The Role of BioPhorum Extractables Data in the Effective Adoption of Single-Use Systems

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The landscape for single-use systems
Single-use systems are increas
ingly popular in
biomanufacturing. Their adoption offers numerous
advantages for greater efficiency and productivity in
applications such as final filtration, mixing and aseptic
connections. Single-use systems can reduce capital
investment in facilities and equipment, eliminate
the need for cleaning procedures and their required
validation, reduce startup times and decrease the risk
of cross-contamination. Further benefits include more
dependable lead times and faster delivery of higher-
quality, lower-cost products.
Despite these advantages, single-use systems can
also contain risk. Polymeric materials in single-use
systems can introduce a range of unwanted chemicals
into the manufacturing process fluid. Substances
such as styrene monomers, stabilizers, lubricants
and slip agents, pigments and antioxidants such
as BHT may either leach out of the system or be
extracted by solvents used in the manufacturing
process. For patient safety, biomanufacturers must
systematically assess and mitigate the risks posed
by any extractables and leachables (E&L) in these
systems. Unfortunately, the burden of obtaining E&L
data and assessing and mitigating any risk found is
the top reason some researchers restrict their use of
single-use systems.
Guidance for evaluating SUS for
extractables and leachables
Although formal guidelines for E&L assessments
have not yet been enacted, there is nonetheless a
regulatory expectation that researchers will test for
these potentially harmful contaminants. Agencies
such as the U.S. Food and Drug Administration (FDA)
Center for Biologics Evaluation and Research (CBER)
recommend a risk-based approach to evaluation.
The Role of BioPhorum Extractables Data in
the Effective Adoption of Single-Use Systems
Author: Jessica Shea, Program Manager, Emprove®
Program, MilliporeSigma
In such an approach, indication, safety, product
characteristics, dosage, formulation and stability are
all factors.
If there appears to be lower risk with the materials
in question, the sponsor can submit supplier data,
a detailed justification for applying this data and
an explanation of why no more testing is required.
Guideline on process validation for the manufacture
of biotechnology-derived active substances and data
to be provided in the regulatory submission, EMA/
CHMP/BWP/187338/2014 If there is relevant risk, the
sponsor may have to determine toxicity based on
maximum dosage of potential leachables derived from
extractables data. If the risk of maximum dosage of
potential leachables remains, leachable evaluation and
testing may be necessary. Furthermore, if product
quality could be affected by a potential leachable,
studies may need to assess the effect on product
quality, including efficacy. These evaluations are
possible when the supplier provides extractables
data, which can supplement final product quality
assessments.
Beyond the regulatory sphere, numerous industry
organizations have created best-practice strategies
for implementing extractables studies. Prominent
among these coalitions is BioPhorum formerly
known as BioPhorum Operations Group (BPOG),
a global consortium of large biopharmaceutical
manufacturers. Many manufacturers are fulfilling
regulatory expectations following BioPhorum
extractables test methods and using compendial
methods from U.S. Pharmacopeia. USP <665> which
is effective in May 2026 is the first guidance specific
to extractables evaluation of single-use components
used in manufacturing. An overview of these standard
extractables testing protocols is shown in Table 1.
MilliporeSigma is the U.S. and
Canada Life Science business of
Merck KGaA, Darmstadt, Germany.

