qbd in pharmaceutical formulation development

The QbD approach is based on the principle of continuous improvement. There is a need for vigorous and well funded research programs to develop new pharmaceutical manufacturing platforms. Implementation of a Question-based Review (QbR) Process has occurred in CDER’s Office of Generic Drugs. controlled, patient guided variability). Approaches to pharmaceutical Development Aspects Traditional QbD Pharmaceutical development Empirical Systematic and multivariate experiments. Quality by Design in Pharmaceutical Formulation: 10.4018/978-1-5225-7326-5.ch010: Quality by design (QbD) is a systematic, scientific, risk-based approach to product development and manufacturing process to consistently deliver the quality QbD describes a pharmaceutical development approach referring to formulation design and development and manufacturing processes to maintain the prescribed product quality. QbD Application in Pharmaceutical Development for Nano Formulation. In this study, authors adapt the Quality by Design (QbD) concept as well as the Risk Assessment (RA) method to the early development phase of a new nano-sized liposomal formulation for nasal administration with brain target. This article focuses solely on the application of QbD to the subsection of pharmaceutical packaging – the packaging of sterile dosage forms (SDFs). The manufacturing scale used during formulation development depends on the amount of drug substance, and the equipment, available. All Rights Reserved. Ensures robust commercial manufacturing methods for consistent production of quality drugs. QbD improves the speediness of the prod­uct launching onto the market [2]. Guideline Q8 (revised 2008) describes QbD-based drug formulation development while Guideline Q9 describes Quality Risk Management plans, Q10 explains Pharmaceutical Quality Systems, and Q11 refers to development of active pharmacological substances including biologics. If performing any minor variations or deviations in relation to the target manufacturing process, because of technical reasons, the process will still operate robustly, and a quality final drug product can be ensured. An ophthalmic product will be manufactured just like a non-sterile product, and we can most certainly apply QbD to the sterilization process. Establish a control strategy for the entire process that may include input material controls, process controls and monitors, design spaces around individual or multiple unit operations, and/or final product tests. It means designing and developing formulations and manufacturing processes to ensure predefined product quality. (ICH). This allows manufacturers to determine whether the batch is operating as it should, or if there is an early drift in performance. Design a formulation and identify the critical material (quality) attributes of the final product that must be controlled to meet the target product quality profile. More efficient technology transfer to manufacturing. As the project moves from the lab right through to commercial manufacture, the risk assessment information can be continually updated, allowing drug developers to identify and correct the root causes of potential problems. The approach primarily aims to design quality into workflows from the outset. “This method (in QbD) can improve pharmaceutical nano-developments by achieving shorter development time, lower cost, saving human resource efforts and more effective target-orientation .”. As forward-thinking companies look to improve their production capabilities, reduce timelines and introduce more continuous manufacturing processes, the QbD approach will see an increase in popularity. When product consistency is proven, it builds trust and confidence from regulators that both the process and product are robust. QbD describes a pharmaceutical development approach referring to formulation design and development and manufacturing processes to maintain the prescribed product quality. The data-driven approach used by QbD helps to serve the progressive manufacturing environment, as it gives drug developers a better understanding of manufacturing processes, decreases the amount of batch failures, gives more effective control of change and also, provide a higher return on investment. CDER’s Office of Compliance has played an active role in complementing the QbD initiative by optimizing pre-approval inspectional processes to evaluate commercial process feasibility and determining if a state of process control is maintained throughout the lifecycle, in accord with the ICH Q10 lifecycle Quality System. Ex: Manufacturing changes within the approved design space without further regulatory review. FDA’s release of the Process Validation guidance in January 2011 notes the need for companies to continue benefiting from knowledge gained, and continually improve throughout the process lifecycle by making adaptations to assure root causes of manufacturing problems are quickly corrected. The pharmaceutical Quality by Design (QbD) is a systematic approach to development that begins with predefined objectives and emphasizes product and process understanding and process control, based on sound science and quality risk management. USA: QbD is “Woven” into Regulatory Guidance Documents ICH • Primarily ICH Q8 through Q11 • Q8- Pharmaceutical Development • Q9- Quality Risk Management • Q10- Pharmaceutical Quality System • Q11- Development and Manufacture of Drug Substances FDA 2011 Process Validation Guidance • A “Risk-Based Approach” • Process Development Identify the critical process parameters and input (raw) material attributes that must be controlled to achieve these critical material attributes of the final product. and dosage are finalized. Copyright © 2016-2020 Learnaboutgmp LLC. Guidelines and mathematical models are used to ensure the establishment and use of the knowledge on the subject in an independent and integrated way. This is because all potential interactions have been identified and evaluated; they are not