Application Note

Optimization Of The Freeze Drying Process Using Modulated Differential Scanning Calorimetry

By R. L. Blaine and L. C. Thomas

deep freezing cryopreservation GettyImages-952307842

Freeze-drying, or lyophilization, is a widely used method in the pharmaceutical industry for stabilizing biologically active substances. The process involves sublimating ice at low temperatures, creating a porous, low-density structure that retains the drug's stability and activity. However, freeze-drying is challenging due to its high cost, energy demands, lengthy processing times, and the need to optimize parameters such as time, temperature, pressure, and component concentration. Achieving an optimal drying temperature is critical, as sublimation rates can double with a 5 °C increase, enhancing efficiency and reducing costs.

The physical characteristics of the freeze-dried formulation, including its structure and transition temperatures, play a vital role in determining process success. Bulking agents, which can be crystalline or amorphous, define the structure and interact with ice and unfrozen water in the frozen solution. These interactions impact physical properties like viscosity or modulus, which can shift dramatically around transition temperatures. Understanding these structural transitions is essential for selecting the correct drying parameters.

Traditional Differential Scanning Calorimetry (DSC) has limitations in analyzing frozen solutions due to overlapping transitions. In contrast, Modulated DSC™ (MDSC™) offers improved accuracy and precision in identifying critical structural transitions, enabling better optimization of freeze-drying processes. This paper demonstrates how MDSC™ provides a more reliable assessment of the key structural and temperature changes required for efficient and successful lyophilization.

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