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BATCH vs CONTINUOUS PROCESSING
CAN CONTINUOUS PROCESSING WORK FOR YOUR GMP FACILITY/PROCESS OPERATION?
Eric Sipe, Senior Process EngineerTim J. Hancock, Ph.D, Senior Process Engineer
Batch processing has dominated the Pharmaceutical industry due to available technologies, risk aversion and expectations of regulatory hurdles. However continuous processing can often be more efficient and lucrative and is an acceptable processing method per the FDA and EU Regulatory Authorities.
Emerging technology has opened up a lot of options in this area to make continuous more feasible in drug manufacturing.
Process methodologies, implementation, current and emerging technologies, and expectations will be discussed.
Overview
From: Perry’s Chemical Engineerings’ HandbookPerry’s 23-4 CHEMICAL REACTORS - MODELING CHEMICAL REACTORS
“The general characteristics of the main types of reactors—batch and continuous—are clear.
Batch processes are suited to small production rates, to long reaction times, or to reactions where they may have superior selectivity, as in some polymerizations. They are conducted in tanks with stirring of the contents by internal impellers, gas bubbles, or pumparound. Temperature control is with internal surfaces or jackets, reflux condensers, or pumparound through an exchanger.”
Why Use Batch?
Batch processing is used for smaller quantity higher value products – APIs, perfumes, specialty chocolates
Continuous processing is used for high throughput lower margin products – gasoline, milk, Chef Boyardee
BATCH vs CONTINUOUS PROCESSING PARADIGMS
However a new paradigm is being realized: There is no reason that continuous processing can not be used to produce a small or large amount of product efficiently whether low margin or high value
WHO WILL BE THE FIRST ONETO CORNER THE MARKET USING
CONTINUOUS?BATCH CONTINUOUS
Gold Panning Sluice
Process Methodology Definitions Batch Processing - raw materials
progress through a unit operation/unit operations in a step wise fashion to produce an end product
Process Methodology Definitions Semi-batch Processing – batchwise
process with aspects of continuous processing (introduction or removal of material; i.e. solvent strip from a batch reactor)
Process Methodology Definitions Continuous Processing – raw materials progress
through a unit operation/unit operations in a contiguous manner to produce an end product
INDUSTRY EXAMPLESNon-GMP:• Formulation of plastic
mixtures• Sedimentation of solids in
waste water treatment plant
• Electroplating of parts• Manufacture of sodium
aluminate
Pharma:• Centrifugation of API
chemical entity• Crystallization of API
chemical entity• Extraction of product from
reaction mixture• Milling of a lot of material• Isolation of a biopharm
product via adsorption column
• Tablet coating• Autoclaving of stoppers• Washing of filler change
parts
Non-GMP:• Fed-batch solvent recovery
from a contaminated solvent waste stream
• Hydrogenation reactions• Metered quenching
reactions
Pharma:• Fed-batch cell
culture/fermentation• Diafiltration• Solvent exchange• Exothermic reaction of API
material
Non-GMP:• Refining of crude oil• Manufacture of granular
aluminum sulfate• Manufacture of bleach in
pipeline reactor• Manufacture of water
treatment polymers• Stripping of solvents from
aqueous waste stream
Pharma:• Production of WFI/Clean
Steam• Vial Filling Operations• Biowaste Inactivation
Operations• Perfusion Fermentation
BATCH SEMI-BATCH CONTINUOUS
The Biopharmacuetical industry typically has relied on Product Discovery and Product Innovation for entering and sustaining
product market for profitability
This has always been followed by a continued reliance on existing batch technology that provided a risk averse, safe and reliable
process.
Process Innovation has not been a significant feature in biopharmaceutical development and manufacturing
Many new product processes have and are being fit into existing facilities and their available batch equipment leading to processing inefficiencies
and increased costs, especially as product titers improve.
Biopharmaceutical Product Processes Historically
“However, today significant opportunities exist for improving pharmaceutical development, manufacturing, and quality assurance through innovation in product and process development, process analysis, and process control…….
….One reason often cited [for lack of change] is regulatory uncertainty…….