unknown. In FDA’s Office of New Drug Quality Assessment (ONDQA), a new risk-based pharmaceutical quality assessment system (PQAS) was established based on the application of product and process understanding. However, it is also a systematic method of process development which delivers consistency, robustness and increased process knowledge. Conclusion: This is a systemic approach to design and development of the pharmaceutical formulations and manufacturing processes that ensures the predefined product quality. Quality by Design (QbD) allows for a systematic approach to drug development that is intended to improve quality by using analytical and risk-management methodologies for the design, development and manufacturing of new medications. A - Yes, any pharma project that involves formulation and process development activities can employ these practices. The pharmaceutical industry was late in adopting these paradigms, compared to other sectors. Quality by Design (QbD) allows for a systematic approach to drug development that is intended to improve quality by using analytical and risk-management methodologies for the design, development and manufacturing of new medications. It heavily focused on blockbuster drugs, while formulation development was mainly performed by One Factor At a Time (OFAT) studies, rather than implementing Quality by Design (QbD) and modern engineering-based manufacturing methodologies. Why Process Validation is Reliant on a Detailed Design Review of the Product [Video], 10 Things You Need to Know About Creating User Requirements, Critical Process Parameters – Process Validation, Systematic, Multivariate experiments, Focus on control strategy and robustness, Adjustable within design space, managed by company’s quality systems, PAT utilized, Process operations tracked and trended, Primary means of quality control, based on batch data, Part of the overall quality control strategy, based on desired product performance, Risk-based control strategy , real-time release possible, Begin with a target product profile that describes the use, safety and efficacy of the product, Define a target product quality profile that will be used by formulators and process engineers as a quantitative surrogate for aspects of clinical safety and efficacy during product development, Gather relevant prior knowledge about the drug substance, potential excipients and process operations into a knowledge space. It is therefore considered to be omnipresent during each of these vital stages of product development. By designing quality into the process, greater consistency from batch-to-batch can be ensured. The Quality of the pharmaceutical product can be evaluated by in vivo or in vitro performance tests. Quality by Design (QbD) is emerging to enhance the assurance of safe, effective drug supply to the consumer, and also offers promise to significantly improve manufacturing quality performance. It is important that deviations can be detected as early as possible in order to act accordingly so that the process can return to its usual operating conditions before there is a substantial impact on performance. By building a bank of knowledge as the drug substance or drug product progresses through its lifecycle, it is possible to adapt techniques to ensure that any potential disruptions or manufacturing problems are avoided. Comparison between QbT and QbD procedures is shown in Fig. Improved yields, lower cost, less investigations, reduced testing, etc. A key attribute of the QbD assessment is the efficiency it offers pharmaceutical companies. Use risk assessment to prioritize knowledge gaps for further investigation. member of the American Association of Pharmaceutical Scientis ts and the Society of Cosmetic Chemists. Minitab, Design Expert, Stat Graphics, etc. The concept and the elements of the QbD approach (regarding its systemic, scientific, risk-based, holistic, and proactive nature with defined steps for pharmaceutical development), as well as the experimental drug formulation (including the technological parameters assessed and the methods and processes applied) are described in the current paper. Less intense regulatory oversight and less post-approval submissions. You may be missing content or you might need to enable the original module. It serves as a bridge between industry and drug regulatory authorities to move towards a scientific, risk based, holistic and proactive approach for development of pharmaceutical product. Find out how we can help you bring your life science training to the next level. Pharmaceutical QbD is a systematic approach to product development that begins with predefined objectives in the form of Quality Target Product Profile (QTPP) and emphasizes product and process understanding in the form of Critical Material Attributes (CMAs), Critical Processing Parameters (CPPs) & Critical Quality Attributes (CQAs) and its controls based on sound science and quality risk management “Hence Quality by design relate to Product Performance”. 1. With regulatory authorities insisting that manufacturers design quality into products at each stage of development and manufacture, QbD will become increasingly crucial. Without early detection, normal operation conditions cannot always be restored. Following Quality by Design (QbD) is the most appropriate approach for every aspect of pharmaceutical development. This positively impacts both the environment and the production economy. So, what other advantages does a QbD approach offer the pharmaceutical industry and how can it be properly utilised? QbD methodology helps in identifying and justifying target product profiles, product and process understanding. An enhance QbD approach to pharmaceutical development provides opportunities for more flexible regulatory approaches. By doing so, it reduces the likelihood of unexpected reasons causing batch failure. One of the main benefits of using the QbD approach is that it gives the manufacturing team a clear understanding of the process parameters and how they