Fast freeze-drying cycle design and optimization using a PAT based on the measurement of product temperature

This paper is focused on the use of an innovative Process Analytical Technology for the fast design and optimization of freeze-drying cycles for pharmaceuticals. The tool is based on a soft-sensor, a device that uses the experimental measure of product temperature during freeze-drying, a mathematical model of the process, and the Extended Kalman Filter algorithm to estimate the sublimation flux, the residual amount of ice in the vial, and some model parameters (heat and mass transfer coefficients). The accuracy of the estimations provided by the soft-sensor has been shown using as test case aqueous solutions containing different excipients (sucrose, polyvinylpyrrolidone), processed at various operating conditions, pointing out that the soft-sensor allows a fast estimation of model parameters and product dynamics without involving expensive hardware or time consuming analysis. The possibility of using the soft-sensor to calculate in-line (or off-line) the design space of the primary drying phase is here presented and discussed. Results evidences that by this way, it is possible to identify the values of the heating fluid temperature that maintain product temperature below the limit value, as well as the operating conditions that maximize the sublimation flux. Various experiments have been carried out to test the effectiveness of the proposed approach for a fast design of the cycle, evidencing that drying time can be significantly reduced, without impairing product quality.