Application of feedback control and in situ milling to improve particle size and shape in the crystallization of a slow growing needle-like active pharmaceutical ingredient

Growth of broken crystals tracked in 4D using X-ray computed tomography and its influence on impurity incorporation

Crystallization is a commonly used unit operation for separation and purification. During processing, crystals may break due to mechanical stress, e.g., intentionally by milling or unintentionally through collision with stirrers. This study investigates the growth of broken crystals in three dimensions using X-ray micro-computed tomography. The results show that damaged regions of crystals grow faster than faceted regions, and crystals become faceted through growth. Initially, this happens on a microscale, producing faceted but concave regions on the crystal surface. Eventually, crystals become convex. Shape-healing through growth incorporates inclusions in the crystals. These findings have important implications for designing and optimizing crystallization processes in the pharmaceutical, food, and chemical industries, as purity is often a critical quality criterion adversely affected by inclusions. In addition, the kinetics in crystallization processes are likely to be strongly affected by the growth of non-faceted and concave crystals.

Polymer-mediated and ultrasound-assisted crystallization of ropivacaine: Crystal growth and morphology modulation

The objective of this research was to modify the crystal shape and size of poorly water-soluble drug ropivacaine, and to reveal the effects of polymeric additive and ultrasound on crystal nucleation and growth. Ropivacaine often grow as needle-like crystals extended along the a-axis and the shape was hardly controllable by altering solvent types and operating conditions for the crystallization process. We found that ropivacaine crystallized as block-like crystals when polyvinylpyrrolidone (PVP) was used. The control over crystal morphology by the additive was related to crystallization temperature, solute concentration, additive concentration, and molecular weight. SEM and AFM analyses were performed providing insights into crystal growth pattern and cavities on the surface induced by the polymeric additive. In ultrasound-assisted crystallization, the impacts of ultrasonic time, ultrasonic power, and additive concentration were investigated. The particles precipitated at extended ultrasonic time exhibited plate-like crystals with shorter aspect ratio. Combined use of polymeric additive and ultrasound led to rice-shaped crystals, which the average particle size was further decreased. The induction time measurement and single crystal growth experiments were carried out. The results suggested that PVP worked as strong nucleation and growth inhibitor. Molecular dynamics simulation was performed to explore the action mechanism of the polymer. The interaction energies between PVP and crystal faces were calculated, and mobility of the additive with different chain length in crystal-solution system was evaluated by mean square displacement. Based on the study, a possible mechanism for the morphological evolution of ropivacaine crystals assisted by PVP and ultrasound was proposed.

Process intensification of atorvastatin calcium crystallization for target polymorph development via continuous combined cooling and antisolvent crystallization using an oscillatory baffled crystallizer

In this paper, continuous crystallization of Atorvastatin calcium (ASC) using a continuous oscillatory baffled crystallizer (COBC) has been investigated. Like most API manufacturing, ASC is manufactured batchwise and the pure API is recovered via batch combined cooling and antisolvent crystallization (CCAC) process, which has the challenges of low productivity, wide crystal size distribution (CSD) and sometimes polymorphic form contamination. To overcome the limitations of the batch crystallization, continuous crystallization of ASC was studied in a NiTech (United Kingdom) DN15 COBC, manufactured by Alconbury Weston Ltd. (AWL, United Kingdom), with the aim to improve productivity and CSD of the desired polymorph. The COBC has the advantage of high heat transfer rates and improved mixing that significantly reduces the crystallization time. It also has the advantage of spatial temperature distribution and multiple addition ports to control supersaturation and hence the crystallization process. This work uses an array of process analytical technology (PAT) tools to assess key process parameters that affect the polymorphic outcome and CSD. Two parameters were found to have significant impact on the polymorph, they are ratio of solvent to antisolvent at the point of mixing of the two streams and presence of seeds. The splitting of antisolvent into two addition ports in the COBC was found to give the desired form. The CCAC of ASC in COBC was found to be -30-fold more productive than the batch CCAC process. The cycle time for generating 100 g of desired polymorphic form of ASC also significantly reduced from 22 h in batch process to 12 min in the COBC. The crystals obtained using a CCAC process in a COBC had a narrower CSD compared to that from a batch crystallization process.

Impact of Excipients and Seeding on the Solid-State Form Transformation of Indomethacin during Liquid Antisolvent Precipitation

Long-acting injectables are a unique drug formulation strategy, providing a slow and sustained release of active pharmaceutical ingredients (APIs). In this study, a novel approach that combines liquid antisolvent precipitation with seeding to obtain a stable form of the API indomethacin while achieving the desired particle size distribution is described. It was proven that when a metastable form of indomethacin was initially nucleated, the rate of its transformation to the stable form was influenced by the presence of excipients and seeds (17.10 ± 0.20 μm), decreasing from 48 to 4 h. The final particle size (D50) of the indomethacin suspension produced without seeding was 7.33 ± 0.38 μm, and with seeding, it was 5.61 ± 0.14 μm. Additionally, it was shown that the particle size distribution of the seeds and the time point of seed addition were critical to obtain the desired solid-state form and that excipients played a crucial role during nucleation and polymorphic transformation. This alternative, energy-efficient bottom-up method for the production of drug suspensions with a reduced risk of contamination from milling equipment and fewer processing steps may prove to be comparable in terms of stability and particle size distribution to current industrially accepted top-down approaches.

