Nefopam
hydrochloride is extensively used in most of the European
countries until today as an analgesic because of its non-opiate (non-narcotic)
and non-steroidal action with fewer side effects compared with opioid
and other analgesics, which cause more troublesome side effects. A
multikilogram synthesis of nefopam hydrochloride has been achieved
in one pot using a single solvent (toluene). A ≥99.9% purity
of the active pharmaceutical ingredient (API) was achieved in excellent
overall yield (≥79%). The one-pot, five-step synthetic process
involves formation of an acid chloride (3) from benzoylbenzoic
acid (2) followed by amidation (4), reduction
(5), cyclization (6), and formation of the
hydrochloride salt (1). The major advantages include
(i) use of a single solvent, (ii) >90% conversion in each step,
(iii)
a cost-effective and operationally friendly process, (iv) averting
the formation of genotoxic impurities, and (v) improved overall yield
(≥79%) provided by the one-pot operation. For the first time,
we report the characterization data of API 1, intermediates 3, 4, and 5, and also a possible
impurity (5a).