Polymorph Selection and Process Intensification in a Continuous Crystallization–Milling Process: A Case Study on l-Glutamic Acid Crystallized from Water

Investigation of Temperature Cycling with Coupled Vessels for Efficient Deracemization of NMPA

Chiral compounds can exist as pairs of nonsuperimposable stereoisomers (enantiomers) possessing the same physical properties but interacting differently with biological systems. This makes them interesting materials to be explored by the pharmaceutical and food industries. In this study, to obtain pure enantiomers from their conglomerates, a method that involves using a two-vessel system for deracemization of N-(2-methylbenzylidene) phenylglycine amide (NMPA) was developed. In this method, a suspension was transferred with a pulsating pumping profile between two inter-connected stirred vessels that were set at constant temperatures. As the suspension was exposed to more rapid changes in temperature, it resulted in the speeding up of the process and thus enhancing productivity in comparison to a single vessel system. The results confirmed successful deracemization of NMPA. A modified pumping profile and tubing design eliminated the issue of clogging of the transfer tubes and ensured effective suspension transfer for longer durations. Operating parameters, such as initial enantiomeric excess, vessel residence time, and suspension density were also investigated. In this method, optimization of residence time was necessary to enhance the efficiency of the process further. Results confirmed that this methodology has the potential to be more adaptable and scalable as it involved no mechanical attrition.

Process Performance and Operational Challenges in Continuous Crystallization: A Study of the Polymorphs of L-Glutamic Acid

The crystallization of the two polymorphs of l-glutamic acid (LGA) is carried out in a continuous crystallization process, and its performance according to different criteria is evaluated. The study aims at identifying suitable operating conditions for producing either αLGA or βLGA with a high polymorphic purity. To this end, we investigate the process both from a theoretical perspective and through experiments using either a single stirred-tank crystallizer or a cascade of two stirred-tank crystallizers in series. In terms of theory, we extend the MSMPR-based steady-state stability analysis of Farmer et al. (Farmer, T. C. et al. AIChE J.2016, 62, 3505-3514) by accounting for the possibility of a nonrepresentative withdrawal of the solid phase from the crystallizer. Additionally, the process is simulated using population balance equations, thereby investigating the effect of operating conditions on polymorphic purity, yield, and productivity. Guided by the model-based conclusions, we identified suitable operating conditions and experimentally tested them. The experimental campaign has demonstrated that βLGA could be successfully and continuously produced in both process configurations according to the theory with performance as expected, whereas that was not possible for αLGA. The difference between the two stems from different operational challenges, whose consequence is that steady-state operation is attained in the case of βLGA but not in that of αLGA. In the former case, the needle-like βLGA crystals, which exhibit no agglomeration, tend to be only slightly oversampled; in the latter case, the prismatic αLGA crystals undergo major agglomeration and hence are very difficult to suspend and effectively withdraw from the crystallizer.

Integrated Purification and Formulation of an Active Pharmaceutical Ingredient via Agitated Bed Crystallization and Fluidized Bed Processing

Integrated API and drug product processing enable molecules with high clinical efficacy but poor physicochemical characteristics to be commercialized by direct co-processing with excipients to produce advanced multicomponent intermediates. Furthermore, developing isolation-free frameworks would enable end-to-end continuous processing of drugs. The aim of this work was to purify a model API (sodium ibuprofen) and impurity (ibuprofen ethyl ester) system and then directly process it into a solid-state formulation without isolating a solid API phase. Confined agitated bed crystallization is proposed to purify a liquid stream of impure API from 4% to 0.2% w/w impurity content through periodic or parallelized operations. This stream is combined with a polymer solution in an intermediary tank, enabling the API to be spray coated directly onto microcrystalline cellulose beads. The spray coating process was developed using a Design of Experiments approach, allowing control over the drug loading efficiency and the crystallinity of the API on the beads by altering the process parameters. The DoE study indicated that the solvent volume was the dominant factor controlling the drug loading efficiency, while a combination of factors influenced the crystallinity. The products from the fluidized bed are ideal for processing into final drug products and can subsequently be coated to control drug release.

Reactive crystallization: a review

Reactive crystallization is not new, but there has been recent growth in its use as a means of improving performance and sustainability of industrial processes.

Design Space Identification and Visualization for Continuous Pharmaceutical Manufacturing

Progress in continuous flow chemistry over the past two decades has facilitated significant developments in the flow synthesis of a wide variety of Active Pharmaceutical Ingredients (APIs), the foundation of Continuous Pharmaceutical Manufacturing (CPM), which has gained interest for its potential to reduce material usage, energy and costs and the ability to access novel processing windows that would be otherwise hazardous if operated via traditional batch techniques. Design space investigation of manufacturing processes is a useful task in elucidating attainable regions of process performance and product quality attributes that can allow insight into process design and optimization prior to costly experimental campaigns and pilot plant studies. This study discusses recent demonstrations from the literature on design space investigation and visualization for continuous API production and highlights attainable regions of recoveries, material efficiencies, flowsheet complexity and cost components for upstream (reaction + separation) via modeling, simulation and nonlinear optimization, providing insight into optimal CPM operation.

Synthesis, structural characterization, physicochemical properties and transformations of dehydroevodiamine and its hydrochloride salts

Five kinds of dehydroevodiamine (DHED) related crystals were harvested and transformations among evodiamine (EVO), DHED, DHED·HCl·2H₂O and rutaecarpine (RUT) were revealed.