Patent Grant
11878076
The present disclosure relates to compositions of storage-stable lyophilized Phenobarbital Sodium having high purity that are essentially void of impurities upon reconstitution in water.
The background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
All publications and patent applications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
Phenobarbital Sodium is a well-known barbiturate that is most commonly administered as an anti-convulsant for the treatment of seizures and may also be administered as a sedative, a sleep aide, or a pre-anesthetic. Phenobarbital Sodium is typically a liquid formulation administered intramuscularly (IM) or intravenously (IV) with crystalline granules or crystals dissolved in an aqueous solvent. For example, WO 2017/085687 to Parker et al. discloses a liquid formulation of Phenobarbital Sodium dissolved in water along with a C1-C4 alcohol and a glycol.
The stability of solubilized Phenobarbital Sodium has been a recurring problem because it readily hydrolyzes in water forming various degradation products. In particular, in water alone or in water with an increase in pH, Phenobarbital Sodium forms the degradation products phenylethylacetylurea (PEAU), 2-ethyl-2-phenylmalonamide (2EPMM), and alpha-phenylbutyrylguanidine (PBG). While these degradation impurities may not directly compromise the effectiveness of the Phenobarbital Sodium for its therapeutic activity, these degradation impurities are toxic and cause severe side effects. Specifically, PEAU was previously administered as Pheneturide for severely affected epileptics. However, the Food and Drug Administration (FDA) withdrew approval of Pheneturide due to its toxic effects. In particular, Pheneturide is reported to be a potent liver enzyme inducer that disrupts both calcium and folate metabolism. (Nayyar et al., 2012, J. of Appl. Pharm Sci., 2:230-235.) Prior to its removal as an FDA-approved drug, patients treated with Pheneturide showed low levels of serum calcium and folate.
Over the years of medical administration, efforts have been made to decrease the formation of the toxic degradation products in the Phenobarbital Sodium liquid formulation. For example, Gupta, V. D., (J. Pharm Sci., 1984, 73:1661-1662) describes the effects of ethanol, glycerol, and propylene glycol on the stability of Phenobarbital Sodium in aqueous solutions. Specifically, Gupta discloses that ethanol has the best effect followed by propylene glycol and glycerol relative to water alone. Years after Gupta, Parker et al., (WO 2017/085687) focused on minimizing the total amount of water to reduce the hydrolysis and consequently the formation of the degradation products. Parker addresses the hydrolysis issue by limiting the amount of water (e.g., to no more than 50 mg/mL) in the liquid formulation. Parker's minimized water formulations also include a C1-C4 alcohol such as ethanol and a glycol such as propylene glycol. However, while the amount of impurities in Parker's liquid formulation may have decreased compared to prior formulations, impurities such a PEAU are still present in undesirable amounts, particularly after extended storage.
In addition to the degradation impurities, the current marketed liquid formulation of Phenobarbital Sodium (e.g., Phenobarbital Sodium for Injection USP, 65 mg/mL or130 mg/mL), includes organic solvents such as alcohol, which are not desirable in general and indeed not suitable for administration to newborns as described in the art, e.g., Williams et al., 1998, “Evaluating Toxic Alcohol Poisoning in the Emergency Setting,” Laboratory Medicine, Vol. 29, No. 2; Wood et al., 2007, J. of Perinatology, 27:183-185; Kumar, 1985, “Adverse Drug Reactions in the Newborn,” Annals of Clin. And Lab. Sci, Vol. 15, No. 3; and Cuzzolin, 2018, J. Pediatric and Neonatal Individualized Med., doi:10.7363/070112.
Accordingly, there is still a need for a stable Phenobarbital Sodium formulation in a formulation that is storage stable and void or essentially void of degradation impurities upon solubilization in water.
Disclosed herein are compositions of, methods of producing, and use of a lyophilized Phenobarbital Sodium formulation. The contemplated composition is an amorphous lyophilized Phenobarbital Sodium with high stability and purity. The lyophilized composition may include no less than 98% Phenobarbital Sodium. The amorphous composition is a storage-stable form of lyophilized Phenobarbital Sodium.
The lyophilized amorphous formulation that was produced resulted in surprising, unexpected and desirable results. The quantity of undesirable and/or toxic degradation impurities that are produced from this formulation are less than those in current commercial products. And the stability of this formulation is superior to that of current commercial products. These results are particularly surprising and unexpected in view of the fact that conventional wisdom teaches that crystalline material is more stable than amorphous material (see e.g., C. Ahlneck and G. Zografi “The Molecular Basis for Moisture Effects on the Physical and Chemical Stability of Drugs in the Solid-State,” Int. J. Pharm. 1990, 62, 87-95). Thus, one of ordinary skill in the art would want to avoid using amorphous material in pharmaceutical formulations.
