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Einbrennsilikonisierung bei pharmazeutischen Glaspackmitteln - Analytische Studien eines Produktionsprozesses
Mathematisch-Naturwissenschaftliche Fakultät I
Heat Curing Siliconization of Pharmaceutical Glass Containers The heat curing siliconization has long since been used to introduce special properties to pharmaceutical glass containers. Silicone oils are usually applied to the containers to form lubricating films on the inner surface of prefilled syringes or to gain hydrophobic container walls for clear draining aqueous solutions, e.g. in injection vials. Furthermore the deactivation of the glass wall reduces adsorption of hydrophilic drug compounds and increases the hydrolytic stability of the glass surface. Due to the parenteral targeting the glass containers are made from glass type 1 according to the European Pharmacopoeia. The silicone oil films (= trimethylsiloxy endcapped polydimethylsiloxane, PDMS) are spread from diluted aqueous silicone oil emulsions on the inner surface and successively heat treated above 300°C for 10-30 minutes. Apart from sterilization and depyrogenation, the silicone layer is changed by the burning-in treatment. In literature the process has previously been designated as heat fixing or heat curing assuming that silicone oil is immobilized by bonding to the glass or branching. Further effects such as vaporization or degradation were suggested along with the heating. Proving these suggestions analytically was therefore the aim of the dissertation. The properties of siliconized glass containers can be characterized by simple experiments. Extraction of the glasses with suitable organic solvents (e.g. toluene, dichloromethane) recovers most of the silicone (approximately 80%) after a typical heat curing process. Still, after exhaustive solvent extraction there are persisting hydrophobic properties of the glasses evidenced by high contact angles of water and changed draining behaviour of fluids in the containers. From this observations it was assumed that a bound and a soluble silicone species is present after the heat curing siliconization. All analytical studies were based on the two-layer hypothesis and thus divided in two parts. Several surface analysis techniques were employed to detect and characterize the fixed silicone layer among them the combined X-ray photoelectron and augerelectron spectroscopy (XPS/AES) and time-of-flight secondary ion mass spectroscopy (TOF-SIMS). The formation of new bonds between silicone and glass was evidenced by chemical state plots and mass spectroscopic structural analysis. Contact angle measurements showed that the bound silicone was thermostable up to 400°C and pyrolyzed at temperatures above 450°C. The extractable silicone was also studied with several analytical techniques in comparison with the respective uncured starting materials. Chromatographic studies using size exclusion (SEC) and high temperature gas chromatography (GC) revealed significant changes in the composition of the silicone polymer. The molecular weight averages increase because low molecular weight siloxanes (LMWS) with 0-100 dimethylsiloxane units are removed through the heat curing process. These deficits can be related to vaporization (molecules from 0-50 units) and degradation (molecules from 0-100 units) effects. A Fourier transform infrared spectroscopic (FTIR) investigation of the molecular structure of the extractable PDMS after heat treatment showed no chemical changes e.g. by hydrolysis, branching or oxidation. The emulsifiers are destroyed in the heating process which was proved by a proton nuclear magnetic resonance (1H-NMR) study. The thermostability of the silicones is decreased by katalytic effects of auxiliary substances in the emulsions and the presence of oxygen. This was concluded from model thermogravimetric studies (TGA) with commercial medical grade silicone oils and emulsions. To evaluate migration of silicone traces to drug formulations in siliconized glass containers a trace analytical method by graphite furnace atomic absorption spectrometry (GF-AAS) was developed and validated according to the ICH guidelines. In liquid formulations levels of 10µg/L can be properly quantified. It was concluded that two main species of silicone can be differentiated on the glass surface after heat curing siliconization. The bonded thin layer is insoluble and sufficient for hydrophobic deactivation. The oil properties are lost. The extractable fraction is altered by removal of LMWS which increases molecular weight and viscosity and determines the lubricating properties. Its amount depends on the used silicone mass. No toxicological concern has to be made about LMWS and emulsifiers in the drug product due to their removal in the curing step.