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Integrating green analytical chemistry and analytical quality by design: an innovative approach for RP-UPLC method development of ensifentrine in bulk and inhalation formulations
BMC Chemistry volume 19, Article number: 70 (2025)
Abstract
Background
Chronic obstructive pulmonary disease (COPD) is a significant global health issue, worsened by pollution and modernisation. Ensifentrine (EFT), a new dual inhibitor of phosphodiesterase PDE3 and PDE4, is being developed for inhalation to target airway inflammation, bronchodilation, and ciliary function in COPD treatment.
Objective
This study aims to develop and validate a new quantification method for Ensifentrine, as no previous techniques are available, by integrating analytical quality-by-design (AQbD) and green analytical chemistry (GAC) principles.
Methods
An AQbD framework, utilizing Design-expert® software and a central composite design, optimized the RP-UPLC method. The optimized conditions involved isocratic separation on an ACQUITY UPLC HSS C18 SB column at ambient temperature, with a mobile phase of 0.01 N KH2PO4 (pH 5.4) and acetonitrile (66.4:33.6 v/v), a flow rate of 0.27 mL/min, and PDA detection at 272.0 nm.
Results
The statistical analysis confirmed the model’s significance and normal distribution. The method, validated according to ICH guidelines, showed good linearity (r2 = 0.9997) over a range of 3.75–22.5 μg/mL, with an LOD of 3.3 μg/mL and LOQ of 10 μg/mL. It was successfully applied to bulk materials and pharmaceutical formulations with statistical comparisons.
Green chemistry assessment
The greenness of the developed method was evaluated using tools such as ComplexMoGAPI, AGREE, BAGI, Green certificate-modified Eco-scale, and ChlorTox Scale. Additionally, the EVG method evaluation tool was also used to assess environmental impact, with the results shown in a radar chart.
Conclusion
This study presents a sensitive and robust RP-UPLC method for quantifying Ensifentrine, combining AQbD and GAC principles. The method, validated according to ICH guidelines, also ensures environmental sustainability. This approach sets a precedent for future analytical method development in pharmaceutical sciences with a focus on sustainability.
Graphical abstract

Introduction
Chronic obstructive pulmonary disease (COPD) is characterized by chronic respiratory inflammation, airway remodelling, acute exacerbations, and excessive mucus production, leading to irreversible airflow blockage. Despite available treatments, new therapies are needed to alleviate symptoms, provide bronchodilation, and reduce exacerbations without the adverse effects of corticosteroids or oral PDE4 inhibitors [1, 2]. Many patients continue to experience symptoms with existing treatments. Phosphodiesterase (PDE) 3 and PDE4 inhibitors play crucial roles in respiratory functions, as PDE3 regulates cAMP and cGMP in airway smooth muscle, influencing bronchial tone, while PDE4 modulates cAMP in inflammatory cells. Dual inhibition of PDE3 and PDE4 may have additional bronchodilator and anti-inflammatory effects [3,4,5]. Ensifentrine (RPL554), a novel dual PDE3 and PDE4 inhibitor designed for inhalation, targets airway inflammation and ciliary function [6]. Two Phase 3 maintenance therapy trials for COPD have been completed, and it is now in late-stage clinical development [7, 8]. Ensifentrine (EFT), developed by Verona Pharma plc, inhibits PDE3 and PDE4 and focuses on treating respiratory diseases such as COPD. Branded as OHTUVAYRE™, it was approved by U.S. regulatory authorities in June 2024 for COPD maintenance treatment in adults, marking a significant milestone in COPD management [9]. Figure 1 illustrates the structure of the drug EFT. The IUPAC name of EFT is 2-(9,10-dimethoxy-4-oxo-2-(2,4,6-trimethylphenyl) imino-6,7-dihydropyrimido(6,1-a) isoquinolin-3-yl) ethylurea, with a molecular formula of C26H31N5O4 and a molecular weight of 477.6 g/mol [10]. EFT, derived from the trequinsin nucleus, is a potent small molecule with dual selectivity for PDE3 and PDE4. It shows a high affinity for PDE3, approximately 3700 times greater than for PDE4, making it a promising candidate for treating diseases associated with dysregulated PDE activity [11].
