Rational Design of Stable Lyophilized Protein Formulations: Theory and Practice

Abstract

For ease of preparation and cost containment by the manufacturer, and ease of handling by the end user, an aqueous therapeutic protein formulation usually is preferred. However, with many proteins it is not possible—especially considering the time constraints for product development—to develop sufficiently stable aqueous formulations. Unacceptable denaturation and aggregation can be induced readily by the numerous stresses to which a protein in aqueous solution is sensitive; e.g., heating, agitation, freezing, pH changes, and exposure to interfaces or dénaturants (Arakawa et al., 1993; Cleland et al., 1993; Brange, 2000; Bummer and Koppenol, 2000). Furthermore, even under conditions that thermodynamically greatly favor the native state of proteins, aggregation can arise during months of storage in aqueous solution (e.g., Gu et al., 1991; Arakawa et al., 1993; Chen et al., 1994; Chen et al., 1994; Chang et al., 1996a). In addition, several chemical degradation pathways (e.g., hydrolysis and deamidation) are mediated by water. In aqueous formulations, the rates of these and other (e.g., oxidation) chemical degradation reactions can be unacceptably rapid on the time scale of storage (e.g., 18–24 months) for pharmaceutical products (Manning et al., 1989; Cleland et al., 1993; Goolcharran et al., 2000; Bummer and Koppenol, 2000).