1 Development of molecular adsorption processes for the removal of genotoxic impurities from active pharmaceutical ingredients Mariana Duarte de Pina Instituto Superior Técnico, Universidade de Lisboa Avenida Rovisco Pais, 1049-001 Lisboa, Portugal Abstract: Most of the drugs available in the market are synthesized using highly reactive molecules. These molecules may be present in the final API as impurities, that may be genotoxic or carcinogenic. The risk for patient’s health caused by these impurities has become an increasing concern of pharmaceutical companies and regulatory authorities. A broad range of unrelated chemicals from very different chemical families have been categorized as genotoxic. These compounds have the ability to react with DNA, preventing its normal replication, resulting in an associated carcinogenic risk. Although it is desirable to avoid the use of GTIs in the manufacture of APIs, this is not always possible, since these compounds are synthetically useful. It is fundamental to produce APIs with low GTI content, controlled below the Threshold of Toxicological Concern (TTC) established by regulatory authorities (1,5 μg/day). So, it is necessary to find simple, robust and economical routes to remove GTIs from APIs. During the development of this thesis, conventional purification techniques (recrystallization, ionic exchange resins and adsorbents), as well as emergent techniques (nanofiltration, molecularly imprinted polymers (MIPs)) were studied. The results achieved suggest that recrystallization is not a cost-effective process. In that sense, it is necessary to find new ways to increase its yield. Using ionic exchange resins and MIPs, it is possible to make recrystallization a viable process for the pharmaceutical industry. Keywords: Genotoxic impurity, purification, recrystallization, molecular imprinting 1. Introduction Carcinogenesis includes three stages: initiation, promotion and progression. Usually, mutational events are involved in the initiation stage; these events are usually corrected almost immediately by DNA repairing mechanisms. Yet, sometimes these mechanisms fail to repair the DNA and the mutated cells start to proliferate – promotion state. Then, the cells undergo differentiation, creating new genes. After differentiation, the mutated cells transported by the bloodstream invade healthy tissues; this process in known as metastasis and occurs in the progression stage 1a,1b . Mutagenicity is the capacity to induce transmissible genetic damage, including gene mutations or chromosomal aberrations. The term genotoxicity refers to all genetic damage, including genetic alterations that may result in mutations, which are not transmitted to daughter cells 2 . Genotoxic compounds attack the nucleophilic centers of the DNA, which can lead to strand breaks. The nucleophilic centers of DNA are the nitrogen and oxygen atoms of pyrimidine and purine bases and the phosphodiester backbone 1a,2a,3 . The stereospecificity of the reaction depends on the chemical nature of the genotoxic compound, steric factors and nucleophilicity; the most nucleophilic sites of the DNA bases are endocyclic nitrogens; on the contrary, exocyclic oxygens are the less nucleophilic 4 . Chemical
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Development of molecular adsorption processes for the removal of genotoxic
impurities from active pharmaceutical ingredients
Mariana Duarte de Pina
Instituto Superior Técnico, Universidade de Lisboa
Avenida Rovisco Pais, 1049-001 Lisboa, Portugal
Abstract: Most of the drugs available in the market are synthesized using highly reactive
molecules. These molecules may be present in the final API as impurities, that may be genotoxic or
carcinogenic. The risk for patient’s health caused by these impurities has become an increasing
concern of pharmaceutical companies and regulatory authorities. A broad range of unrelated
chemicals from very different chemical families have been categorized as genotoxic. These
compounds have the ability to react with DNA, preventing its normal replication, resulting in an
associated carcinogenic risk. Although it is desirable to avoid the use of GTIs in the manufacture of
APIs, this is not always possible, since these compounds are synthetically useful. It is fundamental to
produce APIs with low GTI content, controlled below the Threshold of Toxicological Concern (TTC)
established by regulatory authorities (1,5 µg/day). So, it is necessary to find simple, robust and
economical routes to remove GTIs from APIs. During the development of this thesis, conventional
purification techniques (recrystallization, ionic exchange resins and adsorbents), as well as emergent
techniques (nanofiltration, molecularly imprinted polymers (MIPs)) were studied. The results achieved
suggest that recrystallization is not a cost-effective process. In that sense, it is necessary to find new
ways to increase its yield. Using ionic exchange resins and MIPs, it is possible to make
recrystallization a viable process for the pharmaceutical industry.
increasing of time until the equilibrium. 5 minutes is
enough to reach equilibrium.
3.3.2. DMAP in water and MeOH (1:1)
When MeOH is added to the solution, the
binding capacity of the resins lowers, especially
with activated charcoal (60%). AG 50W-X2,
Amberlite IRC50 and Amberlite IRC86 were able to
remove 97%, 92% and 95% of DMAP, respectively.