Preferably the percentage of the lyophilized formulation that is amorphous is at least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95%. Alternatively, the percentage of the lyophilized formulation that is amorphous can be 100%. In addition, the percentage of the lyophilized formulation that is amorphous can be within any range between (and including) 20% to 100% (e.g., 20%-100%, 25%-95%. etc.).
Methods for producing the storage-stable form of lyophilized Phenobarbital Sodium composition result in a lyophilized powder in which the impurity phenylethylacetylurea (PEAU) is below detection limit and is never more than 0.2% of the specification limit even after storage of the lyophilized Phenobarbital Sodium for up to 6 months under accelerated stability conditions (40° C., 75% RH). In some embodiments, the method for producing the storage-stable lyophilized Phenobarbital Sodium includes adding Phenobarbital Sodium to water to form a Phenobarbital Sodium solution, having a pH between 9.2 to 10.2, and lyophilizing the bulk solution. In some embodiments, the water is Water for Injection.
In preferred embodiments, the Water for Injection is sparged with nitrogen prior to adding the Phenobarbital Sodium. Typically, the Water for Injection is sparged with nitrogen for at least 30 minutes prior to adding the Phenobarbital Sodium. In additional embodiments, the water (e.g., Water for Injection) is cooled to or between 2 to 8° C. prior to adding the Phenobarbital Sodium.
For adjusting the pH of the Phenobarbital Sodium solution, the method for producing the storage-stable form of lyophilized Phenobarbital Sodium composition may also include measuring the pH of the Phenobarbital Sodium solution, wherein if the pH is higher than 10.2, the adjusting includes adding hydrochloric acid (HCl).
Typically, the resulting lyophilized Phenobarbital Sodium forms no more than 0.1% PEAU when reconstituted in an aqueous solution after storage of the lyophilized Phenobarbital Sodium for up to 6 months both at RT and accelerated stability conditions. More typically, the resulting lyophilized Phenobarbital Sodium forms no more than 0.05% PEAU when reconstituted in an aqueous solution after storage of the lyophilized Phenobarbital Sodium for up to 6 months at room temperature (RT) and under accelerated stability conditions (40° C.). Additionally, or alternatively, the resulting lyophilized Phenobarbital Sodium forms either an amount below the quantitative limit (BQL, 0.05%) or no detectable amount of PEAU, 2-ethyl-2-phenylmalonamide (2EPMM), or alpha-phenylbutyrylguanidine (PBG) when reconstituted in the aqueous solution after storage of the lyophilized Phenobarbital Sodium for up to 6 months at RT and accelerated stability conditions.
According to contemplated embodiments as disclosed herein, the amorphous lyophilized Phenobarbital Sodium composition is stable up to at least 6 months under accelerated stability conditions which is equivalent to 24 months at RT. In this respect, in some embodiments, the stability of the lyophilized Phenobarbital Sodium is determined by reconstituting the lyophilized Phenobarbital Sodium in an aqueous solution and measuring the amount of or the presence of phenylethylacetylurea (PEAU), 2-ethyl-2-phenylmalonamide (2EPMM), and/or alpha-phenylbutyrylguanidine (PBG).
Additional embodiments include the method for producing the storage-stable form of lyophilized Phenobarbital Sodium composition as disclosed in which the Phenobarbital Sodium solution is filtered prior to lyophilization.
Further embodiments include the method for producing the storage-stable form of lyophilized Phenobarbital Sodium composition as disclosed in which the Phenobarbital Sodium solution is aliquoted into a vial prior to lyophilization, and after lyophilization, a closure is applied to the vial under vacuum.
Aspects of the present disclosure also include a method of reducing formation of degradation products of Phenobarbital Sodium reconstituted in an aqueous solution, in which the method includes adding Phenobarbital Sodium to water to form a Phenobarbital Sodium solution, adjusting the pH of the Phenobarbital Sodium solution to or between 9.2 to 10.2, and lyophilizing the Phenobarbital Sodium solution to form stable white lyophilized powder of Phenobarbital Sodium.
In preferred embodiments, the Water for Injection is sparged with nitrogen prior to adding the Phenobarbital Sodium. Typically, the Water for Injection is sparged with nitrogen for at least 30 minutes prior to adding the Phenobarbital Sodium. In additional embodiments, the water (e.g., Water for Injection) is cooled to or between 2 to 8° C. prior to adding the Phenobarbital Sodium.
For adjusting the pH of the Phenobarbital Sodium solution, the method of reducing formation of degradation products of Phenobarbital Sodium reconstituted in an aqueous solution may also include measuring the pH of the Phenobarbital Sodium solution, wherein if the pH is higher than 10.2, the adjusting includes adding Hydrochloric acid (HCl).
In typical embodiments, the degradation products of Phenobarbital Sodium reconstituted in an aqueous solution include phenylethylacetylurea (PEAU), 2-ethyl-2-phenylmalonamide (2EPMM), and/or alpha-phenylbutyrylguanidine (PBG), and analysis of the formation of the degradation products includes reconstituting the stable lyophilized Phenobarbital Sodium in an aqueous solution to form a reconstituted solution, and quantitating the amount of or presence of PEAU, 2 EPMM, and/or PBG in the reconstituted solution.
