The production of stable solid crystalline material is an important issue in the pharmaceutical industry and the challenge to control the desired active pharmaceutical ingredient (API) with the specific chemical and physical properties has led to more development in the drug industry. Increasing the solubility and the dissolution of the drug will increase its bioavailability; therefore the solubility can be improved with the change in the preparation method. The formation of co-crystals has emerged as a new alternate to the salts, hydrates and solvate methods since the molecules that cannot be formed by the usual methods might crystallise in the form of co-crystals. Co-crystals are multicomponent crystals which can be known as supramolecules and are constructed by the non covalent bonds between the desired former and co-former. Therefore the synthon approach was utilised to design co-crystals with the specific properties, this involves the understanding of the intermolecular interactions between these synthons. These interaction forces can be directed to control the crystal packing in the design of the new crystalline solid with the desired chemical and physical properties. The most familiar synthon was the amide group with its complementary carboxylic group, in this work isonicotinamide and benzoic acid were chosen to design co-crystal and much literature exist that introduce the determination of co-crystal growth from these two compounds. The growth of co-crystals was carried out in water, ethanol and ethanol / water mixed solvent (30 - 90 % ethanol) by utilising the Cryo-Compact circulator. Co-crystals (1:1) and (2:1) were grown in ethanol and water respectively and a mixture of both phases were grown in the mixed solvent. All the phases were examined by powder X-ray diffraction (PXRD), Raman, Infrared and 1H-NMR spectroscopy. The solubility of isonicotinamide, benzoic acid, co-crystals (1:1) and (2:1) in water, ethanol and ethanol/water mixed solvent (30 - 90 % ethanol) were determined at 25 °C, 35 °C and 40 °C by utilising the React-Array Microvate. It was important to understand some of the thermodynamic factors which control the formation of these polymorphs such as the change in the enthalpy and the change in the entropy. Also it was important to study the pH behaviour during dissolution of the former, co-former and co-crystals in water, ethanol and ethanol/water mixed solvent (30 - 90 % ethanol) in-order to examine the affect of the solvent composition on the solubility and to identify if some ions were formed during the dissociation and how this could affects the formation of co-crystals. A discussion has been introduced in this research of how similar solubility of the compounds maps the formation of the typical ternary phase diagram of the mixture of 1:1 while compounds with different solubility maps the formation of skewed phase diagram as shown in section 1.6.2.3. In this project an isotherm ternary phase diagram at 20 °C and 40 °C was constructed to map the behaviour of benzoic acid and isonicotinamide and to show all possible phases formed and the regions where all phases are represented in the ternary phase diagram were determined by the slurry method. The ternary phase diagram was used to design a drawn out and cooling crystallisation at 100 cm3 solution of 50 % ethanol / water mixed solvent and a study of the impact of seeds of co-crystals 1:1 on the cooling crystallisation method.

