FREEZE-DRIED PRODUCT

Abstract

A freeze-dried product continuously manufactured by being dried while smoothly moving in a state of receiving a mechanical force in a freeze-drying apparatus 1. The freeze-drying apparatus 1 includes a freezing unit 2 for producing a frozen substance by spraying a raw material solution; and a drying unit 3 for drying the frozen substance. The drying unit 3 has a tubular shape and includes a tubular member 31 kept in a vacuum state, and a spiral wall or groove portion is formed on an inner wall of the tubular member 31 continuously in a longitudinal direction of the tubular member 31. A heat is transferred to the inner wall of the tubular member 31 and the spiral wall or groove portion. The tubular member 31 is configured to be rotated to transfer the freeze-dried product in the longitudinal direction of the tubular member 31 and sublimate or dry the freeze-dried product. A flow-start angle is less than 44 degrees or a repose angle is less than 55 degrees and larger than the flow-start angle, and a residual amount is 3 g or less with respect to 10 g of the raw material solution fed into freeze-drying apparatus when a length of the tubular member 31 is 30 cm in the longitudinal direction.

Claims

1. A freeze-dried product manufactured by being dried while moving in a state of receiving a mechanical force in a freeze-drying apparatus, wherein the freeze-drying apparatus includes: a freezing unit for producing a frozen substance by spraying a raw material solution; and a drying unit for drying the frozen substance while transferring the frozen substance, the freezing unit is configured to produce the frozen substance by discharging the raw material solution from a nozzle into a vacuum or into a cold air blowing environment, the drying unit has a tubular shape linearly extending in a horizontal direction, the drying unit includes a tubular member kept in a vacuum state, a spiral wall or groove portion is formed on an inner wall of the tubular member continuously in a longitudinal direction of the tubular member, the drying unit is divided into three or more sections in the longitudinal direction to surround a periphery of the tubular member, a temperature-controlled air or liquid is configured to be supplied to each of the three or more sections of the periphery of the tubular member to transfer a heat to the inner wall of the tubular member and the spiral wall or groove portion, the tubular member is configured to be rotated to transfer the frozen substance or the freeze-dried product in the longitudinal direction of the tubular member while sliding on the spiral wall or groove portion, sublimate or dry the frozen substance or the freeze-dried product while transmitting the heat to the frozen substance or the freeze-dried product from the inner wall of the tubular member and the spiral wall or groove portion, and discharge a moisture evaporated when the frozen substance or the freeze-dried product is sublimated or dried to an outside, a flow-start angle is less than 44 degrees or a repose angle is less than 55 degrees and larger than the flow-start angle, and a residual amount is 3 g or less with respect to 10 g of the raw material solution fed into freeze-drying apparatus when a length of the tubular member is 30 cm in the longitudinal direction.

2. The freeze-dried product according to claim 1, wherein the flow-start angle is 38 degrees or less, the repose angle is 40.5 degrees or less and larger than the flow-start angle, and the residual amount is 0.4 g or less.

3. The freeze-dried product according to claim 1 or 2, wherein the raw material solution includes at least one of a sugar alcohol and a disaccharide as an excipient.

4. The freeze-dried product according to claim 3, wherein the sugar alcohol is an erythritol or a mannitol, and the disaccharide is a sucrose or a trehalose.

5. The freeze-dried product according to claim 1, wherein the freeze-dried product is an injectable substance or a drug in a solid formulation.

6. The freeze-dried product according to claim 5, wherein the injectable substance or the drug is selected from the group consisting of: a vaccine preparation including a COVID-19 vaccine preparation, a smallpox vaccine preparation or an influenza vaccine preparation; a bio-pharmaceutical including a nucleic acid or an antibody; an antiviral agent; and a stem cell.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 is a front longitudinal section view of a vacuum freeze-drying apparatus used for performing the present invention.

[0021] FIG. 2 is a front view showing a drying unit of the vacuum freeze-drying apparatus of FIG. 1.

[0022] FIG. 3 is a plan view showing the drying unit of the vacuum freeze-drying apparatus of FIG. 1.

