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Suitability and quality of packaging materials for drugs
1.
Suitability and Quality of Packaging Materials for Drugs & Biologicals Dr. Bhaswat S. Chakraborty Sr. Vice President, Research & Development, Cadila Pharmaceuticals Ltd., Ahmedabad Good packaging system is an integral part of an effective, safe and quality medicine. It is not merely a good dressing to create an attractive market image of the product. A packaging system or container closure system is a technical name for all those packaging components that contain, protect and maintain the quality of such a medicine (drug, biological or vaccine). Such a system includes primary packaging components and sometimes secondary components as well, when additional protection or other purposes are to be served. Glass and plastics are often used as the material in the primary packaging of bottles, ampoules, vials, pre‐filled syringes etc., whereas cardboard paper is extensively used in the secondary packaging. In addition, a market package contain labeling, dispensing accessories and wraps, and this entire market package is the one that a retail consumer receives. This article briefly summarizes the Suitability and Quality Control guidelines for Packaging Materials mainly based on USFDA suggestions. Figure 1: Factors governing the suitability and quality control of the container closure system (also known as packaging system) used in an NDA, ANDA or BLA. Regulatory agencies would require the sponsor of the New Drug or Biologics application to provide full description of the container and closure system and its compatibility with the drug and excipients. Each system must be specific for the drug or biologic for which it has been designed. Figure 1 depicts the factors governing the suitability and quality control of the packaging system used in an application. The quality and quantity of information also depend on route of administration of the dosage form and the likelihood of its interaction with packaging components. For example, information of an inhalation product packaging has to be more elaborate than that of oral solution or tablet (Figure 2).
2.
Suitability of Packaging System for Intended Use Needless to say, a packaging system must be suitable for its intended use. Suitability, here, has a specific meaning in that it should adequately protect the dosage form, be compatible with the latter and Figure 2: Examples of packaging concerns for common classes of drug products (adapted from US FDA guidance). The higher the concerns and the likelihood of interaction of packaging material and dosage form, more elaborate information would be required by the regulators. be composed of materials that are safe for use with the dosage form and the route of administration. In addition, if it has a performance feature in addition to containing the product, the composite container closure system must function properly. Detailed description of the tests, methods, acceptance criteria, reference standards, and validation information for the studies should be provided directly in the application or indirectly through a DMF. Protection: Packaging system must provide adequate protection from exposure to light, loss of solvent, exposure to reactive gases (e.g., oxygen), absorption of water vapor, microbial contamination or any other contamination. Not all products would be affected by all these factors. Well designed laboratory studies can determine which factors are actually affecting a particular drug product. There are standard ways of achieving protection from the factors listed above. For example, protection from light is achieved by using an opaque or amber‐colored Container. Loss of solvent can be avoided by sealing the leaks or using a less permeable barrier. Similarly, absorption of water vapor can be stopped by using proper glass containers with effective sealing. Protection from microbial contamination can be achieved by maintaining container integrity after the packaging system has been sealed. There are also innovative and emerging technologies that can be used to give an adequate and measurable protection by packaging of the drug products.
3.