Les entreprises pharmaceutiques ont progressivement adopté le concept de Process Analytical Technology (PAT) afin de contrôler et d'assurer en temps réel la qualité des produits pharmaceutiques au cours de leur production. Le PAT et un composant central du concept plus général de Quality-by-Design (QbD) promu par les agence régulatrices et visant à construire la qualité des produits via une approche scientifique et la gestion des risques.Une méthode basée sur la spectroscopie proche infrarouge (PIR) a été développée comme un outil du PAT pour contrôler en ligne la cristallisation d'un principe actif pharmaceutique. Au cours du procédé les teneurs en principe actif et en solvant résiduel doivent être déterminées avec précision afin d'atteindre un point d'ensemencement prédéfini. Une méthodologie basée sur les principes du QbD a guidé le développement et la validation de la méthode tout en assurant l'adéquation avec son utilisation prévue. Des modèles basés sur les moindres carrés partiels ont été construits à l'aide d'outils chimiométriques afin de quantifier les 2 analytes d'intérêt. La méthode a été totalement validée conformément aux requis officiels en utilisant les profils d'exactitude. Un suivi du procédé en temps réel a permis de prouver que la méthode correspond à son usage prévu.L'implémentation de cette méthode comme à l'échelle industrielle au lancement de ce nouveau procédé permettra le contrôle automatique de l'étape de cristallisation dans le but d'assurer un niveau de qualité prédéfini de l'API. D'autres avantages sont attendus incluant la réduction du temps du procédé, la suppression d'un échantillonnage difficile et d'analyses hors ligne fastidieuses. / Pharmaceutical companies are progressively adopting and introducing the Process Analytical Technology (PAT) concept to control and ensure in real-time product quality in development and manufacturing. PAT is a key component of the Quality-by-Design (QbD) framework promoted by the regulatory authorities, aiming the building of product quality based on both a strong scientific background and a quality risk management approach.An analytical method based on near infrared (NIR) spectroscopy was developed as a PAT tool to control on-line an API (active pharmaceutical ingredient) crystallization. During this process the API and residual solvent contents need to be precisely determined to reach a predefined seeding point. An original methodology based on the QbD principles was applied to conduct the development and validation of the NIR method and to ensure that it is fitted for its intended use. Partial least squares (PLS) models were developed and optimized through chemometrics tools in order to quantify the 2 analytes of interest. The method was fully validated according to the official requirements using the accuracy profile approach. Besides, a real-time process monitoring was added to the validation phase to prove and document that the method is fitted for purpose.Implementation of this method as an in-process control at industrial plant from the launch of this new pharmaceutical process will enable automatic control of the crystallization step in order to ensure a predefined quality level of the API. Other valuable benefits are expected such as reduction of the process time, and suppression of a difficult sampling and tedious off-line analyzes.

Le développement d’un médicament pour une cible thérapeutique donnée passe par plusieurs étapes qui se résument en une étape de criblage, une phase préclinique et plusieurs phases cliniques. Ces étapes permettent de sélectionner une substance active et de démontrer son efficacité thérapeutique et sa sécurité toxicologique. Ces deux critères définissent la qualité du médicament qui, une fois démontrée, doit être garantie pendant toute sa durée de validité. La qualité est évaluée au moyen d’études de stabilité qui sont réalisées d’abord sur la matière première de la substance active au cours de la phase de pré-développement du médicament, ensuite sur le produit fini. La stabilité intrinsèque de la substance active concerne à la fois ses propriétés chimiques et ses propriétés physiques qui sont liées à la nature de la substance. L’étude de stabilité repose d’abord sur la caractérisation de ces propriétés, et ensuite sur l’étude de la sensibilité de la substance à l’égard des facteurs environnementaux pouvant modifier les propriétés intrinsèques de la substance. L’approche adoptée dans ce travail repose d’une part sur l’évaluation de la stabilité chimique c’est à dire de la réactivité chimique des substances à usage pharmaceutique au travers des études de pureté chimique et des études de dégradation forcée de ces substances en solution, et d’autre part, sur l’évaluation de la stabilité physique. Dans ce cadre, l’étude du polymorphisme cristallin revêt une grande importance, tout comme l’aptitude à la formation d’hydrates ou de solvates. Cette étude, basée sur la thermodynamique, consiste pour l’essentiel à construire un diagramme de phases pression-température permettant de définir les domaines de stabilité relative des différentes formes cristallines. Cinq substances actives, existant à l’état solide et entrant dans la composition de médicaments administrés par voie orale, ont été étudiées dans le cadre de ce travail. L’analyse chimique du tienoxolol, présentant un effet anti-hypertenseur, a montré qu’il est très sensible à l’hydrolyse et à l’oxydation. Sept produits de dégradation ont été identifiés pour ce produit dont un schéma probable de fragmentation a été établi. Des diagrammes