* These authors contributed equally
Positron-emission tomography (PET) imaging sites that are involved in multiple early clinical research trials need robust and versatile radiotracer manufacturing capabilities. Using the radiotracer [18F]Clofarabine as an example, we illustrate how to automate the synthesis of a radiotracer using a flexible, cassette-based radiosynthesizer and validate the synthesis for clinical use.
The development of new positron-emission tomography (PET) tracers is enabling researchers and clinicians to image an increasingly wide array of biological targets and processes. However, the increasing number of different tracers creates challenges for their production at radiopharmacies. While historically it has been practical to dedicate a custom-configured radiosynthesizer and hot cell for the repeated production of each individual tracer, it is becoming necessary to change this workflow. Recent commercial radiosynthesizers based on disposable cassettes/kits for each tracer simplify the production of multiple tracers with one set of equipment by eliminating the need for custom tracer-specific modifications. Furthermore, some of these radiosynthesizers enable the operator to develop and optimize their own synthesis protocols in addition to purchasing commercially-available kits. In this protocol, we describe the general procedure for how the manual synthesis of a new PET tracer can be automated on one of these radiosynthesizers and validated for the production of clinical-grade tracers. As an example, we use the ELIXYS radiosynthesizer, a flexible cassette-based radiochemistry tool that can support both PET tracer development efforts, as well as routine clinical probe manufacturing on the same system, to produce [18F]Clofarabine ([18F]CFA), a PET tracer to measure in vivo deoxycytidine kinase (dCK) enzyme activity. Translating a manual synthesis involves breaking down the synthetic protocol into basic radiochemistry processes that are then translated into intuitive chemistry "unit operations" supported by the synthesizer software. These operations can then rapidly be converted into an automated synthesis program by assembling them using the drag-and-drop interface. After basic testing, the synthesis and purification procedure may require optimization to achieve the desired yield and purity. Once the desired performance is achieved, a validation of the synthesis is carried out to determine its suitability for the production of the radiotracer for clinical use.
An increasing array of biological targets can be dynamically visualized in living subjects via the molecular imaging modality PET. PET provides in vivo assays of specific biological, biochemical, and pharmacological processes by using specific radiotracers (molecules labeled with positron-emitting radionuclides) that are injected into the subject prior to imaging1. The increased use of PET to study a wide variety of these processes in basic science and clinical research2,3,4, and in the discovery, development, and clinical use of drugs in patient care5,6, is leading to a growing demand for diverse radiotracers7,8. To avoid radiation exposure to the radiochemist and to ensure a reproducible production of these short-lived tracers, they are typically manufactured using an automated radiosynthesizer operating inside a "hot cell". Recent radiosynthesizers use a disposable-cassette/kit architecture to simplify the task of complying with clinical-grade manufacturing while also providing the flexibility to prepare multiple types of radiotracers simply by swapping out cassettes9. However, in early clinical stages, there are usually no commercially-available cassettes/kits to perform the automated radiosynthesis; consequently, PET drug manufacturing facilities struggle to customize systems to implement cGMP-grade tracer production capabilities within a suitable timeframe and at a reasonable cost. Thus, radiosynthesizers have been developed that combine the cassette/kit architecture with features to facilitate the development and optimization of tracers.
The ELIXYS FLEX/CHEM (ELIXYS) is an example of a flexible cassette-based radiosynthesizer with a wide reagent, solvent, and reaction temperature compatibility10. It has three reaction vessels and uses a robotic mechanism to dynamically configure the fluid pathway as required by any particular synthesis protocol11. The synthesizer software allows the creation of synthesis programs (Sequences) for different tracers by dragging and dropping Unit Operations such as Trap Isotope, Elute Isotope, Add Reagent, React, and Evaporate12. Each unit operation has a variety of programmable parameters available to the operator, such as Duration, Temperature, or inert gas driving pressure (Pressure). By understanding the nature of each unit operation, a manual synthesis can be readily translated into a sequence of unit operations and then be modified during the optimization of the protocol13. In combination with the ELIXYS PURE/FORM module, the integrated system can also perform an automated purification and formulation of the PET tracer. Using this radiosynthesizer, we have previously reported the automated synthesis of 24 different 18F-labeled tracers and prosthetic groups11,14,15,16, as well as the automated enzymatic radiofluorination of biomolecules17, by simply changing reagents and not the configuration of the system. Others have shown the automated synthesis of [18F]RO6958948 for the imaging of tau neurofibrillary tangles18, the automated synthesis of the prosthetic group [18F]F-Py-TFP with a subsequent labeling of peptides19, and the automated synthesis of [18F]AM580 for the imaging of phosphodiesterase 10a (PDE10A)20. Furthermore, several groups have shown the production of tracers suitable for clinical use, including 4-[18F]Fluorobenzyl-triphenylphosphonium ([18F]FBnTP) for the imaging of mitochondrial membrane potential21, [18F]DCFPyL for the imaging of prostate-specific membrane antigen (PSMA)22, and [18F]THK-5351 for the imaging of tau23.
