version: 6 november, 2015 · web viewcondition it by running 95% water/5% methanol (or whatever...

Distributed Pharmaceutical Analysis Laboratory

Procedures for system suitability and pharmaceutical analysis

November, 2015

Prof. M. Lieberman, Dept of Chemistry and Biochemistry, University of Notre Dame, Notre Dame IN 46556 USA

Contact information: [email protected], +1-574-631-4665

1. Version: 6 November, 2015......................................................................................... 2

2. Caveats................................................................................................................................ 2

3. Limitations of this analytical methodology............................................................3

4. Sample preparation........................................................................................................ 4Sample storage and tracking:........................................................................................................4External standards:........................................................................................................................... 4Pharmaceutical dosage forms:......................................................................................................5

5. Method Validation (copy this form) Analyte:______________.................................7

6. Suggested instrument parameters, solvents, and gradients.............................9a) Column storage, conditioning, and washing......................................................................9b) Amoxicillin and Amoxicillin/clavulanate (or clavulanic acid)...................................10c) Ciprofloxacin............................................................................................................................... 12d) Azithromycin (this procedure is under development/testing by Dil Ramanathan at Kean State University)..............................................................................................................13e) Oxytetracycline (this procedure is under development/testing).............................13

7. Analytical metrics......................................................................................................... 14

8. Sample assay and Quality Control procedures....................................................15

9. HPLC Method (copy this form) Analyte:_______________.....................................16

10. Control Chart (copy this page) Analyte: ______________......................................17

11. Revision History.......................................................................................................... 18

1. Version: 6 November, 2015

2. Caveats

Participants in the DPAL must be aware of some legal issues related to pharmaceutical analysis. We report poor quality drugs to the medical regulatory authority (MRA) in the country where the drugs originated, and also to the WHO Rapid Alert system. Since we are doing single tablet analysis, analytical results must be replicated on several samples before triggering a report to the MRA or WHO. If your laboratory turns up a poor quality product that meets these criteria, Prof. Lieberman will work with you to report to the appropriate authorities. Please preserve such samples carefully; in some cases, we may want to subject the sample to LC-MS, or the country MRAs may want to analyze the samples themselves (eg to support legal action).

Second, due to the prevalence of counterfeit and improperly labeled products in developing world markets, it is possible that information such as manufacturer name, lot numbers, or expiration dates on the packaging materials are falsified or missing. Legal counsel at UND recommends that we all use the term "stated to be manufactured by thus and such company" in communications about specific pharmaceutical products.

Third, pictures of products, analytical data, or other product-specific information that are posted in a public forum such as a poster session, news article, web site, or social media posting must adhere to the necessary wording describing the origin of the drugs ("stated to be manufactured by ____") and all comments about the products must be factual and non-inflammatory. Students must obtain written permission from their instructor before posting, and the instructor must certify that the posting is factual and non-inflammatory.

Distributed Pharmaceutical Analysis Laboratory DRAFT validation manual July 2015

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3. Limitations of this analytical methodology

Our procedures for quantifying the active ingredients in pharmaceutical dosage forms are based on monographs published in the United States Pharmacopeia (USP) or British Pharmacopeia (BP), but they are not pharmacopeia methods. Modifications must be made to the assay methodology to accommodate the circumstances of sample collection. For example, we analyze single drug tablets, rather than pooled samples of 20-50 tablets, simply because the samples available are single packs that do not include large numbers of tablets. Because the analysis is carried out in academic facilities or teaching laboratories, we may not have the level of quality assurance, maintenance, and record keeping in our HPLC facilities that a commercial lab must maintain.

In order to ensure that the strengths and limitations of the analytical methods are well understood by each user, we require that DPAL participants jump through a few hoops. First, before any pharmaceutical products can be assayed, the user must demonstrate the accuracy, precision, and linearity of their method and instrumentation according to standards laid out in USP <1226> and detailed below. We call this step method verification. Second, specific quality control samples must be run during the assay of pharmaceutical products. If these control samples do not assay correctly, as described in the directions for each analyte, the results from the pharmaceutical products must be thrown out and the samples re-run. We call this step quality control. Data from method verification must be satisfactory before pharmaceutical products are sent to participant laboratories for analysis, and quality control data must be submitted to the DPAL database along with the product results.


