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Review
Impact of preformulation on
drug development
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Introduction
2.
3.
4.
5.
Chirality
6.
Hygroscopicity
8.
Drug stability
9.
Drug solubility
10.
Physical incompatibilities
11.
Biopharmaceutical
aspects -- absorption,
distribution, metabolism and
excretion
12.
13.
Conclusion
14.
Expert opinion
1.
Introduction
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Article highlights.
.
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humans through the maximum absorbed dose and the biopharmaceutics classification system (BCS) paradigms. Therefore, a
strong preformulation team in the drug discovery setting is critical for optimizing the pharmaceutical properties of a drug.
This can considerably reduce attrition rate, time and cost of
developing a new drug [4-7]. An alternative approach would be
to have quick proof of concept for first-time-in-man studies to
make a decision on the drug candidate. This early proof of
concept is an alternative view for rapid, slimmed down development both in terms of cost and time.
It has been shown that inadequate preformulation data is
one of the reasons for product recalls. The information
required on preformulation will, to a certain extent, be dictated by the final product, the proposed route of administration and the development plan. A schematic overview of
preformulation characteristics is depicted in Figure 1.
An extensive number of research papers have been published on different techniques and protocols for estimation
of preformulation parameters [8], as well as there are several
reviews [9-11] on the theoretical aspects of preformulation.
Szunyogh et al. [10] reviewed (written in Hungarian language)
the importance of decreased particle size in preformulation.
Hageman [9] has discussed the assessment of key physicochemical properties and how they are implicated in both discovery enablement and in final product developability of
selected candidate. Ashizawa [11] reviewed (in Japanese language) the importance of physicochemical profiling and preformulation studies at the drug discovery stage. However,
there is no review available where the significance of individual preformulation parameters in product development is
elaborated using case studies of drug candidates. Furthermore,
a critical analysis of preformulation-related product recalls is
missing in earlier reviews. The present review provides a critical account on how understanding of chemical and pharmaceutical properties of medicinal chemistry leads plays a vital
role in product development. This has been elaborated using
case studies of drug candidates wherein preformulation data
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proved to be crucial in the drugs preclinical/clinical development. Additionally, case studies of product recalls have been
discussed wherein some additional preformulation data would
have avoided these withdrawals. Preformulation requisites and
regulatory aspects of preformulation for investigational new
drug (IND) applications have also been discussed. The chemical structures of drugs (1 -- 28) discussed in the following
sections are shown in Figure 2.
2.
The chemical, biological, physical and economic characteristics of drug candidates can be manipulated by converting
them to a salt form. Pharmaceutical chemists and formulation
scientists modify these characteristics by selecting an appropriate salt form of a drug substance. This permits development
of dosage forms with good bioavailability, manufacturability
and stability along with patients acceptance. Salts are most
frequently employed for altering aqueous solubility; however,
selected salt forms also influence a range of other properties
such as melting point, chemical stability, hygroscopicity, solution pH, dissolution rate, crystal form and mechanical properties [12,13]. Pharmaceutical salts frequently exist as hydrates,
which create difficulties during formulation development,
particularly in wet granulation. It often becomes difficult to
monitor and control the anhydrate/hydrate form during the
wet mixing, fluid bed drying and aqueous film coating processes. This factor has led to the deselection of a particular
salt form in further development process many times [14,15].
During the drug development process, discovery of new
crystal forms offers an opportunity to select an optimal form
of a drug candidate [16]. Cocrystals have also been utilized
for modifying the physicochemical parameters of drugs.
Tsutsumi et al. [17] studied miconazole salts and cocrystals
for improving physicochemical properties. They reported
hemisuccinate as a novel cocrystal form of miconazole with
an improved dissolution rate and superior stability, making
it an alternative for nitrate salt. Pharmaceutical cocrystal strategy compliments the salt formation to enhance bioavailability
of drug product and stability [18].
