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Luennot helmikuu 2006 Helsingin Yliopisto, Farmasian tiedekunta, teknologia, lääkevalmisteblokki. FaT Marja Ritala
Tuotekehityksen vaiheet
Product development? Drug development? Technical development? Pharmaceutical development? Drug delivery technology? Chemistry and manufacturing?
M. Ritala 2006
Tuotekehityksen vaiheet
Drug Development Process PROOF OF CONCEPT
SAFETY AND EFFICACY
Tuotekehityksen vaiheet
Contents (1)
DISCOVERY
PRE-CLINICAL
CLINICAL CLINICAL PHASE I PHASE II
CLINICAL PHASE III
PHASE IV
PHARMACEUTICAL DEVELOPMENT
MAINTENANCE
IND
NDA
Definitions Trends in the pharmaceutical industry Processes Preformulation Formulation Analytical development Specifications, quality Choice of manufacture Stability
MA, LAUNCH
PRODUCT LIFE CYCLE MANAGEMENT M. Ritala 2006
M. Ritala 2006
Tuotekehityksen vaiheet
Contents (2)
Biostudies New chemical entities Life cycle management of products Generic drug substances and products Marketing authorisation applications Case studies of formulation and life cycle management Skilled people needed Pharmaceutical development in the future
Trends in the Pharmaceutical Industry
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Trends in the Pharmaceutical Industry (1)
Trends in the Pharmaceutical Industry (2)
Market growth Mega mergers Consolidation Networking (emerging technologies) Biotechnology in addition to chemistry Cost containment of healthcare R&D productivity challenge
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Fully integrated pharmaceutical companies Virtually integrated pharmaceutical companies Outsourcing strategic partnerships contract services Networking Spin-offs Intensive life-cycle management
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Drug Development Process PROOF OF CONCEPT
Processes
DISCOVERY
SAFETY AND EFFICACY
PRE-CLINICAL
CLINICAL CLINICAL PHASE I PHASE II
CLINICAL PHASE III
PHASE IV
PHARMACEUTICAL DEVELOPMENT
IND
MAINTENANCE
NDA
MA, LAUNCH
PRODUCT LIFE CYCLE MANAGEMENT M. Ritala 2006
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Drug Development Process
Tuotekehityksen vaiheet
Development data brings new information to the pharmaceutical development DISCOVERY
DISCOVERY
PRE-CLINICAL
PRE-CLINICAL PHASE I
Pharmceutical development
PHASE I
P II
PHASE III
P II
IND DRUG SUBSTANCE FORMULATION
NDA
PHARMACOKINETICS IN HUMANS AND DOSING
MA, LAUNCH
INDUSTRIMFR PROCESS DEVELOPMENT ALISATION
PRODUCT MAINTENANCE
PRE-CLINICAL ADME, PHARMACOLOGY TOX PROFILE
ANALYTICAL DEVELOPMENT STABILITY
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PHASE III
PHASE IV
PRIMARY STABILITY
FOLLOWUP STAB.
MOLECULAR PROPERTIES
COMMERCIAL PRODUCT STRENGTH(S)
PHASE IV LIFE CYCLE MANAGEMENT AND BRAND DEVELOPMENT
TO BE USED FOR: - DRUG SUBSTANCE DEVELOPMENT - ANALYTICAL DEVELOPMENT - ADMINISTRATION ROUTE SELECTION - DOSAGE FORM SELECTION AND DESIGN - UNIT DOSES AND DOSING - ETC.
