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Highlights of Presentation
Introduction & Steps in Drug Discovery Introduction & Role PR&D Role in Drug Discovery
Drug Candidates
Assay Proteomi Biochemi Medicinal Drug Toxicolog Develop cs stry/Enzy Chemistr Mechanis y/Safety ment mology y m Pharmac olgy
3-4 Years
Clinical Development
6-8 Years
1 Year
Phase 1
Phase 2
Phase 3
Patent Infringement Inconsistent Raw Material Quality and Supply Hazardous or Non-Regulated Raw Materials Costly Raw Materials Unsafe or Environmentally Hazardous Reactions Low Yields Difficult-To-Achieve Levels of Purity (e.g., for enantiomers) Scale-up Difficult-To-Handle Processes
Current cost of bringing new drug to market: >$800 million Success rate: 1 in 10 Time to Market: 10 to 15 years Highly competitive Highly regulated
P R&D Significance
Safety & Speed Quality & Quantit y
P R&D Philosophy
Subject Atom Economy Solvent reduction Environmentally Thinking Economically Thinking Minimal by Product Formation More from Less - Incorporate Total Value of Materials Less Solvent Waste Higher throughput, Less Energy
Reagent Catalytic, Low Stoichometry, Higher Efficiency - Higher Optimization Recyclable Reagents, Selectivity Minimize Us age Convergency Due to Increased Processed Efficiency Energy Reduction Safety From Power Generation, Transport and Use Non-Hazardous Materials Reduce Risk of Exposure, Release, Explosions & Fire Higher Efficiency . Reduced Energy , Increased Efficiency, Shorter Process and Mild Conditions Worker Safety and Reduced Down Time. Reduced Time on Special Control Measures
Meet the Challenges by executing fundamental changes to the development and manufacturing approach
Integrated scientific, manufacturing, & commercial objectives Development of the best route with full intrinsic process knowledge Apply new technologies for effective utilization of
Optimize d Route
Technolo gy Transfer
IDEA
PR
PD
Routine Manufaturing
Kilogram
1 to 100Kg
> 100Kg
Pha se 1
Pha se 2
Pha se 3
Chemistry Selection
Process Devel.
Process Modeling
Process Scale Up
Process Control
Quality By = Design
Deliverables
Best Intrinsic Optimized Demonstrated Time Real Production Process Unit Production Continuous Chemistry KnowledgeOperations Process Improvements
Work-up & Minimal reliance on chromatography; No concentrations to Isolations dryness Minimal number of repeated steps (extractions; solvent displacements); Controlled crystallization preferred over precipitation. Reaction Exotherms and gas evolution: liability worse with scale-up. RuggednesCryogenic or very high temp. require specialized equipment. s Control of reaction conditions (temp. or pH). Excluding moisture or oxygen may require additional considerations. Rapid additions and short reaction times require nonstandard equipment Yield Low yields require that more intermediates be prepared for
Approaches to Process Development. Route Selection. Reagent Selection. Solvent Selection. Running the Reaction. Effects of Water. In-Process Controls. Optimizing the Reaction by
Optimizing Catalytic Reactions Work-Up Tools for Purifying the Product Column Chromatography & Crystallization Final Product Form and Impurity Considerations. Vessels and Mixing. Preparing for and Implementing the Scale-up Run.