The information generated from preliminary crystallization
studies is often helpful to the process chemistry group, which
investigates possible manufacturing routes for the molecule of
interest. The manufacturing route may be the same as used by
the discovery chemistry group, but it can also significantly differ. Both the process chemistry and preformulation groups
extensively collaborate for the next 12 -- 18 months in order
to ensure a viable synthetic route for the chosen salt form of
the drug candidate. A significant portion of this batch is destined for the preparation of 3 -- 4 g of each salt that were
thought to be viable from smaller-scale studies. A similarsized portion of free base/acid is also taken for comparison
purposes. The combination of individual studies undertaken
on each of these 3 -- 4 g portions varies depending on the
type(s) of dosage form ultimately required for marketing.
Analytical
Physical
a) TLC
b) HPLC
Reverse phase
Chiral
Physical analysis
f) Microscopy
a) Melting point
i) Particle shape
b) Hygroscopicity
c) Differential scanning calorimetry ii) Particle size
g) Powder
d) Thermogravimetry
i) Compaction
e) X-ray crystal determination
ii) Flow
2
a) Synthetic impurities
b) Residual solvent
c) Residual water
d) Heavy metals
e) Degradants 1
microbiology
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Candidate drug
Pharmaceutical
A) Biopharmaceutical properties B) Chemical compatibility
a) Monolayer adsorption
I) Processing
b) ADME
II) Excipients
C) Regulatory stability
Physicochemical
B) Physicochemical properties
A) Chemical stability
3
I) Log P
a) Oxidation
II) pKa
b) Light
III) Solubility
c) pH
Degradants
a) Solvent
d) Temperature
b) pH
e) Solvent
c) Dissolution
Figure 1. Map of preformulation studies revolving around the candidate drug. Studies would commence in the analytical
segment and swing around to the pharmaceutical segment as the compounds development progressed. As early studies
affect later studies, the dotted pointer indicates one linkage, the determination of the UV/VIS spectrum is useful for HPLC
method development, which is influenced by synthetic impurities and degradants, which then allows degradation studies to
be conducted [8].
Occasionally, it may be necessary to undertake a pharmacokinetic evaluation of each salt in comparison with the free acid/
base. At this stage in the development process, the aim is to
quickly manufacture 50 -- 200 g of promising candidate(s)
for initial clinical evaluation. The alternative approach is to
proceed with the free base or acid form, if the drug candidate
displays efficacy in animal studies. In such cases, the extensive
process chemistry efforts can be skipped and the medicinal
chemistry synthetic route could be employed to quickly prepare free base/acid form. Formulation strategies could be
employed in order to achieve adequate exposure of the drug.
Dosage forms most commonly used for drug substances
encountered during preliminary clinical investigations are tablets/capsules, inhalation dosage forms and injections [19]. Of
the many salts synthesized, the preferred form is selected by
a pharmaceutical chemist primarily on a practical basis (raw
materials employed, ease of crystallization process and percentage yield). Other basic considerations include stability,
hygroscopicity and flowability of the resulting bulk drug.
The following representative examples illustrate how and
why selection of proper salt forms is necessary during preformulation and before going forward to product development.
