In this study, an AQbD-compliant chaotropic chromatography method for ziprasidone and the determination of its five impurities was developed. The influence of critical method parameters (initial and final methanol fraction in the mobile phase, gradient duration) on the set of selected critical method attributes (t_{_imp. V}, t_{_imp. V} − t_{_imp. I}, S and <W_USP>) was studied by Box–Behnken design. The errors resulting from the calculation of the model coefficients were propagated to the selected responses by Monte Carlo simulations, and their predictive distribution was obtained. The design space was computed (π ≥ 80%), and a working point was selected: initial methanol fraction 38.5%, final methanol fraction 77.5%, and gradient duration 16.25 min. Furthermore, the quantitative robustness of the developed method was tested using the Plackett–Burman design. P_{_imp II} and P_{_imp V} were found to be significantly affected, the first by mobile phase flow rate and the second by gradient duration. Finally, the method was validated, and its reliability for routine quality control in capsules was confirmed.

Impurity profiling is of significant analytical and regulatory importance, particularly in the context of lifecycle quality management. A robust chaotropic chromatography method was developed for the determination of olanzapine and its two oxidative degradation products in tablets, in accordance with the ICH Q14 guideline and the principles of Analytical Quality by Design (AQbD). Risk assessment was performed using a combination of the Ishikawa diagram, CNX (Control, Noise and eXperimental) classification, and Failure Mode and Effect Analysis (FMEA). This multistep evaluation identified the critical analytical procedure parameters (APPs) as the acetonitrile content in the mobile phase, the concentration of perchloric acid in the aqueous phase, and the pH of the aqueous phase. These APPs were studied using an experimental design approach to model their effects on key analytical procedure attributes and to compute a multidimensional design space. Robust optimization supported by Monte Carlo simulations ensured compliance with predefined acceptance criteria with a probability of at least 95%. Method validation demonstrated adequate selectivity, limits of quantification of 0.75 µg/mL and 0.5 µg/mL for impurities B and D, linearity with correlation coefficients ≥0.990, accuracy of 98–102% for olanzapine and 70–130% for impurities, and repeatability with RSD ≤2% for the assay and ≤10% for impurities. The method was successfully applied to commercial tablet analysis.