All tests for assuring protection must be well designed and completely validated. Compatibility: Sometimes a packaging component can interact with the drug product (drug or excipient). Examples of such interactions include degradation of the active drug induced by a chemical leaching from the packaging component or reduction in the concentration of the excipients because of absorption. Changes in drug product pH, discoloration of dosage form or the packaging component brittleness of the latter due to such interaction constitute some other examples. Qualification studies on the container closure system can detect some of these interactions. In order to detect other interactions one must carry out suitable stability indicating assays. Any change that is indicative of an interaction between the dosage form and packaging component should be investigated such that its root cause is identified, corrected and documented. Safety: The materials used in packaging system and its components must be such that they will not exude or leach any toxic or undesirable substances that will cause an adverse reaction in patients who are being treated with the drug product. This is especially true for those components which are in direct contact with the dosage form or may diffuse into the dosage form such as an ink or an adhesive. As depicted in Figure 2, the safety concerns (because of interaction between dosage form and packaging) may increase the depending on the route of administration. Therefore, good amount of experimentations along with knowledge from literature must be used to minimize the safety risks. For an injection, inhalation, ophthalmic, or transdermal, a comprehensive safety study is appropriate. An extraction study on the packaging component determining the concentrations of the chemicals leaching out of the packing component must be followed by a toxicological evaluation of those chemicals. The toxicological evaluation of the chemicals posing safety risks are based on standard scientific principles that take in to account a packaging component, the drug product, the route of administration and chronic or acute exposure. For many injectable and ophthalmic drug products, data from the USP Biological Reactivity Tests and USP Elastomeric Closures for Injections provide sufficient evidence of material safety. In USA, materials used for packaging components in containing many solid and liquid oral products, can be tested using food additive regulations (21 CFR 174‐186). These regulations include purity criteria and limitations pertaining to the use of specific materials for packaging foods that may be acceptable for the evaluation of drug product packaging components. Performance: A container closure system should be able to function in a manner for which it is intended to. It does more than simply containing the dosage form. When evaluating its performance, its functionality and drug delivery — both are considered. Container closure system functionality may improve patient compliance (e.g., a cap that contains a counter), minimize waste (e.g., a two‐chamber vial or IV bag) or improve ease of use (e.g., a Pre‐filled syringe). Drug delivery is the performance of a packaging system to deliver the dosage form in the amount or at the rate described in the package insert. A prefilled syringe, a transdermal patch or a metered tube is an example of such delivery performance.
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Additional performance of the packaging material may have to withstand the rigors of loading, shipping and storing. Quality Control of Packaging Components Suitability for intended use of the packaging material must be complemented with appropriate use of quality control measures to assure its standard and consistency in all batches of production of the dosage form. These will limit the variation in specification of manufacturing procedures and raw materials for packaging construct. Table 1 summarizes principal physicochemical considerations applied in the quality control of pharmaceutical packaging systems. Table 1 : Quality control of packaging components based on physical characterization and chemical composition Physical characteristics Chemical composition Dimensional criteria Change in formulation Physical parameters for consistent manufacturing Change in processing aid Performance characteristics
Change in the manufacturing process Other parameters Change in supplier of raw materials Among the physical characteristics, dimensional criteria include control of shape, neck finish, wall thickness, design tolerances, etc., whereas manufacturing parameters of a packaging component indicate consistency in unit and weight, etc. Performance characteristics, on the other hand, is exemplified by metering a valve delivery or ease of a syringe movement. Variations in dimensional parameter may affect package permeability and drug delivery performance. Variation in physical manufacturing parameter can affect the quality of a dosage form. The chemical composition of the material that has been used to construct the packaging can affect safety, compatibility and performance of the drug product. New or unknown materials can interact with the drug or excipinets or change the flow properties of the formulation. A composition change may be a result of a change in formulation, in a processing aid or because of a new supplier of raw materials. The use of stability indicating assays and stability studies with pre‐defined specifications to preserve chemical compositions are the key to a successful quality control program. These programs definitely ensure protection and performance of the packaging system. Except for inhalation products, however, right now there is no regulation for strict monitoring of packaging system to ensure safety. In most of the pharmaceutical companies, packaging inspection is part of quality control. These days, this function is as much automated as possible. However, in the physical and chemical checks, there are still areas which are best done manually with bare human senses with adequate training. Conclusion Modern packaging systems for drug and biological products are well suited for their intended use. They not only give protection to the contents, they are also reliably safe, compatible with the drug and
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excipents. Packaging components perform up to the functional standard specified in their intended use and also deliver the dosage form in the amount or at the rate described in the package insert. Quality control of the packaging materials including the raw chemicals to construct these materials is carried out to maintain consistency in both physical characters and chemical composition.
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