WO2006084902A2

WO2006084902A2 - Method of purifying a surfactant by ultrafiltration

Info

Publication number: WO2006084902A2
Application number: PCT/EP2006/050856
Authority: WO
Inventors: Constantin Busoi; Maria Rotaru; Bogdan-Mihai Oghina; Mariana Surmeian
Original assignee: Sindan Pharma SRL
Current assignee: Sindan Pharma SRL
Priority date: 2005-02-10
Filing date: 2006-02-10
Publication date: 2006-08-17
Anticipated expiration: 2007-08-10
Also published as: CA2597223A1; WO2006084902A3; AU2006212177A1; WO2006084902A8

Abstract

A method of purifying a surfactant for use in a pharmaceutical formulation, which comprises mixing the surfactant with a solvent and bringing said mixture into contact with a semi-permeable membrane so as to allow impurities present in the surfactant and having a molecular weight lower than the molecular weight cut-off of the membrane to pass through the membrane, whilst retaining the purified surfactant.

Description

Method of purifying a surfactant

Description

The present invention relates to a method of purifying a surfactant. In particular, _the present invention relates to a method of purifying a surfactant for use in a stabinzed liquid pharmaceutical formulation, using a semi-permeable membrane filtration technique.

Poorly water-soluble pharmaceutically active agents can often present challenging formulation issues, especially if such drugs are to be administered in liquid form. Significant difficulties have been encountered, for example, with formulation of the potent antineoplastic agent paclitaxel, which is particularly insoluble in water. The structure of paclitaxel and some of its more important derivatives is shown below.

Taxol^® is a commercially available paclitaxel formulation produced by Bristol- Meyers Squibb Company, 345 Park Avenue, New York, New York, USA 10154-

0037. Taxol contains paclitaxel in combination with a 50:50 mixture of dehydtated ethanol and Cremophor* EL (polyethoxylated castet oil available from BASF Aktiengesellschaft, Carl-Bosch-StraBe 38, 67056 Ludwigshafen, Germany; other designations include European Pharmacopeia, 4^th Edition, 2002: Castor oil, polyoxyl; United States Pharmacopeia - National Formulary: Polyoxyl 35 Castor Oil). Cremophor* EL is a non-ionic surfactant made by reacting castor oil with ethylene oxide in a molar ratio of 1:35. In Taxol*, Cremophor* EL is used as a drug delivery vehicle: after reconstitution for intravenous injection with a suitable fluid, such as physiologically acceptable saline or 5% dextrose solution, it forms large polar micelles to transport and deliver the entrapped drug to the target (see, for example, van Tellingen O. */ */., British Journal of Cancer (1999) 81, 330-335).

Relatively high concentrations of Cremophor* EL are required to compensate for the insolubility of paclitaxel, and some patients have shown allergic reactions when administered such high concentrations of this surfactant. Moreover, certain fatty acid components of Cremophor* EL, particularly ricinoleic acid and octadecanoic acid, can lead to hepatotoxicity. To compound these problems, Cremophor* EL contains impurities which can catalyse the degradation of paclitaxel, the latter being susceptible in particular to mild basic hydrolysis; paclitaxel formulated with a mixture of dehydrated ethanol and commercial grade Cremophor* EL is therefore not sufficiently stable over time and has been shown to exhibit a loss of potency of greater than 60% after storage for 12 weeks at 50⁰C (see, for example, EP 0,645,145). In view of these problems, various methods of purifying commercial grade Cremophor* EL have been investigated.

The main component of Cremophor* EL is glycerol polyethylene glycol ricinoleate, and this forms the hydrophobic part of the product together with fatty acid esters of polyethylene glycol; the smaller hydrophilic part consists of free polyethylene glycols and ethoxylated glycerol. Cremophor* EL forms clear solutions in water, and, in such aqueous solutions, it is stable towards electrolytes, e.g. acids and salts, provided that their concentration is not too high. Cremophor* EL has a molecular weight determined by steam osmometry of approximately 1630 (Fiedler, H. P., Lexicon der Hilfsstoffe fur Pharmazie, Kosmetik angrenzende Gebiete, Editio Cantot, 1989). As paclitaxel is thought to be susceptible to mild basic hydrolysis, some investigations have focused on removing anionic catboxylate impurities in Cremophor^® EL and/or controlling the pH of Cremophor* EL. WO 94/12031, for example, discloses that the stability of a composition comprising paclitaxel,

Cremophor* EL and dehydrated ethanol can be improved by adding an acid to the composition to reduce its pH to the range 1 to 8, preferably 5 to 7. Powdered acids, especially citric acid, are preferred, but other acids such as acetic acid can also be used.