2
Table 1. Comparison of BioPhorum and USP protocols for extractables testing
BioPhorum Requirements USP <665> (November 2021)
Scope Single-use components in contact with fluid path
(for biopharmaceutical manufacturing)
Single-use and multi-use components and devices with fluid path
contact (for pharmaceutical and biopharmaceutical manufacturing)
Solvents 1. 50% Ethanol
2. 0.5 N NaOH
3. 0.1 M Phosphoric Acid
4. WFI
1. 50% Ethanol
2. 0.2 M KCI, pH 3
3. 0.1 M Phosphate buffer, pH 10
Analytical methods HPLC-DAD
/
MS (APCI, ESI, +/–) NVR
ICP / MS TOC
DI-GC / MS, HS-GC / MS pH
Described in USP <1663>. Broader scope in methods selection.
Time points 1–3, dependent on component 1, dependent on component
Pre-treatment If an item is pre-treated prior to actual use,
the item should be pre-treated exactly the same
way before being tested for extractables.
Polymeric components are most appropriately tested when they have
been conditioned or processed in a manner consistent with their
intended use and as specified in the manufacturer’s
instructions for
use.
Timing Revised BioPhorum Protocol published in
Apr 2020
Effective May 2022
Note that while these protocols are not identical,
the general idea is similar and at least one or the other
can apply to most drug products and substances.
Testing is performed at various time points and tem-
peratures. Resulting extraction solutions are subjected
Figure 1. Schematic of a 32-component Mobius®
filtration assembly containing various types of single-use filters and bags
STOP!
2 31
15 31 20 30 13 30 21 29 12 29 21 30 13 30 20 31 15 31 1 29
31
29
26
26
11 11
29
29
5 5
3
9
16 31 19 31 17 28
30
14
18
27
6
3
9
22
23
8
5
23
8
7
31
4
10
30
FLOW
to robust and extensive analyses to determine what
levels of volatile, semi-volatile and nonvolatile organic
compounds, and metals, have been extracted. Either
approach will produce an array of data that must then
be evaluated in the context of the proposed process.
Supplier-provided single-use system extractables data saves time and resources
The task of gathering all the product information required to assess risk and optimize E&L test strategies for a
process can be daunting. Consider the filtration setup shown in Figure 1. This one assembly exposes the contact
fluid to multiple components as indicated.
A proper E&L assessment must account for the risk
imposed by each component in the fluid path. Once
each component’s materials of construction (MOC),
resin identity and manufacturing process have been
documented, similar components may be grouped
together for analysis. Two to three lots of worst-case
representative samples are extracted as per the
chosen testing protocol, under worst-case conditions.
Finally, sample analysis yields an extractables profile
quantifying all volatile, semi-volatile and nonvolatile
organic compounds found, as well as elemental
impurities.
This complex process is much simpler when the sup
plier provides comprehensive, organized datasets for
its single-use components, such as filters and bags.

3
The overall strategy for E&L validation
Determining risk and interpreting extractables data to construct a reasonable validation strategy is a complex
process; expert assistance can be valuable. The general steps in evaluating each single-use component are as
outlined in Figure 2.
Figure 2. Risk-based approach to E&L assessment
Assess the Risk
•
Define the process –
feed formulation,
filtration and process
conditions
Assess the Risk
to Patient Safety
•
Patient safety
evaluation
Identify and
Quantity the
Extractables
• Extractables
data
Identify and
Quantity
individually the
Leachables
•
Leachables tests
• Flushing / risk
mitigation
Regulatory
Submission
Re-assess the Risk
to Patient Safety
• Update patient
safety evaluation
A B
In general, drug manufacturers must evaluate the
single-use components that are in product contact
under the given process conditions such as duration,
temperature, solvents, material characteristics,
etc. Any risk-mitigating steps occurring later in the
process can be taken into consideration. At this stage,
an extractables profile, if available, would facilitate
product, process and dosage-specific assessment.
If, thus far, the patient safety evaluation indicates
no risk, the findings may simply be reported and
monitored for future changes. On the other hand, if
there is a risk to the patient, a leachables study may
be conducted under normal product application or
storage conditions. Risk may also be mitigated through
a process-step modification, such as including an
additional flush. A final option could be to change the
material of the component.
The following case study demonstrates this approach
to risk assessment.
Figure 3. Monoclonal antibody final sterilization system including a
single-use Millipore Express®
SHC filter and a PureFlex™ Plus Mobius®
single-use bag
Case study:
A risk-based approach to EL assessment of a final sterilization,
single-use assembly
Figure 3 illustrates a representative, single-use
system for which EL assessment might be required:
a single-use final sterilization assembly including
a capsule filter and a product collection bag. This
assembly serves a commercial monoclonal antibody
(mAb) application with typical excipients. The aqueous
drug product solution includes 2% API, 0.02% PS80
surfactant and 2% dextrose, buffered to a pH of
5. Filter contact time is eight hours with a filtration
temperature of 25 °C.
Extractables test data prepared by the single-use
system component manufacturer can be used to
analyze this system. The availability of such data in an
easy-access format saves significant time and effort. If
these components were evaluated in accordance with
BPOG guidelines, they were tested under worst-case
conditions, as shown in Table 2.