[0023] FIG. 4A is a perspective view, FIG. 4B is a front view, FIG. 4C is a cross-sectional view,

[0024] FIG. 4D is a front longitudinal section view and FIG. 4E is a partially enlarged view showing one of a plurality of tubular portions constituting the tubular member provided with the drying unit.

[0025] FIG. 5 is an explanation drawing of a measuring method of a repose angle of the present invention.

[0026] FIG. 6 is a perspective view of a measuring apparatus a flow-start angle of the present invention.

[0027] FIG. 7 is a front view showing a measuring state of the flow-start angle.

[0028] FIG. 8 is a measurement data of the repose angle and the flow-start angle of the experiment samples No. 1 to 8 and reference examples 1 to 2 of the freeze-dried product.

[0029] FIG. 9 is a measurement data of the repose angle and the flow-start angle of the experiment samples No. 9 to 17 and reference example 3 of the freeze-dried product.

[0030] FIG. 10 is a data of analyzing fluidity based on the measurement data of the repose angle and the flow-start angle.

MODES FOR CARRYING OUT THE INVENTION

[0031] The preferable embodiments of the present invention will be described below in detail based on the drawings. Refer to the above described Patent document 4 (Japanese Patent No. 6777350) about the vacuum freeze-drying apparatus used for manufacturing the freeze-dried product of the present invention. Note that the freeze-dried product includes an injectable substance or a drug in a solid formulation. For example, the freeze-dried product is: a vaccine preparation including a smallpox vaccine preparation or an influenza vaccine preparation; a bio-pharmaceutical including a nucleic acid or an antibody; an antiviral agent; and a stem cell.

[0032] FIG. 1 is a front longitudinal section view of the vacuum freeze-drying apparatus used for performing the present invention. FIG. 2 is a front view showing the drying unit of the vacuum freeze-drying apparatus of FIG. 1. FIG. 3 is a plan view showing the drying unit of the vacuum freeze-drying apparatus of FIG. 1.

[0033] A vacuum freeze-drying apparatus 1 includes a freezing unit 2, a drying unit 3, a connecting unit 4 and a collecting unit 5. The freezing unit 2 discharges the raw material solution from a nozzle 21 into a vacuum vessel. The discharged raw material solution is frozen in the vacuum and the frozen substance is produced. The raw material solution is self-frozen in the middle of being discharged or dripped when the moisture is evaporated and latent heat is taken. Thus, the frozen substance, which is fine frozen particles, is generated by sublimation. Then, the frozen substance is dropped toward a collection unit 22 and collected by the collection unit 22 which has a tapered shape tapered downward. The connecting unit 4 is a unit for connecting the freezing unit 2 with the drying unit 3 and transferring the frozen substance produced in the freezing unit 2 to the drying unit 3. The drying unit 3 sublimates and dries the frozen substance.

The collecting unit 5 is a unit for collecting the dried object discharged from the outlet of the drying unit 3. In the vacuum freeze-drying apparatus, it is also possible to produce the frozen substance by discharging the raw material solution from the nozzle into a cold air blowing environment. When using the above described cold air freezing method, the cold air is blown from a lateral side when the raw material is dropped.

[0034] The drying unit 3 includes a tubular member 31 for transferring the frozen substance or the freeze-dried product. The tubular member 31 has a tubular shape linearly extending in a horizontal direction. The both ends of the tubular member 31 are opened. The tubular member 31 includes an inlet 31b from which the frozen substance transferred by the connecting unit 4 is entered and an outlet 31c which functions as the outlet of the dried object after it is sublimated and dried. The inlet 31b includes a reception port 302 for receiving the frozen substance. In the tubular member 31, a spiral transfer means 31a is provided near the inner wall of the tubular member 31 so that the spiral transfer means 31a is continuously formed from the inlet 31b toward the outlet 31c. The frozen substance transmitted from the connecting unit 4 is entered from the inlet 31b of the tubular member 31 and transferred to the outlet 31c by the spiral transfer means 31a.