In typical embodiments, the method of reducing formation of degradation products of Phenobarbital Sodium reconstituted in an aqueous solution results in the reconstituted solution having no less than 96% Phenobarbital Sodium. In more typical embodiments, the reconstituted solution has no less than 97% Phenobarbital Sodium. In some preferred embodiments, the reconstituted solution has no less than 98% Phenobarbital Sodium, and in other preferred embodiments between 95% and 105% Phenobarbital Sodium. In additional or alternative embodiments, the reconstituted solution has no more than 0.2% PEAU, 2 EPMM, and/or PBG, and preferably has 0.05% or less PEAU and no detectable amount of 2 EPMM or PBG.
Further aspects of the present disclosure include methods of treating an individual in need of Phenobarbital Sodium. These methods include adding saline or dextrose to the lyophilized powder of Phenobarbital Sodium as disclosed herein immediately prior to administration to form a Phenobarbital Sodium reconstituted solution and administering the Phenobarbital Sodium reconstituted solution to the individual. In some embodiments, the individual in need of Phenobarbital Sodium suffers from epilepsy. In particular embodiments, the individual in need of Phenobarbital Sodium is a newborn suffering from neonatal epilepsy. In other embodiments, the lyophilized amorphous Phenobarbital Sodium is a powder dose of 65 mg, 130 mg, 100 mg or 200 mg. In typical embodiments, the administering of the Phenobarbital Sodium reconstituted solution to the individual includes intramuscular injection or intravenous injection.
Additional aspects of the present disclosure include a pharmaceutical product including a vial containing the white lyophilized powder of Phenobarbital Sodium for reconstitution prior to administration, in which the composition was lyophilized in the vial and the vial includes a closure positioned in order to seal the vial under vacuum after Lyophilization.
Therefore, the inventors also contemplate lyophilized Phenobarbital Sodium.
Various objects, features, aspects, and advantages will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawings.
The inventors have surprisingly discovered a method for making a storage-stable and highly purified Phenobarbital Sodium composition that is void of any detectable impurities in its lyophilized powder form and is essentially void of impurities upon reconstitution in water. The contemplated Phenobarbital Sodium composition is a lyophilized powder that is no less than 98% Phenobarbital Sodium and is stable (25° C., 65% RH and 40° C., 75% RH) for up to at least 6 months under accelerated conditions which is equivalent to 24 months at RT. Upon reconstitution (e.g. solubilization/resuspension) in water, the lyophilized Phenobarbital Sodium forms no more than 0.05% of 2-ethyl-2-phenylmalonamide (2EPMM) or alpha-phenylbutyrylguanidine (PBG), and phenylethylacetylurea (PEAU).
The Phenobarbital Sodium composition as described herein refers to Phenobarbital Sodium having an IUPAC (International Union of Pure and Applied Chemistry) name of sodium 5-ethyl-4,6-dioxo-5-phenyl-1H-pyrimidin-2-olate, a Chemical Abstract Service (CAS) No. 57-30-7, and a molecular formula of C12H11N2NaO3.
In order to avoid hydrolysis of Phenobarbital Sodium and therefore the formation of its toxic degradation products, the inventors have unexpectedly discovered that a lyophilized Phenobarbital Sodium formed by the methods disclosed herein results in a storage-stable lyophilized powder of Phenobarbital Sodium. In particular, with reference to the polarized light photomicrographs of
The contemplated method for producing a storage-stable lyophilized Phenobarbital Sodium composition includes adding purified Phenobarbital Sodium to water. Preferably the purified Phenobarbital Sodium solid is purchased from a chemical supplier that adheres to the United States Pharmacopeia (USP) manufacturing and synthesis guidelines. The USP grade of the Phenobarbital Sodium is preferably USP “purified” or “practical” (P) grade indicating that it is a good quality chemical. As understood in the art, the USP grade (P) active pharmaceutical ingredient (API) of Phenobarbital Sodium is not suitable for administration because it is not sterile, is hygroscopic, and as such, maintaining anhydrous conditions of this grade of API is not feasible. Structurally, the analyzed USP grade P API is polymorphous—containing both crystalline and non-crystalline material. With reference to
Considering the need to avoid hydrolysis of the Phenobarbital Sodium, the Phenobarbital Sodium is preferably added to Water for Injection and later lyophilized to obtain a stable lyophilized finished product. In order to remove dissolved oxygen (O2) gas from the water (e.g., Water for Injection), it is also preferred that the water is sparged with nitrogen (N2) or other inert gas prior to the addition of the Phenobarbital Sodium solid. For effective sparging, a volume of about 100-200 ml water is sparged with nitrogen gas for at least 30 minutes. In exemplary protocols for producing either 65 mg, 130 mg of lyophilized Phenobarbital Sodium, 100 milliliters (ml) of Water for Injection is nitrogen sparged for 30 minutes. In additional embodiments, the water may also be cooled to approximately 2 to 8° C. In preferred embodiments, the water is cooled to approximately 2 to 8° C.
