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The application of quality by design (QbD) is becoming an integral part of the formulation and process development for pharmaceutical products. An essential feature of the QbD philosophy is the design space. In this sense, a new approach to construct a process design space (PDS) for the primary drying section of a freeze-drying process is addressed in this paper. An effective customized design of experiments (DoE) is developed for freeze-drying experiments. The results obtained from the DoE are then used to construct the product-based PDS. The proposed product-based PDS construction approach has several advantages, including (1) eliminating assumptions on the heat transfer coefficient and dried product resistance, as it is constructed from experimental results specifically obtained from a given formulation, yielding more realistic and reliable results and (2) PDS construction based on a narrow range of product temperatures and considering the variations in product temperature and sublimation rate of vials across a shelf. This guarantees the effectiveness and robustness of the process and facilitates the process scale-up and transfer. The PDS developed herein was experimentally verified. The PDS predicted parameters were in excellent agreement with the experimentally obtained parameters.

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Background: The compliance of lipid admixtures to physical emulsion stability parameters is extremely important to ensure the safety of patients. For example, admixtures containing a percentage of fat globules larger than 5 mm in diameter (concept known as PFAT5) of more than 0.05% might produce toxic effects in lung and liver. This concern is mainly based on a limited number of animal studies investigating admixtures with high PFAT5 levels resulting from 48 h of admixture storage. However, all effects observed in these studies might as well be attributed to chemical instability like lipid oxidation, which was not analysed and therefore could not be excluded. Aims: This study aims at investigating the correlation of high levels of PFAT5 in lipid emulsion admixtures with lipid oxidation parameters under different storage conditions. Methods: We studied the physical (PFAT5 value) as well as the chemical (pH, primary and secondary oxidation parameters) stability of an admixture of a lipid emulsion and an amino acid solution after up to 48 h following different storage conditions (exposure to oxygen, exposure to artificial light).