We present the enantioselective synthesis
of sodium (3S)-5-(benzyloxy)-2-(diphenylacetyl)-6-methoxy-1,2,3,4-tetrahydroisoquinoline-3-carboxylate
(EMA401, olodanrigan), an angiotensin II type 2 antagonist. The manuscript
features the process optimizations of the end game used for late phase
clinical supplies, an overview of synthetic strategies identified
in a route scouting exercise to a key intermediate phenylalanine derivative,
and the analytical control strategy of the potentially formed highly
toxic impurity bis(chloromethyl) ether (BCME). Starting from the phenylalanine
derivative, we describe the optimizations of the end game from early
phase to late phase processes with consequent improvements in the
PMI factor. This sequence includes a Pictet–Spengler cyclization
and an amide coupling as the last bond-forming steps, and the manufacturing
process was successfully implemented on a 175 kg scale in a pilot
plant setup. The modified process conditions eliminated one step by in situ activation of the carboxylic acid, avoided the REACH
listed solvent DMF, and resulted in a PMI improvement by a factor
of 3. In the final crystallization, a new, thermodynamically more
stable modification of the drug substance was found in the complex
solid-state landscape of EMA401 during an extensive polymorph screening.
A process suitable for large-scale production was developed to prepare
the new polymorph, avoiding the need of any special equipment such
as fluidized bed drying required in the early phase process. In the
second section, some of the synthetic approaches investigated for
the route scouting of the phenylalanine derivative key intermediate
are presented. To conclude, we discuss the analytical control strategy
for BCME, the formation of which, due to the simultaneous presence
of HCl and CH2O in the Pictet–Spengler cyclization,
could not be ruled out. The BCME purge factor calculations using the
tools of ICH M7 control option 4 are compared to actual results from
spiking experiments.