US 5,925,776 discloses the treatment of Cremophor^® EL by heating at around 50 ^*C to remove water, followed by addition of dehydrated alcohol and contact with a strong cationic exchange resin, particularly styrene divinyl benzene resin, which exchanges cations for H⁺ ions. The pH of the solution is thereby reduced to lower than 4.2, and the solution can be used for the preparation of paclitaxel formulations.

WO 00/23070 discloses a method of contacting a solution of Cremophor^® EL and dehydrated ethanol with an activated carbon column, to absorb water and unsaturated aliphatic and aromatic impurities. The solution is then contacted with a mixed bed ion exchange resin column, which replaces anions such as carboxylate anions with OH- and cations such as potassium ions with H⁺. Residual water and ethanol is evaporated off, and the treated Cremophor^® EL is redissolved in dehydrated ethanol and used to prepare a paclitaxel formulation. This formulation is shown to be more stable than one prepared with untreated Cremophor^® EL.

EP 0,645,145 discloses that stabilized paclitaxel formulations can be obtained by adding acid to the Cremophor^® EL used in their preparation, thereby neutralizing the carboxylate anions therein. The acid is preferably a mineral acid. Alternatively, Cremophor^® EL can be contacted with aluminium oxide, for example in a chromatography column, to remove the carboxylate anions.

Other investigations have focused on the addition of a particular stabilising agent to Cremophor^® EL. WO 01/72300, for example, discloses the treatment of Cremophor* EL with a non-toxic metal salt of an acid, such as zinc, coppet or ferrous sulphate or gluconate, by heating them together or by passing the Cremophor* EL through a column containing the salt. Alternatively, chromatography has been used. The chromatographic purification of Cremophor* EL produces a less hepatotoxic drug vehicle (Oliver P. Flint et. ai, 2001 American Society of Clinical Oncology Annual Meeting).

The purified version of Cremophor* EL available from BASF, Cremophor* ELP, was developed for sensitive pharmaceutical ingredients, and has a lower water content, pH and viscosity, and also a reduced potassium ion and free fatty acid content, particularly with regard to ricinoleic, oleic and palmitic acids. Even Cremophor* ELP, however, does not provide an entirely satisfactory stability profile of paclitaxel formulations, and methods for further purifying this surfactant have been studied. For instance, WO 00/32186 discloses that a composition comprising paclitaxel and Cremophor* ELP can be stabilized by addition of an antioxidant such as sodium metabisulfite, sodium sulfite, sodium bisulfite, dextrose, a phenol, a thiophenol, or a combination thereof.

The method described in US 5,925,776 is also disclosed to be applicable to the treatment of Cremophor* ELP. WO 03/103714, however, describes a disadvantage with the use of strong cationic exchange resins, such as those used in US 5,925,776, that this can lead to a partial decomposition of the polyoxyethylated castor oil and an increased amount of free fatty acids. It states that the commercially available Cremophor* ELP has a lower content of basic compounds than Cremophor* EL, but still contains acidic impurities such as fatty acids and oxyethylated forms thereof, polyethyleneglycol diricinoleate and small amounts of corresponding free glycols. It discloses that treatment of Cremophor* ELP with an adsorbent such as silica gel or aluminosilicate can reduce the content of polar and acidic impurities, and paclitaxel formulations prepared with the treated Cremophor* ELP show a significantly lower degree of degradation into products such as 10-deacetylpaclitaxel and 7-epi-paclitaxel. Despite these investigations, the factors influencing the decomposition of paclitaxel are still not fully understood.