[0035] The tubular member 31 is divided into three or more sections (at least three sections) in the longitudinal direction to surround a periphery of the tubular member 31. Temperature controllers 30a to 30j are provided for controlling the temperature of each of the three or more sections of the periphery of the tubular member 31 by dripping and supplying temperature-controlled air or liquid. The temperature controllers 30a to 30j are provided on the outer peripheral portions of the tubular member 31 to adjust the temperature of the outer surface of a plurality of areas 40a to 40j of the tubular member 31. The plurality of areas 40a to 40j are provided from the inlet 31b to the outlet 31c of the tubular member 31 so that the temperature can be independently controlled for each of the areas 40a to 40j. The temperature controllers 30a to 30j control the temperature of each portion of the tubular member 31 corresponding to the plurality of areas 40a to 40j by adjusting the temperature of the plurality of areas 40a to 40j. The number of the temperature controllers 30a to 30j is ten and the number of the plurality of areas formed by ten temperature controllers 30a to 30j is also ten.

[0036] The heat is transferred from the temperature-controlled areas 40a to 40j to the inner wall of the tubular member 31 and a transfer means 31a provided inside the tubular member 31. The frozen substance or the freeze-dried product is sufficiently contacted with the inner wall or the transfer means 31a. Thus, the frozen substance or the freeze-dried product is transferred in the longitudinal direction of the tubular member 31 and the heat is transferred efficiently by the sliding movement between the frozen substance or the freeze-dried product and the transfer means 31a. Consequently, the frozen substance or the freeze-dried product inside the tubular member 31 is sublimated or dried and the evaporated moisture is discharged to the outside of the tubular member 31. The area of the periphery of the tubular member divided into three or more sections includes at least a minus temperature area, a temperature area 40? C. higher than the minus temperature area, and a temperature area of plus 20? C. or more from the inlet to the outlet of the tubular member 31.

[0037] A rotating unit 7 for rotating the tubular member 31 is provided. When the tubular member 31 is rotated by the rotating unit 7, the frozen substance entered from the inlet 31b of the tubular member 31 is sequentially transmitted toward the outlet 31c in the tubular member 31 through the spiral transfer means 31a. In the above describe process, the frozen substance is continuously sublimated and dried. The rotating unit 7 is configured to rotate only the tubular member 31. Thus, the temperature controllers 30a to 30j located at the outer periphery of the tubular member 31 are not rotated. The temperature controllers 30a to 30j are fixed so as not to be rotated.

[0038] The rotating unit 7 includes a motor 71, pulleys 72, 73, a belt 74, rotation axes 75, 76 and rotary rollers 77, 78. The belt 74 is wound around the pulleys 72, 73. The rotational force of the motor 71 is transmitted via the belt 74. The rotary roller 77 are arranged below the both ends of the tubular member 31. The tubular member 31 is placed on the rotary rollers 77 which are arranged on both sides. The pulley 73 is attached to near one end of the rotation axis 75. The rotary roller 78 attached to a fixing stand is provided inside the pulley 73 and the rotary roller 78 attached to a fixing stand is also provided on the other end of the rotation axis 75. Eight rotary rollers 77 are attached to the rotation axis 75 between the rotary rollers 78, 78. The rotary rollers 78 attached to a fixing stand are provided on one end of the rotation axis 76 and the rotary rollers 78 attached to a fixing stand are also provided on the other end of the rotation axis 76. Eight rotary rollers 77 are attached to the rotation axis 76 between the rotary rollers 78, 78. The rotary rollers 77 attached to the rotation axis 75 are driving rollers while the rotary rollers 77 attached to the rotation axis 76 are driven rollers.

[0039] When the motor 71 is rotated, the belt 74 is rotated via the pulley 72 and the rotation axis 75 is rotated by the rotation of the pulley 73. The tubular member 31 is rotated when the rotary rollers 77 fixed to the rotation axis 75 are rotated, and the rotary rollers 77 are rotated as the driven rollers attached to the rotation axis 76. As for the rotating speed of the tubular member 31, the rotation speed rotated by the rotating unit 7 is preferably more than 1/30 rotation per minute or more and one rotation per minute or less.

[0040] Then, the transfer means 31a used for performing the present invention in the drying unit will be explained. FIGS. 4A to 4E show a tubular portion 31B which is one of a plurality of tubular portions constituting the tubular member 31. FIG. 4A is a perspective view of the tubular portion 31B, FIG. 4B is a front view of the tubular portion 31B, FIG. 4C is a side view of the tubular portion 31B, FIG. 4D is a front longitudinal section view of the tubular portion 31B and FIG. 4E is a partially enlarged cross-sectional view where B-portion shown in FIG. 4D is enlarged.