4
Table 2. BioPhorum conditions for extractables testing of the single-use components in the mAb system
Gamma-compatible Millipore Express®
SHC Filter PureFlex™ Plus Mobius®
Single-Use Bags
• Three different lots
• Gamma-irradiated at 45–55 kGy
• Two time points at 1 day/7 days
• Temparature 40 °C
• SA/V = 4:1
• Three different lots
• Gamma-irradiated at 45–55 kGy
• Three time points at 1 day/21 day/70 days
• Temperature 40 °C
• SA/V = 6:1
Summary results of this testing are shown in Figures 4 and 5. The data includes numerous compounds that were
produced through extraction using the solvents listed. Darker dots indicate compounds found in the highest
concentrations.
Component 1
Extractables Data for Gamma-Sterilized Millipore Express®
SHC Filter
32 Individual Compounds Identified
WFI •
• •
• •
• •
• •
•
0.1 M H3PO4 •
• •
• •
• •
• •
•
50% EtOH •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•
•
• Highest Concentrations
•
• Below highest Concentrations
Individual Quantitation
Compound Evaluation
Figure 4. Summary of extractables test results for the single-use filter. The highlighted compounds are present in multiple components.
WFI •
• •
• •
• •
• •
•
0.1 M H3PO4 •
• •
• •
• •
• •
•
50% EtOH •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•

5
Component 2
Extractables Data for PureFlex™ Plus Film
22 Individual Compounds Identified
WFI •
• •
• •
•
0.1 M H3PO4 •
•
0.5 N NaOH •
• •
• •
• •
• •
•
50% EtOH •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•
•
• Highest Concentrations
•
• Below highest Concentrations
Individual Quantitation
Compound Evaluation
Figure 5. Summary of extractables test results for the film used to make the single-use bag. The highlighted compounds are present in
multiple components.
WFI •
• •
• •
•
0.1 M H3PO4 •
•
50% EtOH •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•
Water (WFI), phosphoric acid (0.1 M H2PO4) and
ethanol (50% EtOH) are most applicable to this
process based on the pH and formulation of the
drug product. Hence, the focus is on the compounds
extracted by these solvents. One observation is
that the two compounds highlighted – 2,4-di-tert-
butylphenol and 1,3-di-tert-butylbenzene – are
common degradants and appear in the extraction
data for both the filter and the single-use bag. In such
cases, once the single-use system contributions have
been scaled to the actual system in question, it is the
sum of these contributions that must be evaluated for
toxicity.
To illustrate this calculation, here is the analysis
of 2,4-di-tert-butylphenol. The first step is to scale
the data for each component’s contribution. Filter
data is provided as 0.36 mg for a 10” filter, which has
a surface area of 0.54 m2
. However, the 5” device in
use has a surface area of 0.23 m2
. The proportionately
scaled contribution of this compound by the filter,
then, is:
(0.23/0.54) 0.36 mg = 0.153 mg = 153 µg
Similarly, the extractables data for the bag must be
scaled, as it is reported per cm2
. The 10 L bag has
a surface area of 3,077 cm2
, so the bag’s contribution
is:
(2.81 µg/cm2
) 3,077 cm2
= 8,646 µg
Note that the bag contributes the majority of the total
2,4-di-tert-butylphenol, which is 8,799 µg/assembly.
The next consideration is, how much of this will be
delivered to patients? If the minimum process volume
is 4 L, and a 1 L flush is added, the total volume is 5 L.
The final concentration of 2,4-di-tert-butylphenol is:
8,799 µg/5,000 mL = 1.76 µg/mL
Aspects of posology such as dosage, frequency and
route of administration are then used to calculate the
actual patient exposure, as shown in Figure 6.