The addition of the Phenobarbital Sodium solid to the water (e.g., deionized nitrogen sparged water cooled to 2 to 8° C.) may be carried out using any suitable mixing. Preferably, the water (e.g., Water for Injection) is first added to a glass/stainless steel container for nitrogen sparging and cooling, and this prepped water remains in the glass/stainless steel container or a measured amount is transferred to a preferably weighed glass container/stainless steel container and the Phenobarbital Sodium solid is added thereto. For mixing, any suitable mixing may be used. For example, a magnetic stir bar may be added to the glass/stainless steel container. Upon addition of the Phenobarbital Sodium solid to the water, the mixture is stirred.
An additional consideration for stability of the Phenobarbital Sodium is maintaining a pH between 9.2 and 10.2 in the bulk solution of Phenobarbital Sodium. After dissolution of the Phenobarbital Sodium solid in the water, the pH is adjusted to within this range of 9.2 and 10.2. Accordingly, the pH of the water solubilized Phenobarbital Sodium is first measured upon dissolution. If the pH is higher than 10.2 or lower than 9.2, the pH is adjusted. For example, if necessary, the pH may be lowered to or between 9.2 and 10.2 using Hydrochloric acid (HCl) and the pH may be increased to or between 9.2 and 10.2 using Sodium Hydroxide (NaOH).
Following the pH measurement and any adjustment, the Phenobarbital Sodium solution is preferably filtered to remove any foreign particles. For example, the Phenobarbital Sodium solution may be filtered using a 0.2 μm (or 0.22 μm) membrane filter. For example, the membrane filter may be polyvinylidene difluoride (PVDF) or any other compatible filter membranes such as Polyethersulfone (PES) filter.
According to aspects of the contemplated method, the Phenobarbital Sodium solution dissolved in the water (e.g., nitrogen sparged Water for Injection cooled to 2 to 8° C.) having a pH of or between 9.2 and 10.2 and preferably filtered is ready for Lyophilization. Depending on the desired amount of the lyophilized Phenobarbital Sodium product, the Phenobarbital Sodium solution may be lyophilized in any amount or the solution may be aliquoted into sterile containers (e.g., vials). For example, in order to obtain a measured dose of lyophilized Phenobarbital Sodium in a container, the glass container, water, and Phenobarbital Sodium solid are weighed prior to mixing in order to determine an actual weight of the Phenobarbital Sodium after pH measurement and adjustment. For example, to produce 65 mg or 130 mg doses of lyophilized Phenobarbital Sodium, a batch may be dissolved, mixed, pH adjusted if necessary, and filtered and then aliquoted into single use dose vials for lyophilization. In a specific example, a 50 mL batch of Phenobarbital Sodium solution may be prepared where for 65 mg doses, 3.25 grams of Phenobarbital Sodium solid (e.g., USP Grade P) is added to 40 ml of water (e.g., nitrogen sparged Water for Injection cooled to 5 to 8° C.) and for 130 mg doses, 6.5 grams of the Phenobarbital Sodium is added to the 40 ml of water. Following dissolution, pH adjustment if necessary, adjusting final volume to 50.0 mL and filtering, 1 ml aliquots of this Phenobarbital Sodium solution are added to open (e.g., unstoppered) vials and then loosely stoppered (e.g., with lyophilization rubber stoppers) prior to lyophilization. Following lyophilization, each vial contains 65 mg or 130 mg of lyophilized Phenobarbital Sodium.
In further embodiments, following lyophilization, the vials may be completely closed (e.g., stoppered) under vacuum.
Another embodiment is directed to a pharmaceutical composition that consists of lyophilized amorphous Phenobarbital Sodium.
Another embodiment is directed to a method of producing a storage-stable form of lyophilized Phenobarbital sodium that forms no more than 0.2% phenylethylacetylurea (PEAU) when reconstituted in an aqueous solution. The method comprising: includes adding Phenobarbital Sodium to water to form a Phenobarbital Sodium solution, if necessary, adjusting the pH of the Phenobarbital Sodium solution to or between 9.2 to 10.2; and lyophilizing the Phenobarbital Sodium solution.
In one embodiment, the water is Water for Injection.
In another embodiment the Water for Injection is sparged with nitrogen prior to adding the Phenobarbital Sodium.
In another embodiment, the Water for Injection is sparged with nitrogen for at least 30 minutes prior to adding the Phenobarbital Sodium.
In another embodiment, the water is cooled to or between 2 to 8° C. prior to adding the Phenobarbital Sodium.