[0041] Edge portions 31d are formed on the tubular portion 31B to protrude from both opening ends in a radial direction. A part of the spiral transfer means 31a is continuously formed from one end of the tubular portion 31B to the other end. The wall portions are continuously formed on an inner wall of the tubular portion 31B as a part of the transfer means 31a (e.g., a wall portion 31a1 of the first round, a wall portion 31a2 of the second round). The height of wall portion 31a1 and the height of the wall portion 31a2 are the height of the transfer means 31a. For example, the height of the transfer means 31a is preferably within the range of 3 mm or more and 50 mm or less. A pitch P between the wall portion 31a1 and the wall portion 31a2 is the pitch of the spiral transfer means 31a. For example, the pitch of the spiral transfer means 31a is preferably within the range of 5 mm or more and 20 mm or less. It is possible to form spiral groove portions on an inner peripheral surface of the tubular member 31 as the transfer means 31a having a rotating axis as a center. Thus, the function of spirally feeding the material in the tubular member 31 is given. Accordingly, the frozen substance or the freeze-dried product can be transferred.

[0042] It is required to find the property capable of smoothly transferring the dried product in the drying unit 3 and extracting the produced dried product from the drying unit 3. Thus, the relation between the residual material of the dried product in the apparatus and the property was revealed. Namely, the property is related to the transfer of the freeze-dried product. Specifically, the property is the repose angle and the flow-start angle where the transfer starts. When the measurement was performed focusing on the flow-start angle and the repose angle, it was revealed that the repose angle should be larger than the flow-start angle and the repose angle should be less than 55 degrees as the property of the freeze-dried product capable of being smoothly transferred in the tubular member 31. In addition, it was revealed that the flow-start angle should be less than 44 degrees as the property of the freeze-dried product capable of being smoothly transferred in the tubular member 31.

EXAMPLES

[0043] Hereafter, the preferable examples of the present invention will be explained.

[0044] First, the preparation method of the samples will be described. Here, the raw material solution is a raw material reagent. A drug and a medical agent are not contained in the raw material solution for convenience purposes. As an example of the method of preparing the raw material solution containing 10%-D-Mannitol, water is added to 50 g of D-Mannitol until the total weight becomes 500 g and the mixture is stirred. As an example of the method of preparing a mixed solution containing 5%-D-Mannitol/5%-sucrose, 25 g of sucrose is added to g D-Mannitol, then water is added until the total weight becomes 500 g and the mixture is stirred. Hereafter, when the similar description is used, this means the weight % of the excipient with respect to the raw material solution.

[0045] (1) 10%-D-Mannitol/10%-sucrose, (2) 8%-D-Mannitol/2%-sucrose, (3) 5%-D-Mannitol/5%-trehalose, (4) 5%-erythritol/5%-sucrose, (5) 5%-D-Mannitol/5%-sucrose, (6) 10%-trehalose, (7) 10%-sucrose, (8) 10%-D-Mannitol, (9) 10%-erythritol, (10) 5%-D-Mannitol/5%-trehalose, (11) 5%-D-Mannitol/5%-sucrose, (12) 10%-erythritol, (13) 5%-erythritol/5%-sucrose, (14) 10%-trehalose, (15) 10%-D-Mannitol, (16) 10%-sucrose and (17) 8%-D-Mannitol/2%-sucrose were prepared as the raw material solution which were the bases of the samples used for the experiment of the present invention.

[0046] In the raw material solution prepared as described above, the freeze-dried product was produced by the freeze-drying apparatus 1 (spray freeze-drying apparatus) about the raw material solution (1)-(8) and named as the samples No. 1, No. 2, No. 3, No. 4, No. 5, No. 6, No. 7 and No. 8 respectively. In addition, the freeze-dried product was produced by the shelf-type freeze-drying apparatus about the raw material solution (9)-(17), crushed by a stainless spatula, and sieved with a mesh having an aperture of 850 ?m and named as the samples No. 9, No. 10, No. II, No. 12, No. 13, No. 14, No. 15, No. 16 and No. 17.