In this paper, we use our experience with [18F]CFA to illustrate how a manual radiosynthetic procedure can be straightforwardly and rapidly translated into an automated synthesis suitable for routine production following cGMP guidelines. The tracer [18F]CFA was designed for the imaging of dCK activity. The manual radiosynthesis of [18F]CFA was originally described by Shu et al.24 as a procedure using two reaction vessels, intermediate silica cartridge purification, and a final HPLC purification step (see Supplementary Material, Section 1 for details). Recent in vitro and preclinical studies have shown the exceptional specificity of this tracer to dCK, and first-in-human studies have shown favorable biodistribution25. There is an immediate interest in wider-scale clinical studies to confirm the sensitivity of [18F]CFA PET to variations in dCK activity and a longer-term interest in the potential clinical applications of this tracer26. It may be a useful biomarker for therapies that trigger T-cell activation, induce DNA damage, or rely on dCK-dependent nucleoside analog prodrugs. In particular, [18F]CFA may enable the stratification of patients for a potential response to treatment with Clofarabine. [18F]CFA may also facilitate the study and development of dCK inhibitors that are advancing toward clinical trials. Since this tracer has traditionally been synthesized manually, advancing all of these studies requires a reliable, automated synthesis of [18F]CFA suitable for clinical use.
Although we previously reported an automated synthesis of [18F]CFA for preclinical studies16, this protocol builds further on these efforts and describes additional modifications needed for the clinical production of this tracer, including the integration of fully-automated purification and formulation, protocol validation, and quality-control testing. The general procedures described here are not limited to developing an automated and clinically-suitable synthesis of [18F]CFA but can be generalized in a straightforward manner to develop automated syntheses suitable for clinical use of other radiotracers labeled with fluorine-18.
1. General Procedure for the Automation and Validation of a Radiosynthesis Protocol for Clinical Manufacturing
2. Example: Automated Synthesis of [18F]CFA for Clinical Use
A method to automate the production of [18F]CFA was developed and three validation batches were synthesized. Synthesis, purification, and formulation of [18F]CFA was achieved in 90 ± 5 min (n = 3) and the non-decay-corrected radiochemical yield was 8.0 ± 1.4% (n = 3). The activity yields of the three runs were 3.24 GBq, 2.83 GBq, and 3.12 GBq, starting from 34.3 GBq, 41.8 GBq, and 41.1 GBq, respectively. The obtained [18F]CFA formulations passed all quality control tests (Table 1). The automated protocol is currently being used for the production of clinical-grade [18F]CFA to support clinical trials.
Quality control data | Validation run 1 | Validation run 2 | Validation run 3 |
[requirement for “Pass”] | |||
Appearance | Pass | Pass | Pass |
[clear, colorless, free of particulate matter] | |||
Radioactivity concentration at EOS | 213 MBq/mL | 210 MBq/mL | 180 MBq/mL |
[≤ 740 MBq/mL @ EOS] | |||
pH | 6 | 5.8 | 6 |
[5.0 – 8.0] | |||
Half-life | 115 min | 108 min | 112 min |
[105 – 115 min] | |||
Radiochemical purity | 99% | 99% | 99% |
[> 95%] | |||
Radiochemical identity by relative retention time (RRT) | 1.01 | 1.01 | 1.01 |
[1.00 < RRT < 1.10] | |||
Molar activity | 314 GBq/µmol | >370 GBq/µmol | >370 GBq/µmol |
[≥ 3.7 GBq/µmol] | |||
Total carrier mass in final product | 3.1 µg | <1 µg | <1 µg |
[≤ 50 µg/dose] | |||
Total impurity mass in final product | ND | ND | ND |
[≤ 1 µg / dose] | |||
Maximum allowable injection volume based on total carrier mass ≤ 50 µg/dose AND total impurity mass ≤ 1 µg/dose | Whole batch | Whole batch | Whole batch |
Residual EtOH content by GC | 8.90% | 9.50% | 9.60% |
[≤ 10%] | |||
Residual EtOAc content by GC | <1 ppm | <1 ppm | <1 ppm |
[≤ 5000 ppm] | |||
Residual MeCN content by GC | <1 ppm | <1 ppm | <1 ppm |
[≤ 410 ppm] | |||
Residual K222 by color spot test | Pass | Pass | Pass |
[< 50 µg/mL] | |||
Filter membrane integrity test | Pass | Pass | Pass |
[bubble point ≥ 50 psi] | |||
Bacterial endotoxins | Pass | Pass | Pass |
[≤ 175 EU/batch] | |||
Radionuclidic purity by gamma spectroscopy | Pass | Pass | Pass |
[>99.5%] | |||
Sterility | Pass | Pass | Pass |
[meet USP <71> requirements] |
Table 1: Quality control (QC) test data summary for three validation batches. EOB = end of bombardment; EOS = end of synthesis; ND = not detected.