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4. Sample preparation

Sample storage and tracking:

The pharmaceuticals sent for analysis are forensic samples. They must be stored in a way that does not promote degradation or contamination, and you must keep good records of each sample so you can track who performed what tests on it and what the results were.

Samples must be stored in a cool, dark environment. We recommend a plastic bin with a snug lid in a refrigerator. Allow the sample to come to room temperature before you work with it, so water does not condense on the cold surfaces.

Each product sample in the batch you will receive consists of at least 3 tablets or capsules which will be shipped in a plastic bag labeled with a UND tracking number. The tracking number will be of the form "14-xxxx" for a sample collected in 2014. When you run tests on individual tablets or capsules, label them as "14-xxxxa, b, c, etc" Have the students sign out samples for analysis and make sure they use the proper sample tracking number in their records and chromatogram labels.

External standards:

External calibration standards are created from analytical grade reagents that are traceable to USP or BP standards. The standard should include a certificate of analysis, and you must take the reagent purity, protonation state, and hydration state into account when calculating final concentrations (the Excel template will guide you through this process). Store dry standards as directed on the bottle. Most must be kept cold.

paracetamol standard Aldrich PHR1005-1G 52.6ampicillin standard Aldrich PHR1393-1G 57amoxycillin standard Aldrich PHR1127-1G 52.6clavulanate standard Aldrich 33454-100MG 125ciprofloxacin standard Aldrich PHR1167-1G 52.6azithromycin standard Aldrich PHR1088-1G 58

The "known" API standard should contain about 0.5 mg/ml of ampicillin, amoxicillin, or ciprofloxacin, and 0.5 mg/ml of amoxycillin plus 0.2 mg/ml of clavulanate if you're analyzing amoxi-clav. The exact concentration does not matter, but you must know it exactly, so use the analytical balance and volumetric fluid measurements. You will use this external standard to determine the sample concentrations.


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Reuse of standards: It is best to make the standard up fresh each time you need it. However, that is expensive and time consuming. If you reuse standards, it is best to do at least one experiment where you assay the reused standard against a fresh one. The information on standard reuse comes from our lab's experience, and your lab may have different results. It would be a good mini-experiment to run periodic chromatograms for a standard sample that is left out at room temperature for several days.

For method verification, you will need the known standard, five calibration standards; a set of normal, overdosed, and deficient "unknowns"; and a dosage form of the product that will be used for a spike-recovery experiment. The HPLC experiment only requires 20 ul per injection, but in order to get accurate dilutions, you must prepare the solutions using volumetric glassware. Excess solutions may be aliquoted into Eppendorf tubes and frozen for up to 1 month.

Calibration standards should span the range from 5% to 200% of the expected API concentration in the experimental samples and at least 5 standards should be used to construct the calibration curve. For example, use 5%, 20%, 80%, 120%, and 200% to establish linearity. A calibration curve generated on one day cannot be used to assay concentrations of samples run on another day. Since it takes 5 runs to do the calibration curve we prefer to establish linearity and then use a single-point external standard to assay concentrations of unknown.

Prepare a "normal" unknown sample in the 95-105% range, an "overdosed" sample in the 140-160% range, and a "deficient" sample in the 20-50% range. Also prepare a method blank, which is nominally 0%. For the spike recovery experiment, we can send you a dosage form, or you may be able to obtain a sample of the right drug and dosage form from a physician or extra tablets from a personal prescription. Prepare the sample as described below under "pharmaceutical dosage forms," weighing out about 50 mg of the powdered tablet. Weigh out 25 mg of the API and add, then prepare and filter the sample as described below; the nominal concentration should be around 150% of the expected API content (calculate it exactly).

Pharmaceutical dosage forms:

Samples for analysis should contain about 0.5 mg/ml of ampicillin, amoxicillin, or ciprofloxacin, and 0.5 mg/ml of amoxycillin plus 0.2 mg/ml of clavulanate if you're analyzing amoxi-clav.

Accurately weigh a tablet or the contents of a gel capsule and take a portion of the powder that will give a 0.5 mg/ml solution of the API when diluted to volume. It may be easier to weigh the contents of a gel cap by difference: weigh the entire capsule, then dump most of the powder out and blow the rest out with a stream of air, finally reweigh the empty capsule. The entire tablet should be crushed to fine


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powder in a mortar and pestle and well mixed, and contents of capsules should be well mixed. For preparation of the analytical sample, weigh out at least 50 mg of powder on an analytical balance; remaining powder should be labeled and frozen for storage.