AU the above methods involve purification of a surfactant by chemical means, each with their own associated problems. For example, treatment with cationic resins or by addition of acids alters the pH of the surfactant away from physiological pH, which can be a disadvantage especially for injectable formulations. On the other hand, methods involving the addition of stabilizing chemicals carry the risk of introducing further toxic impurities contained in such chemicals. There is therefore a need in the art for a simple, mild but effective method of purifying a surfactant for use in a pharmaceutical formulation, particularly formulations comprising active agents that are sensitive to chemical reaction such as taxanes. The present invention solves this problem by purifying the surfactant using membrane filtration.

Membrane filtration is a technique widely used in the life sciences, most commonly for the separation, purification or concentration of proteins. Depending on membrane type it can be classified as microfiltration (membrane pore size between 0.1 and 10 μm) or ultrafiltration (membrane pore size between 0.001 and 0.1 μm). Ultrafiltration membranes are used for concentrating dissolved molecules (protein, peptides, nucleic acids, carbohydrates, and other biomolecules), desalting or exchanging buffers, and gross fractionation. An ultrafiltration membrane retains molecules that are larger than the pores of the membrane, while smaller molecules such as salts, solvents and water, which are 100% permeable, freely pass through the membrane. There are two main membrane filtration methods: in Single Pass / Dead End / Direct Flow Filtration pFF), the fluid to be filtered is directed perpendicular to the membrane. In Cross Flow / Tangential Flow Filtration (TFF), the fluid flows tangential to the surface of the membrane; TFF solves the problem of membrane clogging by re-circulating the retentate.

In a first aspect of the invention, there is provided a method of purifying a surfactant for use in a pharmaceutical formulation, which comprises mixing the surfactant with a solvent and bringing said mixture into contact with a semipermeable membrane so as to allow impurities present in the surfactant and having a molecular weight lower than the molecular weight cut-off of the membrane to pass through the membrane, whilst retaining purified surfactant.

In a second aspect of the invention, there is provided a purified surfactant obtainable by a method according to the invention in its first aspect.

In a third aspect of the invention, there is provided a solvent system comprising a purified surfactant according to the invention in its second aspect.

In a fourth aspect of the invention, there is provided a stabilized liquid formulation comprising a purified surfactant according to the invention in its second aspect.

In further aspects of the invention, there are provided pharmaceutical formulations comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate, which contain:

- less than 0.1% baccatine III;

- less than 0.1% ethyl ester side chain of paclitaxel;

- less than 0.1% 10-deactyl-paclitaxel;

- less than 0.1% lO-deacetyl-7-epipaclitaxel; and/or - less than 0.2% 7-epipaclitaxel.

In a final aspect of the invention, there is provided a method of purifying a surfactant for use in a pharmaceutical formulation, which comprises forming a colloidal suspension of the surfactant in a solvent and subjecting the suspension to a physical separation technique, so as to remove impurities having a different molecular weight than that of the colloidal surfactant.

Preferred embodiments of the invention in any of its various aspects are as described below or as defined in the sub-claims.

When combined with a solvent, surfactants are capable of self-aggregating into numerous supramolecular structures including monolayers, bilayers and micelles having a wide variety of shapes. Such aggregates tend to exist in equilibrium with monomeric (i.e. non-aggregated) surfactant molecules. Micelles may be formed above a particular concentration of surfactant termed the critical micelle concentration; at this concentration there is a discontinuity in various physical properties such as surface tension, tubidity, molar conductivity and osmotic pressure. The critical micelle concentration can be affected by temperature and the presence of electrolytes; for example, micelles of ionic surfactants may only form above a particular temperature known as the Krafft temperature. Non-ionic surfactant solubility, however, has a temperature limit called the cloud point. These parameters are known for any particular surfactant or can be determined experimentally by known methods.

Micelles of a micellar solution tend to have an aggregation number (i.e. the number of aggregated surfactant molecules) around 20 - 100. In one embodiment of the invention, the surfactant forms micellar aggregates having an average molecular weight higher than the molecular weight cut-off of the membrane, which do not pass through the membrane during the filtration. Impurities present in the surfactant that have a molecular weight lower than the average molecular weight of the surfactant in its aggregated form can be separated by appropriate choice of the molecular weight cut-off of the membrane. The molecular weight of the surfactant in its monomeric form can be higher or lower than the molecular weight cut-off of the membrane. The invention is particularly useful for the removal of impurities having a molecular weight similar to or higher than that of monomeric surfactant, but lower than that of the surfactant micelles.

