The rapid evolution of mRNA vaccines as a result of the Covid pandemic has accelerated further utilization of mRNA technology as a modality for vaccines. The following presentation discusses Moderna’s challenges and opportunities in establishing a platform process. Scale-up considerations also become a challenge when establishing a platform. Variations to the platform, though necessary, take careful consideration to allow full utilization of the established platform.
The presentation will discuss PDA Technical Report 89 - Strategies for vaccine development and life cycle management, discussing control strategy, comparability assessment and how to leverage previous product & process knowledge.
The session will dive into FDA inspection and enforcement actions for the year 2022, specifically highlighting trends and areas of focus. The session will continue to build on the recent trends with the recent policy advancements in the areas of mutual recognition, user fees act updates, and biosimilars.
The success of the first vaccines for SARS-CoV-2 demonstrated both the effectiveness of mRNA technology and the speed at which new vaccines could be developed using such a platform.
The sudden emergence of this novel modality has necessitated the rapid development of analytical methodologies to ensure product quality and meet the evolving regulatory requirements. This challenge is further complicated by the different nature of mRNA drug substance and the formulated drug product. We will discuss the use of cutting-edge technologies to assess critical quality attributes of both mRNA drug substance and drug product.
Jay Jariwala and Manoj Bhargava, Sidley Austin LLP
As part of the new revision of Annex 1 “Manufacture of Sterile Medicinal Products”, which will become effective on 24 August 2023, the process for manufacturing facilities getting ready for the change, challenges to align with new requirements and the value of a robust contamination control strategy will be discussed.
Richard Denk leads the development of the PDA Points to Consider for the Manufacturing of ATMPs and Andiyanto Sutandar is one of the members within the task force. In their presentation, Andiyanto will share his experience contributing to his first Points to Consider document. Subsequently, Richard and Andiyanto will give the audience their first glimpse of the content of this PtC focused on contamination control strategy, room and facility layout and BioSafety.
The exponential growth of technology, especially in the areas of Artificial Intelligence (AI) and automation, have changed the way we think and operate. Highly regulated industries such as pharmaceutical industry is not exempted. We are being challenged to speed up the Research & Development (R&D), and supply of new and existing medicinal products through the adoption of AI and automation. The fast rate of change has also added pressure to current workforce to adapt to new technologies quicker, and to shorten the time to competence. One of our bold aspirations is to apply standardization to the human factor accordingly to parallel advances on the equipment and processing side. Recognizing that the human workforce will remain its individual character, we try anyway to standardize the human workforce by generic and quantifiable patterns. To do so we utilize VR technology, not only to overcome the constraints of equipment availability for training, but to achieve long lasting knowledge retention and behavioural change through the combination of knowledge of human psychology and VR technology to allow visualizing the invisible. Behaviour patterns, particularly in aseptic processing, are divided and categorized in “key moments”. Operators are getting trained and refreshed on these “key moments” proactively using VR technology. The deployment of VR technology as one of the training methods to qualify operators in Good Manufacturing Practice (GMP) environment, requires more actions as compared to VR offerings in gaming and entertainment industries. Two (2) critical elements are system validation to fulfil regulatory requirements, and connectivity to Learning Management System (LMS) to manage training activities efficiently with proper documentation. Compliance analysis is a must, and it is the starting point to assess the risk based on the intended use of the VR system, GxP applicability, and regulatory considerations associated with the business processes. Output from compliance analysis drives the formation of Compliance Plan that governs the overall validation effort.
The new Annex 1 does enable and require new Technologies like Robotics for Aseptic Manufacturing to keep operators out of critical processes like sterile filling in aseptic Isolators. Robotics alone does not make a gloveless Isolator-System as all the manual operations and transfers needs to be redesigned to make them automated. The design for the Filling needle set up and the design for the stopper bowl and transfers needed to be new investigated and automated to mention only a few . The viable monitoring needs also to be automated and the loading and unloading for Lyo in a different way to have a track and trace of each container on the Lyo Shelves. During the presentation the topic of First Air will also be covered and what impact this have on the positioning of the Robots.
The United States Pharmacopeia (USP) continues the generation of contemporary standards in the field of pharmaceutical microbiology which are relevant to drug and device manufacturing and testing. These standards are recognized by global health authorities and the likes of International Council for Harmonization (ICH). The USP General Chapters Microbiology Expert Committee is responsible for sustaining >50 chapters and has an ambitious workplan to add a significant number of new chapters on critical topics over the next year. This presentation will briefly re-introduce you to the USP standard setting process, introduce you to current priorities, and comprehensively update you on the committee’s advancement of chapters on endotoxins and pyrogens, rapid (modern) microbiological methods, bioburden contamination testing, microbial control, and sterility assurance. This will equip with you a clear understanding of future chapters, their content and how you may contribute to these standards.
Quality and Microbiology personnel often struggle with finding root causes of contamination events, and assessing risk of contaminants on product and patient is a daunting task. To conduct a fruitful investigation, one must start with the understanding that the contaminant well followed by mapping out the ingress and transport path and ensure that the contamination is not proliferating within the clean environment or product. Exploring solutions on how to prevent recurring instances is key to the remedial process. Finally, the impact of the contaminants on the product should be assessed and this cannot be done unless the contaminant is well understood. Learn investigative processes never discussed before to help implement effective corrective and remedial actions.