In another embodiment, the adjusting includes measuring the pH of the Phenobarbital Sodium solution, and if the pH is higher than 10.2, the adjusting includes adding Hydrochloric acid (HCl).
In another embodiment, the lyophilized Phenobarbital Sodium forms no more than 0.1% phenylethylacetylurea (PEAU) when reconstituted in an aqueous solution after storage of the lyophilized Phenobarbital Sodium for up to 6 months at room temperature (RT) and accelerated stability conditions (ACC).
In another embodiment, the lyophilized Phenobarbital Sodium forms no more than 0.05% phenylethylacetylurea (PEAU) when reconstituted in an aqueous solution after storage of the lyophilized Phenobarbital Sodium for up to 6 months at room temperature (RT) and accelerated stability conditions (ACC).
In another embodiment, the lyophilized Phenobarbital Sodium forms no detectable amount of 2-ethyl-2-phenylmalonamide (2EPMM) or alpha-phenylbutyrylguanidine (PBG) when reconstituted in an aqueous solution after storage of the lyophilized Phenobarbital Sodium for up to 6 months at room temperature (RT) and accelerated stability conditions (ACC).
In another embodiment, the lyophilized Phenobarbital Sodium is stable up to at least 6 months at accelerated stability conditions (ACC) which is equivalent to 24 months at room temperature (RT).
In another embodiment, the stability of the lyophilized Phenobarbital Sodium is determined by adding the lyophilized Phenobarbital Sodium to an aqueous solution to form a reconstituted lyophilized Phenobarbital Sodium and analyzing to quantitate the amount of phenylethylacetylurea (PEAU), 2-ethyl-2-phenylmalonamide (2EPMM), and/or alpha-phenylbutyrylguanidine (PBG) in the reconstituted lyophilize Phenobarbital Sodium.
In another embodiment, the Phenobarbital Sodium solution is at a concentration of 65 mg/mL, 100 mg/mL, 130 mg/mL or 200 mg/mL.
In another embodiment, the method further includes filtering the Phenobarbital Sodium solution prior to lyophilizing.
In another embodiment, the method further includes aliquoting the Phenobarbital Sodium solution into a vial prior to lyophilization; and after lyophilization, applying a closure to the vial under vacuum.
Another embodiment is directed to a method of treating an individual in need of Phenobarbital Sodium. The method includes adding saline or dextrose to a composition containing lyophilized amorphous Phenobarbital Sodium immediately prior to administration to form a Phenobarbital Sodium solution; and administering the Phenobarbital Sodium solution to the individual.
In another embodiment, the individual suffers from epilepsy.
In another embodiment, the individual is a newborn suffering from neonatal epilepsy.
In another embodiment, the composition is a powder dose of 65 mg, 100, 130 mg or 200 mg.
In another embodiment, the administering includes intramuscular injection or intravenous injection.
Surprisingly, the inventors have determined that the presently disclosed method produces a storage-stable lyophilized Phenobarbital Sodium that maintains its stability up to at least 6 months under accelerated stability conditions which is equivalent to 24 months at RT. With reference to
In a comparison analysis, the presently disclosed lyophilized powder of Phenobarbital Sodium at 65 mg or 130 mg doses was reconstituted in water and assayed for impurities and stability along with marketed liquid formulation of Phenobarbital Sodium for Injection USP, 65 mg/mL or 130 mg/mL (Westward Pharmaceuticals). The formulation details for this comparative analysis are presented in Table 1. Representative chromatograms from HPLC analysis are shown in
With reference to Tables 2 and 3, the presently disclosed 65 mg lyophilized Phenobarbital Sodium composition was reconstituted in water and compared to the 65 mg Liquid Phenobarbital Sodium for Injection USP (65 mg/mL marketed Liquid Formulation) (Table 2) (
In typical embodiments, the method of reducing formation of degradation products of a lyophilized Phenobarbital Sodium composition reconstituted in water results in the reconstituted solution having no less than 96% Phenobarbital Sodium. In more typical embodiments, the reconstituted solution has no less than 97% Phenobarbital Sodium. In more preferred embodiments, the reconstituted solution has no less than 98% Phenobarbital Sodium. In additional or alternative embodiments, the reconstituted solution has no quantitative amount (e.g., 0.05% or less) of PEAU, 2 EPMM, or PBG.
According to contemplated embodiments, assaying the stability of the lyophilized Phenobarbital Sodium composition includes reconstituting the composition in water at a concentration of 65 mg/mL, 100 mg/mL, 130 mg/mL or 200 mg/mL.