The solvent is preferably a polar solvent, in particular water. In one embodiment of the invention, the surfactant is mixed with water in a concentration of at least its critical micelle concentration before being subjected to membrane filtration, preferably TFF. The large micelles are retained, whereas smaller impurities in the colloidal suspension pass through the membrane. After the tangential flow filtration, water can be removed from the retentate by distillation at low pressure. Optionally, after the water removal, the surfactant is treated with activated charcoal or an ion exchange resin to reduce the coloration (absorbance at λ = 425 nm) and improve the stability of the resultant pharmaceutical formulation. Preferably, the surfactant is treated with activated catbon with stirring for 30 minutes at room temperature, followed by filtration. Preferably, the surfactant is treated with the ion exchange resin with stirring for 30 minutes at room temperature, followed by filtration.

The surfactant may be of any type including ionic and non-ionic, but is preferably non-ionic. In one embodiment of the invention, the surfactant to be purified is a polyoxyl castor oil such as Cremophor^® EL or ELP. Cremophor* EL or ELP forms large polar micelles in aqueous solutions, which will be retained by the membrane during filtration; the critical micelle concentration is approximately 0.02 %. In contrast, smaller molecules, which can cause degradation of active agents such as paclitaxel, do not form micelles and will pass through the membrane. Such impurities may be ionic species, e.g. carboxylate anions or metal cations, or non- ionic species. The purified surfactant may also have a lower concentration of fatty acids than commercially available Cremophor* ELP.

Suitable conditions for the membrane filtration can be determined by the skilled person. For example, suitable flow rates may be in the range 30 — 100 ml/min, preferably 50 - 80 ml/min in respect of the retentate and 0.5 — 10 ml/min, preferably 0.5 - 5 ml/min, especially preferably 1 — 2 ml/min in respect of the filtrate. The membrane is preferably an ultrafiltration membrane; suitable molecular weight cut-offs may be in the range 2 - 20 kD, preferably 3 - 15 kD, especially preferably 5 — 10 kD. The filtration may be conducted under a pressure of 0.1 — 20 bats.

Although the invention has been described above in relation to the use of a membrane filtration technique, the skilled person will appreciate that similar physical separation techniques such as sucrose gradient centrifugation may be used in the alternative.

A suitable solvent system is needed to solubilise the active agent and ensure stability of the formulation, providing a sufficiently long shelf life. In addition, in the case of injectable formulations, these are often diluted prior to administration with a fluid, and the solvent system must be capable of maintaining the stability of the diluted form.

A potentially useful solvent system for this purpose would be a mixture of a pharmaceutically acceptable polar solvent, such as ethanol, and a surfactant. The surfactant in general acts as a solubiliser or emulsifier in the stabilised liquid formulation. Many useful surfactants are condensation products of an alkylene oxide, such as ethylene oxide, and a fatty acid or fatty alcohol. Polyoxyl castor oils and polysorbates (ethoxylated sorbitan esters), in particular, have been found to be of value in the invention. In appropriate cases, the surfactant may consist of a mixture of surfactant compounds.

The purified surfactants of the invention are particularly suitable for use in a wide range of stabilized liquid formulations comprising lipid-soluble drugs, especially injectable formulations. For instance, Cremophor* EL or ELP purified according to the invention can be used to prepare various solutions of numerous drugs including miconazole, hexedetine, clotrimazole and benzocaine, and also fat-soluble vitamins. Drugs that are particularly susceptible to degradation, such as paclitaxel, docetaxel, teniposide and camptothecin derivatives, are of major interest.

In embodiments of the invention, the pharmaceutical formulations comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate contain: less than 0.06% baccatine III; less than 0.05% ethyl ester side chain of paclitaxel; - less than 0.06% 10-deactyl-paclitaxel; no detectable 10-deacetyl-7-epipaclitaxel; and/or less than 0.16% 7-epipaclitaxel.