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Main Processes in Pharmaceutical Development
Drug substance development Preformulation Formulation Development of Specifications Analytical methods development Stability studies
Manufacturing process development Industrialisation Process validation Documentation of data Project planning and management
Drug substance development
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Drug substance development
A robust synthesis process with consistent batch-to-batch quality Selection of salt Analytical methodology Mastering the physical properties like particle size and polymorphism Stability Scaling up and technlogy transfer Documentation
Preformulation
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Preformulation
Solubility (aqueous, pKa, log P, log D) Molecular optimization (salt, hydrate, solvate, new analogs,…) Crystal Engineering (polymorph, habit, size, surface characteristics…) Crystal structure determination Biopharmaceutical classification (BCS) (solubility, dissolution, absorption) Drug stability evaluation (physical, chemical, solution phase, solid phase, …) Compatibility analyses (drug substance, excipient, packaging materials)
Formulation
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Formulation
Composition + process = formulation Product design Formulation determines how the drug is delivered A good composition
is simple, but innovativeness may be needed utilises standard compendial excipients easy to manufacture good stability facilitates straightforward analytics protects the product against generic competition
Formulation work is based on information gained through preformulation and biostudies Laboratory scale work The guidelines of authorities give a roadmap
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Formulation work is based on science
molecule properties physiology, biology delivery technology
The consumer needs are identified Target product profile is defined There is a clear view of the indication and target population There is an understanding of administration route, dose and dosage form
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Oral controlled release
Biovail, Elan, Alza (JJ), Skye Pharma, Cardinal Health...
Transdermal delivery
Altea, Alza (JJ), 3M...
Respiratory delivery
Nectar (Inhale), Biovail, Elan, Skye Pharma...
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Commercialised drug delivery technologies today
Oral controlled release Transdermal Implants Quick dissolve Single isomers Liposomes
$$$$$$ $$$$$ $$$$ $$$ $$ $
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Drug delivery companies and technologies
Underpinning science must be sound Uniqueness it solves a problem can be patented creates cost advantage can be used as an asset when forming exclusive partnerships Technology can be validated
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Characteristics of a sound innovation
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Prerequisites of a successful formulation :
Tuotekehityksen vaiheet
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The largest drug delivery products of the 1990’s Drug
Developer
Peak sales
Marketer
Procardia XL
Alza
1,250 Mill.$
Pfizer
Duragesic
Alza
1,200 Mill.$
Johnson & Johnson
Lupron
Tap
1,100 Mill.$
TAP
Cardizem SR/CD Elan
1,000 Mill.$
Hoechst
Nicotine Patch
Several developers
800 Mill.$
Novartis
Nitro Dur
Key
600 Mill.$
Schering Plough
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Procardia XL: A pharmaceutical company's dream scenario
Technology selection criteria
Instead of suffering a monumental loss when an important drug goes off patent, the company launches a new, vastly improved version that eclipses both the original drug and its generic competition. That's exactly what Pfizer did when it partnered with ALZA to develop Procardia XL®, which incorporates ALZA's OROS® osmotic technology.
ALZA's technology gave Procardia XL® several major advantages over Pfizer's original product, Procardia®, and generic nifedipine. As a result, the label indication for Procardia XL® was expanded to include treatment of both angina and hypertension. In Finland marketed under name Adalat Oros
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Scientific understanding Similarity of compounds or problems addressed Realistic assessment of success Stage of development Freedom to operate (drug type, therapeutic area) Manufacturing capability Scope for intellectual property Development timescale Costs Predicted sales and profitability
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Why analyse products during development? Analytical development
Formulations are often fine-tuned after analysing concentrations of the drug and it’s metabolites in blood or target organ Stability study results determine the shelf-life Validated analysis methods are used to control and assure the quality of the drug
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Analytical development
HPLC, TLC, IR, NIR, UV, GC, MS, CE... are the methods to analyse
Assay of drug substance Degradation profile Identification Content uniformity Dissolution Organic volatile impurities
Specifications and quality
The methods are validated in regard to accuracy, sensitivity, robustness, selectivity...
according to ICH
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A typical specification for a tablet formulation (1)
A typical specification for a tablet formulation (2)
Appearance: White film coated tablet, scored on both sides, engraving MR1 on one side Identification: HPLC: same as active standard solution TLC: same spot and Rf as active standard solution Mean weight: target mg±5%. Uniformity of mass: 90% of tablets between mean weight found ±5%. 100% of tablets between mean weight found±10%. Water content (KF): ≤2% Disintegration: water, <30 minutes Hardness: 140-160 N
Dissolution: 30 min Q>80% Assay (HPLC): Active substance 95-105% Chromatographic purity:
Microbiological quality*: total aerobic bacteria≤10² moulds per gram or ml. Absence of E. Coli
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Known individual impurity ≤0,3% Unknown individual impurities ≤0,1% Total impurities ≤1%
*) the parameter is controlled once every 10 batches or at least once a year
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Choise of manufacture
Choice of manufacture
Make, byu or outsource? Europe, U.S., China or India? Investment on new buildings, new machinery? Calculations on volumes and costs
batch sizes? cost of goods? sourcing strategy?
