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1
Centro de InmunoEnsayo
Calle 134 y Avenida 25. Cubanacn, Playa, La Habana, Cuba
2
Centro de Ingeniera Gentica y Biotecnologa
Ave. 31 e/158 y 190, Cubanacn, Playa, CP 11600, La Habana, Cuba
arien.nmgmbh@gmail.com
ABSTRACT
The system for phenylketonuria diagnostic in newborns (UMTEST PKU) is produced at the Center for Immunoassay (Havana, Cuba). L-leucyl-L-alanine is one of the kit components and requires lyophilization due to its limited
aqueous solution stability. Results from Diffferential Thermal Analysis/Impedance (DTA/ Zsin) and lyomicroscopy
determinations, identify that during the freezing step product temperature must be below 30 C, while throughout
the primary drying process product temperature at sublimation front cannot exceed 18.9 C. The use of a procedure
based on the critical variables determinations, allow the lyophilization of three industrial batches that finally fulfilled
the quality specifications and achieve a reduction of 32 % in the cycle total time.
Keywords: lyophilization, L-leucyl-L-alanine, sublimation, electrothermal analysis, lyomicroscopy
RESEARCH
RESUMEN
Diseo del ciclo de liofilizacin de una formulacin del dipptido L-leucil-L-alanina basado en sus
propiedades trmicas. El sistema para la deteccin de la fenilcetonuria (UMTEST PKU) en recin nacidos, se
produce en el Centro de Inmunoensayo (CIE, La Habana, Cuba). La L-leucil-L-alanina, uno de los componentes
del diagnosticador, requiere ser liofilizado debido a su limitada estabilidad en solucin acuosa. La utilizacin de las
tcnicas de Anlisis Trmico Diferencial/Impedancia (ATD/Zsin) y la liomicroscopa permitieron definir que en la
liofilizacin de este reactivo, la congelacin requiere ser realizada a temperaturas inferiores a 30 C, mientras que
en el secado primario la temperatura del frente de sublimacin no puede sobrepasar el valor de temperatura de
colapso (Tc) de 18.9 C. La liofilizacin de tres lotes a escala industrial, ejecutada con el procedimiento diseado
segn los resultados de las determinaciones previamente descritas, garantiz la obtencin de un producto acorde
a las especificaciones de calidad, con una reduccin del 32 % en el tiempo total del ciclo.
Palabras clave: liofilizacin, L-leucil-L-alanina, anlisis trmico diferencia, impedancia, liomicroscopa
Introduction
Phenylketonuria (PKU) is an inborn metabolic error
manifested as an autosomic-inherited recessive monogenic disorder [1]. From the biochemical point of
view, it leads to the accumulation of phenylalanine
(Phe) in blood and other organic fluids and tissues,
also slightly decreasing tyrosine levels [2]. PKU patients without control treatment could suffer from
post-natal brain damage, further developing irreversible cognitive impairment, skin modifications and
absence or difficulty of speech [3].
For these reasons, neonatal screening programs
for the massive detection and treatment of hyperphenyalaninemias started as early as in 1961, with the
Guthries Bacterial Inhibition test [4]. That assay was
used in Cuba from 1983 to 2000, with an incidence of
1:50 000 inhabitants been detected [5]. A pilot program started that year for PKU screening using the
UMTEST PKU kit, which consists on a fluorescent
ultramicroassay for the quantitative detection of Phe
in dry blood on filter paper, by using the ultramicroanalytical system (SUMA) developed at the Center of
Immunoassays (CIE), Cuba [6]. The screening compound, L-Leucyl-L-alanine, requires to be lyophilized
to guarantee its two-year validity.