Further aspects of the present disclosure include methods of treating an individual in need of Phenobarbital Sodium. For administration to an individual (e.g., a human patient) the lyophilized powder of Phenobarbital Sodium powder may be reconstituted in saline or dextrose as disclosed herein immediately prior to administration to form a Phenobarbital Sodium reconstituted solution. In particular embodiments, the individual in need of Phenobarbital Sodium suffers from epilepsy. In preferred embodiments, the individual in need of Phenobarbital Sodium is a newborn suffering from neonatal epilepsy. In other embodiments, the lyophilized Phenobarbital Sodium is a powder dose of 65 mg, 100 mg, 130 mg or 200 mg. In typical embodiments, the administering of the Phenobarbital Sodium reconstituted solution to the individual includes intramuscular injection or intravenous injection.
Lyophilization Microscopy. Lyophilization microscopy (
Lyophilization parameters for the lyophilization microscopy including a start temperature of −50° C. with heating at 1° C./minute to −40° C. followed by heating at 0.5° C./minute to −32.0° C.
HPLC Assays. High Performance Liquid Chromatography (HPLC) was used to assay Phenobarbital Sodium standards and sample solutions as disclosed herein (e.g., Tables 2, 3,
An exemplary HPLC assay protocol is provided in the following:
Instruments/Apparatus: HPLC with UV detector/PDA Detector, Analytical balance, Sonicator, Volumetric flasks, Beakers, Pipettes.
Reagents, Solvents, Standards: Phenobarbital Reference Standard, Deionized water/Water for Injection, Potassium Monobasic Phosphate, Acetonitrile.
Preparation of Mobile Phase Solutions: Potassium phosphate monobasic (7 mM) and Acetonitrile (70:30) pH 4.5-6.5; Diluent: Mobile phase as a diluent.
Wash Solvent: Water: Acetonitrile (70:30)
CHROMATOGRAPHIC CONDITIONS: The liquid chromatography equipped with a
Phenobarbital Assay Standard Solution: 0.2 mg/mL to 0.8 mg/mL in diluent; Phenobarbital Related Substances Standard Solution: 0.26 μg/mL to 15.6 μg/mL in diluent; Phenobarbital Related Substances resolution standard solution: 0.475 mg/mL Phenobarbital and about 1μg/mL for related substances (2-Ethyl-2-Phenyl malonamide, monohydrate (2EPMM), Phenylbutyrylguanidine (PBG) and Phenylethylacetylurea (PEAU) in diluent; Phenobarbital Sodium Sample Solution for Assay: 0.26 mg/mL to 0.78 mg/mL in diluent
Phenobarbital Sodium related Substances sample solution: 0.52 mg/mL of Phenobarbital Sodium and related substances 2-Ethyl-2-Phenylmalonamide, monohydrate (2EPMM), Phenyl butyrylguanidine (PBG) and Phenylethylacetylurea (PEAU) and any unspecified degradation products at 0.26 μg/mL to 13.2 μg/mL
SYSTEM SUITABILITY REQUIREMENTS: The relative standard deviation of Phenobarbital peak from Six replication injections of related substances standard should not be more than 6.0%. The related standard deviation of Phenobarbital peak from five replicate injections in assay standard solution should not be more than 2.0%. Tailing factor for the Phenobarbital is not more than 2.0. USP Plate count for the Phenobarbital is not less than 2500. The S/N Ratio of the Sensitivity Standard Solution is NLT 10 for related substance test. The resolution between Phenobarbital peak and nearest impurity peak is NLT 1.5
Two alternative formulations are disclosed in Table 6. One of these formulations is 200 mg/vial, Phenobarbital Sodium reconstituted in 10 mL of Water for Injection or 5% Dextrose to obtain a concentration of 20 mg/mL. A second formulation is 200 mg/vial of Phenobarbital Sodium along with 90 mg Sodium Chloride reconstituted in 10 mL of Water for Injection to obtain a concentration of 20 mg/mL Phenobarbital Sodium for Injection and 9 mg/mL or 0.9% Sodium Chloride.
These formulations along with the previously disclosed formulations were developed to enable physicians and medical staff at hospitals to easily reconstitute to a desired concentration (e.g., 20 mg/mL) and administer the medicine to patients in need thereof. The reconstituted solution is stable at 2-8° C. for 24 hrs and 3 to 4 hrs when stored at RT (see e.g., Tables 7, 8 and 9).
Six months stability data for Phenobarbital Sodium for Injection, USP, 65 mg/vial is included in Table 10. Six months stability data for Phenobarbital Sodium for Injection, USP, 130 mg/vial is included in Table 11. Three months stability data for Phenobarbital Sodium for Injection, USP, 200 mg/vial is included in Table 12. Three months stability data for Phenobarbital Sodium for Injection, USP (Phenobarbital Sodium and 9% Saline), 200 mg/vial is included in Table 13.
Data for Osmolality, Particulate matter and assay for Sodium Chloride is disclosed in Table 14.
Lyophilization parameters used for the 65 mg/vial, 100 mg/vial, 130 mg/vial and 200 mg/vial are disclosed in Table 15.
Six months stability data for Phenobarbital Sodium for Injection USP, 100 mg/vial is included in Table 16.