The following examples are intended to demonstrate the invention but are not intended to limit the claims in any manner. Example 1

80 g Cremophor^® EL (BASF Aktiengesellschaft) were mixed with 400 g water for injection. The solution obtained was subjected to tangential flow filtration (TFF) using a Minimate^® TFF System fitted with a 5 kD ultrafiltration membrane (Pall Corporation, 2200 Northern Boulevard, East Hills, NY 11548, USA) for 48 hours at room temperature. The filtration pressure was between 2 and 3 bar. A water volume equal to the volume of filtrate was added to the retentate every hour. The total amount of water added to the retentate was approximately 4500 ml. The aqueous solution obtained was distilled at low pressure (500 μbar) on a water bath. 58 g of purified Cremophor^® EL was obtained (Cremophor^® EL-TFF-I).

The Cremophor^® EL-TFF-I was mixed with dehydrated ethanol and paclitaxel to obtain a pharmaceutical formulation (Formulation 1).

Formulation 1:

Example 2

80 g Cremophor^® ELP were mixed with 400 g water for injection. The solution obtained was subjected to TFF using a 5 kD membrane and a Minimate^® TFF System from Pall for 40 hours at room temperature. The filtration pressure was between 2 and 3 bar. A water volume equal to the volume of filtrate was added to the retentate every hour. The total amount of water added to the retentate was approximately 4400 ml. The aqueous solution obtained was distilled at low pressure (500 μbar) on a water bath. 59 g of purified Cremophor^® ELP was obtained (Cremophor^® ELP-TFF-2).

The Cremophor^® ELP-TFF-2 was mixed with dehydrated ethanol and paclitaxel to obtain a pharmaceutical formulation (Formulation 2). Formulation 2:

CpBlPftiative Ef flfflpl? 1

A paclitaxel formulation containing commercial grade Cremophor^® EL and dehydrated ethanol is prepared as follows (Formulation 3):

Formulation 3:

Com innaarraattiivvee E A paclitaxel formulation containing commercial grade Cremophor ®⁰ - ELP and dehydrated ethanol is prepared as follows (Formulation 4):

Formulation 4:

^-^f>πipⁱirfltii^ve Ey^rπplc 3

A paclitaxel formulation containing commercial grade Cremophor® EL, dehydrated ethanol and citric acid is prepared as follows (Formulation 5):

Formulation 5:

Formulations 1 — 4 were subjected to an accelerated degradation study (36 hours at 56 °C) and tested for the presence of the following degradation products: baccatine III, ethyl ester side chain, lO-deacetylpaclitaxel, lO-deacetyl-7-epi-paclitaxel and 7- cpi-paclitaxel. The results are presented in Table 1.

Table 1:

ND = not detected

The stability of Formulation 2 in 0.9 % NaCl perfusable solution (1.2 mg/ml paclitaxel /ml diluted solution) was tested and compared with the stability in the same conditions of the product Taxol* and Formulation 5. The paclitaxel assay was comparable for Formulation 2, Taxol^® and Formulation 5 ^Table 2). The turbidity of the solution prepared with Formulation 2 was lower than the turbidity of the perfusable solutions obtained with Taxol^® and Formulation 5 (Table 3). Table 2:

Table 3:

80 g Cremophor* ELP were mixed with 400 g water for injection. The solution obtained was subjected to TFF using a 10 kD membrane and a Minimate* TFF System from Pall for 30 hours at room temperature. The filtration pressure was between 2 and 3 bar. A water volume equal to the volume of filtrate was added to the retentate every hour. The total amount of water added to the retentate was approximately 3200 ml. The aqueous solution obtained was distilled at low pressure (500 μbar) on a water bath. 70 g of purified Cremophor* ELP was obtained (Cremophor* ELP-TFF-3).

Purified Cremophor* ELP-TFF-3 (15 g) was mixed with dehydrated ethanol and paclitaxel to obtain a pharmaceutical formulation (Formulation 6).

Formulation 6:

Purified Cremophor* ELP-TFF-3 (15 g) was mixed with dehydrated ethanol (1/1 v/v). The solvent mixture was treated with activated carbon (Merck) with stirring for 30 minutes at room temperature, followed by filtration. The charcoal treated solvent was added to paclitaxel to obtain a pharmaceutical formulation (Formulation

T).

Formulation 7:

Purified Cremophor* ELP-TFF-3 (15 g) was mixed with dehydrated ethanol (1/1 v/v). The solvent mixture was treated with the weak cationic exchange resin Purolite Cl 06EP with stirring for 30 minutes at room temperature, followed by filtration. The resin-treated solvent was added to paclitaxel to obtain a pharmaceutical formulation (Formulation 8).