The conventional method development approach relies on molecular properties like polarity, pKa, and solubility, ofteemploying trial and error or one-variable-at-a-time techniques. However, these methods fail to reveal relationships between multiple variables. In contrast, a statistical QbD methodology offers significant advantages by understanding variable interactions and identifying potential risks and failures [12,13,14]. This research employed a statistical optimization process to determine the most optimal parameters for a reliable analytical method, utilizing AQbD-driven development to ensure precise and accurate quantification of EFT [15, 16]. Moreover, to implement GAC principles while maintaining efficiency, it is crucial to monitor and understand the interrelationships of various analytical factors [17]. The AQbD technique, part of ICH Q8 (R2) standards, facilitates this by establishing a thorough foundation for method variables from the outset [18]. This approach reduces time and resources, enables seamless method transfers, and integrates GAC and AQbD to develop efficient, environmentally friendly, and flexible technologies [19,20,21].
As there are no stability study reports, analytical method validation, or development for EFT using UPLC with AQbD and GAC, this study aims to develop a robust analytical method by creating a UPLC method for EFT that integrates GAC and AQbD using eco-friendly solvents. It will conduct a forced degradation study of EFT following ICH Q1A and Q1B standards, validate the method for specificity, precision, accuracy, and detection limits per ICH Q2 guidelines, and apply the method to various matrices to confirm its practical applicability. The study will also assess the method's robustness by introducing intentional changes in parameters such as mobile phase composition, flow rate, and column temperature, measure reductions in solvent usage and waste production to highlight sustainable practices and explore potential applications for other pharmaceutical compounds. This research aims to establish a robust, validated analytical approach and contribute to understanding sustainable analytical practices in drug development [22, 23].
Materials and methods
Chemicals and reagents
Pure Ensifentrine (> 99%) and Ohtuvayre 3 mg/2.5 mL were provided by Spectrum Pharma Labs Pvt. Ltd., Hyderabad, India. The Nebulizer Inhalation Solution was purchased from a local market. All AR-grade chemicals, including acetonitrile, potassium dihydrogen orthophosphate, H2O2, orthophosphoric acid, HCl, and NaOH, were sourced from Rankem in Gurugram, Haryana, India. The Milli-Q water from Millipore Technologies in Mumbai, India was used for solution preparation.
Apparatus and equipment
A Water Acquity UPLC system with a PDA detector was used to develop, optimize, and validate the ensifentrine method. A HSS C18 SB column (2.1 × 100 mm, 1.8 μm) and Empower-2 software were utilized for chromatographic separation. The Design-Expert® software version 13.0.0 facilitated parameter optimization. For spectrophotometric measurements, a PG Instruments T60 UV–VIS spectrophotometer was used. An HTLP Engineering forced-air circulating oven was used for thermal degradation studies. An Ultrasonic bath sonicator from Analab Scientific Instruments was used to dissolve samples, and a BVK enterprises pH meter measured the mobile phase pH. A hot plate from Optima Laboratory Hot Plates was used for forced degradation studies. The pure EFT drug and other chemicals were weighed using a Denvar DWS-124C balance from New Delhi, India.
The RP-UPLC method optimization and development via AQbD
The method development strategy was based on AQbD principles, involving the creation of an analytical target profile (ATP) to define performance requirements. Critical analytical attributes (CAT) were identified, and a risk assessment was conducted. Preliminary method development and design of experiments established the design space, with a robustness study identifying key high-risk factors such as column flow rate, column temperature, and buffer pH, while other factors were deemed low-risk.
Sample and standard preparation
Diluent
The diluent, a 50:50 acetonitrile–water mixture, was chosen to ensure the drug’s solubility.
KH2PO4 (0.01N) Buffer
1.36 g of potassium dihydrogen orthophosphate was weighed and added to a 1000 mL volumetric flask containing approximately 900 mL of milli-Q water. The solution was degassed using a sonicator, and then was filled to the final volume. The pH was adjusted to 5.4 using dilute H3PO4.
Standard stock solutions
Weighed 7.5 mg of EFT, transferred it to a volumetric flask of 50 mL, and added a portion of the (25 mL) diluent. Sonicated for 10 min, then filled the flask with diluent to create a 150 µg/mL EFT standard stock solution.
Standard working solutions
In addition, to achieve a 15 µg/mL EFT concentration, 1 mL from the standard stock solution was taken and diluted to 10 mL with diluent in a volumetric flask.
Sample stock solutions
The suspension liquid weight (Ohtuvayre 3 mg/2.5 mL EFT) was transferred to a 10 mL volumetric flask. The volume was diluted with 1 mL of diluent and then sonicated for 25 min. The flask was filled to the mark with diluent to a total volume of 10 mL, and the solution was passed through UPLC filters to achieve a 300 µg/mL EFT concentration.