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Manufacturing process development in different scales •Screening studies for identification of critical control parameters (CCPs)
•Update of CCPs
• FMEA
• Use of database
• Use of database
•Quality team meetings
• Optimisation study
• Update of FMEA
•Quality team meetings
Laboratory scale
Process development/Deliverables
Pre-pilot scale
Pilot scale
Process Validation & Production Commercial manufacture scale
Product eval. mtg 1 M. Ritala 2006
Product eval. mtg 2
Product eval. mtg 3
Product eval. mtg 4
Product eval. mtg 5
Quality targets and metrics specified for the product and manufacturing process Limits set for critical process control parameters Risk analyses (FMEA, statistical predictions) Process database system established to be used during commercial manufacture Finalised master formula Fine tuning of product specifications
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Common Tools for Successful Drug Development Work
Portfolio management Project management Scientific networks Knowledge management Information mgmt systems Well described processes Balanced Scorecard
Target Product Profile Drug Product Concept Statistical methods Optimisation methods Risk assessment and management Failure modes and effects analysis Six sigma
Stability
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Shelf-life of a product
Shelf-life is the period during which drug product conforms to a given set of specifications Based on the results of stability studies Proposed and justified in regulatory documentation 12 month data from three batches required at the time of submission (NCE’s) 6 month data from two batches required for generic products Storage conditions to be studied:
Biostudies
25˚C, 60% RH 40˚C, 75% RH 30˚C, 60% RH
Usually enough data gathered at the time of approval for a shelf-life of 24 months
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Biostudies
Give important feedback for the formulators of
dosage form selection and design selection of strengths in vivo-in vitro correlation bioequivalence of generic products
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Bioanalytics and pharmacokinetics Analysis of the drug and its metabolites from body fluids, tissues and excretions. ADME: A = absorption D = distribution M = metabolism E = excretion
Drug concentration in plasma 100 Concentration, µg/ml
0.25 mg/kg/day 2.5 mg/kg/day
10
2.5 mg/kg/day
1 0,1 0.01 0
1
3
6 Time, h
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Drug Development Process DISCOVERY
New chemical entities
PRE-CLINICAL
Pharmceutical development
PHASE I
P II
PHASE III
PHASE IV
DRUG SUBSTANCE NDA
FORMULATION MFR PROCESS DEVELOPMENT
LAUNCH
INDUSTRIALISATION
PRODUCT MAINTENANCE
ANALYTICAL DEVELOPMENT STABILITY
PRIMARY STABILITY
FOLLOWUP STAB.
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Tuotekehityksen vaiheet
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Keys to success with NCE’s in the pharmaceutical industry
New chemical entities
how long from discovery to market? what does it cost? Who is financing it? is there a medical need? indications? target population? ...and risks?
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High quality basic and biomedical research Sufficient R&D funding Experience in drug development resulting in proprietary medicines Sufficient number of skilled people Networking and collaboration Becoming international, global strategies
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Generic drug substances and drug products Generic drug substances and drug products
patents expiring how fast and how cheap can one do it? life cycle management using technological innovations Keys to success:
be fast, be there when the patent expires have several products on the market and under development
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Marketing authorisation applications Marketing authorisation applications
FDA: NDA and ANDA EU: centralised and mutual regocnition procedures JAPAN Applications are written in CTD-formats
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Case 1: Development and life cycle management of Clarityn® (1)
Clarityn from Schering Plough Inc. Originator of loratadin The largest allergy product? First pass metabolism over 50% Generic competition begun in 2001-02 well before that Schering Plough made an agreement with a drug delivery company R.P. Scherer (now Cardinal Health) of developing a new formulatoin which could be patented.