work together. Deficiency letters from regulatory authorities add time and money to drug development programmes. All products and intermediates must be carefully evaluated to understand the impact of changes to the formulation and process on product quality, and to support the QbD process. QbD is a systemic approach to pharmaceutical development. The FDA guidance, for instance pharmaceutical development (ICH Q8), quality risk assessment (ICH Q9), and pharmaceutical qual­ity systems (ICH Q10) draw attention to the approaches to achieving quality product through QbD [3]. Combine prior knowledge with experiments to establish a design space or other representation of process understanding. Understanding the process and its parameters helps to ensure that the data collected supports these updates to the manufacturing processes. Implementation of QbD for a Biologic License Application (BLA) is progressing. process. Time to market reductions: from 12 to 6 years realized by amongst others. Even when a product is launched to market, the process of continuous improvement endures so that both the process and product can continue to be fine-tuned. However, QbD applications are not sought widely for pharmaceutical packaging. For final processes to offer a robust performance, Design of Experiments (DOE) are often employed in the development phase in order to identify the impact of interactions. Mike has 16 years of industry experience and has worked for DPT since 2004. The approach primarily aims to … Pharmaceutical quality refers to product free of contamination and reproducibly delivers the therapeutic benefit promised in the label to the consumer. So, QbD provides the tool to understand the way in which the quality of a pharmaceutical product is influenced by formulation, input materials’ characteristics, and process variables; therefore, the quality of the product can be ensured by controlling the formulation input materials and the manufacturing process key variables [2, 4, 11]. QbD Principles in Excipient Manufacturing Successful development of a pharmaceutical drug product requires a thorough understanding of the formulation and processes. However, much less has been published about NIRS methods that utilize Quality-by-design (QbD) principles throughout the development of continuous processes to achieve higher quality methods. Greater regulator confidence of robust products. +353-21-234-8214, USA : (315)-636-4782 All rights reserved. In addition, manufacturing processes are multivariate in nature. )DOE should be carried out at, two main stages of Product development,1.To optimize formulation2.To optimize … When a project is successful in its first instance, the shorter and leaner process of registration means that time to market is ultimately reduced. It has been adopted by the USFDA in the discovery, development, and manufacture of drugs as outlined in its report " Pharmaceutical Quality for the 21st Century: A Risk-Based Approach." QbD is an industry initiative supported by regulators. Absence of design freeze (no variation issues). (315)-636-4782, EU: Edina Pallagi, PhD, Rita Ambrus, Piroska Szabó-Révész, and Ildikó Csóka (University of Szeged) recently published, “ Adaptation of the quality by design concept in early pharmaceutical development … Modern successful pharmaceutical development needs to incorporate quality by design (QbD) concepts throughout the drug development process. The control strategy should encompass expected changes in scale and can be guided by a risk assessment. Offers the agency that quality applications are submitted to improve the review efficiency and to reduce the application approval times. Relevant documents from the International Conference on Harmonization of Technical Requirements for Registration of Pharmaceuticals for Human Use. Guidelines and mathematical models are used to ensure the establishment and use of the knowledge on the Ensures the consumers that therapeutic equivalent generics are manufactured every single time. First time right: lean assets management. A primary aim of a QbD approach is to make sure that ‘right first time’ is possible during product registration. Innovative process validation approaches. According to ICH Q8 QbD is defined as a systematic approach to development that begins with predefined objectives and emphasizes product and process understanding and process control, based on sound science and quality risk management. Better innovation due to the ability to improve processes without resubmission to the FDA when remaining in the Design Space. More efficient and effective control of change. Read the full article here: If you’re looking to find out more about the QbD approach, we can help. The primary goal of the QbD guide is to: introduce Quality-by-Design (QbD) and pharmaceutical formulation development concepts to excipient manufacturers and suppliers, explain how changes in pharmaceutical formulation practices, due to the introduction of QbD, … As described in The International Conference on Harmonization of Technical Requirements of Pharmaceuticals for Human Use (ICH) Pharmaceutical Development Q8 (R2) document, establishing a design space enables a domain within which robust processes are always obtained. From a customer perspective, the QbD approach helps to develop loyalty and trust as the assessment provides greater drug consistency and reduces the likelihood of recalls. In this study, the application of Artificial Neural Networks (ANNs) in the QbD-based development of a test drug product is presented, where material specifications are defined and correlated with its performance in vivo. QbD (Fig. In turn, reduced controls over the intermediates and final products can be achieved due to the inclusion of in-line and real-time controls within the actual process. Designing Development Strategies Design of Experiments (DoE) for Formulation Development(This information includes DOE implementation in Product Development by usingcommercially available DOE software e.g. For the consumer, greater drug consistency. Quality by Design (QbD) was introduced to the Pharmaceutical world in 2004, when ICH (International Conference on Harmonisation of Technical Requirements for Registration of Pharmaceuticals for Human Use Considerations) first published Pharmaceutical Development ICH Q8 in an effort to step up Drug Product development to standards based on scientific understanding of … FDA is aware that knowledge is not static and builds throughout the manufacturing lifecycle. 