Sample working solutions (100% solution)
The filtered sample stock solution (0.5 mL) was added to a 10 mL volumetric flask and diluted with a solvent to achieve a 15 µg/mL EFT concentration.
Stress degradation studies
EFT was assessed under various stress conditions, including thermal, oxidation (peroxide), hydrolytic (alkaline and acidic), neutral (diluent), and photolytic, following ICH guidelines Q1A (R2) and Q1B. All the stress experiments were conducted at a final concentration of 15 ppm [24, 25].
Investigation of hydrolytic degradation
For the acid and base degradation studies, the following procedures were followed:
Acid degradation: 1 mL of the stock EFT solution was mixed with 1 mL of 2 N HCl and refluxed at 60 °C for 30 min. The resulting solution was then neutralized with 2 N NaOH, made to volume with the diluent, and further diluted to a concentration of 15 µg/mL. A 10 µL aliquot of this final solution was injected into the UPLC system for stability assessment.
Base degradation: In a separate procedure, 1 mL of the stock EFT solution was combined with 1 mL of 2 N NaOH and refluxed at 60 °C for 30 min. The solution was subsequently neutralized with 2 N HCl, made to volume with the diluent, and diluted to a concentration of 15 µg/mL. A 10 µL aliquot of this final solution was also injected into the UPLC system for stability evaluation.
Studies on oxidative, photolytic, neutral, and thermal degradation
1 mL EFT stock solution was combined with 1 mL of 20% H2O2 and left at 60 °C for 30 min. After diluting the resultant solution to 15 µg/mL, 10 µL was added to the UPLC system to test for stability. For photochemical stability, in a UV chamber, a 400 µg/mL solution was exposed to Ultra Violet radiation for 200-W hrs/m2 or 7 days in a photostability chamber [26]. Following a 15 µg/mL dilution of the solution, 10 µL was added to the UPLC system to record chromatograms and assess stability. Under neutral conditions, for 6 h, the drug was refluxed in water at 60 °C. The standard drug medication solution was heated for 6 h at 105 °C to undergo thermal degradation.
Method validation
The finalized analytical method validation (AMV) evaluated specificity, system suitability, accuracy, robustness, precision, solution stability, Range, LOD, LOQ, and linearity according to the protocols outlined in the ICH guidelines Q2 (R1) [25, 27].
System suitability test
Parameters for standard injections included the resolution (R) and theoretical plate count (N) between the degradation product and EFT peak, and peak asymmetry (T) of the EFT peak.
Specificity and stress testing analysis
Moreover, to find any interference from blank injections, the specificity was assessed. The drug substance was subjected to stress in solution under neutral, alkaline, acidic, and oxidative conditions, as well as humidity, thermal, and photolytic conditions. The method's specificity was assessed using purity threshold and purity angle values. These stress studies optimized the analytical method for EFT under various conditions, establishing it as a stability-indicating assay method.
Analysis of precision and accuracy
The precision of X-ray analysis was evaluated by injecting the sample solution six consecutive times at a concentration of 15 ppm. The intermediate precision (interday precision) was assessed by injecting a freshly prepared sample solution six times on a different day using a different apparatus. For intra- and interday analysis, the relative standard deviation (%RSD) was calculated. The system precision was determined through 6 injections from the same standard solution. The accuracy was evaluated using the standard addition method, where the reference standard was spiked at 50%, 100%, and 150% of the 15 ppm test concentration. The findings were presented as the percentage of the expected finding (EFT) from the sample matrix which is recovered.
Linearity and calibration range
The linearity of this method was evaluated over a concentration range that spanned approximately 25% to 150% of the expected test concentrations for EFT. A linear regression model was used to establish the relationship between the area under the curve and the concentration of EFT. This evaluation was conducted across a concentration range of 3.75–22.5 μg/mL, and the results were graphically represented to demonstrate the linearity of the method. The correlation coefficient, slope, and y-intercept of the regression line were calculated to confirm the direct proportionality between the analyte concentration and the signal produced.
Limit of detection (LOD) and limit of quantification (LOQ) determination
The LOD and LOQ were determined using the standard deviation (σ) and slope (S) of the calibration curve, according to the following formulas: LOD = 3.3 × σ/S, LOQ = 10 × σ/S. These calculations are based on the guidelines provided by the International Conference on Harmonisation (ICH) and utilize the standard deviation of the response and the slope of the calibration curve to establish these critical limits.
