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Particulate Matter - Visual Detection   to   Identification Scott Aldrich PDA Visual Inspection, October 19-20, 2009
Concepts ,[object Object],[object Object],[object Object]
Rules for Products ,[object Object],[object Object],[object Object],[object Object],[object Object]
Visual Inspection ,[object Object],[object Object],[object Object],[object Object]
Tracking Product Physical Stability ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Visible Sub-visible Sub-micrometer Size Domains 1µm 25µm 10µm 150µm Increasing Probability of Detection What size domain matters for the product stability? Visible  Gray zone
Pharma Liquid Products and Presentations – A Complex Array ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Pharma Liquid Products and Presentations – A Complex Array ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Development Timeline & Distractions Small Scale Crud, ignored Package is Changing Small Batches, Few Containers Used First of many API Processes Clinical Scale Package and Presentation Defined – Set? Customer Use Experience ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Commercial Product Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Compendial Requirements Robust, Safe, Sterile, Pure and Effective ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
PARTICULATE MATTER QUANTITATION ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Particle Count by Light Obscuration – First Tier Groves, 1993 CONSTITUTES KEY FILING DATA
Counting by Membrane Assay  – Second Tier ,[object Object],[object Object],[object Object],[object Object],[object Object],MOST IMPORTANT IN PRODUCT DEVELOPMENT
The ID Process ,[object Object],[object Object],[object Object],[object Object],[object Object]
What Constitutes a Defect? … Appearance and Evident Changes ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Just What is Acceptable?  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Isolation Methods ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Capillary Removal and Transfer
Isolate What’s Seen ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Inspect – Detect – Isolate - Identify ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Inspection at Microscopy Bench Tools of the Trade The Particle Atlas
Microscopy Pathway ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Observations via Microscopy ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Microscopy Tricks of the Trade ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Microscopy Tricks of the Trade ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Membrane Method for ID Isolation
PLM Spectroscopy Hotstage Schemes for Material Ultramicroanalysis (Light Obscuration) Membrane Isolate Picking Direct SEM-EDS Optical Count PLM-Spectroscopy Direct SEM-EDS ID Quant
The Nature of Material ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
PARTICULATE MATTER ORIGINS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Studying the Occurrence ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Thanks for Your Attention Questions?
Membrane Microscopic Count is Key Bio: Scott Aldrich is a long-standing member of American Chemical Society, AAPS, State Microscopical Society of Illinois, PDA and Microscopy Society of America.  He is a member of the United States Pharmacopeia (USP) Parenteral Products – Industrial Expert Committee for the current (2005-2010) term.  He is a 38 year veteran of the pharmaceutical industry, through employment at Upjohn, Pharmacia, and Pfizer.  Scott is President of Ultramikro, LLC an independent consulting firm specializing in microscopy training and particulate matter control programs.
Parenteral and Ophthalmic Limits  – A Comparison
What’s Visible? It Depends… ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
FDA Review of Recent PM Data 295 Drug Applications (SVP’s, by LO)* * Nath, et al.  Particulate Contaminants of Intravenous Medication and the Limits set by USP General Chapter <788>, 2005 Pharm. Forum n/a n/a 151 1504 Mean + 3SD 13 (27)/mL 59 (89)/mL 15 (43)/pkg 219 (415)/pkg Mean (± 1SD) 1983 data (19 LVP products by membrane) ALL – 406 lots (354 in glass vials) 10 (24)/pkg 82/pkg 154 (289)/pkg 1021/pkg 17 (45)/pkg 153/pkg 245 (438)/pkg 1560/pkg Mean (± 1SD) Mean + 3SD 600 ≥25  m 6000 ≥10  m 600 ≥25  m 6000 ≥10  m USP <788> Limits 112 294 # Batches TERMINAL STERILE PROCESS ASEPTIC PROCESS

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Visual Detection and Identification of Particulate Matter in Pharmaceutical Products

  • 1. Particulate Matter - Visual Detection to Identification Scott Aldrich PDA Visual Inspection, October 19-20, 2009
  • 2.
  • 3.
  • 4.
  • 5.
  • 6. Visible Sub-visible Sub-micrometer Size Domains 1µm 25µm 10µm 150µm Increasing Probability of Detection What size domain matters for the product stability? Visible Gray zone
  • 7.
  • 8.
  • 9.
  • 10.
  • 11.
  • 12.
  • 13. Particle Count by Light Obscuration – First Tier Groves, 1993 CONSTITUTES KEY FILING DATA
  • 14.
  • 15.
  • 16.
  • 17.
  • 18.
  • 20.
  • 21.
  • 22. Inspection at Microscopy Bench Tools of the Trade The Particle Atlas
  • 23.
  • 24.
  • 25.
  • 26.
  • 27. Membrane Method for ID Isolation
  • 28. PLM Spectroscopy Hotstage Schemes for Material Ultramicroanalysis (Light Obscuration) Membrane Isolate Picking Direct SEM-EDS Optical Count PLM-Spectroscopy Direct SEM-EDS ID Quant
  • 29.
  • 30.
  • 31.
  • 32. Thanks for Your Attention Questions?
  • 33. Membrane Microscopic Count is Key Bio: Scott Aldrich is a long-standing member of American Chemical Society, AAPS, State Microscopical Society of Illinois, PDA and Microscopy Society of America. He is a member of the United States Pharmacopeia (USP) Parenteral Products – Industrial Expert Committee for the current (2005-2010) term. He is a 38 year veteran of the pharmaceutical industry, through employment at Upjohn, Pharmacia, and Pfizer. Scott is President of Ultramikro, LLC an independent consulting firm specializing in microscopy training and particulate matter control programs.
  • 34. Parenteral and Ophthalmic Limits – A Comparison
  • 35.
  • 36. FDA Review of Recent PM Data 295 Drug Applications (SVP’s, by LO)* * Nath, et al. Particulate Contaminants of Intravenous Medication and the Limits set by USP General Chapter <788>, 2005 Pharm. Forum n/a n/a 151 1504 Mean + 3SD 13 (27)/mL 59 (89)/mL 15 (43)/pkg 219 (415)/pkg Mean (± 1SD) 1983 data (19 LVP products by membrane) ALL – 406 lots (354 in glass vials) 10 (24)/pkg 82/pkg 154 (289)/pkg 1021/pkg 17 (45)/pkg 153/pkg 245 (438)/pkg 1560/pkg Mean (± 1SD) Mean + 3SD 600 ≥25  m 6000 ≥10  m 600 ≥25  m 6000 ≥10  m USP <788> Limits 112 294 # Batches TERMINAL STERILE PROCESS ASEPTIC PROCESS