting, illegal cross border trading Multiple studies for different packs vs. Year-on-Year manufacturing costs Pharmacogenomics - Personalised medicines Demographic change - Ageing population
Presentation e.g. for solid dose US prefer bottles EU/RoW prefer blister packs
Child resistance requirements US Legal requirement with few exceptions Clear blisters, peel-push, tear notch, secondary CR pack
EU/RoW Legal requirement in only 4 EU member states & for very limited list of products Push through blisters, opaque
Packaging Development
container wall thickness permeability of the packaging material difference between the external and internal relative humidity environments Driving force for the water flux through the container
Waterman et al (1) determined the theoretical rate of water permeation through a standard 60-cc bottle when stored at 40C/75%RH. This equated to an uptake of 1mg of water per day. They commented that even if the product had been packed under low water vapour conditions the relative humidity conditions within the container would be re-equate to 50%RH within 1 day. The WVTRs (see Table) for some common packaging materials were reported by Waterman et al (2).
References:
(1) K.C. Waterman, R.C. Adami, K.M. Alsante, A.S. Antipas, D.R. Arenson, R. Carrier, J. Hong, M.S. Landis, F. Lombardo, J.C. Shah, E. Shalaev, S.W. Smith and H. Wang, Pharm. Dev. and Tech., 7 (2002b) 113.
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 6
Packaging Development
Desiccants have been utilised to control the exposure of products to the ingress of moisture. Desiccants vary in their capacity and the rate that they adsorb/absorb ingressed moisture.
Silica gel is very efficient at absorbing moisture at high relative humidities, but comparatively poor at lower relative humidities Molecular sieve desiccants - the opposite scenario prevails As a consequence, more molecular sieve is required at higher relative humidities, and the greater the handling precautions that are required during packaging operations. Based on the calculated WVTR of known container components and the rate of moisture adsorbed by desiccants, the amount of desiccant that would be required to maintain a specified relative humidity over the products shelf-life can be determined (4).
0.00 0.08 0.11 - 0.12 0.22 0.23 - 0.26 0.31 - 0.34 0.31 0.39 - 0.42 0.42 0.47 - 0.6 0.7 - 0.75 0.7 - 1.47 2.4 - 4
Stability driver
Barrier
ACLARRx160 PVC/PE/PVDC
PVC/PVDC 40gsm
PP
PVC Cost
Cost driver
Packaging Development
Similar considerations are relevant to protection of products that are labile to oxidative degradation. The permeability of plastic containers to oxygen ingress has also been evaluated (OVTR), and is summarised. Derived from Wang et al, 1998 (4)
References: (4) Y. Wang, A.J. Easteal, and X.D. Chen, Packag. Technol. Sci., 11 (1998) 169
Packaging Development
Waterman et al (1) determined the theoretical rate of oxygen permeation through a standard 30-cc bottle when stored in a well sealed container
This equated to an uptake of 0.2mMol of oxygen per year
In addition to permeation through the container walls, the key vulnerability in any container-closure system is the closure.
With screw-topped closures leakage can be significant. Hence for oxidatively labile dosage forms an oxygen impermeable seal is required, and induction heat sealed containers are particularly useful. Levels of oxygen in the headspace of the container-closure can be significant, and packaging under an inert atmosphere although doable is problematical.
