Analytical Test Method Validation for API Raw Material, In Process Control, and Early Intermediate Material Tests
System Suitability Testing
Introduction
This guidance provides guidance for the validation of analytical test methods. These analytical test methods include those tests which evaluate API Raw Materials, In Process samples (e.g. reaction monitoring) and early intermediate materials (prior to the introduction of the first critical intermediate).
Per ICH Q7A, the degree of analytical validation performed should reflect the purpose of the analysis and the stage of the API production process. Material, In-Process Control and Early Intermediate Material Tests.
System Suitability is a predetermined set of tests and applied method requirements that are used to determine if an analytical method is performing within its validated parameters and is acceptable for its intended use. The method validation exercise may include statistical interpretation of data to provide adequate justification for reduced System Suitability Testing (SST) and numbers of standard and sample injections. Suggested System Suitability recommendations are established in Appendix 1 for different types of API “In-Process testing”.
Recommended SST Data
System suitability criteria from compendial general chapter methods may be used for some test methods but should be evaluated against the intended use of the test method as to applicability.
Resolution can be calculated between the major component and an internal standard, the major component and an expected impurity found in the reference standard, two impurity peaks in the reference standard (resolution material), or two peaks that are the most difficult to separate (often referred to as “the critical pair”). Since resolution is the primary criterion for specificity and robustness, it serves as a rigorous parameter for suitability. If there is no critical pair to establish a resolution criterion, a retention time window may be used in its place. Minimum criteria should be that there is baseline resolution between the peaks.
Efficiency, as measured by theoretical plates, may be of importance as a measurement of column performance, especially in cases where there are no other peaks with which to perform resolution determinations.
Peak symmetry, as measured by the tailing factor, may be of importance to report, especially in impurity testing. If tailing is too extensive, it may mask other impurities. When the tailing factor increases, integration becomes less reliable and precision can be compromised. Peak fronting may also cause integration problems and may become a factor as columns age.
It is considered that repeatability is normally used as an essential criterion for system suitability testing but this may not be possible for all types of IPC test methods. For example, Area % methods do not require repeatability. System repeatability is regarded as the contribution of the instrumental variability to the precision.
Demonstration of specificity may be required for certain applications and may involve resolution between two significant peaks, peak efficiency by theoretical plates or peak symmetry by tailing factor. It is recommended that the specificity be demonstrated as part of the SST criteria where variability of sample make up is possible (e.g. for a chromatographic method or TLC method, the sample diluent is prepared on day of analysis or may be of a different batch/lot of solvent to that used during validation). It may be of benefit to demonstrate adequate specificity between the diluent (blank solvent) and the sample solution. This is particularly useful when investigating low-level impurities as the detection and attribution of a novel impurity to the sample may be discounted by its presence in the sample diluent.
For non-chromatographic testing, the use of control samples or day/ time of use calibration may sometimes be appropriate for some technologies. Examples include but are not limited to KF, LOD (day/time of use calibration), and particle size (control samples).
Other pharmacopoeias should be consulted if required, however, the US Pharmacopoeia recommends that to determine system suitability % RSD, 5 replicate injections if the % RSD is 2.0 or less and if the % RSD is greater than 2.0, six replicate injections are recommended. While the USP recommends the above % RSDs, these criteria may not be adequately low to assure method performance (e.g. when the %RSD of the assay is 1% or when the specification is tight such as 99.0 – 101.0%). Therefore, it may be relevant to consider using the EP Pharmacopoeia recommendation for a tighter % RSD of 1/3 of the specification range to have a 95% confidence that the result is within the limit. The EP recommends that system suitability for repeatability is based on the limit range and number of standards used in the test, where n can vary from three to six.
Recommended SST Criteria
The acceptance criteria used should assure adequate precision and specificity for the intended use. One approach is to set chromatographic SST criteria based on data collected during a validation exercise. Equivalency may be demonstrated as follows,
If resolution is no less than 0.8 times of the average typical value; tailing is no greater than 1.3 of typical value; and efficiency is no less than 0.8 times of the average typical value. It is recommended that a sensitivity standard at the 0.05% level for API impurity and degradation methods be utilized.