The Problem of Worst-Case Variability in Cleaning Validation and Cross-Contamination Control: A Quality by Design Approach on Some Cephalosporin Residuals

Abstract

Pharmaceutical manufacturers are globally forced to follow international guidelines on cleaning validation. Cleaning validation is related to the concept of the worst-case product; however, the worst-case product is a function of the manufacturer and the product portfolio. Consequently, manufacturers are faced repeatedly by cycles of worst-case product alteration, and repeated cycles of worst-case oriented analytical method development. Generally, this problem is hardly controlled due to the various products manufactured by the same facility. However, Analytical Quality by Design (AQbD) offers a possible solution through the development of robust and sensitive multicomponent analytical methods that span a wide spectrum of possible products. Cephalosporin antibiotics are a broadly manufactured class of antibiotics that can lead to anaphylaxis in extremely small quantities; therefore, an ultra-level of cleanness is required for facilities involved in such products. A group of the highest market share cephalosporin products was used to present the application of AQbD to introduce a reliable solution to cleaning validation that can be employed in pharmaceutical facilities. A multivariate optimization approach was utilized for the development of a sensitive multicomponent HPLC method; in addition to the proposal of a novel chemometric approach to troubleshoot the developed method.