Use of a soft sensor for the fast estimation of dried cake resistance during a freeze-drying cycle

This paper deals with the determination of dried cake resistance in a freeze-drying process using the Smart Soft Sensor, a process analytical technology recently proposed by the authors to monitor the primary drying stage of a freeze-drying process. This sensor uses the measurement of product temperature, a mathematical model of the process, and the Kalman filter algorithm to estimate the residual amount of ice in the vial as a function of time, as well as the coefficient of heat transfer between the shelf and the product and the resistance of the dried cake to vapor flow. It does not require expensive (additional) hardware in a freeze-dryer, provided that thermocouples are available. At first, the effect of the insertion of the thermocouple in a vial on the structure of the product is investigated by means of experimental tests, comparing both sublimation rate and cake structure in vials with and without thermocouple. This is required to assess that the temperature measured by the thermocouple is the same of the product in the non-monitored vials, at least in a non-GMP environment, or when controlled nucleation methods are used. Then, results about cake resistance obtained in an extended experimental campaign with aqueous solutions containing different excipients (sucrose, mannitol and polyvinylpyrrolidone), processed in various operating conditions, are presented, with the goal to point out the accuracy of the proposed methodology.