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Sterile Drug Product Development: Formulation, Stability, and Packaging

Presenter: Jeff Schwegman, Ph.D.
Date: Wednesday, February 10, 2027
Time: 3 pm ET | 2 pm CT | 1 pm MT | 12 pm PT 
Duration: 90 minutes


Course Description

This comprehensive webinar details the end-to-end process of taking a purified drug compound, or active pharmaceutical ingredient (API), and converting it into a stable, sterile, injectable drug product in both liquid and lyophilized (freeze-dried) presentations. The session explores preformulation strategies, focusing on selecting the appropriate pH to achieve optimal chemical stability and aqueous solubility, as well as choosing a suitable buffer system with adequate buffer capacity to maintain formulation pH.

The discussion covers functional excipients in detail, including tonicity-modifying agents for osmolality adjustment, solubilizing agents to enhance drug solubility, stabilizers to minimize degradation, and surfactants to help prevent physical instability. For multi-dose products, considerations for the use of antimicrobial preservatives will also be addressed. When developing a lyophilized formulation, the webinar explains how excipient selection must be modified, including the role of bulking agents, and how these formulation decisions influence the critical thermal properties of the product during freeze-drying.

Finally, the webinar addresses the selection of an appropriate container closure system based on the formulation and product presentation, including components such as vials, stoppers, and seals. It will also explain how specialized surface coatings and packaging chemistries can influence product stability and potentially improve compatibility between the formulation and the container closure system.


Learning Outcomes

        • Understand the fundamentals of pre-formulation studies for sterile products.
        • Identify key steps in sterile pharmaceutical formulation development.
        • Evaluate the impact of pH, solubility, and buffer capacity on product stability.
        • Select appropriate excipients for sterile liquid and injectable formulations.
        • Understand formulation differences between liquid and lyophilized products.
        • Assess how excipients influence thermal properties and freeze-drying behavior.
        • Understand the role of accelerated stability studies in product development.
        • Evaluate formulation requirements for small and large-molecule products.
        • Select suitable container closure systems based on product compatibility.
        • Understand the impact of specialized coatings and container materials on product stability.

        Areas Covered in the Session

          • Pre-Formulation Studies
            • Drug characterization, solubility, and stability assessment.
            • Key considerations before developing sterile injectable formulations.
          • pH, Solubility, and Stability
            • Selecting optimal pH conditions.
            • Evaluating the impact of pH on drug solubility and stability.
          • Buffer Systems and Buffer Capacity
            • Selection of suitable buffer systems.
            • Maintaining formulation pH throughout product development.
          • Pharmaceutical Excipients
            • Tonicity-modifying agents, solubilizers, and preservatives.
            • Excipient selection and concentration considerations.
          • Liquid vs. Lyophilized Formulations
            • Key differences in formulation development.
            • Excipient selection for liquid and freeze-dried products.
          • Stabilizers and Surfactants
            • Their role in maintaining drug product stability.
            • Addressing degradation and aggregation challenges.
          • Thermal Properties of Formulations
            • Understanding critical thermal characteristics.
            • Impact of excipients on lyophilization behavior.
          • Small Molecule vs. Large Molecule Formulations
          • Accelerated Stability Studies
          • Container Closure System Selection
            • Compatibility between the formulation and packaging materials.
            • Selection of suitable container closure components.
          • Specialized Container Closure Coatings and Technologies
            • Different coating materials and surface chemistries.
            • Their impact on product compatibility and stability.
          • Sterile Injectable Product Development
            • Converting purified drug compounds into stable sterile injectable products.
            • Key formulation considerations for final product development.
          • Interactive Live Q&A Session with speaker

          Recommended Participants

                • Pharmaceutical Formulation Scientists and Specialists
                • Formulation and Process Development Scientists
                • Pharmaceutical Chemists
                • Biochemists and Analytical Chemists
                • Pharmaceutical Research and Development (R&D) Professionals
                • Sterile Manufacturing and Production Managers
                • Aseptic Processing and Sterile Manufacturing Personnel
                • Compounding Pharmacists and Pharmacy Managers
                • Quality Control (QC) Managers and Analysts
                • Quality Assurance (QA) Professionals
                • Pharmaceutical Stability and Compatibility Scientists
                • Drug Product Development Scientists
                • Lyophilization and Freeze-Drying Specialists
                • Container Closure and Packaging Development Specialists
                • Pharmaceutical Engineering and Technical Operations Professionals

                About the Presenter  

                J. Jeff Schwegman, Ph.D., is currently the Founder and Chief Executive Officer of Labyrinth BioPharma, where he develops formulations, lyophilization cycles, and manufacturing processes for injectable drug products, diagnostics, and tissues used in surgery.

                Additionally, Dr. Schwegman specializes in speaking and consulting on parenteral pre-formulation, formulation, analytical development, and lyophilization of both small and large biomolecules. He also holds patents and develops new technologies in the field of lyophilization.

                Dr. Schwegman received his B.S. in Biochemistry from Indiana University in 1992 and began working at Cook Imaging in Bloomington, Indiana, where he gained experience in analytical, formulation, and process development. In 1999, he began graduate studies in the Department of Industrial and Physical Pharmacy at Purdue University under the direction of Dr. Steve Nail. His research focused on studying changes in the physical structure of biological molecules during lyophilization.

                Dr. Schwegman received his Ph.D. from Purdue University in 2003 and returned to Bloomington, where he worked as a Research Scientist in the Pharmaceutical Development group at Baxter Pharmaceutical Solutions.

                He has founded several companies, including BioConvergence and AB BioTechnologies. He currently serves as the Course Director for a four-day course titled “Lyophilization Cycle Development & Optimization: A Hands-On Laboratory Course,” which he teaches through SP Scientific. He also regularly lectures worldwide on formulation, stabilization, and process development of lyophilized products.


                Additional Information

                After Registration:
                You will receive an email with login information and handouts (presentation slides) that you can print and share with all participants at your location.

                System Requirement:
                • Internet Speed: Preferably above 1 Mbps
                • Headset: Any decent headset and microphone which can be used to talk and hear clearly

                Can't Listen Live?
                No problem. You can get access to an On-Demand webinar. Use it as a training tool at your convenience.

                For more information, you can reach out to the below contact:

                Toll-Free No: 1-302-444-0162
                Email: care@skillacquire.com
                Address: 651 N. Broad Street, Suite 206, Middletown, DE 19709

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