Applications of Headspace Moisture Analysis for Investigating the Water Dynamics within a Sealed Vial Containing Freeze-dried Material

Abstract

We compare frequency modulation spectroscopy (FMS) as a method of headspace water analysis with the method of Karl Fischer coulometric titration (KF), which is widely used in the analysis of residual water in a freeze-dried material. Parameters relating to the type of formulation (amorphous, crystalline) and the freeze-drying cycle (temperature, pressure, time) were investigated in relation to the resulting headspace moisture (HSM) and total water. We describe the effect of stopper treatment and storage conditions on the HSM levels observed using FMS as a non-destructive method, which also allowed individual vials to be reanalyzed at a series of time points as part of a long-term monitoring exercise. The results of this study enabled a better understanding of the effect of stopper type and pre-lyophilization treatment on the HSM levels both immediately after freeze-drying and upon subsequent storage of the sealed vials of lyophilized material at different temperatures. A clear, linear relationship was observed between HSM and KF values for vials containing freeze-dried sucrose, implying a relatively straightforward interaction between water and the lyophilized cake for this material. Moisture mapping of all vials on one shelf of the freeze-dryer enabled further information to be obtained on the relationship of the formulation, vial, process conditions, equipment geometry, and performance on the intra-batch variability in HSM level and dynamics. It is believed that this could therefore represent a potentially useful technique for quality assurance and in the validation of lyophilization cycles, equipment, and scale-up.

LAY ABSTRACT: Lyophilization, also known as “freeze-drying,” is a relatively old technique that has been used in its most basic form for thousands of years (e.g., preservation of fish and meat products). In its more advanced form it is used to preserve many medical products, for example, many vaccines are not stable in solution and therefore need to be dried to allow long-term storage. In order to produce a freeze-dried vaccine a complex understanding of the processes and critical temperatures is required. Once these have been understood the material is dried to give relatively low moisture content (e.g., 2% w/w). This low moisture content is critical for the long-term stability of the product, allowing doctors/chemists to store these goods on site for use when required. This research paper provides further information on a technique called frequency modulation spectroscopy (FMS) that could be used to further our knowledge of the water dynamics within a freeze-dried product, enabling us to increase our understanding of the role various materials and processing conditions play; this in turn could assist in improving quality assurance and ultimately the final product that reaches the consumer.