The process for producing a stable chlortetracycline (1) suspension was developed at Lederle Laboratories between
1951 and 1954 [20]. Berge et al. [21] observed that hydrochloride salt was highly unstable in aqueous solution, but calcium
salt was very stable. They also reported that potassium salt of
1241
OH
O
OH
OH
OH
H2N
H
H
HO
OH
N
O
H
N
O
OH
Cl
NH
3 REV-5901
2 Penicillin G
1 Chlortetracycline
4 LY333531
Cl
HO
OH
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Cl
OH
10 Thiamine
9 Theophylline
N
HO
O
Cl
S
HN
HO
NH HN
O
OH
H2N
S
O
15 Phenylbutazone
O
OH
HO
O
O
NH
HN
N
N
O
17 Tolbutamide 18 Hydrochlorothiazide
O
H
OH
16 Oxytetracycline
14 Rotigotine
H
OH
Cl
O
OH
OH
12 Ritonavir
H
N
N
N
O-
13 Chloramphenicol
HO
O
N
H
O
H2N
HN
8 Nelfinavir
11 Erythromycin
OH
H
N
H
N
OH
OH
N
H
Cl
O HO
O
OH
O
HO
HO
OH
N
H
OH
OH
O
NH2
H
N
O-
7 L-649923
5 Diclofenac
NH
N
N
N
NH
19 Irbesartan
OH
I
F
21 RPR 200765
HO
22 NBI 75043
H3CO
NH2
O
F
Cl
OH
HO
OH
O
O
27 Warfarin
OH
HH
OCH3
25 Combretastatin A4
HO
23 Levothyroxine
O
N
OCH3
OAc
OH
H3CO
20 Rapamune
O
O
O
O
OH
26 Flavopiridol
HN
24 Fluocinonide
NH
NH
NH2
28 Metformin
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parameters such as polymorphism, stability, purification, filterability and relative bioavailability in dogs. Results obtained
from these efforts indicated that mesylate salt can be developed as the optimal salt form of LY333531.
Apart from salt form selection, the stability of the selected
salt is imperative. Chemical and physical aspects associated
with preparation of pharmaceutical salt are formation of
hydrates, polymorphism and amorphization. These aspects
are also important from a technological point of view, as
they affect solubility, dissolution rate and bioavailability of
drugs. Therefore, each pharmaceutical salt must undergo a
careful preformulation study in order to define experimental
conditions of its stability. Fini et al. [24] prepared salts of diclofenac (5) with various salt-forming agents in order to find the
optimally stable and soluble salt form. Diclofenac salts with
eight different cyclic aliphatic amines, such as pyrrolidine,
piperidine, morpholine, piperazine and their N-hydroxyethyl
analogs, were prepared and characterized. However, these
salts were found to possess poor aqueous solubility as compared with diclofenac sodium. Hence, each pharmaceutical
salt must undergo a careful preformulation study in order to
define its solubility and stability. Ionizable and non-ionizable
prodrugs can also be prepared to improve bioavailability of
drug candidates. However, use of free base form of the
molecule with alternative formulation strategy (nanodelivery
systems, such as nanoparticles, liposomes, nanoemulsions/
microemulsions, micelles and longer circulating half-life of
the drugs by PEGylation) is equally straight forward. Typically, the salt formation is considered as the most practical
approach to enhance bioavailability.
The maleate salt of a basic drug dibenzo-(b,f)-oxepen10-yl-methyl-methyl-prop-2-ynyl-amine (6) was found to be
more stable than free base. This selected salt was developed
for oral administration in the treatment of neurodegenerative
disorders, such as Parkinsons disease and amyotrophic lateral
sclerosis. Hard gelatin capsules of various potencies (0.25,
2.5 and 10 mg) were selected for Phase I clinical studies. After
initial clinical testing using capsules in Phases I and IIA, scientists decided to switch the dosage form from capsule to tablet
with the same potencies for the Phases IIB and III clinical
studies, for commercialization purpose. Tablets were developed with a minimal change in composition from the capsule
formulation to maintain continuity between developmental
activities of two dosage forms and to ensure that their stability
would be similar. Tablet formulations of the maleate salt of
this drug showed major loss in potency and lack of mass balance upon storage under accelerated stability testing. No such
stability problem was observed in capsules that were similar in
composition. Interestingly, the tablet was found to be stable
when it was encapsulated in a capsule shell. It was identified
that the reason behind the instability of the drug in tablets was
conversion of salt to its free base form in the microenvironment
of tablet formulation [25-27].
The free base of an orally active leukotriene D4 antagonist
L-649923 (7) was found to be highly unstable because of its
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Crystal engineering studies are important in the pharmaceutical industry to develop stable and robust solid dosage forms.