….. Efficient pharmaceutical manufacturing is a critical part of an effective U.S. health care system……. …..Therefore pharmaceutical manufacturing will need to employ innovation, cutting edge scientific and engineering knowledge, along with the best principles of quality management to respond to the challenges of new discoveries (e.g., novel drugs and nanotechnology) and ways of doing business…”
Implementing Continuous vs. Batch Manufacture
Guidance for Industry PAT - A Framework for Innovative Pharmaceutical Development, Manufacturing, and Quality Assurance ; U.S. Department of Health and Human Services Food and Drug Administration Center for Drug Evaluation and Research (CDER) Center for Veterinary Medicine (CVM) Office of Regulatory Affairs (ORA) Pharmaceutical CGMPs September 2004
Multi-step synthesis processes with additional unit operations to isolate desired chemical entity
A + B C + D E Laboratory development of
chemical entities has historically been done via discrete batch operation.
Historically continuous flow options were not available for chemical synthesis operations
SOME REASONS FOR BATCH PROCESSING OF SMALL MOLECULE PHARMA PRODUCTS
Historically continuous flow options were not commercially available for both upstream and downstream processes
Bind and Elute Chromatography is a batch process
TFF has been developed as a batch operation
Laboratory development of biologics has historically been done via discrete batch operation.
SOME REASONS FOR BATCH PROCESSING OF BIOLOGICS PRODUCTS
Process and Business Driving Forces for Going Continuous
Smaller equipment Smaller facility
Better facility/equipment utilizationEasier/more robust scale-up
Better control and product qualityContinuous product quality assurance
Improved yield Reduced waste
Reduced in process materials such as buffers
Decrease development risks, costs and time to market When introducing new products scale-up may be eliminated Continuous development is significantly faster Much smaller amounts of material are needed.
Manufacturability Batch production of complex, less‐stable proteins is often impossible Continuous manufacturing can eliminate a fixed batch size, allowing
one to make as little or as much as needed. Continuous manufacturing product lead times are typically
significantly less than for batch which can substantially reduce inventory carrying costs.
Improved safety
Process and Business Driving Forces for Going Continuous
Unit Operation Cycle Times Reaction Kinetics Drying Rates
Separability of Constituents Ease of aqueous/organic layer seperation
Robustness of Intermediate and Product Effect of Temperature Effect of agitation
Some Physiochemical Factors that Influence Change from Batch to Continuous: Small Molecule
Cell Culture Cell stability and robustness, Excretion of product from cell (cell culture vs fermentation) Production/removal of toxins during cell growth Product stability Ability to grow at a steady state Cell cycles
Chromatography Bind and Elute (IEX and affinity chromatography) is
inherently a batch process Robustness of Intermediate and Product
Effect of temperature, pH and agitation
Some Physiochemical Factors that Influence Change from Batch to Continuous: Biologics
DISTILLATION BATCH VS CONTINUOUS
HOW ACCOMPLISHED BATCH
HOW MONITORED BATCH
HOW ACCOMPLISHED CONTINUOUS
HOW MONITORED CONTINUOUS
AGITATED AND JACKETED VESSEL WITH CONDENSER
TEMPERATURE, PRESSURE, REFRACTIVE INDEX
DISTILLATION COLUMN
TEMPERATURE, PRESSURE, REFRACTIVE INDEX
REACTIONS BATCH VS CONTINUOUS
HOW ACCOMPLISHED BATCH
HOW MONITORED BATCH
HOW ACCOMPLISHED CONTINUOUS
HOW MONITORED CONTINUOUS
METERED ADDITION OF REACTANT TO REACTION VESSEL
TEMPERATURE, pH, TIME
PIPELINE REACTOR, CSTRs IN SERIES, PLATE REACTORS
TEMPERATURE, PRESSURE, pH, REFRACTIVE INDEX, FLOW
Process MethodologiesBatch and Continuous Cell Culture
Batch Add materials at the beginning, production yield is nominally 1x
Fed-Batch (Semi-Batch) Media addition to increase production yield up to 2x to 3x.
Continuous Perfusion culture to increase production yield up to 10x.
BATCHFERMENTATION Concentrated
Feed
FED BATCHFeed
SpentMedium &Product
CellRetention
Device
CONTINUOUS(PERFUSION)
CULTURE
Overview of Perfusion Culture Continuous addition of fresh media
(nutrient feed) Continuous removal of waste
products (harvest) Animal cells retained at high
concentration Separation by Size Exclusion (TFF, ATF,
spin-filtration) Separation by Particle Mass
(sedimentation, hydrocyclones, centrifugation, acoustic resonance)
Types of Perfusion Heterogeneous perfusion
(microcarriers) Homogeneous perfusion (Cells in
suspension)
Single-pass TFF eliminate the recirculation loop. It allows continuous operation at high conversion. The retentate exits the retentate port and does not
return to a hold tank. Concentrated product or waste either exits at the retentate or permeate ports.