Formulation 8:

Formulations 4 and 6 - 8 were subjected to an accelerated degradation study (7 days at 56 ⁰C) and tested for the presence of the following degradation products: baccatine III, ethyl ester side chain, 10-deacetylpaclitaxel, 10-deacetyl-7-epi- paclitaxel and 7-epi-paclitaxel. The results are presented in Table 4.

Table 4:

ND = Not Detected

The results of the accelerated degradation study at 56 ⁰C and the stability tests in perfusable solutions showed that the polyoxyl castor oil purified according to this invention is suitable for the preparation of stabilized formulations containing paclitaxel.

Claims

1. A method of purifying a surfactant for use in a pharmaceutical formulation, which comprises mixing the surfactant with a solvent and bringing said mixture into contact with a semi-permeable membrane so as to allow impurities present in the surfactant and having a molecular weight lower than the molecular weight cut-off of the membrane to pass through the membrane, whilst retaining purified surfactant.

2. A method as claimed in claim 1, wherein the surfactant forms one or more aggregates in the mixture.

3. A method as claimed in claim 1 or 2, where the surfactant is present in the solvent in the form of a colloidal dispersion or suspension.

4. A method as claimed in any one of the preceding claims, wherein the surfactant is present in the mixture at a concentration of at least its critical micelle concentration.

5. A method as claimed in any one of the preceding claims, wherein the mixture contains surfactant in the form of micelles having an average molecular weight higher than the molecular weight cut-off of the semi-permeable membrane.

6. A method as claimed in claim 5, wherein at least one impurity has a molecular weight that is lower than the average molecular weight of the micelles.

7. A method as claimed in any one of the preceding claims, wherein at least one impurity has a mo&cular weight that is higher than that of the surfactant when the surfactant is not present in admixture with the solvent.

8. A method as claimed in any one of the preceding claims, wherein the surfactant, in the absence of the solvent, has a molecular weight lower than the molecular weight cut-off of the semi-permeable membrane.

9. A method as claimed in any one of the preceding claims, wherein the mixture is an aqueous mixture

10. A method as claimed in claim 9, which further comprises recovering purified surfactant and dehydrating purified surfactant, wherein the dehydrating preferablycomprises distillation of water present in the purified surfactant.

11. A method as claimed in any one of the preceding claims, wherein the surfactant is a non-ionic surfactant.

12. A method as claimed in any one of the preceding claims, wherein the surfactant is derived from a vegetable oil, preferably wherein the surfactant is a polyethoxylated vegetable oil, preferably wherein the surfactant is a condensation product of castor oil and ethylene oxide, preferably wherein the surfactant comprises glycerol polyethylene glycol ricinoleate.

13. A method as claimed in any one of the preceding claims, wherein the semipermeable membrane is an ultra-filtration membrane, preferably having a molecular weight cut-off in the range 2 - 20 kD.

14. A purified surfactant obtainable by a method as claimed in any one of the preceding claims.

15. A solvent system comprising a purified surfactant as claimed in claim 14 and a pharmaceutically acceptable solvent carrier.

16. A stabilized liquid pharmaceutical formulation comprising a solvent system as claimed in claim 15.

17. A pharmaceutical formulation comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate, which contains less than 0.1% baccatine III.

18. A pharmaceutical formulation comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate, which contains less than 0.1% ethyl ester side chain of paclitaxel.

19. A pharmaceutical formulation comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate, which contains less than 0.1% 10-deactyl paclitaxel.

20. A pharmaceutical formulation comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate, which contains less than 0.1% 10-deacetyl-

7-epipaclitaxel.

21. A pharmaceutical formulation comprising paclitaxel, dehydrated alcohol and glycerol polyethylene glycol ricinoleate, which contains less than 0.2% 7- epipaclitaxel.

22. A method of purifying a surfactant for use in a pharmaceutical formulation, which comprises forming a colloidal suspension of the surfactant in a solvent and subjecting the suspension to a physical separation technique, so as to remove impurities having a different molecular weight than that of the colloidal surfactant.