For example, the total contents of an amoxicillin capsule with a nominal dose of 500 mg amoxicillin might weigh 627 mg due to excipients. To prepare a 0.5 mg/ml solution, a portion of roughly 63 mg would be accurately weighed and dissolved in 100 ml of solvent. Samples should be thoroughly mixed (eg by stirring on a magnetic stirrer for 5 min, or 5 min sonication) plus 2 min of hand shaking and inversion of the volumetric flask. All samples must be filtered through a fresh 0.45 micron syringe filter to remove particulates that might clog the HPLC column. Typically we will filter about 1 ml of the sample into an autosampler vial, discarding the first drops of filtrate.

Amoxicillin: Use 20 mM monobasic sodium phosphate at pH of 4.4 to make the samples. The pH is important, as amoxicillin hydrolyzes rapidly at basic pH. Keep standards and standard solutions refrigerated. Use standard solutions within 3 weeks. Alternatively, freeze for storage up to 2 months.

Ampicillin: Use 20 mM monobasic sodium phosphate at pH of 6.7 to make the samples. Keep standards and standard solutions refrigerated. Use standard solutions within 3 weeks. Alternatively, freeze for storage up to 2 months.

Amoxi-clav: Use DI water to make the samples. Clavulanate is thermally unstable and these samples should be used within 6 hours of preparation.

Ciprofloxacin: Use 25 mM phosphoric acid, adjusted to a pH value of 3, to make the samples. Keep standards and standard solutions refrigerated. Use standard solutions within 3 weeks. Alternatively, freeze for storage up to 2 months.


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5. Method Validation (copy this form) Analyte:______________

The goal is to establish that a standard method, when run on your instrument and with your reagents, satisfies analytical metrics. These directions are specific for HPLC using an external standard with a fixed-wavelength UV-Vis or diode-array detector. Separate this checklist and the method validation results from the routine assay results. A minimum of 24 injections will be required, past validations have taken 30-70 hours.

Precision: The relative standard deviation (RSD) for the integrated intensities of 6 consecutive injections of the known standard should be below 2%.

Results:

Linearity: Prepare and run at least five calibration standards over the concentration range of 5% to 200%. Calculate a regression line for the calibration data, including correlation coefficient, y-intercept, slope, and residual sum of squares. The correlation coefficient should be 0.98 or better and the y intercept should be zero, within the error of measurement.

Results:

Establish control chart: Use the page 16 to track metrics such as the peak shape, resolution, and integrated intensity of the known standard for different analysts and days of operation. The control limits for the integrated intensity of the signal will be set at the average value from the precision measurement±10% (eg, if the average was 20,000 units, the control limits would be 20,000±2,000). OK to adjust for concentration as long as all standards used are in the linear range. Place the control chart at the front of the binder.

Accuracy and range: Perform three replicate injections each of the overdosed sample, the normal sample, the deficient sample, and a solvent blank (total of 12 determinations). Run the external standard after every 5 runs and check that the values of the integrated intensity for the external standard fall within 2% RSD. Use the average external standard signal to determine the concentrations of the overdosed, normal, deficient, and blank samples. The measured concentration of each sample should be within ±2% absolute of its true concentration.

Results:


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Accuracy via spike recovery: If available, a sample of a pharmaceutical dosage form (tablet or capsule) of the target drug should be prepared for analysis and a portion spiked with an extra 30% of the API. Calculate the % recovery of the spike; it should be within 90-110%.

Results:

Specificity: This can be demonstrated by showing that a spike can accurately be recovered from a dosage form matrix (the test in the "accuracy via spike recovery" section). A more robust demonstration is to stress the dosage form (eg by baking the tablet or powder for an hour at 60˚C), then use that as the matrix for a spike recovery experiment.

Results:

Optional: LOD and LLOQ: LOD or LLOQ determination is carried out using the slope of the calibration curve and the SD of low concentration samples. Best practice is to prepare a sample at about 2-3 times the expected LOD; you could also use the SD for the blank runs. However you measure the LOD and LLOQ, samples near the LOD or LLOQ limit should be run and their chromatograms shown in the report.

Results:

What to do if a test fails: This indicates that there may be a problem with your system--review the instrumental parameters and reagents, making necessary changes before repeating the test. For example, maybe your buffer is bacterially contaminated, or the column is dirty or


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has passed its useful lifetime. Best practice is to start the tests over from the beginning, but time may not permit you to do that.