6
Patient Exposure
Posology
Maximum Drug Dosage 100 mL
Route of Administration Intravenous
Frequency Once per week
Expected Duration Lifetime
Risk is acceptable
Drug dosage
= 100 mL
Concentration
of 2,4-di-tert-
butylphenol =
1.76 µg/mL
No
Yes
176 µg/person/
day of 2,4-di-
tert-butylphenol
Compound-
specific
evaluation
Quantity above the
TTC (ICH M7)
Figure 6. Patient exposure as a function of posology
The result is then assessed for risk. If the risk were
acceptable in reference to the threshold of toxicological
concern (TTC), that finding could be reported and
no further investigation would be required. However,
in this case, the exposure exceeds the TTC. Further
analysis is needed to determine the compound-specific
permitted daily exposure (PDE) for this particular
Factors: Starting dosage:
75 mg/kg bw/day
No-observed-adverse-effect level (NOAEL)
when orally administered to rats
Interspecies extrapolation F1 5 Rats - humans
Intraspecies variability F2 10 Default
Exposure duration F3 10 4 weeks - chronic
Severity of effects F4 1 No severe effects
LO(A)EL - NO(A)EL F5 1 NOAEL available
Bioavailability correction F6 10 Oral - parenteral, no data
Overall safety factors 5,000
Permitted daily exposure (PDE) 75 mg/kg bw/day
/
5,000 = 15 µg/kg bw/day
PDE for 50 kg adult human 750 µg/day
Table 3. Converting the result of an animal study of 2,4-di-tert-butylphenol toxicity to a compound-specific PDE for humans
compound. To do that, results from pre-existing rat
toxicology studies are converted to equivalent human
values using the ICH Q3C modifying factors for relating
the data to humans, F1–F5. An additional bioavailability
correction accounts for the incomplete absorption seen
when drugs are administered orally, as they were in
the rat study. The overall approach is shown in Table 3.
The calculated PDE for 2,4-di-tert-butylphenol – 750 µg/
day – can now be compared to the total exposure
calculated above – 176 µg/day. The risk has now
been shown to be acceptable and can be reported as
such. If the risk were still too high, a method for
mitigating risk elsewhere in the process would need
to be applied. The overall process of risk evaluation
is summarized in Figure 7.

Acceptable Risk
Patient Safety
Figure 7. EL risk evaluation decision tree
Risk is acceptable
Risk is acceptable
Risk Mitigation
Leachables?
Dilution?
Process Change?
Risk is acceptable
Yes
Yes No
176 µg/person/
day of 2,4-di-
tert-butylphenol
Quantity above
The PDE?
Quantity above the
TTC (ICH M7)
No
Summary
Regulatory expectation does require patient safety
evaluations with supporting data for manufacturing
components that directly come into contact with drug
manufacturing process streams. Readily available
extractables data can help manufacturers using single-
use technology to accelerate product qualifications,
risk assessments and process optimization. EL risk
analysis is a complex process, and expert guidance is
helpful to ensure compliance and drug safety. While
the task of analytical EL test data interpretation and
submission can be daunting, the right single-use system
supplier can save time by providing single-use system
EL data in well-organized, easy-to-use formats.
Emprove®
Program
Accelerating Drug Regulatory Approvals
The Emprove®
Program entails organized, detailed
product information and assistance to help custom-
ers with material qualification and risk assessment of
biomanufacturing devices, as well as process optimi-
zation. By avoiding the need to develop test meth-
ods, search quality-related documents or evaluate
scientific data, customers can reduce the time, effort
and resources needed to prepare documents for drug
approval submissions.
The program covers more than 30 filter and single-
use product families, as well as over 400 pharma raw
and starting materials and selected chromatography
resins and cell culture media. Each product portfolio
is supported with Emprove®
Dossiers which provide
comprehensive, up-to-date documentation to help
navigate regulatory challenges, manage risks, and
improve manufacturing processes. The Material
Qualification Dossier supports product qualification
and speeds up regulatory filing preparation. It includes
a manufacturing flow chart and information on a
material’s fundamental properties, product validation
and qualification, regulatory statements and more.
The Quality Management Dossier include a quality
self-assessment while documenting detailed supply
information for the material, including its complete
chain-of-custody from manufacture to final release.
This dossier present additional useful information such
as shelf-life data, sterilization validation and packaging
requirements. The Operational Excellence Dossier
available with a subscription to the Emprove®
Suite
includes product quality information such as elemental
impurities and extractables data, and specifies
the analytical procedures used to obtain this data.
Convenient 24/7 access to regulatory information and
comprehensive documentation reduces time and effort
and enables the optimal use of resources throughout
all stages of the manufacturing process.
Lit. No. MS_WP3014EN Ver. 0.1
03/2022
© 2022 Merck KGaA, Darmstadt, Germany and/or its affiliates. All Rights Reserved.
MilliporeSigma, the Vibrant M, Millipore, PureFlex, Plus Mobius, Millipore Express, Mobius and Emprove are trademarks of Merck KGaA, Darmstadt, Germany and/or
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