Robustness assessment
The method’s robustness was assessed by systematically altering parameters such as flow rates (between 0.1 and 0.3 mL/min), mobile phase compositions (between 62B:38A to 69B:34A), and column temperatures (between 24 °C and 35 °C).
Solution stability
Standard and sample solutions were assessed by injecting freshly prepared solutions at different time intervals.
Statistical research
The data were presented in the form of mean ± SD. In Excel, the regression coefficient, mean, SD, and % RSD were calculated. A p-value of < 0.05 was considered statistically significant, and ANOVA was utilized to evaluate the model’s and its terms’ significance.
Results and discussion
Preliminary method development investigation
This study optimized the UPLC technique for analysing (EFT) in its inhalation form. The optimal wavelength was identified as 272.0 nm, enhancing sensitivity and reducing noise. After testing various columns, the ACQUITY UPLC HSS C18 SB column (2.1 × 100 mm, 1.8 μm) was found to be the most suitable. The optimal mobile phase consisted of 0.01 N aqueous KH2PO4 (pH 5.4) and acetonitrile in a 66.4:33.6 ratio. Adjustments to the acetonitrile-to-phosphate buffer ratio, pH, and flow rate significantly impacted the tailing factor, retention time, and theoretical plate count, highlighting the importance of carefully controlling these parameters.
Method development by AQbD
Using AQbD, three key parameters were optimized for the analytical method: column temperature (24.95–35.05 °C), flow rate (0.2495–0.3505 mL/min), and organic solvent percentage in the mobile phase (21.59–38.41%). The organic solvent ratio was a high-risk factor requiring meticulous optimization. The optimized UPLC method involved a flow rate of 0.27 mL/min, a mobile phase of 66.4:33.6 acetonitrile to 0.01 N aqueous KH2PO4 buffer at pH 5.4, and a column temperature of 29.6 °C. The optimal UV absorption wavelength was 272.0 nm. Sample preparation used a 50:50 ACN and H2O mixture as a diluent, with a sample temperature of 15 °C and an injection volume of 2 μL. This method was applied to both stable and stressed samples, ensuring robust development for accurately assessing EFT quality in the presence of its degradation products.
Optimizing methods using experimental design
In this study, the effects of three independent variables on three dependent variables were investigated using 20 trials of central composite design. The independent variables included flow rate (Factor 1, A), the percentage of organic phase in the mobile phase (Factor 2, B), and temperature (Factor 3, C). The dependent variables analysed included retention time (RT) (Response 1, Fig. 2a), the number of theoretical plates (NTP) (Response 2, Fig. 2b), and tailing factor (Response 3, Fig. 2c), with the results summarized in Table 1. Second-order polynomial equations were derived by fitting the gathered results to different mathematical models to examine the effects of the independent variables on each dependent variable. ANOVA was utilized to evaluate the statistical significance of the model terms. Additionally, to illustrate relationships between the dependent and independent variables, 2D contour plots and 3D response surface plots were generated. Lastly, based on predefined acceptance criteria, methods for numerical optimization were used to forecast the optimum chromatographic. The results of the ANOVA tests for Retention Time, Number of Theoretical Plates (NTP), and Tailing Factor (Symmetry) (TF) using Central Composite Design (CCD) for different responses are shown in Table 2a, b, and c.
a 3D-response surface (1–2–3) and 2D-contours (4–5–6) plots showing the influence of CMPs, i.e., flow rate (A), mobile phase concentration (B), temperature (C) on retention time (Response 1) as the CAA. b 3D-response surface (1–2–3) and 2D-contours (4–5–6) plots showing the influence of CMPs, i.e., flow rate (A), mobile phase concentration (B), temperature (C) on theoretical plates (Response 2) as the CAA. c 3D-response surface (1–2–3) and 2D-contours (4–5–6) plots showing the influence of CMPs, i.e., flow rate (A), mobile phase concentration (B), temperature (C) on the tailing factor (Response 3) as the CAA. d Overall Desirability (1, 2, and 3) 2D plot for optimized conditions to predict retention time, theoretical plates, and peak area
Calibrating the model to response data
The Design-Expert tool was used to fit the observed responses from 20 runs to various mathematical models, with the quadratic model selected as the best fit based on high R2 values, low SD, and close matches between adjusted and predicted R2 values. The relationships between responses (retention time, NTP, and tailing factor) and factors were visualized in 3D response surface plots and 2D contour plots (Fig. 2A, B, and C). A composite desirability function identified optimal conditions, with desirable values ranging from 0 to 1. For asymmetry, retention time, and peak area, a composite desirability of 1 indicated an optimal flow rate of 0.27 mL/min. The validation involved six replicate injections of a 15 µg/mL EFT solution, confirming that the observed retention time, asymmetry, and theoretical plates were within the predicted ranges, with differences of less than 5%. This validated the accuracy of the optimum conditions.