6. Suggested instrument parameters, solvents, and gradients

a) Column storage, conditioning, and washing

For 4.6 mm ID columns, typical column volumes are 4.2 ml for a 25 cm column, 2.5 ml for a 15 cm column, and 1.7 ml for a 10 cm column.

Column storage: 50% organic solvent (methanol or acetonitrile), 50% water

Conditioning the column: If you run a buffer solution through the column while it is full of 50% methanol, the buffer salts may precipitate and clog the column. Condition it by running 95% water/5% methanol (or whatever your initial water/organic ratio is) for 5 column volumes; pick a flow rate that gives back pressures in the 1500-2400 psi range. Next run 95% buffer/5% methanol (the initial conditions, with buffer) for 10 column volumes. Do a blank run and check that the background is clean.

Conditioning will take 1-2 hours, during which time you can make samples. Washing the column: do NOT leave the column with low-organic buffer solution (<30% methanol or acetonitrile) on it, as bacterial growth will occur. If you are going to store the column overnight or longer, protect it by washing it. Run 5 column volumes of 100% water to remove traces of buffer salts, then run 5 column volumes of 50% methanol:50% water (or 50% acetonitrile:50% water if your method uses acetonitrile). The column can be left on the HPLC or removed and capped for storage.


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b) Amoxicillin and Amoxicillin/clavulanate (or clavulanic acid)

Instrument: Waters e2695 High Performance Liquid ChromatographColumn: Symmetry 100 x 4.6 mm C18 column, 5 μm particle size and 100 Å

(an earlier procedure used a Kinetix column; many C18 column types are OK for this assay)Temperature: 30°CDetector: Waters 2998 Photodiode Array DetectorAnalytical Wavelength: 220 nmColumn washing: After each analysis session, it is important to wash out accumulated buffer salts and degraded clavulanic acid. Use 5 column volumes of 95/% water / 5% methanol, 5 column volumes of 50% methanol/ 50% water, 5 column volumes of 95% methanol / 5% water, then 5 column volumes of 50% methanol / 50% water again.

Amoxicillin and Amoxicillin-clavulanate

Mobile Phase Buffer

Concentration of Buffer (mM)

pH of Buffer Sample Injection Volume (μL)

Monosodium Phosphate

20 4.4 10

Time (min) Methanol (%) Buffer (%) Flow (mL/min)

Ramp

0.0 5 95 0.5 None

0.5 5 95 0.5 None

7.0 90 10 0.5 Linear

8.0 90 10 0.5 None

11.0 5 95 0.5 Linear

12.0 5 95 0.5 None

Table 2. Amoxicillin or Amoxicillin/Clavulanate Gradient


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Analytical metrics for amoxicillin:

Column capacity factor 1.1-2.8 (if isocratic program is used),column efficiency >1700 theoretical plates,

tailing factor <2.5 ,RSD for replicate injections <2.0%.

Analytical metrics for amoxi-clav:resolution between the amoxicillin and clavulanate peaks must be at least 3.5,

column efficiency for each peak at least 550 theoretical plates,tailing factor below 1.5,

RSD for replicate injections less than 2.0%.


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c) Ciprofloxacin

Instrument: Waters e2695 High Performance Liquid ChromatographColumn: XTerra 100 x 4.6 mm C18 column, 5 μm particle size and 100 ÅTemperature: 30°CDetector: Waters 2998 Photodiode Array DetectorAnalytical Wavelength: 255 nmMobile phase: 965 ml of pH 3.0 25mM phosphoric acid, 35 ml of acetonitrile.

(keep mobile phase in fridge & equilibrate to RT before use) Isocratic at 1.0 ml/min; retention time of ciprofoxacin 5.1-5.3 minutes

Analytical metrics:column efficiency >2500 theoretical plates,

tailing factor <4.0,RSD for replicate injections <1.5%


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d) Azithromycin (this procedure is under development/testing by Dil Ramanathan at Kean State University)

e) Oxytetracycline (this procedure is under development/testing)

(usually this will be a veterinary product)


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7. Analytical metrics

Measuring theoretical plates: We recommend the British Pharmacopia method due to the simplicity of measuring peak width at 1/2 max height. tr is the retention time of the peak. This method will slightly underestimate column efficiency.