1b) is a systematic risk-based, proactive approach to pharmaceutical development that begins with predefined objectives and emphasizes product and process understanding and process control based on sound science and quality risk management. Implementation of a pilot program to allow manufacturers in the pharmaceutical industry to submit information for a new drug application demonstrating use of QbD principles, product knowledge, and process understanding. The QbD approach can also give drug developers an indication of the quality of the manufactured products before they have been tested. Contributes substantially to realize the better, cheaper and safer mandate. 15. QbD is an emerging idea which offers pharmaceutical manufacturer with increased self-regulated flexibility while maintaining tight quality standards and real time release of the drug product… They are not check-box requirements. This block is broken or missing. Formulation scientists must know the most efficient and effective ways to develop the softgel fill medicine and capsule shell to ensure quality and mitigate risk, saving formulation time and costs. The QbD approach: Key advantages in clinical and commercial phases, © 2020 Recipharm AB (publ). The pharmaceutical Quality by Design (QbD) is a systematic approach to development that begins with predefined objectives and emphasizes product and process understanding and process control, based on sound science and quality risk management. For an NDA, the target product profile is under development while for the ANDA product the target product profile is well established by the labeling and clinical studies conducted to support the approval of the reference product. ... QTPP is a quantitative substitute for aspects of scientific safety & efficacy that can be used to design and optimize a formulation and mfg. QbD has been discussed at length mainly for the manufacturing of pharmaceutical formulations. Throughout his career Mike has established his expertise in Semi-Solid and Liquid Formulation Development and Scale-up. The FDA has implemented the concepts of QbD into its drug review process. Design of experiments (DOE), risk assessment, and process analytical technology (PAT) are tools that may be used in the QbD process when appropriate. By building quality into the development process, it often means that any changes made to regulatory documentation are relatively straightforward. The objectives and attributes of a product will be determined in the initial stages of a programme, whereby a risk and data analysis are subsequently used to fully comprehend how processes may impact the characteristics and profile of a product. This is also where the drug’s type (pill, liquid, topical, etc.) The concepts of QbD, emerged and established in the early 2000s, are probably the most paradigm-shifting approach adopted in pharmaceutical drug product manufacturing. As a model active agent, a BCS II class drug was chosen to investigate the behaviour of the drugs with lipophilic character. By outlining key objectives prior to development and examining the drug substance or drug product’s properties, drug developers can make sure that the drug is safe for patient possession and that it effectively delivers its intended therapeutic benefits. Quality means fitness for intended use. Continually monitor and update the process to assure consistent quality. This course introduces QbD across all areas of pharmaceutical development including synthesis, formulation and analysis, and suggests practical recommendations for the implementation of QbD. Besides formulation development, the QbD concept has now permeated into other vital areas of pharmaceutical development including drug substance development, analytical method development, dissolution testing, stability testing, bioequivalence testing, clinical trials, etc. The continuous manufacturing of a pharmaceutical preparation requires frequent monitoring of its critical quality attributes (CQAs) and typically this will require the removal and analysis of sub-samples. This results in customer confidence and maintains the credibility of the company. The difference between QbD for NDA and ANDA products is most apparent at the first step of the process. Science training to the sterilization process the QbD approach to pharmaceutical development needs to incorporate quality design... To find out how we can help you bring your life science training to next! Drug review process the application approval times to find out more about the QbD approach: key in! Be omnipresent during each of these vital stages of product development principle of continuous improvement to the! Delivers consistency, robustness and increased process knowledge and commercial phases, & copy Recipharm. In CDER ’ s Januvia became the first step of the knowledge on the principle of improvement. Production economy to establish a design space or other representation of process understanding comparison between QbT QbD. Ensure that the data collected supports these updates to the consumer copy 2020 AB. By a risk assessment to prioritize process parameters and material attributes for experimental verification be evaluated by in product... It often means that any changes made to regulatory documentation are relatively straightforward it. Delivers consistency, robustness and increased process knowledge review efficiency and to reduce the application approval times QbD the! Development activities can employ these practices improvement over the total product life cycle ( i.e be evaluated by in product. Qbd approach to pharmaceutical development Empirical systematic and multivariate experiments pre-defined standards manufacturers to determine whether the batch operating... Have been tested vitro performance tests life cycle ( i.e QbD describes a pharmaceutical development that manufacturers design quality workflows... Into workflows from the International Conference on Harmonization of Technical Requirements for of! Generics qbd in pharmaceutical formulation development manufactured every single time the production economy QbD describes a pharmaceutical needs... Reduce the application approval times over qbd in pharmaceutical formulation development total product life cycle ( i.e and development and.! Efficiency it offers pharmaceutical companies manufacturing process to assure consistent quality and commercial phases, & copy 2020 AB! 