Current and Emerging TechnologiesHarvest
Single Pass TFF
Retentate
BatchTFF
TFF Centrifugation Chromatography Viral reduction Crystallization Precipitation Membrane adsorption Others
BATCH VS CONTINUOUS PROCESSINGDownstream Processing
PAT promotes continuous monitoring of processes
PAT promotes better process understanding
PAT fosters parametric release (continuous assurance that a process is working correctly and the product is of the right quality) throughout the process
PAT & CONTINUOUS PROCESSING
Process Analytical Technology (PAT) – “a system for the design, analysis and monitoring of pharmaceutical manufacturing by means of real time measurements of critical quality and performance attributes …..with the aim of ensuring the quality of the finished product. “ from GMP-News, September 8, 2003
Parametric Release (Real Time Release) –a quality assurance release program where demonstrated control of the process enables a firm to use defined critical process controls, in lieu of final quality control testing, to fulfill the intent of 21 CFR 211.165(a), and 211.167(a).5
Process Analytical Technology (PAT)
In-line On-line At Line Offline
PAT APPLICATIONS
Focused Beam Reflectance Measurement (FBRM)
Infrared Technologies Raman Spectroscopy UV-visible Particle Imaging Acoustics Fluorescence
SOME PAT TECHNOLOGIES Beyond Traditional In-line Measurements
PAT TECHNOLOGY Examples of where Technology can be used
Focused Beam Reflectance Measurement (FBRM)
Crystallization, Wet Granulation, Compounding
Near Infrared (NIR) Spectroscopy
Dispensing, Reaction Monitoring, API Drying
Raman Spectroscopy Crystallization, Compounding, Blending, Freeze Drying
Mid-IR Fermentation, CrystallizationUV visible Reaction monitoringParticle imaging Wet GranulationAcoustics Wet GranulationFluorescence Hot Melt Extrusion
APPLICATIONS FOR PAT TECHNOLOGIES
SOME RESOURCES FOR PAT TECHNOLOGIES
Nalas Engineering Services (In-house services)
Mettler- ToledoApplied Instrument Technologies
Endress & Hauser
RAPID MICROBIAL TESTING AND CONTINUOUS PROCESSING
Leads to expedited bioburden detection
Leads to expedited sterility assurance
Leads to quicker release of raw materials, in-process materials and final product
ATP BIOLUMINESCENCE - based on ATP (component of all microbes) measurement
CYTOMETRY – fluorescent cell labeling and laser scanning
POLYMERASE CHAIN REACTION (PCR) – microbiology based microbe detection method based on amplification of specific sections of microbial nucleic acids
RAPID MICROBIAL TESTING TECHNOLOGIES
PALL – ATP BIOLUMINESCENCE (PALLCHECK) PALL – POLYMERISE CHAIN REACTION (GENE
DISC) RAPID MICRO BIOSYSTEMS - ATP
BIOLUMINESCENCE (GROWTH DIRECT) MILLIPORE - ATP BIOLUMINESCENCE (MILLIFLEX) AES CHEMUNEX – CYTOMETRY (SCAN RDI) CELSIS - ATP BIOLUMINESCENCE (RAPISCREEN)
RAPID MICROBIAL TESTING VENDORS
Islands of Continuous Processing – segments of a manufacturing process where continuous processing can be executed; needed on way to completely continuous manufacturing processes.
Process Intensification “Process intensification consists of the development of novel apparatuses and techniques that, compared to those commonly used today, are expected to bring dramatic improvements in manufacturing and processing, substantially decreasing equipment-size/production-capacity ratio, energy consumption, or waste production, and ultimately resulting in cheaper, sustainable technologies. Or, to put this in a shorter form: any chemical engineering development that leads to a substantially smaller, cleaner, and more energy efficient technology is process intensification!” - Chemical Engineering Progress January 2000
PATHS FORWARD
No FDA or EU regulations prohibit continuous processing in small
molecule or biologic pharmaceuticals manufacturing
However, methods for meeting all regulatory requirements for continuous processing are still
evolving
Current Regulatory Environment
FDA encouraging continuous manufacturing (presentations C. Moore, 2011, and S. Chatterjee, 2012) – why? Regulatory interests moving to a “Quality by Design”
(QbD) model, with scientifically-based process design and proactive risk assessment (ICH Q8-11).
