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Sun Z, Quon JL, Papageorgiou CD, Benyahia B, Rielly CD. Use of Wet Milling Combined with Temperature Cycling to Minimize Crystal Agglomeration in a Sequential Antisolvent-Cooling Crystallization. CRYSTAL GROWTH & DESIGN 2022; 22:4730-4744. [PMID: 35942120 PMCID: PMC9354031 DOI: 10.1021/acs.cgd.1c01510] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 12/23/2021] [Revised: 07/01/2022] [Indexed: 06/15/2023]
Abstract
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.
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Affiliation(s)
- Zhuang Sun
- Future Continuous Manufacturing and Advanced Crystallization (CMAC), Research Hub at the Department of Chemical Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, United Kingdom
| | - Justin L Quon
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, 40 Landsdowne Street, Cambridge, Massachusetts 02139, United States
| | - Charles D Papageorgiou
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, 40 Landsdowne Street, Cambridge, Massachusetts 02139, United States
| | - Brahim Benyahia
- Future Continuous Manufacturing and Advanced Crystallization (CMAC), Research Hub at the Department of Chemical Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, United Kingdom
| | - Chris D Rielly
- Future Continuous Manufacturing and Advanced Crystallization (CMAC), Research Hub at the Department of Chemical Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, United Kingdom
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2
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Wang L, Yang H, Sun Z, Bao Y, Yin Q. Wet Milling, Seeding, and Ultrasound in the Optimization of the Oiling-Out Crystallization Process. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c04167] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Liping Wang
- School of Chemical Engineering and Technology and State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Huaiyu Yang
- Department of Chemical Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, U.K
| | - Zhuang Sun
- Department of Chemical Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, U.K
- Future Continuous Manufacturing and Advanced Crystallization (CMAC), Research Hub at the Department of Chemical Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, U.K
| | - Ying Bao
- School of Chemical Engineering and Technology and State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
| | - Qiuxiang Yin
- School of Chemical Engineering and Technology and State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300072, China
- The Co-Innovation Center of Chemistry and Chemical Engineering of Tianjin, Tianjin 300072, China
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3
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Yang Y, Ahmed B, Mitchell C, Quon JL, Siddique H, Houson I, Florence AJ, Papageorgiou CD. Investigation of Wet Milling and Indirect Ultrasound as Means for Controlling Nucleation in the Continuous Crystallization of an Active Pharmaceutical Ingredient. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00209] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Yihui Yang
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
| | - Bilal Ahmed
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
- EPSRC Future CMAC Manufacturing Research Hub, Department of Chemical and Biological Engineering, University of Sheffield, Sheffield S1 3JD, U.K
| | - Christopher Mitchell
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
| | - Justin L. Quon
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
| | - Humera Siddique
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
| | - Ian Houson
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
| | - Alastair J. Florence
- EPSRC Future CMAC Manufacturing Research Hub, Institute of Pharmacy & Biomedical Sciences, Technology and Innovation Centre, University of Strathclyde, Glasgow G1 1RD, U.K
| | - Charles D. Papageorgiou
- Process Chemistry and Development, Takeda Pharmaceuticals International Company, Boston, 40 Landsdowne, Cambridge, Massachusetts 02139, United States
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Zhang F, Shan B, Wang Y, Zhu Z, Yu ZQ, Ma CY. Progress and Opportunities for Utilizing Seeding Techniques in Crystallization Processes. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.1c00103] [Citation(s) in RCA: 15] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Fangkun Zhang
- College of Automation and Electronic Engineering, Qingdao University of Science & Technology, Qingdao, 266061, P. R. China
