Freeze-Dried Monoclonal Antibody Formulations are Unexpectedly More Prone to Degradation Than Liquid Formulations Under Shaking Stress

Liquid biopharmaceuticals including monoclonal antibodies (mAbs) have been widely acknowledged to undergo various stresses during shipping/handling and long-term storage. Several mechanical stresses including shaking during shipping has been widely known to cause protein aggregation and sub-visible particle (SbVP) formation in liquid biopharmaceutical formulations. However, shaking-induced degradation of freeze-dried (FD) biopharmaceuticals has seldomly been reported in the literature and therefore this type of stress is widely overlooked in industry due to their presumed high stability, especially when the formulations and freeze-drying processes are fully optimized. In this Lessons Learned article, we report an interesting phenomenon in which the optimized FD biopharmaceutical formulations of three typical mAbs showed much degradation and SbVP formation under shaking stress compared with their liquid counterparts. This is a striking deviation to the notion that mAbs are generally more stable in the FD formulations than in the liquid ones. Therefore, shaking stress experiment should be considered a critical stress condition for early-stage selection of liquid versus FD mAb formulations.