Measuring resolution of two peaks: Again, for peaks with tailing, it's easier to use a formula with peak widths measured at 1/2 max height:

Measuring tailing factor (USP method)

Measuring column capacity factor (for isocratic methods only): k'=(tr - t0)/t0, where tr is the peak retention time and t0 the dead volume of the column (measured by the elution time for the solvent front).


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8. Sample assay and Quality Control procedures

Reproducibility: External calibration standards are created from analytical grade reagents as directed in section 4. Five injections of the external standard must show a peak area within 2% relative standard deviation (RSD), and the range of retention times must be within 0.5 minutes.

Control chart: Each time the method is performed, record the date and the retention time and integrated intensity of the 5th external calibration standard. Also record changes to the method (eg, use of a new column or different batch of buffer). The intensities and retention times should be plotted on a graph. If the intensities or retention times vary outside the control limits, the system suitability is in question and the method verification should be repeated.

Quality check: After every five unknown sample runs, the standard is injected as a quality check and it must assay within 2% RSD of the 5 initial injections and be within the 0.5 minute time range of the initial injections. If a quality check fails, data after the last passed quality check is not used.

Replicate samples: Typically we analyze one pill from each package. If a sample fails analysis (assay value <90% or >120% of stated API content) then two new samples are prepared independently from the remaining powdered pill material and re-assayed (it would be good practice to perform this triplicate assay routinely). Report all three assays and calculate their average and standard deviation. If the average also fails and you want to measure pill-to-pill variability in the packet, two more tablets may be assayed. The spreadsheet posted at the DPAL web site has macros set up to do the analytical calculations--but make sure you understand how those macros work!


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A copy of this Excel spreadsheet is posted on the DPAL site.

9. HPLC Method (copy this form) Analyte:_______________

Instrument:

Detector: detector

Column used: Brand name Column dimensions Packing

Column temperature: RT (no column heater) Column heater, set to

Sample (pick something in the linear range) conc in what solvent?

Notes on sample prep

For isocratic methods: Mobile phase:

% water % organic buffer, pH, and conc. additive concs

How do you make the buffer?

How do you store the buffer? Any notes, safety concerns?

For gradient methods:Mobile phase A:

% water % organic buffer, pH, and conc. additive concs

Mobile phase B: % water % organic buffer, pH, and conc. additive concs

How do you make the buffer?

How do you store the buffer? Any notes, safety concerns?

Describe the gradient:


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Column washing: See section 6a. After use, run 5 column volumes of 100% water to remove traces of buffer salts, then run 5 column volumes of 50% methanol:50% water (or 50% acetonitrile:50% water if your method uses acetonitrile).

10. Control Chart (copy this page) Analyte: ______________

Standard sample conc in what solvent?

Notes on sample prep & storage

how stable is the sample at RT? hours initials, notebook reference

How stable is the sample at 0˚C? hours initials, notebook reference

Optional: How stable is the sample at -80˚C?

Date AnalystRetention

time(s)

Resolution (if there are two

analytes)

Integrated peak intensity

Tailing factor

# theo plates


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11. Revision History

This manual was drafted 11/4/2014Updated 28 Jan 2015 to fix errors in amoxicillin/amoxy-clav gradientsUpdated 16 April 2015 to fix more gradient errors.Updated 15 May 2015 to add QA/QC proceduresUpdated 19 May to add information on column storage, washing, reconditioning

Initials/Date Change PurposeNM 7 August 2015 Deleted Ampicillin analysis

from the Amp, Amox, Amox/Clav analysis

The parameters are only valid for Amox and Amox/Clav. The analyses have been separated to shorten run time. A new section will be added for Ampicillin analysis.

NM 7 August 2015 Gradient for Amox and Amox/Clav has been changed from (time (min), %methanol, %buffer, gradient) (0.0, 5, 95, none; 10.0, 80, 20, linear; 13.0, 5, 95, linear; 18.0, 5, 95, none) flow = 0.5 mL/min

Run time is shorter

ML 7 August 2015 Corrected cipro buffer to include 3.5% acetonitrile

buffer description was incorrect

ML 20 August 2015 Added a form to summarize method

NM and ML 6 Nov 2015 Rewrote some confusing text Clarify verification requirements


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version: 6 november, 2015 · web viewcondition it by running 95% water/5% methanol (or whatever...

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