Representative chromatograms and/or corresponding calculations are shown in
The results for further extended stability studies are presented below in which commercially available phenobarbital sodium, USP Grade P was dissolved in water to produce an aqueous solution having a pH of between 9.2 and 10.2, and in which the aqueous solution was then filled into lyophilization vials in an amount of between 65 mg per vial and 200 mg per vial at a maximum concentration of phenobarbital of 100 mg/ml. Lyophilization was performed as in Table 15 noted above. Stability studies were then performed at standard conditions (RT: 25° C., 60% relative humidity) and accelerated conditions (ACC: 40° C., 75% relative humidity) for a period of up to 37 months.
After the storage conditions indicated in the tables below, the lyophilized product was then dissolved in water (or saline or dextrose) and subjected to analysis for degradation products of phenobarbital. Specifically, the inventors investigated the levels of degradation by quantifying the remaining phenobarbital and by quantifying 2-ethyl-2-phenylmalonamide (2EPMM), alpha-phenylbutyrylguanidine (PBG), and phenylethylacetylurea (PEAU), as well as other unspecified degradation products. Remarkably, and as can be seen from the data below, the lyophilized amorphous phenobarbital had a storage stability at 25° C. and 60% relative humidity for up to and beyond three years and did readily dissolve upon reconstitution.
Table 18 depicts exemplary results for 65 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained below quantitation limit (0.05%).
Table 19 depicts exemplary results for 65 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained below quantitation limit (0.05%) or barely above quantitation limit.
Table 20 depicts exemplary results for 100 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained below quantitation limit (0.05%) or barely above quantitation limit.
Table 21 depicts exemplary results for 130 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained at or below quantitation limit (0.05%).
Table 22 depicts exemplary results for 130 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained below quantitation limit (0.05%).
Table 22 depicts exemplary results for 200 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
Table 23 depicts exemplary results for 200 mg per vial phenobarbital sodium stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%). In contrast to Table 22, this formulation was filled into the vial using a 9% saline solution. The final concentration of the saline after reconstitution in 10 mL of water for injection will be 0.9%.
To further investigate if the nature of the reconstitution solution would have an adverse effect on stability after reconstitution, the inventors used 65 mg of lyophilized amorphous phenobarbital in a vial and dissolved the lyophilized material with 0.9% or 5% dextrose to a final concentration of 1 mg/ml. In an additional set of experiments, the inventors used 130 mg of lyophilized amorphous phenobarbital in a vial and dissolved the lyophilized material with 0.9% or 5% dextrose or water to a final concentration of 20 mg/ml. The so reconstituted solutions were then kept under refrigeration (2-8° C.) or at standard conditions (25° C.) for the indicated times in the tables below. The levels of degradation were determined by quantifying the remaining phenobarbital and by quantifying 2-ethyl-2-phenylmalonamide (2EPMM), alpha-phenylbutyrylguanidine (PBG), and phenylethylacetylurea (PEAU), as well as other unspecified degradation products. Once more, under all tested conditions, the stability of the so reconstituted compositions was unexpectedly high.
Table 24 depicts exemplary results for 65 mg per vial phenobarbital sodium reconstituted with 5% dextrose to 1 mg/ml that was stored under refrigeration or at standard conditions. Under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
Table 25 depicts exemplary results for 65 mg per vial phenobarbital sodium reconstituted with 0.9% saline to 1 mg/ml that was stored under refrigeration or at standard conditions. Under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
Table 26 depicts exemplary results for 130 mg per vial phenobarbital sodium reconstituted with 0.9% saline to 20 mg/ml that was stored under refrigeration or at standard conditions. Under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
Table 27 depicts exemplary results for 130 mg per vial phenobarbital sodium reconstituted with 5% dextrose to 20 mg/ml that was stored under refrigeration or at standard conditions. Under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
Table 28 depicts exemplary results for 130 mg per vial phenobarbital sodium reconstituted with water to 20 mg/ml that was stored under refrigeration or at standard conditions. Under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
In further experiments, the inventors investigated if stable lyophilized phenobarbital preparations could be prepared (in crystalline and/or amorphous forms, depending on solvent) using one or more water miscible co-solvents. To that end, the inventors tested isopropanol, tert-butanol, ethanol, and acetonitrile as co-solvents. Most typically, the co-solvent(s) will be present in an amount of at least 1.0%, or at least 1.5%, or at least 2.0%, or at least 2.5%, or at least 3.0%, or at least 3.5%, or at least 4.0%, or at least 4.5%, or at least 5.0%, or at least 5.5%, or at least 6.0%, or at least 7.0%, or at least 8.0%, or at least 9.0%, or at least 10%, or at least 25%, or at least 50%, or at least 75%. Therefore, suitable quantities of co-solvent(s) include those between 1.0 and 3.0%, or between 2.5% and 5.0%, or between 3.0% and 7.5%, or between 5.0% and 10%, or between 10% and 25%, or between 25% and 50%, or between 50% and 75%, and even higher. For example, and as shown in more detail below, the concentration of the organic co-solvent was as high as 90%. Lyophilization conditions and results are shown below. Tables 29A and 29B depict formulation details used in the lyophilization and stability experiments. Two formulations were prepared for each strength (65 mg and 130 mg), one with 5% Isopropanol and the other with 5% Tertiary Butanol, and other co-solvents (here acetonitrile and ethanol) were also evaluated. The organic solvent was added after the Phenobarbital Sodium was dissolved in water, mixed well and adjusted to final volume with water. Later the bulk solution is filled in vials and lyophilized using the Lyo cycle parameters shown in Table 30. After the Lyo cycle was completed, the finished product was analyzed for assay, related substances, pH, moisture content and residual solvents.