| | - Baoming Shan
- College of Automation and Electronic Engineering, Qingdao University of Science & Technology, Qingdao, 266061, P. R. China
| | - Yinglong Wang
- College of Chemical Engineering, Qingdao University of Science and Technology, Qingdao, 266061, P. R. China
| | - Zhaoyou Zhu
- College of Chemical Engineering, Qingdao University of Science and Technology, Qingdao, 266061, P. R. China
| | - Zai-Qun Yu
- Institute of Chemical & Engineering Sciences, Agency for Science, Technology and Research (A*STAR), 1 Pesek Road, Jurong Island, Singapore 627833
| | - Cai Y. Ma
- Centre for the Digital Design of Drug Products, School of Chemical and Process Engineering, University of Leeds, Leeds, LS2 9JT, United Kingdom
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Sirota E, Kwok T, Varsolona RJ, Whittaker A, Andreani T, Quirie S, Margelefsky E, Lamberto DJ. Crystallization Process Development for the Final Step of the Biocatalytic Synthesis of Islatravir: Comprehensive Crystal Engineering for a Low-Dose Drug. Org Process Res Dev 2021. [DOI: 10.1021/acs.oprd.0c00520] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Eric Sirota
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Thomas Kwok
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Richard J. Varsolona
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Aaron Whittaker
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Teresa Andreani
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Scott Quirie
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Eric Margelefsky
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - David J. Lamberto
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
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6
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Binel P, Mazzotti M. A Selective Dissolution Process Featuring a Classification Device for the Removal of Fines in Crystallization. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c04923] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Pietro Binel
- Institute of Energy and Process Engineering, ETH Zurich, 8092 Zurich, Switzerland
| | - Marco Mazzotti
- Institute of Energy and Process Engineering, ETH Zurich, 8092 Zurich, Switzerland
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Ferreira C, Cardona J, Agimelen O, Tachtatzis C, Andonovic I, Sefcik J, Chen YC. Quantification of particle size and concentration using in-line techniques and multivariate analysis. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.08.015] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
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Wang X, Zhang L, Ma D, Tang X, Zhang Y, Yin T, Gou J, Wang Y, He H. Characterizing and Exploring the Differences in Dissolution and Stability Between Crystalline Solid Dispersion and Amorphous Solid Dispersion. AAPS PharmSciTech 2020; 21:262. [PMID: 32975680 DOI: 10.1208/s12249-020-01802-0] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/24/2020] [Accepted: 08/25/2020] [Indexed: 12/23/2022] Open
Abstract
Solid dispersion is one of the most effective ways to improve the dissolution of insoluble drugs. When the carrier can highly disperse the drug, it will increase the wettability of the drug and reduce the surface tension, thus improving the solubility, dissolution, and bioavailability. However, amorphous solid dispersions usually have low drug loading and poor stability. Therefore, the goal of this work is to study the increased dissolution and high stability of high drug-loading crystalline solid dispersion (CSD), and the difference in dissolution and stability of high-loading and low-loading amorphous solid dispersion (ASD). A CSD of nimodipine with a drug loading of 90% was prepared by wet milling, with hydroxypropyl cellulose (model: HPC-SL) and sodium dodecyl sulfate as stabilizers and spray drying. At the same time, the gradient drug-loaded ASD was prepared by hot melt extrusion with HPC-SL as the carrier. Each preparation was characterized by DSC, PXRD, FT-IR, SEM, and in vitro dissolution testing. The results indicated that the drug in CSD existed in a crystalline state. The amorphous drug molecules in the low drug-loading ASD were uniformly dispersed in the carrier, while the drug state in the high drug-loading ASD was aggregates of the amorphous drug. At the end of the dissolution assay, the 90% drug-loading CSD increased cumulative dissolution to 60%, and the 10% drug-loading ASD achieved a cumulative dissolution rate of 90%.