Solid-state properties have a great impact on physicochemical
and biopharmaceutical properties of drugs. The solid state is
important as it affects filtration, flow, tableting and dissolution. Although there may not be significant differences in bioavailability of drugs with different crystal habits, it is of
importance from a technological point of view. The injection
of a suspension-containing drug in crystal form is influenced
by its habit. Crystal habit also influences the ease of
Chirality
6.
Particle shape and size affect both primary and bulk powder
properties and play a decisive role in controlling dissolution [68].
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Knowledge of particle size and size distribution, flow properties and dissolution are key aspects that should be studied in
the field of dissolution science and during the formulation
development process [69]. The melting point of pharmaceutical
salts is often intrinsically related to their physicochemical properties. The APIs with low melting points often exhibit plastic
deformation during the formulation development process,
which can cause both caking and aggregation, and has an
impact on both flow and compressibility performance. These
in turn affect many critical quality attributes of the drug
product (with low dose) such as disintegration and in vitro
dissolution rates, friability and content uniformity [70].
Bastin et al. [19] demonstrated the importance of flow properties by studying physicochemical properties of various salts
of the anti-arthritic drug RPR 200765 (21). Among four
salt forms investigated (mesylate, camphorsulfonate, hydrochloride and hydrobromide), mesylate salt demonstrated
good handling properties such as good flow (required during
formulation stage) and a non-hygroscopic nature, allowing
straightforward capsule and tablet development. These flow
properties were superior to the alternative salts studied
(hydrochloride, hydrobromide and camphorsulfonate) [71].
7.
Hygroscopicity
Drug stability
Drug solubility
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Physical incompatibilities
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11.
NH2
O HO
HN
HN
N
N
NH HN
H3CO
O
O
OHO
NH
HN
OH
N
NH
NH
NH
29 Lopinavir
30 Saquinavir
31 Atazanavir
H2N
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NH2
HN
N
O
OCH3
O
Br
O
H
HN
O
N
NH
OH
32 Darunavir
33 Etravirine
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1250
13.
Conclusion
Expert opinion
Collaboration of medicinal chemists and formulation scientists in drug discovery research is essential to identify a drug
candidate that has the best chance of clinical and eventually
commercial success. The partnership between medicinal
chemists and formulation scientists in drug discovery produces NCE with structural modifications in order to improve
solubility, stability, permeability and oral bioavailability.
The role of formulation scientists has been recognized for preparing formulations for preclinical in vivo studies and for
identification of final solid-state forms of drugs. Apart from
this, the team work between pharmaceutics and medicinal
chemistry departments at earlier stages of drug discovery
increases the speed of preclinical evaluation and reduces attrition during the development process. The performance of
solid dosage forms is reliant on the physicochemical properties of the active ingredient and excipients. Before going for
Phase I clinical studies, excipients used for the formulation
development process should be identified. The purpose is to
ultimately prevent unnecessary and very costly changes
including time and overall development cost in subsequent
steps. The goal is to identify critical parameters important in
the development of a stable, effective and safe drug delivery system or dosage form. Table 1 depicts examples of drug products
wherein preformulation data showed impact on the drugs
development or its recall from the market. Examples of product recall are primarily because of inadequate preformulation
data where different/more preformulation data might have
avoided market loss.
Most companies perform salt screening in order to have
a molecule with appropriate physicochemical properties
such as crystallinity, low hygroscopicity, dissolution rate, solubility, bioavailability and stability. Improper salt form selection may lead to instability in the final product as seen for
REV-5901 (3) where hydrochloride/sulfate salt was found to
be unstable. The most commonly used pH modifiers for
acidic drugs are sodium, calcium, potassium and so on. For
basic drugs, they are hydrochloride, mesylate, sulfate, citrate
and hydrobromide. REV-5901 is a base with a pKa value of
3.7 and the pH solubility profile of REV-5901 showed that
the pHmax of the compound was 1 indicating that the salt
form would exist only at pH < 1. Therefore, only two salt
forms (hydrochloride and sulfate salts) could be prepared.