de phases pression-température ont été construits pour le bicalutamide et le finastéride, médicaments du cancer de prostate, en utilisant une approche topologique basée simplement sur les données disponibles dans la littérature. Cette étude a montré que la relation thermodynamique (énantiotropie ou monotropie) entre les formes cristallines sous conditions ordinaires peut être modifiée en fonction de la température et de la pression. Ce résultat est important pour la production des médicaments car il montre comment une telle information peut être obtenue par des mesures simples et accessibles aux laboratoires de recherche industrielle, sans que ces derniers soient contraints d’expérimenter sous pression. La méthode topologique de construction de diagramme de phases a été validée ensuite en la comparant à une méthode expérimentale consistant à suivre, par analyse thermique, des transitions de phases en fonction de la pression. La méthode expérimentale a été appliquée à deux composés, la benzocaine, anesthésique local, et le chlorhydrate de cystéamine, médicament utilisé pour les cystinoses. Les deux formes étudiées de benzocaine présentent une relation énantiotrope qui se transforme en relation monotrope à haute pression. Une nouvelle forme cristalline (forme III) du chlorhydrate de cystéamine a été découverte au cours de ce travail. La relation thermodynamique entre cette forme III et la forme I est énantiotrope dans tout le domaine de température et de pression. De plus, le chlorhydrate de cystéamine, classé hygroscopique, a fait l’objet d’une étude quantitative de sa sensibilité à l’eau, montrant qu’il devient déliquescent sans formation préalable d’hydrate (...) / The development of a drug for a given therapeutic target requires several steps, which can be summarized by drug screening, a preclinical phase and a number of clinical phases. These steps allow the selection of an active substance and a verification of its therapeutic efficacy and toxicological safety. The latter two criteria define the quality of the drug, which once demonstrated, must be guaranteed throughout its shelf life. Quality is assessed through stability studies that are carried out with the raw material of the active substance (preformulation phase) and with the final product. The intrinsic stability of the active substance depends on its chemical and physical properties and their characterization is the core of the stability studies, which in addition consists of sensitivity studies of the active pharmaceutical ingredient (API) for environmental factors that can modify the intrinsic properties of the substance. The approach presented in this work is based on the one hand on the assessment of the chemical stability, i.e. the reactivity of APIs through chemical purity studies and forced degradation in solution, and on the other hand on the assessment of the physical stability. For the latter, crystalline polymorphism is of great importance, as is the ability of the API to form hydrates or solvates. The study of crystalline polymorphism is based on the construction of pressure-temperature phase diagrams in accordance with thermodynamic requirements leading to the stability condition domains of the different crystalline forms. The stability behavior of five APIs used or meant for oral applications has been studied as part of this work. The chemical analysis of tienoxolol, an antihypertensive drug, has demonstrated its sensitivity for hydrolysis and oxidation. Seven degradation products were identified and patterns of fragmentation have been established. Pressure-temperature phase diagrams have been constructed for bicalutamide and finasteride, drugs against prostate cancer, using a topological approach based on data available in the literature. The study demonstrates that the thermodynamic relationship (enantiotropy or monotropy) between crystalline forms under ordinary conditions can change depending on the pressure. This is important for drug development as it demonstrates how stability information can be obtained by standard laboratory measurements accessible to industrial research laboratories without the necessity to carry out experiments under pressure. The topological approach for the construction of phase diagrams has subsequently been validated by measuring transition temperatures as a function of pressure. Experiments have been carried out with benzocaine, a local anesthetic, and with cysteamine hydrochloride, a drug used against cystinosis. Two crystalline forms were observed in the case of benzocaine. They exhibit an enantiotropic relationship that becomes monotropic at high pressure. For cysteamine hydrochloride, a new crystalline form (form III) was discovered. The thermodynamic relationship between the new form III and the known form I is enantiotropic for the entire temperature and pressure range. Cysteamine hydrochloride’s sensitivity to water has been studied, as it is hygroscopic. It has been demonstrated that it becomes deliquescent in the presence of water and no trace of a hydrate has been found. Finally, a study combining thermal and chromatographic methods showed that, under the effect of temperature, cysteamine hydrochloride turns into cystamine in the solid as well as in the liquid state, The latter is known to be an important impurity of cysteamine hydrochloride. In conclusion, the approach developed in this work allowed to characterize the stability properties of a number of APIs and to determine the factors that may change these properties and influence the intrinsic stability (...)