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Meng W, Sirota E, Feng H, McMullen JP, Codan L, Cote AS. Effective Control of Crystal Size via an Integrated Crystallization, Wet Milling, and Annealing Recirculation System. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00307] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Wei Meng
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Eric Sirota
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Hanzhou Feng
- Process Analytical Technology, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Jonathan P. McMullen
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
| | - Lorenzo Codan
- Process Research and Development, MSD Werthenstein BioPharma GmbH, Industrie Nord 1, 6105 Schachen, Switzerland
| | - Aaron S. Cote
- Process Research and Development, Merck & Co., Inc., P.O. Box 2000, Rahway, New Jersey 07065, United States
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Kutluay S, Ceyhan AA, Şahin Ö, İzgi MS. Utilization of In Situ FBRM and PVM Probes to Analyze the Influences of Monopropylene Glycol and Oleic Acid as Novel Additives on the Properties of Boric Acid Crystals. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c00551] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Sinan Kutluay
- Department of Chemical Engineering, Faculty of Engineering, Siirt University, 56100 Siirt, Turkey
| | - A. Abdullah Ceyhan
- Department of Chemical Engineering, Faculty of Engineering and Natural Sciences, Konya Technical University, 42130 Konya, Turkey
| | - Ömer Şahin
- Department of Chemical Engineering, Faculty of Engineering, Siirt University, 56100 Siirt, Turkey
| | - M. Sait İzgi
- Department of Chemical Engineering, Faculty of Engineering, Siirt University, 56100 Siirt, Turkey
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11
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Nelson AZ, Kundukad B, Wong WK, Khan SA, Doyle PS. Embedded droplet printing in yield-stress fluids. Proc Natl Acad Sci U S A 2020; 117:5671-5679. [PMID: 32127482 PMCID: PMC7084155 DOI: 10.1073/pnas.1919363117] [Citation(s) in RCA: 32] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022] Open
Abstract
Microfluidic tools and techniques for manipulating fluid droplets have become core to many scientific and technological fields. Despite the plethora of existing approaches to fluidic manipulation, non-Newtonian fluid phenomena are rarely taken advantage of. Here we introduce embedded droplet printing-a system and methods for the generation, trapping, and processing of fluid droplets within yield-stress fluids, materials that exhibit extreme shear thinning. This technique allows for the manipulation of droplets under conditions that are simply unattainable with conventional microfluidic methods, namely the elimination of exterior influences including convection and solid boundaries. Because of this, we believe embedded droplet printing approaches an ideal for the experimentation, processing, or observation of many samples in an "absolutely quiescent" state, while also removing some troublesome aspects of microfluidics including the use of surfactants and the complexity of device manufacturing. We characterize a model material system to understand the process of droplet generation inside yield-stress fluids and develop a nascent set of archetypal operations that can be performed with embedded droplet printing. With these principles and tools, we demonstrate the benefits and versatility of our method, applying it toward the diverse applications of pharmaceutical crystallization, microbatch chemical reactions, and biological assays.
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Affiliation(s)
- Arif Z Nelson
- Biological Systems and Micromechanics, Singapore-MIT Alliance for Research and Technology, 138602 Singapore, Singapore
- Campus for Research Excellence and Technological Enterprise, 138602 Singapore, Singapore
| | - Binu Kundukad
- Biological Systems and Micromechanics, Singapore-MIT Alliance for Research and Technology, 138602 Singapore, Singapore
- Campus for Research Excellence and Technological Enterprise, 138602 Singapore, Singapore
| | - Wai Kuan Wong
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 117585 Singapore, Singapore
| | - Saif A Khan
- Campus for Research Excellence and Technological Enterprise, 138602 Singapore, Singapore;
- Department of Chemical and Biomolecular Engineering, National University of Singapore, 117585 Singapore, Singapore
| | - Patrick S Doyle
- Biological Systems and Micromechanics, Singapore-MIT Alliance for Research and Technology, 138602 Singapore, Singapore;
- Campus for Research Excellence and Technological Enterprise, 138602 Singapore, Singapore
- Department of Chemical Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139
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12
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Szilagyi B, Nagy ZK. Model-based analysis and quality-by-design framework for high aspect ratio crystals in crystallizer-wet mill systems using GPU acceleration enabled optimization. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2019.04.025] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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13
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Jiang M, Braatz RD. Designs of continuous-flow pharmaceutical crystallizers: developments and practice. CrystEngComm 2019. [DOI: 10.1039/c8ce00042e] [Citation(s) in RCA: 55] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/02/2023]
Abstract
This review of recent research advances in continuous-flow crystallization includes a five-step general design procedure, generally applicable process intensification strategies, and practical insights.
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Affiliation(s)
- Mo Jiang
- Department of Chemical Engineering
- Massachusetts Institute of Technology
- Cambridge
- USA
- Department of Chemical and Life Science Engineering
| | - Richard D. Braatz
- Department of Chemical Engineering
- Massachusetts Institute of Technology
- Cambridge
- USA
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