[0047] The moisture content of the freeze-dried product of the target of the present invention is less than 10%. In addition, the particle diameter of the freeze-dried product produced by the vacuum freeze-drying apparatus 1 is 2000 ?m or less.

[0048] As the reference examples, (1) tablettose, (2) potato starch and (3) rice flour were prepared while being sieved with a mesh having an aperture of 850 ?m although they were not the freeze-dried product.

[0049] Then, the method of the characteristic test will be described.

[0050] FIG. 5 is an explanation drawing of the measuring method of the repose angle. The repose angle was measured as described below.

[0051] 200 mg of the dried product finally prepared was collected, entered into a funnel having an inner diameter of a funnel mouth of 6 mm and discharged on a stand having a diameter of 2 cm located 8 cm downward from the funnel mouth by free fall. Thus, the dried product was deposited. At this time, it is not necessary that the deposited state has a simple conical shape. An apex may be located at the other portion than the center. Therefore, when the repose angle is measured, it is necessary to calculate the average value of the inclined angles from the apex to the conical face located below. Namely, the average of the angles was calculated at four positons of the crossed directions passing through the apex to the horizontal surfaces. The later described No. 1 to No. 4 (left column) of the sample No. 1 show the result of four experiments and show the measured values of the repose angle at four positions and the average of them. The same is also applied to the sample No. 2 and later samples. The result of the flow-start angle is also shown in the right column. Regarding the sample No. 1, the flow-start angle was measured for each of four experiments and the average of the flow-start angle was calculated. In addition, the standard deviate of the flow-start angle is shown in the right column. The same is also applied to the following sample No. 2 to the sample No. 20 (shown in FIG. 6).

[0052] FIG. 6 is a perspective view of the measuring apparatus for measuring the flow-start angle of the present invention. FIG. 7 is a front view of the measuring apparatus showing the measuring state of the flow-start angle. The flow-start angle is measured for analyzing the adhesive property of the freeze-dried product to the apparatus and the adhesive property between the freeze-dried products. Here, the freeze-dried product is placed on the tray and the tray is inclined slowly. Thus, the angle is measured when the freeze-dried product starts to flow. A measuring apparatus 10 used in the experiment was formed by installing a flat-bottomed tray 12 in a horizontal state inside a cylinder 11 which was made of resin and the axial center direction of the cylinder 11 was horizontally arranged, adding scales of 180 degrees (a half circle) to one end in the axial direction of the cylinder 11, and attaching a measurement needle rotatably so that the measurement position is always kept upward in the vertical direction at the center of the scales. The measuring apparatus 10 was fixed to the cylinder 11 by a fastener 13 at both ends of the tray 12. The tray 12 was made of SUS430 and a width was 14 cm, a depth was 9 cm and a height was 15 mm. The tray 12 was filled with 200 mg of the freeze-dried product and the tray was tapped ten times by hand to flatten the accumulated freeze-dried product while preventing the freeze-dried product from scattering. Then, the cylinder 11 is inclined (rotated) at the rotating speed of approximately 6 degrees per second. Consequently, the position of the measurement needle on the scales was read when the freeze-dried product started to flow on the tray. Thus, the flow-start angle was determined. FIG. 7 shows the case where the flow-state angle is approximately 31.1 degrees.

[0053] In addition, the residual characteristics of the dried product in the tubular member 31 were measured for evaluating the actual usefulness in the apparatus. As the experiment method, the tubular portion was detached except for the tubular portion 31B having the length of 30 cm in the longitudinal direction of the tubular member 31 shown in FIG. 4, 10 g of the sample was entered into a portion separated 2 cm from the inlet in a state that the tubular portion 31B was rotated around the axial direction for thirty minutes at a rotating speed of one rotation per minute, and the material discharged from the outlet of the tubular portion 31B was collected.

[0054] Then, the residual amount (calculated by subtracting the discharged amount from the fed amount) was measured.