Packaging Development
Impact of Oxidative Instability of Container-Closure
What is First Intent? Preferred range of pack/material options to be used for new products Agreed between R&D and factory Identical global materials Fully aligned with Procurement sourcing strategies Secure/robust sourcing Minimises R&D resource Supports supply site transfers (like for like; identical)
Global blister material first intent in place since 2003 Solid dose bottle and closure first intent under development
1. PVC 250m
2. PVC/PVDC 250m/60gsm
3. Cold Form 25 OPA/45 Al/ 60 PVC 4. PVC/Aclar UltRx 2000
Material should preferably be opaque white unless clear is a specific market requirement (eg US, Japan) Aclar should be restricted to applications where cold form is not technically or commercially acceptable due to product or pack size, ie larger products (further guidance to be defined)
Aclar is registered trademark of Honeywell Inc
Complexity reduction Standardisation and rationalisation of components Reduced number of change-overs at factory sites Resource demand reduction R&D, Pack Dev, Procurement, Sites use off the shelf solution for majority of products. Flexibility across factory sites without increased Regulatory activity. Risk Mitigation Commercial Leverage
Future
PACKAGING Bottles
BOTTLE
Glass type III (solids) type I (for inhaled solutions) Plastic low density polyethylene LDPE high density polyethylene HDPE polypropylene PP polyester PET, PETG Cyclo-olefin copolymer (COC)
PACKAGING Closures
Plastic - wadless or lined, CR (child resistant), CT (continuous thread), snap fit Metal - screw, ROPP Liner cork, pulpboard, EPE; flowed in gasket product contact materials/facings : PVDC, Saran, Saranex, Melinex, EPE, Vinyl, Foamed PVC Induction heat seals
Reseal liner Pulpboard Foil Wax Polyester Induction Liner Heatseal film/coating
THERMOFORM BLISTERS plastic base web blister formed with aid of heating low to high barrier
- Overlacquer
- Print - Aluminium - Primer - Heat seal lacquer
Product contact layers: For PVC or PVC/Aclar = PVC For PVC/PVDC = PVDC For Lid foil = heat seal lacquer
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 19
COLD FORM BLISTER blister formed mechanically (no heat) high barrier
Lidding Foil
Product contact layers: For base = PVC (or PP) For lid foil = heat seal lacquer
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 20
TROPICALISED BLISTER thermoform blister plus cold form tray once tray opened, in use life determined by primary thermoform blister high barrier before use
Lidding Foil
Product contact layers: For PVC = PVC For PVC/PVDC = PVDC For Lid foil = heat seal lacquer
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 21
PACKAGING Injections
Ampoules Vials Syringe
Rubber, plastic
Glass type I Plastic PP, COC
Rubber
Glass type I
Stopper Rubber
Plastic e.g. LDPE
Butyl, chlorobutyl, bromobutyl, halobutyl, TPE ,natural*, buytl/polyisoprene* copolymer or blend; Coatings Flurotech, Omniflex, fluororesin/polymer
* Beware of concern over latex allergy. Need for Department of Medicines Policy and Standards, warning labelling EU & US
Health Technology and Pharmaceuticals 22
PACKAGING Tubes
Aluminium Lacquered Aluminium lined with an epoxy phenolic lacquer Laminate foil laminate body, plastic shoulder Eg, structure for Acyclovir topical ointment
- Clear LDPE - White LDPE - PE - EMAA - Aluminium foil - EMAA - LDPE (product contact)
NOTE:
Specific EU Directives limiting residues in epoxy coatings for food contact use
Mouthpiece
Nebules
Intranasal
KEY POINT TO NOTE EU does NOT have a consolidated container/closure guideline (cf FDA)
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 26
Regulatory requirement FDA Container Closure Systems for Packaging of Human Drugs and Biologics, Chemistry, Manufacturing and Controls Documentation, III,B,I,c Safety Nasal Spray and Inhalation Solution, Suspension, and Spray Drug Products, Manufacturing and Controls Documentation, III,G,1. Metered Dose Inhaler (MDI) and Dry Powder Inhaler (DPI) Drug Products Chemistry, Manufacturing, and Controls Documentation, III,G,a
CPMP CPMP Note for Guidance III/9090/EN (3AQ10a) Plastic Primary Packaging Materials, Introduction CPMP Note for Guidance CPMP/QWP/4359, Plastic Immediate Packaging Materials (effective 1 December 2005)
Defines acceptable starting materials acceptable additives and processing aids limits on residues limits on leachables (eg specific migration limits) Based upon Acceptable or Tolerable Daily Intake in FOOD NOTE US and EU do not use same calculations
THE THEORY
FDA guidelines make significant reference Included in CPMP guideline 3AQ10a and CPMP/QWP/4359 Pack/product interaction Label adhesive migration
GOOD SCIENCE
Identify
Qualification exhaustive extraction to characterise (worst case) Avoids unnecessary stability qualitative and quantitative testing chromatographic profiles show control at the material level (cf. synthetic impurities) Stability monitoring in real product, real time to establish equilibrium concentration value Interaction early detectionIf interaction is between the active and
Packaging Development
Objective
To ensure timely and robust selection of the primary pack for clinical trial and commercial supply.
