Say Goodbye to Activity Loss! A Real‐World Test of Fine‐Scale Mixing and Filling Processes for Peptide‐Protein Materials
In recent years, peptide drugs represented by GLP‑1 receptor agonists have become one of the fastest‑growing segments in the global pharmaceutical market, thanks to their breakthrough therapeutic effects on metabolic diseases such as type 2 diabetes and obesity. The market expansion of blockbuster drugs like semaglutide and tirzepatide has not only spurred a boom in peptide drug R&D and manufacturing, but also imposed higher standards and more stringent requirements on upstream raw material preparation and fine‑scale processing technologies.
At the same time, the application scenarios of peptides and proteins continue to broaden, extending from therapeutic drugs to functional foods, cosmetics, biomaterials, and beyond. The rapid expansion of the industry places greater demands on the preparation processes for peptide‑protein materials. However, traditional mixing equipment, when dealing with heat‑sensitive, highly viscous, and easily denaturable materials such as peptides and proteins, suffers from a series of process bottlenecks – insufficient mixing homogeneity, excessive temperature rise leading to activity loss, and difficulty in completely removing bubbles. These issues have become critical factors limiting product quality and production efficiency. How to achieve efficient, low‑temperature, bubble‑free mixing and deaeration has become an urgent challenge in the industrialisation of peptide‑protein materials.
The Three Major Challenges in Mixing and Deaerating Peptide‑Protein Materials
- Bubble Removal：Peptides and proteins tend to adsorb at the gas‑liquid interface of bubbles, causing structural damage and irreversible denaturation aggregation. Residual bubbles also lead to oxidation of active ingredients, filling volume deviations, and cake defects during lyophilisation. Traditional stirring cannot remove nano‑sized bubbles, and high shear forces can damage biological molecules.
- Temperature Control：Peptides and proteins have poor thermal stability; most undergo thermal denaturation above 50–60°C. Traditional mixing equipment generates considerable shear and frictional heat during high‑speed operation, with even more pronounced temperature rise under high‑viscosity conditions. This accelerates protein degradation, produces aggregates, and reduces the biological activity of the product.
- Mixing Homogeneity：Peptide‑protein formulations often involve blending multiple components with significant differences in density and viscosity. Conventional mixing tends to cause stratification and local concentration imbalances; insufficient mixing uniformity makes it difficult to consistently control batch‑to‑batch product consistency.
Solution
To address these challenges, we conducted a mixing, deaeration, and filling experiment using ZYE Technology’s ZYMC‑200V homogenizer and ZYTF‑M240 manual filling machine.
Client: A biopharmaceutical company
Material: Peptide‑protein
Equipment: ZYMC‑200V homogenizer + ZYTF‑M240 manual filler
ZYE Technology Non‑contact Material Homogenizer ZYMC‑200V
ZYE Technology Manual Filling Machine ZYTF‑M240
Objective: To complete mixing and deaeration with the homogenizer and then perform filling.
Procedure:
- Initial mixing: Combine powder and solvent in the prescribed ratio.
- Homogenization process:Use the ZYMC‑200V homogenizer with a multi‑stage mixing and deaeration program to homogenize and deaerate the slurry, ensuring uniform distribution and bubble‑free material, while significantly improving gloss.
- Stage 1: Revolution speed 500 rpm, run for 60 s, vacuum level 100 kPa
- Stage 2: Revolution speed 2000 rpm, run for 20 s, vacuum level 100 kPa
After homogenization, the material was uniform and free of bubbles, as shown below:
Peptide‑protein material before and after mixing/defoaming
Filling check: Use the ZYTF‑M240 manual filler to fill 5 cc syringes.
After filling with ZYE filler
Results and Analysis
Comparison of material status before and after treatment with the ZYE ZYMC‑200V homogenizer:
1. Morphology improvement
- The material was uniformly mixed, with no separation between solvent and powder.
- During deaeration, the material changed from white to transparent.
- No bubbles were observed inside the syringe during manual filling.
2. Process advantages
- Short mixing and deaeration time (200% improvement over traditional equipment).
- Low temperature rise – after high‑speed operation, the material temperature was only 27°C, which is 10°C lower than that achieved with conventional deaeration equipment.
Application Prospects
As the market demand for peptide drugs such as GLP‑1 receptor agonists continues to grow, high‑quality preparation equipment has become a key competitive factor in the industry.
ZYE’s vacuum defoaming mixer, based on planetary centrifugal mixing technology, independent control of revolution and rotation speeds, and excellent temperature‑rise management, offers a mature and reliable solution for the efficient mixing and deaeration of peptide‑protein materials.
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