A Novel Simulated Moving Plug Flow Crystallizer (SM-PFC) for Addressing the Encrustation Problem: Simulation-Based Studies on Cooling Crystallization

The plug flow crystallizer (PFC) is a promising candidate in the move toward adoption of continuous manufacturing in the pharmaceutical industry. However, a major concern for the smooth running of PFCs is the encrustation or fouling which can result in blockage of the crystallizer or unplanned shutdown of the process. In order to address this problem, simulation studies are carried out to explore the feasibility of a novel simulated-moving PFC (SM-PFC) configuration that can run uninterrupted in the presence of heavy fouling without compromising the desired critical quality attributes of the product crystals. The key concept of the SM-PFC lies in the arrangement of the crystallizer segments where a fouled segment is isolated, while a clean segment is simultaneously brought online avoiding fouling-related issues and maintaining uninterrupted operation. The inlet and outlet ports are also changed appropriately so that the whole operation mimics the movement of the PFC. The simulation results suggest that the proposed PFC configuration could be a potential mitigating approach for the encrustation problem enabling continuous operation of the crystallizer in the presence of heavy fouling while maintaining the product specifications.

Temperature cycling-induced formation of crystalline coatings

The surface of particles is the hotspot of interaction with their environment and is therefore a major target for particle engineering. Particles with tailored coatings are greatly desired for a range of different applications. Amorphous coatings applied via film coating or microencapsulation have frequently been described in the pharmaceutical context and usually result in homogeneous surfaces. In the present study we have been exploring the feasibility of coating core particles with crystalline substances, a matter that has rarely been investigated. The expansion of the range of possible coating materials to include small organic molecules enables completely new product properties to be achieved. We present an approach based on temperature cycles performed in a tubular crystallizer to result in engineered crystalline coatings on excipient core particles. By manipulating the process settings and by the choice of coating substance we are able to tailor surface roughness, topography as well as surface chemistry. Benefits of our approach are demonstrated by using resulting particles as carriers in dry-powder-inhaler formulations. Depending on the resulting surface chemistry and surface roughness, coated carrier particles show varying fitness for delivering the model API salbutamol sulphate to the lung.

Crystal Engineering in Continuous Plug-Flow Crystallizers

Size, shape, and polymorphic form are the critical attributes of crystalline particles and represent the major focus of today's crystallization process design. This work demonstrates how crystal properties can be tuned efficiently in solution via a tubular crystallizer that facilitates rapid temperature cycling. Controlled crystal growth, dissolution, and secondary nucleation allow a precise control of the crystal size and shape distribution, as well as polymorphic composition. Tubular crystallizers utilizing segmented flow such as the one presented in our work can provide plug flow characteristics, fast heating and cooling, allowing for rapid changes of the supersaturation. This makes them superior for crystal engineering over common crystallizers. Characterization of particle transport, however, revealed that careful selection of process parameters, such as tubing diameter, flow rates, solvents, etc., is crucial to achieve the full benefits of such reactors.

Investigation of the Evolution of Crystal Size and Shape during Temperature Cycling and in the Presence of a Polymeric Additive Using Combined Process Analytical Technologies

Crystal size and shape can be manipulated to enhance the qualities of the final product. In this work the steady-state shape and size of succinic acid crystals, with and without a polymeric additive (Pluronic P123) at 350 mL, scale is reported. The effect of the amplitude of cycles as well as the heating/cooling rates is described, and convergent cycling (direct nucleation control) is compared to static cycling. The results show that the shape of succinic acid crystals changes from plate- to diamond-like after multiple cycling steps, and that the time required for this morphology change to occur is strongly related to the type of cycling. Addition of the polymer is shown to affect both the final shape of the crystals and the time needed to reach size and shape steady-state conditions. It is shown how this phenomenon can be used to improve the design of the crystallization step in order to achieve more efficient downstream operations and, in general, to help optimize the whole manufacturing process.

Using flow technologies to direct the synthesis and assembly of materials in solution

In the pursuit of materials with structure-related function, directing the assembly of materials is paramount. The resultant structure can be controlled by ordering of reactants, spatial confinement and control over the reaction/crystallisation times and stoichiometries. These conditions can be administered through the use of flow technologies as evidenced by the growing widespread application of microfluidics for the production of nanomaterials; the function of which is often dictated or circumscribed by size. In this review a range of flow technologies is explored for use in the control of self-assembled systems: including techniques for reagent ordering, mixing control and high-throughput optimisation. The examples given encompass organic, inorganic and biological systems and focus on control of shape, function, composition and size.Graphical abstract.