Synthesis, characterization and assessment of suitability of trehalose fatty acid esters as alternatives for polysorbates in protein formulation.

Nonionic polyethylene glycol-derived surfactants are today's choice as surfactants in protein formulations. Different groups discovered that although surface-induced stresses are reduced by these excipients, the long-term stability of different proteins decreased due to polyethylene glycol-related induction of oxidation processes under static storage conditions. In this paper, the potential of polyoxyethylene-free surfactants for protein formulation was evaluated. Three different sugar-based surfactants, 6-O-monocaprinoyl-α,α-trehalose, 6-O-monolauroyl-α,α-trehalose and 6-O-monopalmitoyl-α,α-trehalose, were synthesized in four reaction steps. These substances lack polyethylene glycol residues and can be produced from renewable resources. The chemical and physical properties of these three surfactants were investigated and compared with polysorbate 20 and 80. 6-O-monopalmitoyl-α,α-trehalose was insoluble in water at room temperature and was hence excluded from some of the further tests. The critical micellar concentration of all surfactants is in a comparable range of approximately 0.001-0.01% (m/V). The sugar-based surfactants showed slightly higher hemolytic activity than the polysorbate references. The surfactants with shorter chain length proved to be comparable to polysorbates in regard to physicochemical properties. Finally for human growth hormone, the protein-stabilizing properties against shaking-induced stress were tested and compared to polysorbate-containing formulations. Whereas in the absence of surfactant, dramatic monomer loss and aggregate formation occurred, it was found that 100% monomer content was maintained when 0.1% (m/V) 6-O-monocaprinoyl-α,α-trehalose or 6-O-monolauroyl-α,α-trehalose was added to the formulation. Polysorbate 80 at a concentration of 0.1% (m/V) also significantly stabilized the protein. Lower amounts of surfactants result in only partial stabilization. Furthermore, adsorption of human growth hormone to the container surface is reduced in the presence of the surfactants. Thus, the new sugar-based surfactants offer a promising alternative and have potential for application in protein formulations.