Figure 1: [18F]CFA radiosynthesis scheme. MMT = Monomethoxytrityl. Please click here to view a larger version of this figure.
Figure 2: Translation of a manual synthesis into an automated sequence of unit operations. (A) This panel gives an overview of the high-level steps in the manual synthesis of [18F]CFA. (B) This panel shows the basic procedures needed to perform each of the high-level steps. (C) Radiosynthesizer-specific unit operations used to perform the basic procedures are shown as cards. Each unit operation has its own set of parameter values (shown as underlined) which are configured through the software. The notation "R1" and "R2" indicate the reaction vessels #1 and #2, respectively. The reagents corresponding to the reagent numbers are identified in Figure 4. The series of unit operations is saved as a Sequence and executed by the software to perform the automated synthesis. Please click here to view a larger version of this figure.
Figure 3: Screenshot of the radiosynthesizer (ELIXYS) software interface to create a synthesis program. Unit operations are placed in the desired order in the Filmstrip using a drag-and-drop interface. In this screenshot, a React unit operation is selected, and its editable parameter values are shown in the main part of the screen. In this example, the fluorination reaction will be carried out in reaction vessel #1 (sealed) at 120 °C for 10 min with active stirring. The vessel will be cooled to 35 °C after the reaction time has elapsed. Details of parameter values that can be programmed for other unit operations are shown in the Supplementary Material, Section 3. Please click here to view a larger version of this figure.
Figure 4: Screenshot of the reagent configuration screen. For the [18F]CFA synthesis sequence, all reagents are loaded into disposable cassette #1, which is shown highlighted in the component selection area. For the [18F]CFA synthesis described here, Eluent is 1.0 mg of K2CO3 + 5.0 mg of K222 in 0.4 mL of H2O/0.5 mL of MeCN, Precursor is 6 mg of CFA precursor in 0.6 mL of MeCN, and HPLC Mobile Phase is 85:15 v/v 25 mM ammonium acetate:ethanol. Please click here to view a larger version of this figure.
Figure 5: Radiosynthesizer set-up for the synthesis of [18F]CFA. (A) This is a schematic showing cassette fluid paths, connections to cartridges, and the connection to transfer final crude product from the radiosynthesis module to the purification/formulation module. (Both modules are controlled with a single computer and software interface.) (B) This is a photograph of the radiosynthesizer inside a hot cell after the preparation for [18F]CFA synthesis. Please click here to view a larger version of this figure.
Figure 6: Screenshot of the purification/formulation module control interface. This screen is accessed by the operator to manually control the HPLC and formulation subsystems during the synthesis setup. Please click here to view a larger version of this figure.
Figure 7: Pre-run checklist screen. The operator enters the serial number of the cassettes installed in the system and must check off each item to ensure the system has been properly configured and prepared for the synthesis. In addition to these sections, the operator is also prompted for a name and description of the synthesis run (Section 1) and lot numbers for all reagents used (Section 2) and is asked to verify all reactor video feeds are functioning correctly (Section 6). Please click here to view a larger version of this figure.