Analytical method validation (AMV)
System suitability
Establishing the system's suitability data is crucial before moving further with the analytical method's validation. The outcomes for these parameters met ICH guidelines and were satisfactory: the tailing factor was < 2, the resolution was > 2, and the theoretical plate count exceeded 2000.
Specificity
The PDA detector was utilized to estimate peak purity and verify the UPLC method's specificity. The developed UPLC method exhibited selectivity and specificity, as there was no interference detected from the blank and placebo solutions at the retention time of EFT (1.207 min). Figure 3 illustrates the chromatograms for the blank, placebo, and EFT drug samples.
Linearity and range
A calibration curve was generated to relate area to concentration over the range of (3.75–22.5) μg/mL. The linear regression equation for this curve is (y = 59680x + 4269.8), with a correlation coefficient of 0.9997 for EFT, showing a highly linear response over the concentration range of the test. The linearity results are depicted in Fig. 4.
Method precision
Repeatability (Intra-day)
The intra-day repeatability was evaluated by determining %RSD from six measurements of a 15 μg/mL solution, all performed on the same day and within the same laboratory setting. The calculated RSD was 0.40%, which signifies the method's high reliability.
Intermediate precision (Inter-day)
The evaluation of inter-day precision was performed by measuring the % RSD from six distinct determinations of a 15 μg/mL solution. This assessment involved inter-day precision tests carried out on various days, utilizing different instruments, columns, and sample preparations, all within the same lab setting. The % RSD for the inter-day precision data was found to be 0.50. The precision outcomes of the method developed are shown in Table 3.
Accuracy
The developed method’s accuracy was assessed using the standard addition method. EFT was spiked at concentrations equivalent to 50%, 100%, and 150% of the test concentration (7.5, 15, and 22.5 ppm) in the test solution. The mean recovery rate was reported to be 100.17%, with a % RSD of less than 2.0, which indicates satisfactory accuracy. The accuracy outcomes are presented in Table 4.
Detection limit (DL) and quantification limit (QL)
DL and QL were determined by the slope method based on linearity, yielding DL values of 3.3 μg/mL or less and QL values of 10.0 μg/mL or less.
Robustness
The robustness of the developed method was verified under various conditions, including different flow rates, mobile phase compositions, and column temperatures, with the method remaining unaffected by changes in flow rate from 0.1 to 0.3 mL/min, column temperature from 24 to 35 °C, and mobile phase composition from 62B:38A to 69B:34A, demonstrating its robustness. The system suitability parameters were largely unchanged, with all parameters meeting the required standards and the percentage relative standard deviation (% RSD) remaining within acceptable limits. The method’s robustness details are shown in Table 5.
Solution stability
The samples and the standard solutions' stability in a diluent made of a 50:50 (v/v) ACN: H2O mixture was assessed and determined to remain stable for 48 h when stored at 5 °C.
Assay
The inhalation product designated as Ohtuvayre, labelled with the claim of EFT at a dosage of 100 mg, underwent an assay utilizing the aforementioned formulation. The analysis produced an average assay result for EFT, which was determined to be 99.93%. These assay results have been systematically compiled and are displayed in Table 6.
Studies of forced degradation
The forced degradation studies of EFT revealed that the drug exhibits minimal degradation (less than 2%) under photolytic and neutral conditions. In conditions of acid hydrolysis, it experienced a degradation of 5.15%, with a degradation peak observed at 0.747 min. Conversely, under basic hydrolysis, the drug showed a degradation of 4.38%, corresponding to a degradation peak at 0.790 min. For oxidative and thermal degradation, EFT demonstrated degradations of 4.81% and 3.23%, respectively. Importantly, the analysis revealed no interference from the degradation peaks. The forced degradation studies observations are presented in Table 7, with corresponding chromatograms displayed in Fig. 5.
Green analytical metric tools assessment
Ideal green analysis seeks to make lab processes eco-friendly by minimizing or eliminating organic solvents, reducing energy use, simplifying sample prep, and avoiding waste. In liquid chromatography, while it is impossible to fully eliminate solvents, strategies such as using safer, biodegradable alternatives, minimizing waste hazards, streamlining processes, and employing miniaturized sample prep can enhance sustainability [28]. Evaluating the ecological friendliness of an analytical procedure is complex, requiring careful consideration of multiple factors. The developed method’s sustainability was evaluated using five tools to assess its environmental impact: ComplexMoGAPI, ChlorTox Scale, AGREE, Analytical Eco-Scale, and BAGI.