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Clarityn-S® (Claritin Reditabs) was developed
Freeze-drying technology, called Zydis ®, was used in Clarityn-S ® Zydis ® technology is wery well protected by patents owned by Cardinal Health Ltd, UK. readily dissolving in the mouth can be taken without water ”speed of melting does not affect speed of relief”. is generic to Clarityn
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Case 1: Life cycle management of Clarityn® (3)
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Case 1: Life cycle management of Clarityn® (2)
Clarityn-S was registred in Finland already 1995 generic, but in Finland not exchengeable, because of different dosage form
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Case 1: Life cycle management of Clarityn® (4)
Composition of Clarityn 10 mg tablet
Loratadine Lactose Maize starch Magnesium stearate
Stability 3 years
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Composition of ClaritynS 10 mg tablet, freeze dried Loratadin Gelatin Citric acid Mannitol Peppermint aroma
Stability 2y, after opening the foil: 6 months
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Case 1: Life cycle management of Clarityn® (5)
Case 1: Life cycle management of Clarityn® (6)
Generic competition in Finland, prices 1.2.2006 and 1.1.2004 (10 mg, 30 tabs)
Loratadin Durascan Geklimon Gea Loratadin Alpharma Loratadin Generics Tuulix, Verman Loratadin ratiopharm Loratadin Biochemie Loratadin Copyfarm Loratadin Hexal Clarityn, Schering Plough Clarityn-S
3.97 € not mark. 4.75 € 4.98 € 4.74 € 5.88 € not mark. 5.89 € 5.89 € not mark. 16.65 €
(4.26 €) (4.58 €) (4.58 €) (4.68 €) (4.98 €) (6.37 €) (7.34 €) not mark. not mark. (15.17 €)
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Composition of Aerius 5 mg tablet, film-coated
Desloratadine is the active metabolite of loratadine Aerius® tablet containing 5 mg of desloratadine was approved by EMEA in January 2001 Well absorbed, no first pass metabolism Suspects of hepatic toxicity have been reported
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Case 1: Life cycle management of Clarityn® (7)
The next step in life cycle management was desloratadine
Desloratadin Gelatin Mannitol Aspartame Polacrilin potassium Dye Opatint Red (red iron oxide, hypromellose) Flavour Tutti-Frutti Citric acid
Case 2: development of a generic product, simvastatin (1)
Originator MSD, ZOCOR 10mg and 20mg tablets Molecule patent expired in 2003 Price in Jan. 06: 46.61 € (20 mg, 98 tabl)
Price in Jan. 04 : 163.54 €
First generic approvals in Finland 2001 12 generic products on the market in Finland in Jan. 06 Cheapest generic price 9.90 €
Stability 2years
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21.42 € in Jan. 05 45.89 € in Jan. 04
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Case 2: development of a generic product, simvastatin (2)
Composition of Zocor 20 mg
Simvastatin* Butylhydroxyanisol* Ascorbic acid* Citric acid* Microcrystalline cellulose* Pregelatinised starch* Lactose* Magnesium stearate* Hypromellose* HPMC Titanium dioxide*, Yellow and Red iron oxide
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Generic competition...
Composition of Simvastatin Alternova 20 mg
Tuotekehityksen vaiheet
all ingredients marked * and Propylene glycol
Marketing authorisation in 2003 Their application probably consisted of a few trial batches in pilot scale, stability studies and a biostudy, where the bioequivalence criteria with Zocor was met. M. Ritala 2006
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Case 3: Concerta depottablets (1)
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Oros-technology from Alza
Concerta® (methylphenidate HCl) CII oncedaily extended-release tablet for the treatment of Attention Deficit Hyperactivity Disorder (ADHD) in patients age six and older. Concerta® uses an advanced OROS® patterned-release delivery system to achieve the desired improvement in symptoms, eliminating the need for in-school and afterschool dosing.