Current Regulatory Environment
FDA has recently redefined how process validation is performed – instead of 3-lots-and-done, now the process is qualified and all lots must be demonstrably in control (Continuous Process Verification, CPV: ICH Q10; Guidance for Industry Process Validation: General Principles and Practices, FDA January 2011 Revision 1).
Continuous processing with PAT and RTRT allows for real-time data collection throughout the process, with statistical process control on monitored variables.
Process is demonstrated to be IN CONTROL at all times.
Current Regulatory Environment
FDA 21 CFR 210.3 Batch - a specific quantity of a drug or other
material that is intended to have uniform character and quality, within specified limits, and is produced according to a single manufacturing order during the same cycle of manufacture
Lot - a batch, or a specific identified portion of a batch, having uniform character and quality within specified limits; or, in the case of a drug product produced by continuous process, it is a specific identified amount produced in a unit of time or quantity in a manner that assures its having uniform character and quality within specified limits.
Must produce a batch but what is a batch?When not processing batchwise?
ICH Q7 A batch or lot is defined as a specific quantity
of material produced in a process or series of processes so that it is expected to be homogeneous within specified limits. In the case of continuous production, a batch may correspond to a defined fraction of the production. The batch size can be defined either by a fixed quantity or by the amount produced in a fixed time interval.
Must produce a batch but what is a batch?When not processing batchwise?
So... as long as it is uniform, can define batch based on: Production time period (ICH, FDA) Quantity manufactured (ICH, FDA) Production variation (input lots, etc.) (FDA) Dependent on equipment cycling capability
(FDA) Other (FDA)
Must produce a batch but what is a batch?When not processing batchwise?
To facilitate a laboratory determination of product compliance with specifications for release
To facilitate assembly of a documentation package for manufacturing operations
To define the boundaries for extended investigations of unexplained discrepancies
To define the extent of material in question in a recall situation
Why Does Defining a Batch Matter?
From C. Moore, FDA, 13SEP2011
Safety - Identity - Strength - Quality - Purity
Validation master plan required prior to implementation
Risk assessment required Initial process qualification and validation
Continuous/ongoing process verification required
Regulatory Approach to Continuous Processing
Risk Assessment Topics – Different from Traditional Batch
Definition of a batchWhat is a valid residency time distribution What are the CPPs and CQAsQuality of the product during non-steady
state situations such as startup and shutdown
What needs to be done to return from Atypical processing situations i.e. planned or unplanned process outages
Regulatory Approach to Continuous Processing
Risk Assessment Topics – Different from Traditional Batch
Component lifespans - Equipment, resin and membranes
What monitoring is needed for continuous process verification
What type of Release Testing is sufficient in addition to continuous monitoring Offline and online testing Offline in process sampling Batch/lot testing Parametric release / Real Time Release Testing (RTRT)
Regulatory Approach to Continuous Processing
Control Strategy should be defined prior to manufacturing and demonstrated in process qualification
Control Strategy should include: Traceability of input lots (based on flow, Residency Time
Distribution) Acceptable steady state turn down ratios
Ability to run at different rates over run time Duration of time the continuous process can run without
required stoppage Raw material and batch stability over run time (Define
space definition)
Control Strategy and Process Qualification & Validation
Control Strategy Should include (continued): Provisions for microbial monitoring and control
Is material growth-inhibiting, growth-neutral or growth-promoting? How can bioburden be controlled, and if a contamination occurs,
how can it be detected? Sampling & monitoring plan in addition to continuous
monitoring Intermediates and final product Instrument delay and testing time vs. Residency Time Distribution
Strategy for how and when to clean process system and how the cleaning operations will be validated
Strategy for documentation of batch and batch package assembly: MES?
