FORMULATION DEVELOPMENT

Formulation DevelopmentFormulation Development

Zencore has a stable and efficient formulation development platform process, and completed formulations are applicable to liquid injections, prefilled syringes and lyophilized powders for injection. The dedicated formulation development team can rapidly and efficiently screen long-term stable formulations for both low-concentration and high-concentration protein products, and thoroughly evaluates the stability of the target protein in the given formulation.

Liquid injectionsPrefilled syringesLyophilized powder for injectionTwo rounds of screening + DoE designPilot-scale GMP filling support
Back to Biologics CDMO Services
3types of dosage forms
One formulation suitable for liquid injections · prefilled syringes · lyophilized powders
2+1 rounds
Two rounds of formulation screening plus one round of DoE to determine the final formulation
7 items
Service coverage from developability assessment to long-term stability
5types of molecules
mAbs · bispecifics · recombinant proteins · fusion proteins · cytokines
Development Workflow

Development workflowFormulation · Process · Components

From formulation screening to container-closure compatibility, advanced through a three-stage platform approach.

STEP 01

Drug product formulation developmentFormulation Screening

  • Based on the proteinBasic physicochemical propertiesunderstanding to conduct screening
  • of the formulation pH/buffer system, types of stabilizers/surfactantsconducting two rounds of initial screening
  • followed by another round of DoE(Design of Experiment)design to determine the final formulation's components and concentration ranges
STEP 02

Drug product process developmentProcess Development

  • Using the defined formulation to develop a suitableDrug product manufacturing processes
  • meetTechnology transfer and scale-upneeds, supporting pilot-scale finished product filling under GMP conditions
  • coveringDrug substance freeze-thaw, drug substance mixing, sterile filtration, filling process parameter studies and lyophilization process parameter studies, etc.
STEP 03

Packaging material screening and compatibility studiesComponents & Compatibility

  • Primary packaging materials can be selected fromZencore's platform materialsselected from
  • At the client's request, packaging materials can beCompatibilityTest experiments
  • as well asContainer closure integrity for packagingTest experiments
What We Offer

Zencore formulation development provides you withService Scope

01Developability assessment (rapid platform methods)
02Drug product formulation development (liquid injections, prefilled syringes and lyophilized products)
03Drug product process development (liquid injections, prefilled syringes and lyophilized products)
04Screening of pharmaceutical packaging materials and compatibility studies
05Drug compatibility stability studies
06Drug product pilot process technology transfer
07Accelerated and long-term stability studies
Zencore Biologics formulation development laboratory
Platform Advantages

Platform advantagesWhy Zencore FD

01

Highly experienced team

Members of the formulation R&D team have strong professional formulation development expertise and rich data analysis experience, and have participated in or led the development of multiple biologic formulation projects,with several having completed China-US clinical filings

02

Broad coverage of development categories

Broadly covering essentially all protein drugs in the biopharmaceutical industry, includingMonoclonal antibodies, bispecific antibodies, recombinant proteins, fusion proteins and cytokines

03

Broad coverage of development technologies

Covering the biopharmaceutical industryvarious drug product processes and workflows. Completed formulations are applicable to liquid injections, prefilled syringes and lyophilized powders, with container-closure compatibility studies.

04

Customized services

High-quality customized services for clients' projectstargeted formulation design, carried out in accordance with various regulations and requirementstemperature, oxidation, light exposureand other accelerated and long-term stability studies for formulation screening, thoroughly evaluating the stability of the target protein in a given formulation.

Case Studies

Case StudiesSuccess Stories

Solving two representative quality issues at the formulation level.

CASE 01

protein oxidation

Study objectives:resolving the yellowing of the finished product
Problem statement

During formulation development for an mAb project, samples were found to turn yellow after light exposure.

Solution strategy

by screening suitablebuffer systems and antioxidantsto find the optimal formulation; investigation revealed that the yellowing was caused by the target protein undergoingOxidation reactions

Final results

Because the investigation was completed quickly, the issue that arose in formulation development did not delay overall process development timelines, and the projectsmoothly advancing to pilot manufacturing

CASE 02

Reversible aggregates

Study objectives:resolving the cause of elevated aggregate content in the finished product
Problem statement

In a bispecific antibody project, the target molecule showed high aggregate content in conventional buffer.

Solution strategy

throughswitching between various buffer systemsas well asOptimizing SEC testing methodsto investigate the cause.

Final results

The study found that the aggregate isReversible aggregates; a specific component had to be avoided during formulation development; excluding that component in formulation screening yielded better SEC performance. The project hasSuccessfully passing IND filing and beginning clinical studies

Key Instruments

Main equipmentKey Equipment

From lyophilization parameter studies to high-throughput particle size/stability characterization.

Lyophilizers

Lyophilizers

Lyophilization process parameter studies and lyophilized drug product development

FlowCAM particle counting and imaging analysis system

FlowCAM

Flow imaging and particle counting to characterize protein particles

High-throughput dynamic light scattering instrument

High-throughput dynamic light scattering instrument

Rapid assessment of aggregation trends supporting formulation and stability screening

DSF differential scanning fluorimetry system

DSF

Differential scanning fluorimetry to determine protein thermal stability (Tm)

Long-term stable protein formulations

Liquid injections, prefilled syringes, lyophilized powders - Zencore's formulation development platform selects the right formulation and process for your product.

Inquire about formulation development