This presentation will cover key components of CCS (Contamination Control Strategy) in a recent biopharma disinfectant field trial. The case study utilized a ready to use quaternary ammonium disinfectant and a hydrogen peroxide/peracetic acid sporicide to control bioburden in a new cleanroom operation post construction. Material flow, engineering controls, utility supplies, and operational procedures will be discussed. In depth field trial environmental monitoring data will be covered. This CCS case study has recently been published in a peer reviewed industry journal.
You have all the pieces, now let’s put the CCS puzzle together! The task of writing a Contamination Control Strategy (CCS) can be overwhelming, but it is less difficult when you have a plan and the right tools to guide your way. This presentation will offer practical insights into effectively implementing and sustaining a contamination control strategy aligned with EU Annex 1 requirements for sterile medicinal products.
In pharmaceutical microbiology labs, bioburden results are traditionally counted visually and documented by analysts and it is usually aided with colony counter and pen. With the implementation of automated colony counting systems, the technology is seen to enhance the data integrity controls for the assays, reduce the result inaccuracy arises from human error and improve the overall testing efficiency. The sharing is to describe the steps and considerations taken during the evaluation and implementation of the alternative and rapid microbiogical method in Roche.
Digitalization offers numerous benefits, including improved efficiency, enhanced access to information, increased innovation and agility, improved data management and analysis making it a crucial driver of growth and transformation. GSK has initiated its digital transformation journey with the aim of attaining enhanced operational efficiencies and mitigating the risk of human errors in our quality control division. We aim to harvest the benefits of improved data management, enhanced access to information, and data analysis. In this presentation, the focus is on the following topics and will include the compliance advantages and challenges met along the implementation process:
-Digitization of Data and Continuous analytical method monitoring
-Implementation of MALDI-TOF.
The revision of Annex 1 encourages the use of new and alternative technologies that meet or exceed the requirements of Annex 1 and follow the principles of QRM. Enzymatic indicators (EIs) as an alternative to biological Indicators (BIs) have been under development for some me and now there are breakthroughs that support the introduction of EIs to improve cycle development efficiencies when developing vH2O2/ VHP bio-decontamination cycles for barrier technology and associated GMP applications (Rooms and Material transfer devices). This presentation will focus on how efficiency improvements can be achieved and the relationship of EIs and BIs in cycle qualification, re-qualification and process monitoring.
The differences and attributes of EIs and BIs and understanding inherent variabilities that need managing in cycle development and qualification studies.
• Bio-decontamination vH2O2/VHP cycle methodology using a combination of BIs and EIs to improve cycle development efficiency (time reduction and improved knowledge on efficacy profile across challenge locations.
• Case study: Filling line for Viral vectors and application of EIs and BIs in cycle development: challenges and benefits.
• Summary and reflection on the future following Annex 1 implementation.
In this session, AWS will brief their life sciences solutions focused on Automated Quality Control, Real time condition monitoring and Digital Twins. This will be explained by how Merck reduced the overall false reject rates in their drug product automatic visual inspection process; how Aizon improves pharma manufacturing with AI; how Moderna delivers mRNA drugs faster and how Multiply labs uses AWS Robomaker to manufacture individualized medicines.
This presentation explores the significant and rapid changes in expectations for data integrity and governance with a focus on both sterile and non-sterile manufacturing. The traditional concepts of data integrity have been replaced by more holistic concepts of end-to-end data governance. Expectations are being applied to all GxP data across the value chain and far beyond the traditional quality control laboratory focus. Regulatory bodies are issuing broad citations for lack of data governance and assurance of integrity of data. The most successful companies and leaders will ensure data integrity "by design" by building holistic, sustainable and demonstratable data governance throughout their business and as a fundamental design objective within their automation and digitization projects. Within this context, the presentation will include a deeper examination of modern data integrity expectations for both sterile and non-sterile dosage forms.
In this session, we will cover the practical implementation of digital technologies in Thermo Fisher Scientific's Pharma Services Group (PSG) global network and Singapore site. The session aims to showcase how various systems' interfaces have resulted in improvements in productivity and quality through the adoption of the digital technologies and advanced analytics. Additionally, we will discuss the use of Augmented Execution System (AES) for training purposes within the company, providing insights into how these innovations contribute to skill development and operational efficiency. Join us to gain valuable insights into the transformative potential of digital applications in the realm of PSG manufacturing.
Early-stage clinical development programs typically prioritize speed, while commercial programs strive to minimize risk at all costs. As the number of biologics innovators outsourcing their CMC operations to Contract Development & Manufacturing Organizations (CDMOs) continues to grow, so do the challenges associated with balancing speed, risk, and cost. In this talk, Max presents two case studies that will help guide innovators who are considering outsourcing their development and manufacturing activities to CDMOs. One focuses on lessons learned from “gene to IND” clinical projects; the other looks at how a tech transfer and scale-up for a monoclonal antibody licensed in China was derisked.
Despite the growing demand for drug product manufacturing, the biopharmaceutical drug product manufacturing sector encounters various challenges in technology transfer, production, and regulatory filings. Specifically, the industry has recognized an trend of increased challenges in sterile drug manufacturing. The following examples illustrate these challenges:
• Non-terminal sterile processes may contain components that cannot be effectively sterilized by filtration, posing difficulties in implementing sterile processes.
• The continuous increase in high-concentration formulation products presents challenges in manufacturing processes and highlights the need for process adaptability and stability.
• Probabilistic detection in visual inspection poses challenges in visible foreign particle control, requiring the development of sensitive detection methods and robust control measures.
Addressing these challenges is crucial for advancing the field of biopharmaceutical drug product manufacturing and ensuring the production of high-quality, safe, and reliable sterile products through outsourcing.