Lyophilization is a freeze-drying operation
commonly used for the long-term stabilization of
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Pc = 1.333 (0.29 10
10 000
) [1]
0.019 Tp
T1 (40.32 C)
1000
T2 (36.29 C)
100
10
0
60
T4 (3.37 C)
50
40
30
Temperature (C)
20
10
Figure 1. Impedance (Zsin) of the L-leucyl-L-alanine dipeptide formulation. Samples were cooled
down to temperatures below 100 C and immediately heated until room temperature at a rate
of 2 C/min. T1 and T3: temperatures of matrix destabilization; T2: recrystalization temperature; T4:
temperature of ice crystals fusion.
T1 (24.5 C)
DT (C)
T3 (22.86 C)
T2 (8.2 C)
60
50
40
30
20
10
Temperature (C)
Figure 2. Differential termal analysis (DTA) curve of the L-leucyl-L-alanine curve. Samples were cooled
down below 100 C, and subsequently heated until room temperature at a rate of 2 C/min. T1:
matrix destabilization tempersature. T2: temperature of ice crystals fusion.
Figure 3. Determination of collapse temperature (TC) of the L-leucyl-L-alanine formulate, by lyomicroscopy technique. Sample frozen at 40 C (3 C/min), followed by heating to 10 C (1 C/min) at 0.01 mBar
pressure. White circles indicate the area where the structure started to collapse. TC onset: 18.9 C.
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220
PC
40
200
TCOND
20
Temperature (C)
matrix progressively softens due to the increased mobility in the interstitial zone [8, 27]. The Tg value is of
the same magnitude, being within the range as reported
in the literature in respect to TC [18, 23], considering
that DTA graph shows the start of an endothermic profile at T1 (24.5 C) differing in 5 C from Tc. This results need to be confirmed by using the DSC technique.
TP2
180
160
TP1
TP3
140
120
20
TSP-S
40
Pressure (mBar)
TFLUID
100
80
60
60
40
20
80
0
1000
2000
3000
4000
0
6000
5000
Time (1:10 s)
Figure 4. Lyophilization process of the L-leucyl-L-alanine dipeptide. TP1, TP2, TP3: Product temperatures
1 to 3. TCOND: Temperature of the condenser. TFLUID: Temperature of the fluid. TSP-S: Safety temperature.
PC: Chamber temperature.
Freezing
Desorption
Freezing Stabilization
Shelf
Pressure
Safety
Shelf
Pressure
temperature
time
temperature (mBar) temperature temperature (mBar)
(C)
(h)
(C)
(C)
(C)
Previous
process
New
process
Difference
35
30
0.050
30
30
< 0.05
30
19
0.148
22
37
< 0.05
11
0.098
Freezing
Desorption
2.8
7.7
6.0
16.5
4.1
11.1
9.0
24.2
1.3
3.4
3.0
7.7
Whole cycle
Table 3. Quality specifications for industrial-scale lyophilizate batches of the L-Leucyl-Lalanine dipeptide
Batch
1
2
3
Organoleptic properties of
Color
Residual
Fluorescence (FU)
the reconstituted solution change (%) moisture (%) Calibrator A Calibrator F
Comply
0
2.9
07.2
115.7
Comply
0
2.2
12.2
136.5
Comply
0
2.6
06.1
124.1
Acceptance
limits
Comply
showed white pills of regular edges and structures devoid of cavities or deformations, these last associated
to alterations during the lyophilization process when
present. The pills dissolved immediately, leading to a
clear solution lacking mechanical particles. The residual moisture was lower than 3 % in all the cases. The
marker performance parameters of the component in
the screening device (fluorescence calibrators A and
F) were within the established limits.
Conclusions
The results of the combination of DTA/Zsin and lyomicroscopy techniques indicate that freezing has to be
1224
20
100-150
carried out at temperatures below 30 C and sublimation up to 18.9 C, for the correct liophilization of the
L-Leucyl-L-alanine dipeptide. The batches obtained
26. Rambhatla S, Ramot R, Bhugra C, Pikal MJ.
Heat and mass transfer scale-up issues during
freeze drying: II. Control and characterization
of the degree of supercooling. AAPS PharmSciTech. 2004;5(4):e58.
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