Activated charcoal is able to adsorb MeOH, which
explains the decrease of the amount of DMAP
adsorbed by charcoal. It was also observed that the
amount of DMAP adsorbed when the pH of solution
is high (12,94) decreases abruptly. Possibly, ionic
species are formed and these species compete with
DMAP to bind to resins. The temperature influenced
the adsorption process, which may be due to the
fact that the temperature changes the equilibrium
constants. After determining the adsorption
isotherms, it was observed that the Sips model was
the best fit. The kinetic studies were performed with
AG 50W-X2. The adsorption capacity of the resin
increases rapidly with increasing of time until the
equilibrium. 1 minute is enough to reach
equilibrium.
3.3.3. DMAP in MeOH
When MeOH is the only solvent, the quantity of
DMAP adsorbed lowers. AG 50W-X2, Amberlite
IRC50 and Amberlite IRC86 removed 90%, 66%
and 64% of DMAP, respectively. Activated charcoal
only removed 17% of DMAP; as stated before, this
may be due to the fact that this adsorbent is able to
adsorb MeOH. Once again, it was observed that at
highest pH value (12,05), the DMAP adsorbed
decreases substantially, which suggests the
formation of ionic species competing with DMAP to
bind to the resins. It was also observed that
temperature does not affect the adsorption process.
The Freundlich isotherm is the best fit for the
adsorption isotherm obtained for AG 50W-X2 and
Amberlite IRC86, while Sips isotherm describes
more properly the adsorption of Amberlite IRC50.
Once again, the adsorption capacity of AG 50W-X2
increases rapidly over time, but in this case, 2 hours
were necessary to reach equilibrium.
Using AG 50W-X2, it is possible to purify the
mother liquor from recrystallization 1; a solution with
29,28 mgDMAP/gMeta was obtained. Since this ratio is
lower than 100, this solution could be fed again to
the recrystallization process.
3.4. OSN
This study was based on a theoretical model.
The data used was based on information available
from the membrane GMT-oNF-2, which shows a
good stability in DCM. This membrane retains Meta
effectively (99,1%), while DMAP can cross the
membrane easily (16,5%).
Figure 4 – GTI removal and API losses using OSN.
0,00
20,00
40,00
60,00
80,00
100,00
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14% o
f G
TI r
emo
val a
nd
AP
I lo
sses
Dilution ratio
Remoção de GTI Perdas de API
20% API losses
95% GTI removal
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OSN is very effective in the removal of DMAP.
GTI removals superior to 95% can be achieved at
the cost of only 2,69% Meta loss at diavolume 3. It
is possible to lower the ratio from 100 mgDMAP/gMeta
to 0,16 mgDMAP/gMeta at diavolume 6. However, the
higher the number of diavolumes, the higher the
API loss and solvent consumption and operation
time. It is possible to use a lower number of
diavolumes and then feed the mother liquor back to
the process and use MIPs to purify the API retained
in the membrane. For that purpose, it is possible to
dissolve the retained compounds in DCM and put
the solution in contact with MIP4 in order to remove
DMAP from the solution. Using this approach it is
possible to lower the ratio from 100 mgDMAP/gMeta to
0,33 mgDMAP/gMeta at diavolume 2 if an additional
step of MIPs adsorption is performed.
3.5. MPTS mitigation
3.5.1. MPTS in MeOH
The same studies as described above for
DMAP were performed with solutions of MPTS in
MeOH. Only Amberlite IRA68, whose functional
group is a tertiary amine, was able to remove MPTS
(96%). The amount of MPTS adsorbed increases
slightly with the increase of temperature, but it is not
significant. The adsorption isotherm may be
described by the Langmuir isotherm, which
describes the formation of monolayers. The
adsorption capacity of Amberlite IRA68 increases
slowly with time being necessary 24 hours to reach
equilibrium.
4. Conclusions
It was not possible to reduce the GTI in API
post reaction streams to levels below the
recommend TTC value using recrystallization. This
process shows a high API loss without
compensation in the API purity achieved, therefore
this process is not cost effective. Since this is the
purification process approved in the manufacture of
APIs, it is necessary to find alternatives to increase
the recrystallization yield. Ionic exchange resins
may be used to purify Meta lost in the mother
liquors, while MIPs are a good alternative to replace
charcoal in the adsorption step.
OSN is another purification process that can be
used instead of recrystallization. OSN requires 6
diavolumes to remove 99,85% of the GTI with
acceptable API losses (5,28%). Adding a step of
MIPs adsorption, only two diavolumes are required
to obtain a solution with 0,33 mgDMAP/gMeta.
MPTS can be removed from solution using ionic
exchange resins and adsorbents. Amberlite IRA68
is very efficient in the removal of MPTS.
5. Acknowledgements
FCT – Fundação para a Ciência e Tecnologia for
funding through the project PTDC/QEQ-
PRS/2757/2012, “Removal of Genotoxic Impurities
from Active Pharmaceutical Ingredients”, and
Hovione for supply of API used. To IST, FFUL and
FCT-UNL team members that participated in this
project.
6. References
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