Figure 8: Screenshot of the radiosynthesizer software while running the [18F]CFA synthesis sequence. The software displays the order of unit operations in the filmstrip area. Completed operations are greyed out and highlighted in white, the current operation is highlighted in grey, and upcoming operations are shown in dark grey. The center area of the screen shows the status of the active unit operation, including which subcommand is being executed, as well as the current system status (reactor video feeds and sensor data). This particular React unit operation is the fluorination reaction. In the Temp area, the current temperature of the reactor is shown next to the target (programmed) temperature. Below this, the Activity area displays the radiation sensor values from the three sensors associated with the reaction step. Finally, a video feed on the left shows a live view of the reactor vial. Please click here to view a larger version of this figure.
Figure 9: Screenshot of the radiosynthesizer user interface while running the Purification unit operation during the synthesis of [18F]CFA. The UV detector and radiation detector outputs of the purification/formulation module are displayed on the central graph in real time. Additional feedback from the detectors and HPLC pump are shown on the right side of the screen. The operator collects the product peak by temporarily selecting Product when the peak begins to appear and then switching back to Waste after the complete peak has been seen. Please click here to view a larger version of this figure.
This protocol defines the basic steps that should be taken when automating a manual synthesis protocol to achieve the production of clinical grade tracer formulation. The entire development cycle, including quality control development, is exemplified by the radiotracer [18F]CFA (for the imaging of dCK activity). Particular attention was paid to modifying the automated synthesis to ensure the tracer's suitability for clinical use. The synthesis entails basic processes such as the activation of [18F]fluoride, radiofluorination of the precursor molecule, intermediate cartridge purification, protecting-group removal, and semi-preparative HPLC purification and formulation for injection. These basic processes comprise a standard repertoire that is sufficient for the synthesis of the vast majority of 18F-labeled PET tracers.
While designing the synthesis, the choice of reagents and their quality assurance is of particular importance for clinical use. Ensuring the correct programming and proper connections by performing a mock synthesis (solvents only) is imperative to eliminate unexpected errors when the synthesis is performed with radioactivity. The subsequent synthesis optimizations (solvents, volumes, amounts, temperatures, reaction times, and purification conditions) depend on the specific PET tracer in development. During these experiments, particular focus should be shone on the chemical and radiochemical purity of the final product that can be achieved, as these must meet stringent requirements for clinical use. A synthesis that reliably produces a pure product in lower but sufficient activity yields is usually preferred over a higher-yielding process that has a risk to fail sporadically. Once the synthesis has been adequately optimized, the final process needs to undergo validation tests (a regulatory requirement) to ensure clinical suitability. The validated synthesis method can then be used to produce the PET tracer for clinical use. When synthesizing a PET tracer according to a validated method, the standard operating procedures should be thoroughly followed. To ensure compliance, the software is programmed to have the operator confirm the completion of key steps via a pre-run checklist after clicking on Run to start the synthesis. While the system will perform the synthesis in an automated fashion, the purification step requires manual intervention. The operator must, therefore, closely observe the chromatographic screen during the HPLC purification step, and manually input in real-time when to start and stop collecting the product fraction.
Within our automation and optimization efforts for the [18F]CFA synthesis, we have streamlined the semi-preparative HPLC purification method of the product mixture by using an injectable solvent system consisting of ammonium acetate solution and EtOH; our previous method required an additional step to exchange the solvent after purification16. The subsequent formulation process, thus, needs only to reduce the EtOH content of the collected fraction to permitted levels, and to ensure its isotonicity, both of which can be accomplished by dilution. The formulation step was performed using a second program consisting of a single Formulation unit operation to allow variable volume additions of NaCl-solutions to the purified product fraction via the formulation module to account for the variable volume obtained after HPLC purification. If the collected product fraction volume was set to be constant instead, the Formulation unit operation could be included in the main synthesis program, avoiding the need for an independent program. An alternative approach to avoid manual intervention would be to use the full functionality of the formulation module (e.g., dilute the purified tracer with water, trap on a C18 solid-phase extraction cartridge, wash it, elute it with a fixed volume of EtOH, and finally, dilute it with a fixed volume of saline).
The technique presented here for automating and validating a synthesis protocol for clinical use is intended to be quite general. Through the choice of radiosynthesizer (ELIXYS), a wide range of syntheses can be automated and validated. This includes complex 3-pot syntheses, or syntheses involving high temperatures of volatile solvents. Optimizing a synthesis can be achieved by changing the parameters of the software program. The synthesizer has features to monitor the impact of changes, such as positioning the reaction vessels for the removal of samples for radio-TLC or radio-HPLC analysis. However, without system modifications, the system currently does not allow for the handling of very low reagent volumes (~5 - 20 µL), intermediate product distillation, or the handling of [18F]AlF, 68Ga, or other radiometals. If the manual synthesis to be automated contains such steps and they cannot be circumvented, automation and validation with another radiosynthesizer platform may be appropriate.
