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This study investigated factors associated with vial filling with a positive displacement piston pump leading to formation of protein particles in a formulation of an IgG. We hypothesized that nanoparticles shed from the pump's solution-contact surfaces nucleated protein aggregation and particle formation. Vials of IgG formulation filled at a clinical manufacturing site contained a few visible particles and about 100,000 particles (1.5-3 mm) per mL. In laboratory studies with the same model (National Instruments FUS-10) of pump, pumping of 20 mg/mL IgG formulation resulted in about 300,000 particles (1.5-3 mm) per mL. Pumping of protein-free formulation resulted in 13,000 particles (1.5-15 mm) per mL. More than 99% of the particles were 0.25-0.95 mm in size. Mixing of protein-free pumped solution with an equal volume of 40 mg/mL IgG resulted in 300,000 particles (1.5-15 mm) per mL. Also, mixing IgG formulation with 30,000/mL stainless steel nanoparticles resulted in formation of 30,000 protein microparticles (1.5-15 mm) per mL. Infrared spectroscopy showed that secondary structure of IgG in microparticles formed by pumping or mixing with steel nanoparticles was minimally perturbed. Our results document that nanoparticles of foreign materials shed by pumps can serve as heterogeneous nuclei for formation of protein microparticles. 2008 Wiley-Liss, Inc. and the American Pharmacists Association J Pharm Sci 98:94-104, 2009

Screening for pharmaceutically viable stability from measurements of thermally induced protein unfolding and short-term accelerated stress underpins much molecule design, selection, and formulation in the pharmaceutical biotechnology industry. However, the interrelationships among intrinsic protein conformational stability, thermal denaturation, and pharmaceutical stability are complex. There are few publications in which predictions from thermal unfolding-based screening methods are examined together with pharmaceutically relevant long-term storage stability performance. We have studied eight developable therapeutic IgG molecules under solution conditions optimized for large-scale commercial production and delivery. Thermal unfolding profiles were characterized by differential scanning calorimetry (DSC) and intrinsic fluorescence recorded simultaneously with static light scattering (SLS). These molecules exhibit a variety of thermal unfolding profiles under common reference buffer conditions and under individually optimized formulation conditions. Aggregation profiles by SE-HPLC and bioactivity upon long-term storage at 5, 25, and 40 °C establish that IgG molecules possessing a relatively wide range of conformational stabilities and thermal unfolding profiles can be formulated to achieve pharmaceutically stable drug products. Our data suggest that a formulation design strategy that increases the thermal unfolding temperature of the Fab transition may be a better general approach to improving pharmaceutical storage stability than one focused on increasing Tonset or Tm of the first unfolding transition.

To study the effect of three nonionic surfactants on the protein-silicone oil interactions.The adsorption of Tween® 80, Pluronic® F68 and Tween® 20 at the silicone oil/water interface (using shifts in frequency (ΔF) and resistance (ΔR) with quartz crystal microbalance) was compared to the adsorption at air/water interface (using surface tension). Effect of surfactants on protein adsorption to the silicone oil/water interface was studied in sequential- and co-adsorption modes. Protein-surfactant binding in the bulk was measured using dynamic surface tension method.Saturation of air/water and silicone oil/water interfaces by surfactants was observed at similar bulk concentrations. ΔF due to protein adsorption to the interface decreased only when surfactant was present as a pre-adsorbed species. Insignificant differences in the dynamic surface tension values of surfactant solutions were observed in the presence of protein.Similar hydrophobic forces were responsible for driving the surfactant adsorption at both air/water and silicone oil/water interfaces. Surfactants were effective in reducing the protein adsorption to the silicone oil only when introduced before or along with the protein. No significant binding between the protein and surfactants was observed in the bulk.

There is evidence in the literature that silicone oil, a lubricant, can induce aggregation in protein formulations delivered through prefilled syringes. Surfactants are commonly used to minimize protein-silicone oil and protein-container interactions; however, these interactions are not well characterized and understood. The purpose of this manuscript was to understand the competitive interactions of a fusion protein with the silicone oil in the presence of Tween(®) 20. An adsorption isotherm for Tween(®) 20 at the silicone oil/water interface, using silicone oil coated quartz crystals, was generated at 25°C to identify surface saturation concentrations. A concentration of Tween(®) 20 providing interfacial saturation was selected for protein adsorption studies at the silicone oil/water interface. The surfactant molecules adsorbed at the interface in a monolayer with a reduced viscoelastic character in comparison to the bound protein layer. A significant reduction in protein adsorption was observed when the surfactant was present at the interface. No desorption of the pre-adsorbed protein molecules was observed when Tween(®) 20 was introduced, suggesting that the protein has strong interactions with the interface. However, both, Tween(®) 20 and protein, adsorbed to the silicone oil/water interface when adsorption was carried out from a mixture of protein and Tween(®) 20.

In this study, we have used quartz crystal microbalance (QCM) to quantitate the adsorption of a protein on silicone oil coated surfaces as a function of protein concentration, pH and ionic strength using a 5 MHz quartz crystal. Protein adsorption isotherms were generated at different solution pH and ionic strengths. Surface saturation concentrations were selected from adsorption isotherms and used to generate adsorption profiles from pH 3.0 to 9.0, and at ionic strengths of 10 mM and 150 mM. At low ionic strength (10 mM) and pH 5.0 (close to the isoelectric point of the protein), maximum adsorption of protein to the silicone oil surface was observed. At higher ionic strength (150 mM), no significant pH influence on adsorption was observed. QCM could be used as a reliable technique to study the binding of proteins to silicone oil coated surfaces.