A salt with weaker acids such as phosphoric, acetic, lactic
and tartaric acid was not feasible. Another interesting point
Biopharmaceutical aspects-ADME
Physical incompatibilities
Drug solubility
Chirality
Bulk properties (particle
size and size distribution,
flow, dissolution, etc.)
Hygroscopicity
Drug stability
Preformulation parameter
Drug product
Lopinavir (29)
Saquinavir (30)
Metformin (28)
Flavopiridol (26)
PN
Erythromycin (11)
Ritonavir (12)
Theophylline (9)
Chlortetracycline (1)
Penicillin G (2)
REV-5901 (3)
LY333531 (4)
Diclofenac (5)
Dibenzo (b,f)oxepen-10-ylmethyl-methyl-prop-2-ynyl-amine
hydrogen maleate (6)
L-649923 (7)
[28]
Free base was very unstable, but the calcium salt was more
pharmaceutically promising than the sodium, ethylenediamine
and benzathine salts
Withdrawn from market due to elevated levels of ethyl methanesulfonate
(cancer-causing contaminant)
Phase transition of stable anhydrous theophylline to
theophylline monohydrate due to wet granulation, which resulted
in decrease in dissolution rate
Conversion of stable thiamine hydrochloride to NSH
due to wet granulation
Conversion to erythromycin dihydrate due to milling and drying
Reduced solubility in the marketed formulation due
to existence of new polymorph
Discovery of presence of biologically less active crystal form
Presence of less stable new polymorphic crystals
Discovery of less soluble new polymorph
Plate-like crystals cause tableting problems
Existence of less soluble crystal of irbesartan due to longer granulation time
Converts to three isomers in aqueous solution with reduced bioavailability
Mesylate salt demonstrated good handling properties among the
four salts (camphorsulfonate, hydrochloride and hydrobromide)
[113]
[114]
[96]
[95]
[86]
[90]
[73]
[77]
[78]
[84]
[42]
[54]
[60]
[62]
[63]
[67]
[71]
[37]
[151]
[36]
[38]
[31]
[21]
[20]
[22]
[23]
[24]
[26]
Refs.
Preformulation observations
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was if the microenvironmental pH rises above 1, the hydrochloride/sulfate salt gets converted to free base. Therefore,
REV-5091 was preferred as a free base over the salt forms.
Trace impurities found during salt formation plays a significant role in the stability of formulations and may affect
potency of API. The starting material used for salt form preparation may also give rise to formation of impurities as a
by-product as seen in the case of nelfinavir mesylate (8).
Another parameter to be studied during the preformulation
stage is polymorphism and phase transitions. These should be
investigated during initial stages of development. In situ phase
transitions during product development (manufacturing
processes and processing conditions) may affect/alter solubility of drug and thus the bioavailability. The manufacturing
processes such as wet granulation [as in case with theophylline
(9), thiamine HCl (10)], milling and drying [as observed with
erythromycin (11)] may have pronounced effect on dissolution rate and stability of drugs. Results of these studies must
be incorporated in the CMC section of NDA. This information is required to demonstrate control over manufacturing
processes. Existence of different crystal forms should be studied because it may impart either harmful or helpful characteristics to particular formulations in terms of bioavailability.
The most cited example is ritonavir (12) and oxytetracycline
HCl (16) wherein new polymorphic forms have less solubility
and thus reduced bioavailability. Discovery of a new crystal
form of chloramphenicol palmitate (13) was biologically less
active thus making formulation less effective. In the case of
rotigotine (14), the new polymorph discovered was less stable.
For this reason, polymorphic study is crucial during the preformulation stage and will decide commercial success of the
final product. The crystal structure of a compound will decide
its physicochemical properties such as crystal habit, melting
point, solubility, rate of desolvation, color, mechanical properties and chemical stability. Plate-like crystals of tolbutamide
(17) were not suitable for tableting and, therefore, not manufacturable. Thus, understanding of these properties during
product development will be beneficial.
