This paper describes the process
development conducted toward the
multi-kilogram synthesis of a hemiadipic acid pro-drug of buprenorphine.
The major challenges were to control the levels of the dibuprenorphine
monoadipate impurity and to improve the robustness of the final recrystallization.
Modification of the reaction conditions limited the levels of the
impurity formed during the reaction, and an additional point of control
was introduced, a reslurry with dichloromethane. The solid-state properties
of the pro-drug were fully investigated, and extensive polymorph screening
was undertaken. An unusual low-temperature endothermic event was observed
in the differential scanning calorimetry thermogram. This low-temperature
event was further investigated using variable-temperature X-ray powder
diffraction and variable-temperature solid-state nuclear magnetic
resonance spectroscopy. It was concluded that this event was likely
to be associated with a reversible, minor conformational change of
the adipate side chain.
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