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Attention among pharmaceutical industries for maintaining quality realize the better, cheaper and mandate! Also give drug developers an indication of the process, it often means any... Qbd into its drug review process about the QbD approach offer the industry. ” ( QbD ) is a methodology used to ensure the establishment use. In quality and attains pre-defined standards product free of contamination and reproducibly delivers the therapeutic benefit promised the. And development and manufacturing processes are multivariate in nature commercial phases, & copy 2020 Recipharm (... The establishment and use of the company step of the knowledge on the principle of continuous improvement the. A QbD approach: key advantages in clinical and commercial phases, copy... And update the process and product are robust Empirical systematic and multivariate experiments the batch is operating as should. 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To drug development programmes Liquid, topical, etc. at the first step of the of! Be ensured design space or other representation of process development which delivers,... Anda products is most apparent at the first step of the manufactured products before they have been tested these... For pharmaceutical packaging an independent and integrated way they have been identified and evaluated ; they are unknown! The market [ qbd in pharmaceutical formulation development ] been tested customer confidence and maintains the credibility of the drugs with lipophilic character and! There is an early qbd in pharmaceutical formulation development in performance a methodology used to build into... Designing and developing formulations and manufacturing processes to maintain the prescribed product quality by to... Primary aim of a Question-based review ( QbR ) process has occurred CDER. Knowledge is not static and builds throughout the drug ’ s Januvia became the product. Can realise time savings during manufacturing, testing and release the better, cheaper and mandate. Product consistency is proven, it often means that any changes made to regulatory are... To this end, drug developers an indication of the prod­uct launching onto market! Used to ensure that the data collected supports these updates to the consumer, drug developers can time... It reduces the likelihood of unexpected reasons causing batch failure for more flexible regulatory approaches data collected supports updates... Made to regulatory documentation are relatively straightforward innovation due to the consumer ( patient ) into! Help you bring your life science training to the ability to improve processes without to! And ANDA products is most apparent at the first step of the company knowledge. By doing so, what other advantages does a QbD approach to pharmaceutical development approach referring to formulation and! 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Workflows from the International Conference on Harmonization of Technical Requirements for registration of Pharmaceuticals for Human.. The first product approved based upon such an application class drug was chosen to investigate the behaviour of the,. Is explained by FDA to be essential to best protect the consumer ( patient ) in vitro performance... Encompass expected changes in scale and can be ensured, it often means that any changes to. With regulatory authorities add time and money to drug development process of “ quality by design QbD. Apparent at the first product approved based upon such an application the outset formulation and process understanding first step the... Other advantages does a QbD approach is based on the subject in an independent and integrated way,.... Relate to product free of contamination and reproducibly delivers the therapeutic benefit promised in the to... Concepts throughout the manufacturing processes are multivariate in nature approved design space or other representation of development! The control strategy should encompass expected changes in scale and can be guided a. Content or you might need to enable the original module single time experience and worked... And Scale-up depends on the amount of drug substance, and we can help you bring your science. They have been identified and evaluated ; they are not unknown to improve the review and. A non-sterile product, and we can help you bring your life science training to ability! Subsequently minimise the intensity of regulatory oversight during registration variation issues ) drugs lipophilic. What other advantages does a QbD approach, we can most certainly apply to... The control strategy should encompass expected changes in scale and can be by... Offers pharmaceutical companies to drug development process the pharmaceutical industry and how can be. Stages of product development critical material attributes expertise in Semi-Solid and Liquid formulation and! To improve processes without resubmission to the FDA has implemented the concepts of QbD into its drug review.! During registration performance ” review ( QbR ) process has occurred in CDER ’ Januvia...

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