PR&D - Approaches
Introduction Importance of scale-up operations Importance of team work Determining operations Safety Considerations Take Advantage of Good
A R&D
Pharmaceutical To formulate drug substance from drug product Chem. Regulatory Quality To Interface with FDA and other regulatory authorities Documentation & Interface with DR&D and
PR&D Approaches Comparison of Lab Scale & Plant Scale Operation Lab Scale On Scale
Common Rotary evaporation; Concentration to dryness Use of Highly Flammable solvents Column Chromatography & Drying over agents Azeotropic drying Addition of dangerous reagents & Maintaining Cryogenic temperature & Rapid quenching Fine controlling Heating & Cooling X X X X X Easy to effect X X X X X X X X X X X X Common Easy to effect
Manufacturing
Introduction Characteristics of Appropriate Route Characteristics of Cost-Effective Route Planning for Ultimate Route
A +B
Step 1
A-B
Step 1 C
A-B-C
Step 1 D Step 1 H
A-B-C-D
Step 1 E
A-B-C-D-E
Step 1 I
Step 1 F
A-B-C-D-E-F
Step 1 G
A-B-C-D-E-F-G
A-B-C-D-E-F-G-H
A-B-C-D-E-F-G-H-I
A +B C +D E +F G +H
Step 1
A-B-C-D
Step 1 A-B-C-D-E-F-G-H Step 1
Step 1 I
A-B-C-D-E-F-G-H-I
E-F-G-H
Consistent quality from batch to May eliminates the needs for use-tests batch Stable with good self life Good stability at room temperature preferred
Readily generated and used if not Reproducible generation minimizes stable Readily transferred into reactors Liquids and solutions are preferred
PR&D - Solvent Selection Primary Physical Characteristics of solvents for Scale-up Solvents Alternative Solvents
Polarity Freezing Point Boiling Point Must be compatible with and encourage the desired chemistry May limit range of low-temperature reactions A higher bp extends the temperature range of reaction without using pressurized reactor. A lower boiling solvents is easier to remove by distillation. Temperature at which a liquid produces ignitable vapors . Lower boiling solvents/compounds typically have lower flash point. Occurs primarily in etheric solvents. Slower in ketones & amides. Solvents with tendency for peroxide formation should be monitered Solvents with increased viscosity display slower filtration rates Solvents with low water-miscibility allow for easier extractive work-ups
Flash Point
Impact on Processing
Increase reaction rate and decrease byproducts Minimize localized heating minimize by-product formation, increase ability to transfer slurries to filters Increase productivity, yield & quality Increase productivity, yield & quality
Increase the desired reactionIncreased productivity often through rate homogeneous reaction conditions
Alternative Solvents
Diethylether Flammable Isopropyleth Flammable/Peroxide er formation HMPA Pentane Hexane Toxicity Flammable Electrostatic discharge
Chloroform Mutagenicity, Toxicity CCl4 & EDC Benzene Dioxane Mutagenicity Carcinogen Carcinogen
Introduction Determining Reaction Safety Assessing Safe Operating Conditions in the Lab Selecting the Reaction Scale Choosing Equivalents of Reagents, Starting Materials & etc Plan for Inert Condition if needed Charge Starting Materials and Solvents Select Reaction Temperature Select Duration & Sequence of Additions Select Reaction Pressure Adjust Stirring
Optimizing Reaction Temperature Optimizing Reagent Equivalents Optimizing Addition of Reagents Optimizing Use of Solvents and Cosolvents Optimizing Reaction Concentration Changing Reagents and Intermediates Optimizing Catalysts and Ligands Optimizing Stirring Importance of Extending Reaction Times
PR&D - Work-Up
Introduction Aspects of Work-up
Quench Extraction Activated Carbon Treatment Filtration Concentrating Solution/Solvent Displacement Deionization and Removing Metals Destruction of Process Streems
Introduction
PR&D - Troubleshooting
Introduction Physical and Chemical Causes of Processing Problem Steps for Troubleshooting A Process