Control Strategy and Process Qualification and Validation
Chromatography single-use columns Disposable TFF cassettes for SPTFF Perfusion bioreactors at 2000L and less easily
utilize existing single use bag based bioreactors Better utilization of high cost single use
Single Use and Continuous Processing
SPTFF (Single Pass TFF) Cadence SPTFF PALL
Corporation Pellicon SPTFF EMD Millipore
Current and Emerging TechnologiesHarvest
ATF (Alternating Tangential Flow Filtration) Refine Technology
Novasep – Sequential Multi-Column Chromatography (SMCC) Prochrom® Varicol technology
GE Healthcare – 3-Column Periodic Counter Current (3C-PCC) Tarpon Biosystems – Bio SMB (Simulated Moving Bed)
Current and Emerging TechnologiesChromatography
Product Load
Equilibration buffer
Wash Buffer
Elution Buffer
Regeneration buffer
Continuous Product Capture
Waste
Spinning disc reactor Microreactors, modular flow reactors, inline
mixers Flow reaction testing equipment/reactor
development Lab-to-manufacturing scale continuous
process intensification services Agitated cell reactor
Current and Emerging Technologiesfor Continuous Synthesis of Small Molecule
Organic Compounds
SPINIDChemtrixUniqsis
Access 2 FlowProteaf
Micronit MicrofluidicsCofloreCorningFluitecLonza
Resources For Current and Emerging Technologies - Continuous Synthesis of Small Molecule Organic
Compounds
ATF Case Study
Manufacturer 2
Manufacturer 3
Manufacturer 4
Idea Innovato
r
Startup
ManufacturerProcess Development
Vendor
ManufacturerPRODUCTION
Engineering Firm(s)Other Vendors
Dave Marks, DME Alliance Engineering Consultants
Abby Johnson, DME Alliance Engineering Consultants
Robert Snow, CPIP- Sanofi Biologics Development
ANY QUESTIONS?
ACKOWLEDGEMENTS
http://www.dmealliance.com/DME Alliance, Inc. Engineering Consultants
7540 Windsor Drive, Suite 311Allentown, PA 18195 Phone: 610-366-1744
Eric Sipe, Senior Process [email protected]
Tim J. Hancock, Ph.D, Senior Process [email protected]
ANY QUESTIONS?
Process Understanding – “A process is generally considered to be well understood when (1) all critical sources of variability are identified and explained, (2) variability is managed by the process, and (3) product quality attributes can be accurately and reliably predicted over the design space established for the materials used, process parameters, manufacturing, environmental and other conditions”.
Quality By Design – quality is designed into the product not achieved by final QC testing of the product.
Design of Experiments – structured approach to assessing process responses to changes in inputs or control changes; important for determining acceptable values/ranges for process critical parameters.
KEY TERMS & DEFINITIONS
Guidance For Industry PAT — A Framework for Innovative Pharmaceutical Development, Manufacturing, and Quality Assurance; U.S. Department of Health and Human Services Food and Drug Administration Center for Drug Evaluation and Research (CDER) Center for Veterinary Medicine (CVM) Office of Regulatory Affairs (ORA) Pharmaceutical CGMPs September 2004
Control Strategy defined prior to manufacturing and demonstrated in process qualification
Should include: Define criteria to determine when process is “in control”
/ steady-state CPPs and CQAs – definitions, specifications; may include
models and distributions Assess start-up/shut-down periods and timing; periods may
not align for all unit operations connected continuously Consider planned transient or changed states (ex: new lot
of RM, refill of hopper) Flow properties of continuous process must be well-defined
compared to a batch process
Control Strategy and Process Qualification and Validation
Control Strategy defined prior to manufacturing and demonstrated in process qualification
Should include: How to handle atypical processing situations
What material is retained or discarded How material is segregated and how process disturbances
are contained Acceptable carryover material
Control Strategy and Process Qualification and Validation
Perfusion Engineering Challenges
Long term aseptic performance Cell damage – shear, cavitation Cell residence time / environment in
separation device Protein retention Ability to selectively retain viable cells Biomass removal requirements Mass balance in bioreactor CIP/SIP Process Validation
Reduced purification suite footprint Eliminates harvest and clarification tanks Buffer and resin usage is significantly reduced Increase productivity (g/L resin-day) Significantly smaller columns (up to 100X) Fully automatic operation (ΔUV PAT) Utilization of small single use columns
BENEFITS OF SIMULATED MOVING BED/CONTINUOUS VERSUS BATCH
CHROMATOGRAPHY