Use of Wet Milling Combined with Temperature Cycling to Minimize Crystal Agglomeration in a Sequential Antisolvent-Cooling Crystallization

The objective of the research was to improve the process design of a combined antisolvent-cooling crystallization to reduce the degree of agglomeration of a real active pharmaceutical ingredient product, which was manufactured using a crystallization stage employing a methanol/water solvent system. Knowledge was gained from the use of process analytical technology (PAT) tools to monitor the process variables, allowing particle size, degree of agglomeration, solute concentration, and supersaturation to be tracked throughout the process. Based on knowledge of the solubility behavior and interpretation of the PAT histories, changes were made to the sequences of antisolvent addition and cooling within the crystallization process to reduce agglomeration in the final product. Different seed loadings and seeding addition points were also investigated to maintain operation within lower supersaturation regions of the phase diagram to limit agglomeration and avoid an undesired polymorphic transformation to an unstable form. The improved sequences of operations and seeding conditions did not provide sufficient improvement in the product quality and so were augmented by applying wet milling for further deagglomeration followed by temperature cycling to remove fine particles generated during milling. Open-loop heating and cooling cycles produced some limited improvements, whereas closed-loop direct nucleation control methods using FBRM as a feedback sensor for particle counts per second were much more successful at producing high-quality crystals of the desired polymorphic form. The work shows that understanding the trajectory of the process through the phase diagram to follow appropriate supersaturation profiles gives improved control of the various kinetic mechanisms and can be used to improve the quality of the final product.

Bending for Better: Flexible Organic Single Crystals with Controllable Curvature and Curvature-Related Conductivity for Customized Electronic Devices

Electronic microdevices of self-bending coronene crystals are developed to reveal an unexplored link between mechanical deformation and crystal function. First, a facile approach towards length/width/curvature-controllable micro-crystals through bottom-up solution crystallization was proposed for high processability and stability. The bending crystal devices show a significant increase beyond seven orders of magnitude in conductivity than the straight ones, providing the first example of deformation-induced function enhancement in crystal materials. Besides, double effects caused by bending, including the change of π electron level as well as the enhancement of carrier mobility, were determined, respectively by the X-ray photoelectric spectroscopy and X-ray crystallography to coexist, contributing to the conductivity improvement. Our findings will promote future creation of flexible organic crystal systems with deformation-enhanced functional features towards customized smart devices.

Development and testing of a novel image analysis algorithm for descriptive evaluation of shape change of a shrinkable soft material

Soft material can undergo non-uniform deformation or change of shape upon processing. Identifying shape and its change is nevertheless not straightforward. In this study, novel image-based algorithm that can be used to identify shapes of input images and at the same time classify non-uniform deformation into various patterns, i.e., swelling/shrinkage, horizontal and vertical elongations/contractions as well as convexity and concavity, is proposed. The algorithm was first tested with computer-generated images and later applied to agar cubes, which were used as model shrinkable soft material, undergoing drying at different temperatures. Shape parameters and shape-parameter based algorithm as well as convolutional neural networks (CNNs) either incorrectly identified some complicated shapes or could only identify the point where non-uniform deformation started to take place; CNNs lacked ability to describe non-uniform deformation evolution. Shape identification accuracy of the newly developed algorithm against computer-generated images was 65.88%, while those of the other tested algorithms ranged from 34.76 to 97.88%. However, when being applied to the deformation of agar cubes, the developed algorithm performed superiorly to the others. The proposed algorithm could both identify the shapes and describe their changes. The interpretation agreed well with that via visual observation.

Application of PAT-Based Feedback Control Approaches in Pharmaceutical Crystallization

Crystallization is one of the important unit operations for the separation and purification of solid products in the chemical, pharmaceutical, and pesticide industries, especially for realizing high-end, high-value solid products. The precise control of the solution crystallization process determines the polymorph, crystal shape, size, and size distribution of the crystal product, which is of great significance to improve product quality and production efficiency. In order to develop the crystallization process in a scientific method that is based on process parameters and data, process analysis technology (PAT) has become an important enabling platform. In this paper, we review the development of PAT in the field of crystallization in recent years. Based on the current research status of drug crystallization process control, the monitoring methods and control strategies of feedback control in the crystallization process were systematically summarized. The focus is on the application of model-free feedback control strategies based on the solution and solid information collected by various online monitoring equipment in product engineering, including improving particle size distribution, achieving polymorphic control, and improving purity. In this paper, the challenges of feedback control strategy in the crystallization process are also discussed, and the development trend of the feedback control strategy has been prospected.