Table 31 depicts results for 65 mg and 130 mg per vial phenobarbital sodium (from a bulk solution containing 5% tert-butanol) stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05%).
Table 32 depicts results for 65 mg and 130 mg per vial phenobarbital sodium (from a bulk solution containing 5% isopropanol) stored at standard and accelerated conditions where under all tested conditions 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Likewise, unspecified degradation products and total degradation products remained near or below quantitation limit (0.05).
Table 33 depicts initial results for 65 mg and 130 mg per vial lyophilized phenobarbital sodium from respective bulk solutions containing ethanol or acetonitrile as co-solvent (to obtain 65 mg/vial, 0.5 mL of the bulk solution was filled in the vials and for 130 mg/vial strength, 1 ml of the bulk solution was filled in the vials prior to lyophilization). For all test products, 2EPMM, PBG, and PEAU remained undetectable or below quantitation limit (0.05%). Notably, unspecified degradation products and total degradation products also remained undetectable or below quantitation limit (0.05%).
Notably, the results indicated that the above formulations were also storage stable over at least three months as evidenced by all known impurities below quantitation limit as shown in Tables 31 and 32. However, an unknown impurity was observed above LOQ level. Interestingly, the residual solvents tertiary butanol and isopropanol were not completely removed after the first cycle of secondary drying. Tertiary butanol and isopropanol were observed above 0.5% in the 65 mg and 130 mg strength products. The same vials were then subjected to additional secondary drying at 25° C. for 30 min and 50° C. for 120 min, and the samples were analyzed for residual solvent after the second cycle of secondary drying.
After the additional secondary drying steps, residual tert-butanol and isopropanol were observed at lower quantities, respectively. As can be readily seen, the organic solvents could be reduced in quantities, but were not completely removed, possibly suggesting that the tested organic solvents could form a bond in the crystal lattice of phenobarbital. However, further process modifications may possibly result in additional reduction of residual co-solvent, requiring extensive experimentation. Similar formulations were prepared in organic solvents ethanol and acetonitrile. Here as well, the residual solvent ethanol was not completely removed, but further process modifications may possibly result in additional reduction of residual co-solvent, requiring extensive experimentation.
Organic solvents such as isopropanol, tertiary butanol, ethanol and acetonitrile were investigated as co-solvents during the lyophilization. Two co solvents tertiary butanol and Isopropanol were used as co-solvents at 5%. The 3M stability data for the formulation with IPA and tert-butanol indicates that although no known degradation products were observed above quantitation limit, the residual solvents could not be removed completely after lyophilization. When ethanol was used as a co solvent similar results were observed. In view of the fact that organic solvents are toxic to all age groups, and in particular to neonates and because residual solvents are typically trapped in the crystal lattice of the Phenobarbital, the lyophilized product with only water as solvent is preferred over formulations containing any organic co solvents.
X-Ray Powder Diffraction. With reference to
The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the full scope of the present disclosure and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the claimed invention.
It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the full scope of the concepts disclosed herein. The disclosed subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
This application is a continuation application of our co-pending U.S. application with the Ser. No. 17/854,914, filed Jun. 30, 2022, which is a continuation-in-part application of our U.S. application with the Ser. No. 17/025,881, filed Sep. 18, 2020, now U.S. Pat. No. 11,406,598, which claims the benefit of U.S. Provisional Patent Application No. 62/903,511, filed on Sep. 20, 2019, which is incorporated by reference in its entirety.
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| 6077545 | Roskos et al. | Jun 2000 | A |
| 20100035904 | Sun et al. | Feb 2010 | A1 |
| 20170143719 | Parker | May 2017 | A1 |
| Number | Date | Country |
|---|---|---|
| 104940149 | Sep 2015 | CN |
| 2017085687 | May 2017 | WO |
| Entry |
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| Number | Date | Country | |
|---|---|---|---|
| 20230157959 A1 | May 2023 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62903511 | Sep 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17854914 | Jun 2022 | US |
| Child | 18100804 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17025881 | Sep 2020 | US |
| Child | 17854914 | US |