Complex modified GAPI (ComplexMoGAPI)
The ComplexMoGAPI (Complex Modified GAPI) is an advanced hazard assessment tool that enhances traditional GAPI methodologies. It offers a detailed evaluation of chemical hazards by incorporating factors such as environmental persistence, bioaccumulation, and toxicity, resulting in a comprehensive risk profile. This model is vital for regulatory assessments where precise hazard evaluations are necessary. The ComplexMoGAPI merges the visual elements of ComplexGAPI with accurate scoring. Researchers such as Tobiszewski and Namieśnik emphasized the value of thorough hazard assessments in chemical risk management. Moreover, by utilizing these advancements, the ComplexMoGAPI improves hazard assessment accuracy, supporting informed decisions in chemical safety and environmental protection [29,30,31,32].
ComplexMoGAPI offers a more detailed assessment compared to the traditional red/green/yellow icons of ComplexGAPI. It evaluates the overall environmental sustainability of an analytical method by generating a cumulative score, considering a wide range of choices within each category. For the developed method, ComplexMoGAPI calculated a score of 71, indicating room for significant environmental sustainability due to the presence of yellow and green icons. Figure 6a visualizes these results with greenness metrics, and Supplementary Table 1 provides detailed method scores. This table allows for a thorough comparison and analysis of the environmental impact of different aspects of the method, helping researchers identify areas for improvement to enhance ecological sustainability.
Chloroform-oriented Toxicity estimation scale (ChlorTox Scale)
The ChlorTox Scale is a tool for assessing chemical risks related to laboratory analytical methods. It evaluates the toxicity and reactivity of chemicals, aiding in the identification of safer alternatives and reducing exposure to hazards. Moreover, by using chloroform, a well-studied reference with known toxicity, the scale offers a reliable risk assessment framework. This comprehensive evaluation considers chloroform's significant hazards, including acute toxicity and carcinogenic potential, which is supported by abundant safety data. The scale emphasizes the importance of personal protective equipment (PPE) and safety measures, facilitating comparisons of risks between different chemicals. Overall, the ChlorTox Scale standardizes chemical risk estimation, offering a broader view of potential hazards. The methodology for the WHN and CHEMS-1Hazard Assessment models uses safety data sheets (SDS) for the chemicals studied. The WHN model condenses hazard assessment by assigning weights to different hazard categories based on severity, yielding a single score for overall hazard. In contrast, the CHEMS-1 model, built on earlier work by Tobiszewski and Namieśnik, provides a more thorough evaluation, considering various factors like toxicity, flammability, reactivity, persistence, and bioaccumulation. CHEMS-1 was preferred over WHN for its precision in detailing chemical hazards, improving risk differentiation and management. This method captures the complexities of chemical risk more effectively than simpler models like WHN [33,34,35,36,37,38]. Table 8 and Fig. 6e displays results from the ChlorTox WHN & CHEMS-1 models. The ChlorTox Scale effectively evaluates chemical risks by utilizing extensive knowledge of chloroform, enhancing assessment accuracy compared to traditional methods. The ChlorTox Scale GAC metric calculation formulas are shown in Equations (1 and 2) [39]. The ChlorTox Scale, Equation (1) uses the value of chloroform, which is a global standard for determining the relative hazard of other compounds, such as CHCHCl3.
Where: CHsub: Overall hazard level of the chemical in question; msub: Amount of substance used in a single analysis; mN: The mass of all the substances used in N analyses; m': The amount of substance used in additional mandatory procedures; N: The most extensive series in the analysis.
The ChlorTox values, which quantify the potential risk associated with different substances, can be aggregated to represent the total chemical risk anticipated for an entire analytical method. This cumulative measure is referred to as the Total ChlorTox value. It is important to note that the ChlorTox value has a purely theoretical significance and does not directly reflect real-world conditions. Instead, it serves as an indicator of the general scale of potential risk involved. In the context of the developed method, the Total ChlorTox values were calculated using two different models: the WHN model and the CHEMS-1 model. According to these calculations, the Total ChlorTox value for the developed method is 1.24 g when using the WHN model and 1.32 g when using the CHEMS-1 model. To put this into perspective, these values suggest that the risk associated with this method is equivalent to using approximately 1.49 g of pure chloroform as the sole hazardous chemical reagent in an alternative method. This comparison helps in understanding the relative risk profile of the developed method in terms of its chemical hazards.