Although this work has focused on the development of a protocol for the automated production of [18F]CFA for clinical use, the synthesis of many other PET tracers could be automated in a manner suitable for clinical production, following the same logic and methods. Following the method presented here, we have also adapted the automated synthesis of 9-(4-[18F]fluoro-3-[hydroxymethyl]butyl)guanine ([18F]FHBG) and validated it for clinical use. User-established protocols can be uploaded to and downloaded from the SOFIE Probe Network, a web portal for sharing synthesis programs and associated documentation among different radiopharmacy sites27. This can avoid a duplication of efforts in the community and facilitate multi-center clinical studies involving PET imaging.
This work has been supported in part by the National Cancer Institute (R44 CA216539) and the UCLA Foundation from a donation made by Ralph and Marjorie Crump for the UCLA Crump Institute for Molecular Imaging.
Name | Company | Catalog Number | Comments |
ELIXYS FLEX/CHEM | Sofie (Culver City, CA, USA) | 1010001 | Radiosynthesizer |
Radiosynthesizer cassette | Sofie (Culver City, CA, USA) | 1861030400 | Cassette for ELIXYS FLEX/CHEM |
ELIXYS PURE/FORM | Sofie (Culver City, CA, USA) | 1510001 | Radiosynthesizer purification module |
[O-18]H2O | IBA RadioPharma Solutions (Reston, VA, USA) | IBA.SP.065 | >90% isotopic purity |
[F-18]fluoride in [O-18]H2O | UCLA | N/A | Produced in a cyclotron (RDS-112; Siemens; Knoxville, TN, USA) by the (p,n) reaction of [O-18]H2O. Bombardment at 11 MeV using a 1 mL tantalum target with havar foil. |
Deionized water | UCLA | N/A | Purified to 18 MΩ and passed through 0.1 µm filter |
Acetonitrile (MeCN) | Sigma-Aldrich (St. Louis, MO, USA) | 271004 | Anhydrous, 99.8% |
Ethanol (EtOH) | Decon Laboratories, Inc. (King of Prussia, PA, USA) | 2701 | Anhydrous, 200 proof |
Sodium hydroxide (NaOH) solution | Merck (Burlington, MA, USA) | 1.09137.1000 | 1M solution |
Hydrochloric acid (HCl) solution | Fisher Chemical (Hampton, NH, USA) | SA48-500 | 1M solution |
Ethyl acetate (EtAc) | Fisher Chemical (Hampton, NH, USA) | E195SK-4 | HPLC grade |
Sodium chloride (NaCl) | Fisher Chemical (Hampton, NH, USA) | S-640-500 | USP grade |
Ammonium acetate | Fisher Chemical (Hampton, NH, USA) | A639-500 | HPLC grade |
Potassium carbonate (K2CO3) | Fisher Chemical (Hampton, NH, USA) | P-208-500 | Certified ACS |
CFA precursor | CalChem Synthesis (San Diego, CA, USA) | N/A | Custom synthesis |
Cryptand 222 (K222; Kryptofix 2.2.2) | ABX Advanced Biochemical Compounds (Radeberg, Germany) | 800.1000 | >99% |
Sodium chloride (NaCl) solution (saline) | Hospira (Lake Forest, IL, USA) | 0409-4888-02 | 0.9%, for injection, USP grade |
Silica cartridge | Waters (Milford, MA, USA) | WAT051900 | Sep-pak Classic |
Quaternary methylammonium (QMA) cartridge | Waters (Milford, MA, USA) | WAT023525 | Sep-pak Light Plus |
Sterile syringe filter (0.22 µm) | Millipore Sigma (Burlington, MA, USA) | SLGSV255F | Millex-GV |
Glass V-vial (5 mL) | Wheaton (Millville, NJ) | W986259NG | Used for reaction vessels |
Septa | Wheaton (Millville, NJ) | 224100-072 | Used for reagent vials |
Crimp cap | Wheaton (Millville, NJ) | 224177-01 | Used for reagent vials |
Amber serum vial (2 mL) | Voigt (Lawrence, KS, USA) | 62413P-2 | Used for reagent vials |
Magnetic stir bar | Fisher Scientific (Hampton, NH, USA) | 14-513-65 | Used for reaction vessels |
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