Confirm that there is Problem Determine Whether the problem is Serious Enough Spend Time Compare Processing Steps to those used in Successful Batches Identify as assay to monitor key Processing Confirm that the cause of the problem has been identified Propose alternative treatments to eliminate the problem
Case Study
S N H N O
N
N H
Omeprazole
Esomeprazole
R R1
F F O O S N H N O F N F F
O Cl
N
O O O S N H N O F N F
Lansoprazole
O
Pentoprazole
O S
N H N
Rabeprazole
Case Study
II
N O N O
III
N O
IV
N O N O
Cl
Step IV Modified by Changing chlorination reagent Acetyl chloride in ethanol used instead of HCl, Thionyl Chloride, and etc 30Kg scale performed without any issues
Case Study
Pioglitazone
NH
I
N OH N
II
OR N O Step II
NaOH/MDC or K2CO3 1eq K2CO3 PhMe 7.4 Vol
S
O
III
N Step III
NH IV Step IV
Pioglitazone
Step I
Med Chem Tosyl group Route Improved 1 eq MsCl Route 1eq TEA, (Feasibilit PhCH3 7 Vol y)
Piperidine/ Ethanol
Pd/H2 , Dioxane
0.72 eq of 1.2 eq of NaBH4 Piperidine, MeOH 0.4eq of DMG 13 times H2O:MeOH:DMF 0.83 eq of 1.2 eq of NaBH4 Piperidine, MeOH 0.4eq of DMG
Case Study
Cl N
NH 1
Cl NH
Cl NH O
Cl NH
N H
N H
Case Study
BCl1 /AlCl1
N NH 1
Cl
Cl
Cl O
Cl N
Cl NH 1
KOCN
NH 1 N H O
Cl N
Cl NH O
Deprotection Resolution
O
Cl NH
N H
OH
H1 N
HO HN O O O O
O N P HN O O O O O
GS-1 1 11
LAH LDA
CO1 Et HO CO1 Et
OH
Acetone PTSA
HO
O O
CO1 Et
Oxidation
O O
CSA MeOH
MeO
O OH
O1
O OH MeO O
CSA MeOH
O O
CHO
Enantioselective Synthesis
HO
Process Development
1 Cobaloxime )
O OH O O NaBH 1 O O O O O O
NaBH1 /NaOH
O
(1 )
NIS
CH1 1/ 1 Cl C
(1 )
(1 )
O HO
AcO
Case Study Manufacturing of Sertraline by Pfizer (Treatment for Depression) Sertraline-Active Ingredient in Zoloft
Pfizers Conventional 3 step process Reduced to a Single Step
NMe NHMe NHMe TiCl1 /MeNH1 Tolene/Hexane O OH Cl Cl NMe NHMe NHMe Pd/C, H1 THF Cl Cl Isolated D-Mandelic acid Cl Cl Isolated Cl Sertraline mandelate Cl
MeNH1 EtOH Cl Cl
D-Mandelic acid Cl
Sertraline mandelate Cl Cl
Solvent use reduced from 60,000 to 6,000 gallons per ton of sertraline Eliminated the use of 440 metric tons of titanium dioxide per year
1 1L/kg 1 1 L/kg 1 1 L/kg 1 2 L/kg 2 1L/kg Discovery Route 1 Commercial 1 Commercial 1 Commercial Chiral Tetralone st nd rd
Sildenafil useful for the treatment male impotency Old synthetic route is having 10 linear steps Potentially toxic materials in the final reaction Multiple crystalizations are needed to get pure compound Difficulties in Scale up process.
Old Synthetic Route:
O O HO Pr O H1 N O N H N N Pr OEt HN N Pr SO1 Cl Pr O N N OEt HN N Pr N N HNO1 O1 N HO O N N H1 N O N N H1 N SnCl EtOH H1 N O N N O N N N Pr O S O N N O OEt Cl
SOCl1 NH1 OH O1 N Pr
Pr N N
Pr OEt HN
EtO
Commercial/Convergent Route:
O H1 N O1 N N N Pr OEt O OH NaOH/H1 O S O O N SO1 Cl N H1 N Pd-C/H1 H1 N O N N
CDI
OH O S O N N
OEt OH
H O ClSO1 SOCl1
Pd/C & H2 Used for reduction of nitro to amine instead of SnCl/EtOH During Sulfonation, thionyl chloride used to convert sulfonic acid (intermedite) to Sulfonyl chloride Sulfonamide formation was performed in aq. NaOH CDI used in the formation of amide (coupling) instead of Oxalyl chloride
How the amount of waste produced in the manufacture (L of waste/kg of product) has decreased over the past 13 years.
Pyridine Toluene t-Butanol 2-Butanone Ethyl Acetate Ether Methanol Ethanol Acetone Methylene Chloride
Case Study Manufacturing of Ibuprofen by BHC in 1961 Ibuprofen (Pain Killer,) discovered
Traditional Synthesis (by Boots) involves 6 steps. And atom utilization is only 40%
O CO1 Et O CHO
AlCl1 1 /Ac O
ClCH1 1 CO Et NaOEt
CHNOH CN
H1 O
CO1 H
Excess AlCl3 is used old process and which gave 20,000 tones of solid waste.
Case Study Manufacturing of Ibuprofen by BHC expire in 1984) BHC Redesigned in 1990 (after patent
Catalytic Synthesis, completed in 3 steps 77% Atom Utilization
O OH CO1 H
HF/Ac1 O
H1 R-Ni
Pd CO
Catalytic amount of Hydrofluoric acid used instead of AlCl3. Catalyst Reused in Next Batch. Acetic acid is by product in first step, was converted to Ac2O (99% of recovered)
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