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Methylphenidate plasma concentrations
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Case 3: Concerta depottablets (2)
Composition
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Methylphenidate HCl Butylhydroxytoluen Cellulose acetate Hypromellose Phosphoric acid Poloxamer Polyethylenoxide Povidone Sodium chloride
Stearic acid Black and yellow iron oxide Lactose Titanium oxide Carnauba wax Macrogol 400 Isopropyl alcohol Propylene glycol Purified water
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Case 4: life cycle management of Comtess (entacapone) (1)
Case 4: life cycle management of Comtess (entacapone) (2)
Originator Orion Pharma Approved 1997-8 by FDA and EMEA COMT-inhibitor To be used together with levodopacarbidopa medication (Sinemet) dose of entacapone is always 200 mg, dose of levo-carbi varies depending on the severity of the disease
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Composition of Comtess
Entacapone Microcrystalline cellulose Mannitol* Croscarmellose sodium* Hydrogenated vegetable oil Hypromellose* Polysorbate 80* Glycerol* Sucrose* Magnesium stearate* Red and yellow iron oxide* Titanium oxide*
Three strengths of Stalevo allow individual adjustment and makes the dosing simple Easy to swallow due to small size Stalevo was approved by EMEA and FDA in 2003 The formulation is patented
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Case 4: life cycle management of Comtess (entacapone) (3)
The dose is adjusted individually and taken 28 times/day Stalevo from Orion Pharma contains entacapone, levodopa and carbidopa in one tablet
Composition of Stalevo
Entacapone Levodopa Carbidopa Maize starch Povidone K30 and ingredients marked * in composition of Comtess
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Case 4: life cycle management of Comtess (entacapone) (4)
Comtess 200 mg
stability 3 years price for 100 tablets 123.20 €* price for Sinemet 100 tablets 100/25 mg (Paranova) 34.57 €*
Stalevo 100/25/200 mg
stability 3 years price for 100 tablets 155.34 €*
originator MSD does not market their Sinemet in Finland anymore Sinemet does not have any generic competitors. Extensive formulation patents!
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* price 01.02.2006 in Finland
Tuotekehityksen vaiheet
The products are developed by people Pharmaceutical development relies heavily on individual expertise!
Skilled people are needed...
Continuous support for personal development and scientific training Continuous training of leadership Provide up-to-date tools and facilities Nurture the human resource
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Prerequisites for successful team work
Shared company values Shared goals Clear roles and responsibilities Co-operation Commitment Empowerment Communication
Quality of work Professional skills Leadership Planning and scheduling Feedback Control and reporting
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To run drug development nice and smoothly (1):
decision making:
escape unnecessary regulations
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kill bad projects early enough (bad projects are not necessarily the painful ones) listen to the scientists do not spend too much time trying to find concensus kill a few comittees and meetings open, honest, professionel relationship with the authorities do not overdevelop
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To run drug development nice and smoothly (2):
do POC properly, but be fast
Pharmaceutical development in the future
maximise the molecule
phase I and II a can give invaluable information use miniaturisation and micro dosing where ever you can do life cycle management early enough remember the dosage forms patiens –consumers- like: -transdermal, eye, oromucosal use the opportunities to develop polymorphs, enantiomers and controlled release formulations
watch the NIH syndrome!
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Opportunities for formulators to aid flow of new products through smart drug delivery
Increased emphasis on life cycle management
new, improved products and indications product differentiation
Growing biopharmaceutical market
More new drugs (molecules!) with sub-optimal properties
high throughput screening and synthesis decreased compound attrition
Increased specificity of delivery systems
simple parenterals will not satisfy the market
cellular targeting and programmed release individualised therapies (... but who can afford them?)
Environmental considerations M. Ritala 2006
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Important future technologies in drug delivery
Oral
oral inhalation (insulin!)
Improved macromolecules
Inhaled insulin, Exubera
controlled release improved solubility rapid absorption
Site specific implants Non-invasive protein/peptide delivery
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Fast acting powder formulation of human insulin inhaled by a simple device Developed by Pfizer (and Aventis) and Nektar Therapeutics approved by FDA and EMEA in January 2006 long term pulmonary safety was a concern that delayed the approval for several years
sustained release injectable
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The challenges of drug development have continued to grow Global strategies Virtually integrated companies Increasing R&D expenses and timelines poor productivity? true value creation? Expanding number of technologies challenging the traditional approaches Increasing need to deliver return to investors, partners and customers M. Ritala 2006
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Tuotekehityksen vaiheet
Have a look at... www.
nam.fi emea.eu.int fda.gov duodecim.fi orionpharma.com apteekit.net controlledrelease.org iirusa.com/drugdelivery partnerships
alza.com cardinal.com bdpharma.com nektar.com pharmaprofiles.co.uk ltslohmann.com
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