[0055] In FIG. 8 and FIG. 9, the repose angle and the flow-start angle were measured three times or four times and the average and the standard deviate were calculated. As an example, regarding SFD10%-Mannitol/10%-sucrose of No. 1, the repose angle is 36.5 degrees in No. 1, 42.8 degrees in No. 2, 42.2 degrees in No. 3 and 40.5 degrees in No. 4. Thus, the average of the repose angle of 1 to 4 was 40.5. In addition, the flow-start angle is 39 degrees in No. 1, 31 degrees in No. 2, 44 degrees in No. 3 and 32 degrees in No. 4. Thus, the average of the flow-start angle was 36.5.

[0056] The experiment raw data of the sample No. 1 to the sample No. 20 are shown in FIG. 8 and FIG. 9 and the analysis result and the evaluation result are shown in FIG. 10. FD means the shelf-type freeze-drying and SFD means the spray freeze-drying in the sample name shown in FIG. 8, FIG. 9 and FIG. 10. FIG. 10 shows the average A)(? of the repose angle, the average B)(? of the flow-start angle, the repose angle-flow-start angle C)(? and the residual material D (g) of the sample No. 1 to the sample No. 17 and the reference examples 1-3.

[0057] In the present invention, the dried product having the transfer characteristics of generating the residual material of 3 g or less when the spiral transfer means 31a (corresponding to the longitudinal length of the tubular member 31) is 30 cm and the fed material is 10 g is used as the example. When the physical property of the freeze-dried product used as the example was analyzed, it was revealed that the following relation was satisfied: the repose angle A was 55 degrees or less and the repose angle is equal to or greater than the flow-start angle (the repose angle?the flow-start angle). In addition, it was revealed that the flow-start angle was less than 44 degrees.

[0058] Namely, the relation between the repose angle and the flow-start angle is satisfied as described above, the suitable dried product can be transferred smoothly. For example, the dried product can be transferred smoothly when the repose angle of SFD10%-D-Mannito 1/10% sucrose of the sample No. 1 is 40.5 degrees, the flow-start angle is 36.5 degrees, the repose angle-flow-start angle is 4.0 degrees and the residual material is 0.2 grams. In the examples shown in FIG. 10, the samples No. 1, 2, 3, 4, 5, 6, 7 and 8 are the object of the present invention, and the sample No. 14 is the comparative example since the condition of the repose angle?55 degrees is not satisfied. The condition of the repose angle?the flow-start angle is not satisfied in the samples No. 9 to 17 except for the sample No. 14. Accordingly, these are the comparative examples.

[0059] As a result, the sample No. 1 to the sample No. 8 are the examples of the present invention since the preferable result could be obtained. The sample No. 9 to No. 17 which are not suitable are comparative examples. In the above described examples, the residual material of the samples No. 1 to 6 was 0.4 g or less (especially small) and the transfer was good. In particular, the dried product could be transferred well when the freeze-dried product was generated by using a mixed solution of the sugar alcohol and the disaccharide was used as the raw material solution and D-Mannitol or erythritol was used as the sugar alcohol and the sucrose or the trehalose was used as the disaccharide.

[0060] When the residual amount is 3 g or less with respect to 10 g of the fed amount and 30 cm of the length of the tubular portion 31B in the transfer direction, the residual amount becomes 30 g to 60 g with respect to the tubular member 31 having the effective drying cylinder length of 3 m to 6 m, which corresponds to the length of ten tubular portions 31B. This means that the residual amount is approximately 100 g or less when the apparatus is operated for a long time. Thus, the residual amount is acceptable as a production apparatus. If the residual amount is 0.4 g or less in the same condition, the residual amount becomes 4 g to 8 g with respect to the effective drying cylinder length of 3 m to 6 m. Thus, it is more preferable from the viewpoint of the yield.

[0061] Although the present invention has been described using above embodiments, it goes without saying that the technical scope of the present invention is not limited to the scope of the above embodiments, and it is clear to those skilled persons in the art that various modifications or improvements added to the above embodiments are possible. Further, it is clear from the description of the scope of claims that the form to which such modifications or improvements are added may be included in the technical scope of the present invention.

DESCRIPTION OF THE REFERENCE NUMERALS

[0062] 1: freeze-drying apparatus; 2: freezing unit; 3: drying unit; 4: connecting unit; 5: collecting unit; 7: rotating unit; 10: measuring apparatus of flow-start angle; 30a to 30j: temperature controller; 31: tubular member; 31a: spiral transfer means; 40a to 40j: area