In the pharmaceutical scenario, particle size and size distribution affects the intrinsic dissolution rate, which is one of the
decisive parameters of drugs after administration. Shape characterization is vital here as different crystal faces dissolve at different rates. At the preformulation stage, one should identify
particle shape and size distribution in order to produce formulations with desired efficacy and with economical production techniques. Good flow properties are preconditions for successful
manufacturing of dosage forms (tablets and hard gelatin capsules). Appropriate fluidity of materials is required for transportation of powder fill/granules through the hopper of the tableting
machine. Elongated particle shape and small particle size may
cause high tablet weight variations, strength, unacceptable blend
uniformity and difficulty in filling containers and dies. Powder
flow is affected by numerous parameters including purity, crystallinity, electrostatic forces, mechanical properties (brittleness,
elasticity), density, size, shape, surface area, moisture content,
1252
direction and rate of shear, storage container dimension and particle--wall interaction. In the case of RPR 200765 (21), mesylate
salt was found to have better handling properties over sulfonate,
hydrochloride and hydrobromide salts.
Drug stability is an essential component of preformulation
testing and preformulation scientists collaboratively work
with analytical departments to develop stability-indicating
assays. During early stages, a perfect stability-indicating assay
may not be available because initial drug lots may not be pure
and purity is improved as the molecule progresses to subsequent development stages. Therefore, the intention of preformulation scientists is to broadly define conditions under
which the drug would be stable. In the case of levothyroxine
sodium (23) it was not stable throughout its shelf life and after
marketing it was found that the reason behind less potency
was a stability issue with levothyroxine sodium. It was sensitive to light, temperature, air and humidity, thus, loss of
potency was the reason behind product recall.
Determination of solubility during preformulation testing
is a decisive parameter during formulation development. Drug
solubility is one of the physicochemical parameters that receive
a lot of attention during preformulation testing. The BCS paradigm can be used to develop strategies for enhancing drug solubility and/or permeability. Generally, the absorption rate constant of
drugs varies by over only ~ 50-fold range (0.001 -- 0.5 mg/min)
whereas drug solubility can vary over six orders of magnitude
(0.1 g/mL -- 100 mg/mL) [150]. Hence, the formulator has superior flexibility in altering the drugs solubility over its permeability. Optimization of drug solubility may be more fruitful if
permeability is overcome by increasing drug solubility, to provide
high drug concentration at the absorption site. However, this may
be difficult if the dose is very high. Alternative formulation
approaches could be considered if the drug is poorly soluble. In
the case of flavopiridol (26), researchers formulated flavopiridol
with HP-b-CD and citric acid to keep the drug in a solubilized
form so that it would not precipitate upon injection.
The role of the preformulation team at every stage of the
drug discovery and development process is to select appropriate
methods to guide or alert other development teams about drug
solubility and permeability issues. There have been consequences
observed of formation of new impurities, incomplete mass balance, destruction of dosage form, unnecessary multiplicity of prototype formulations and changes in physicochemical properties
(stability, solubility, dissolution profile, degree of crystallinity
and hygroscopicity) due to inadequate data on the drug--excipient
interaction. The reason behind this might be incomplete/
insufficient drug--excipient interaction studies at the preformulation stage, which can be one reason for inability to obtain successful drug registration. The bilayer tablet of metformin (28) was
recalled due to a very low recovery of API. This has been attributed to the use of a negatively charged excipient (i.e., croscarmellose sodium), which had an interaction with metformin.
Throughout the process of drug discovery, a carefully
planned preformulation study provides crucial data and
information regarding drug substance and knowledge of
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1.
2.
3.
..
4.
5.
..
6.
7.
12.
14.
15.
..
9.
22.
23.
24.
25.
16.
26.
17.
27.
28.
18.
29.
30.
31.
8.
10.
13.
11.
Declaration of interest
19.
20.
21.
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34.
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36.
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40.
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42.
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..
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53.
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68.
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Affiliation
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