Analytical greenness (AGREE) tool
AGREE is a comprehensive system for measuring greenness, integrating all 12 GAC principles [25, 50] and offering results in both colour and numerical formats. Its assessment process is straightforward, though it shares drawbacks with GAPI. AGREE overlooks compounds, solvents, energy use, waste from pre-extraction, and sample preparation greenness [40, 41].
The RP-UPLC method developed in this research exhibits environmentally friendly characteristics, as evidenced by an overall score of 0.55. Figure 6b presents the AGREE tool pictogram for the method, and Supplementary Table 2 provides a detailed breakdown of the method scores and values obtained using the AGREE tool. These assessments offer valuable insights into the environmental friendliness of the RP-UPLC method, demonstrating its compliance with Green Analytical Chemistry (GAC) criteria and highlighting the accepted greenness of the proposed approaches.
Analytical Eco-scale (AES)
The AES, which was introduced in 2012 [42], is a key tool in GAC for assessing the environmental and health impacts of analytical methods. For ideal green analysis, a maximum of 100 points are awarded, deducting points for associated hazards. The AES allows for a semi-quantitative assessment of methods, making it easy for researchers to calculate and compare scores [43]. However, it lacks detailed insights into specific hazards and sources of environmental impacts, limiting its effectiveness in improving methods during design. To overcome these issues, enhancements like the Green Certificate Modified Eco-Scale have been suggested, which categorize eco-scale values and use colours for visualization [44,45,46,47,48,49,50].
The proposed RP-UPLC method integrates several principles of Green Analytical Chemistry (GAC), enhancing its environmental friendliness and sustainability. The method achieves an eco-score of 58 on the Eco-Scale, indicating a favourable environmental profile. Despite using acetonitrile, a solvent with environmental and health concerns, its use is optimized to minimize waste and reduce overall environmental impact, aligning with GAC principles of using safer solvents. For forced degradation studies, the method employs Sodium hydroxide, hydrochloric acid, and hydrogen peroxide in minimal quantities, reducing their toxicity and occupational hazard score. This approach adheres to GAC principles by preventing waste generation, using safer chemistry, and designing for energy efficiency. The method's sustainability is further enhanced by its instrumental energy efficiency and reduced sample and reagent volumes, aligning with GAC's goals of minimizing sample size and waste generation. Figure 6C illustrates the modified Eco-scale scores, and Supplementary Table 3 details the penalty points, providing a comprehensive view of the method's sustainability metrics. Overall, the method demonstrates acceptable sustainability and compliance with GAC principles, making it a more environmentally friendly approach in analytical chemistry.
BAGI (Blue applicability grade index)
Manousi et al. developed the BAGI [51], a metric in GAC for assessing the practicality and greenness of analytical methods. Based on White Analytical Chemistry, BAGI has a grading system, a colour scale, and an asteroid graphic to denote greenness and practicality, with scores from 25 to 100. It evaluates methods based on 10 criteria, including analysis type, analyte count, techniques, reagent types, and more. BAGI is accessible at its official website (https://bagi-index.anvil.app) for quick assessments. While a useful GAC tool alongside AGREEprep and ComplexGAPI, it lacks a Safety, Health, and Environmental (SHE) evaluation for reagents and waste [52,53,54,55,56,57].
The BAGI tool was utilized to employ UPLC-PDA detection for the quantification of EFT in both bulk and inhalation formulations. The analysis was conducted using a PDA detector set at 272.0 nm, with the equipment being straightforward and commonly available in laboratories. The process involved the simultaneous preparation of samples with varying concentrations using volumetric flasks. After preparing 20 samples, which took approximately 2 h, the total analysis time per sample using UPLC-PDA was 10 min. This resulted in a sample throughput of 12 samples per hour. The results indicated that no preconcentration was necessary, as the required sensitivity was achieved directly. However, the manual treatment and analysis steps could be considered a limitation, which might be mitigated by automating specific analytical steps in the future. Miniaturized extraction was employed for sample preparation, utilizing a sample volume of 100 μL for the analytical matrix. Consequently, the method achieved a BAGI score of 70, suggesting promising applicability potential for the entire protocol. Figure 6d illustrates the method's environmental friendliness in the BAGI pictogram, with detailed information provided in Supplementary Table 4, including the UPLC method and its corresponding BAGI score.
