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Moisture mapping using headspace moisture analysis Isobel Cook BSc MRSC Principal Scientist Biopharma Technology Limited – specialists in freeze drying research and development www.btl-solutions.net
Importance of residual moisture ,[object Object],[object Object],[object Object],[object Object],Incorrect drying /moisture too high
Moisture in the freeze dried product ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Sampling product for moisture analysis ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Frequency Modulation Spectroscopy (FMS) ,[object Object],[object Object],[object Object],[object Object],[object Object]
FMS / KF moisture correlation Water can have different association/affinity within the freeze dried material which varies with the formulation For amorphous  sucrose  the intercept is at 1% w/w by KF Indicate moisture retained in cake when none observed in headspace.  This is not unsurprising given the hygroscopicity of sucrose
Moisture mapping for Sucrose  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Shelf front
Moisture mapping for Sucrose ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Shelf front
Vial heat transfer in a freeze dryer Vapour escapes through  gap in stopper Top layer dries first Freeze dryer shelf Heat transfer by direct conduction from the shelf to the vial and product Heat transfer by gaseous convection Heat transfer by  radiation from side  Walls of the freeze  dryer Central vials have greater  shielding from side wall  radiation This observation can be explained by radiation and shielding effects Edge vial effects bigger at lower temperatures
Factors affecting moisture variation ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Samples in a tray Direct shelf contact
FMS and Karl Fischer moisture correlations ,[object Object],Intercept and gradient vary with the formulation based on intrinsic properties of excipients and active
Moisture mapping variations for Mannitol Primary drying conducted at -5°C after annealing, vacuum set at 1000 mTorr ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Significant variation within each sample set Tray samples have a lower standard deviation – slower cooling rate! Similar moisture content – gaseous convection plays a role!
Moisture mapping variations for Mannitol Primary drying at -40°C after annealing, vacuum set at 50 mTorr, shortened secondary drying ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Sample sets have similar moisture content – gaseous convection not a factor Significant variation within each tray
Mannitol – Frozen structure ,[object Object],[object Object],[object Object],Structure reduces impact of heat transfer variation due to shelf contact Gaseous convection not observed as open structure allows for efficient drying Material structure and treatment can have large impact on moisture
Mannitol – further investigations ,[object Object],[object Object],[object Object],[object Object],Further analysis and closer inspection of the KF/FMS correlation revealed a deviation and lack of correlation for some samples This variation appeared to be related to a change in the mannitol form  (observed by comparing FMS data over several days)
Mannitol – FMS ratio variations ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Ratio change= Day 3 / Day 1
Mannitol – FMS ratio variations ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Ratio change= Day 3 / Day 1
Factors affecting moisture variation ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
FMS summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Thank you Any questions? Isobel Cook Principal Scientist BSc MRSC Biopharma Technology Limited – specialists in freeze drying research and development www.btl-solutions.net
Presented during  “Emerging Technologies in Freeze Drying”,  Cambridge, 11 th  May 2011. Event organised by BPS and BTL,  www.biopharma.co.uk   www.btl-solutions.net

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Moisture Mapping of Freeze Dryer

  • 1. Moisture mapping using headspace moisture analysis Isobel Cook BSc MRSC Principal Scientist Biopharma Technology Limited – specialists in freeze drying research and development www.btl-solutions.net
  • 2.
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  • 6. FMS / KF moisture correlation Water can have different association/affinity within the freeze dried material which varies with the formulation For amorphous sucrose the intercept is at 1% w/w by KF Indicate moisture retained in cake when none observed in headspace. This is not unsurprising given the hygroscopicity of sucrose
  • 7.
  • 8.
  • 9. Vial heat transfer in a freeze dryer Vapour escapes through gap in stopper Top layer dries first Freeze dryer shelf Heat transfer by direct conduction from the shelf to the vial and product Heat transfer by gaseous convection Heat transfer by radiation from side Walls of the freeze dryer Central vials have greater shielding from side wall radiation This observation can be explained by radiation and shielding effects Edge vial effects bigger at lower temperatures
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  • 20. Thank you Any questions? Isobel Cook Principal Scientist BSc MRSC Biopharma Technology Limited – specialists in freeze drying research and development www.btl-solutions.net
  • 21. Presented during “Emerging Technologies in Freeze Drying”, Cambridge, 11 th May 2011. Event organised by BPS and BTL, www.biopharma.co.uk www.btl-solutions.net

Editor's Notes

  1. The Tg is the point at which a material can be observed to undergo structural change, this has a direct effect on the
  2. KF total moisture if 100% soluble in solution
  3. Need to take into account variable factors where possible
  4. Frequency 1400nm
  5. Once a material/system has demonstrated a good KF/HSM correlation then the moisture can be mapped for an entire shelf of a freeze dryer.
  6. The plot indicates that vials close to the edge as well as the front or back of the shelf have moisture contents below 2% (w/w), while higher moisture values were recorded in the centre of the tray.
  7. This observation can be explained by radiation and shielding effects; the vials towards the centre of the tray take longer to dry as they receive less radiative heat from the freeze dryer walls/viewing window as they are shielded by the vials around them
  8. -5 drying, sublimation cooling at ~25degC, variation to do drying at temp of crystallisation, though annealing should have done it
  9. Lower temp keep below crystalization temp, though annealing should have done it