Our approach:
To use, where possible, a limited range of standard, well characterised pack materials and packs To ensure thorough testing, characterisation and understanding of our pack materials and packs.
Objective
Our approach:
Will generally use Limited range of standard, characterised packs, eg, HDPE bottles for sold dose forms Inert packs, eg, fluororesin laminated injection stoppers Packs and materials chosen to ensure pharmacopoeial and regulatory compliance is well understood Material performance is well characterised or known Pack selection is supported by stability testing for each product
Objective
Approach:
1. Identify Pack Options
2. Material Selection & Testing 3. Development Stability Testing 4. Controls Defined
5. Pack Selection
6. Pivotal Stability Testing
Department of Medicines Policy and Standards, Health Technology and Pharmaceuticals 33
Product attributes, e.g., dosage form, physical and chemical robustness Product protection needs, e.g., moisture & gas sensitivity, thermal stability, photostability, chemical compatibility etc Clinical requirements, e.g., dosing regimen, titration dosing, route of administration, need for dosing device Patient requirements, e.g., specific handling requirements, patient handling studies Commercial requirements, e.g., market presentation, pack sizes, market specific needs, patient handling needs Manufacturing requirements, e.g., equipment capability, critical process parameters, Regulatory requirements, e.g., material compliance, pharmacopeial monographs
Product contact materials chosen to meet global and local regulations. Product contact materials, particularly, plastics confirmed as compliant with relevant food contact regulations, e.g. US, EU etc Pharmacopoeial compliance established, e.g. USP, Ph Eur, JP Performance testing conducted, e.g., moisture permeation, light transmission Chemical characterisation, e.g., extractables and leachables studies, especially for parenteral, ophthalmic and inhalation products Toxicological assessment of extractables and leachables conducted We maximise our pack and product knowledge and understanding and achieve commercial efficiency by using a limited range of First Intent, preferred pack materials, wherever possible.
4. Controls Defined
Data from material and product testing used to identify critical quality and process attributes for pack and packaging process, e.g.:
Need for RH controls during packing Need to inert gassing of pack headspace Seal integrity testing Need for extractables testing as a routine control Manufacturing controls/specifications for the pack components and suppliers, eg, dimensional and performance specifications, need for clean room manufacture etc Manufacturing controls for the packaging process
5. Pack Selection
Data from the previous steps, together with the clinical, patient, commercial and manufacturing requirements, are used to identify and agree the intended market packs.
Phase 3 - Launch
Secondary packaging is defined note, if needed for product protection, this will be defined with the primary pack and included in pivotal stability
Define market presentations, graphics, patient information leaflets Conduct line, engineering and technical trials on pack components and equipment
Pack Changes?
Our aim:
to avoid pack changes between pivotal stability and launch by ensuring a quality by design approach to pack selection and understanding of product stability and packaging
But changes can occur at late stage due to, for example,
Unpredictable outcome in pivotal stability Newly identified impurities or need for tighter specification limits Inclusion of desiccant in bottle packs Need for higher barier (eg foil/foil) blister packs
By use of First Intent pack materials and packs, we aim to have a thorough understanding of our materials to minimise impact of change and have readily available, well characterised pack options.