The results from these greenness assessment tools collectively indicate that our analytical method exhibits strong environmental sustainability and compliance with Green Analytical Chemistry principles. The detailed scores and color-coded representations from each tool provide valuable insights into the method's strengths and areas for potential improvement, ensuring that the method is both effective and environmentally benign.
Balance point display using the EVG tool
The proposed chromatographic method employs the EVG tool to assess three critical dimensions: validation, efficiency, and greenness—each rated on a scale from 0 to 3 using five assessment criteria. A radar chart in Fig. 6f illustrates the performance of the EVG-UPLC method in these aspects. Efficiency focuses on the development of the method in isocratic mode, utilizing advanced columns for UPLC to achieve effective separation of EFT from its impurities. Validation looks at essential parameters that ensure the reliability of the method, including precision, LOQ, robustness, and system suitability. Lastly, the greenness component in analytical chemistry highlights the application of five advanced greenness tools, taking into account factors such as sample treatment, reagents used, solvent choice, instrumentation efficiency, energy consumption, and waste production. This comprehensive evaluation aims to strike a balance among these aspects, ensuring that the method developed is not only effective but also environmentally friendly and scientifically valid [58,59,60]. The scoring for the EVG aspects is detailed in the Supplementary material file.
Conclusion
The principles of the GAC and AQbD approach were utilized to develop a robust analytical method and validation of EFT. The greenness was evaluated utilizing tools such as ComplexMoGAPI, AGREE, ChlorTox Scale, and Analytical Eco-scale, resulting in a greenness certificate. The AQbD method, created with Design Expert software, involved a central composite design to assess three responses with three factors, revealing that flow rate and mobile phase composition significantly impacted EFT peak shape and resolution. Validation of the method was performed for specificity, accuracy, precision, robustness, LOD, and LOQ according to guideline ICH Q2 and met all acceptance criteria. Stability studies under different stress conditions, following ICH Q1A and Q1B guidelines, identified one degradation product under acidic and alkaline conditions. In addition, to quantify ETS, a robust, simple, and validated method was developed using greener solvents, minimizing hazardous solvents, and adhering to green analytical principles and AQbD for routine and quality control analysis of EFT samples. An Efficiency, Validation, Greenness (EVG) radar chart framework was introduced for chromatographic method development to evaluate EFT in pure and pharmaceutical inhalation formulations.
Availability of data and materials
The datasets used and/or analysed during the current study are available from the corresponding authors on reasonable request.
Abbreviations
- COPD:
-
Chronic obstructive pulmonary disease
- EFT:
-
Ensifentrine
- AQbD:
-
Analytical quality-by-design
- GAC:
-
Green analytical chemistry
- PDA:
-
Photodiode Array
- LOD:
-
Limit of detection
- LOQ:
-
Limit of quantitation
- PDE:
-
Phosphodiesterase
- AR:
-
Analytical Reagent
- ATP:
-
Analytical target profile
- CAT:
-
Critical analytical attributes
- AMV:
-
Analytical method validation
- RSD:
-
Relative standard deviation
- EFT:
-
Expected finding test
- PRESS:
-
Predicted residual sums of squares
- NTP:
-
Number of Theoretical Plates
- AGREE:
-
Analytical Greenness
- BAGI:
-
Blue Applicability Grade Index
- SHE:
-
Safety, Health, and Environmental
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Acknowledgements
The authors extend their appreciation to the JBR Educational Society, Kampala International University, DPSR University and Deanship of Research and Graduate Studies at King Khalid University for funding this work through Large Research Project under grant number RGP2/530/45.
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The author(s) received for funding this work through Large Research Project under grant number RGP2/530/45.
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Conceptualisation: V. M. G, S. P. N. B, K. P. K Methodology and investigation: S. P. N. B, V. M. G, K. P. K, C. T Analysis, interpreted the data and writing—original draft preparation: S. P. N. B, V. M. G, K. P. K, B. R. N, C. T Writing—review and editing: S. P. N. B, V. M. G, K. P. K, B. R. N, C. T
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Vanga, M.G., Bukke, S.P.N., Kusuma, P.K. et al. Integrating green analytical chemistry and analytical quality by design: an innovative approach for RP-UPLC method development of ensifentrine in bulk and inhalation formulations. BMC Chemistry 19, 70 (2025). https://doiorg.publicaciones.saludcastillayleon.es/10.1186/s13065-025-01448-8
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DOI: https://doiorg.publicaciones.saludcastillayleon.es/10.1186/s13065-025-01448-8