Antisolvent crystallization in porous hollow fiber devices

Key Parameters Impacting the Crystal Formation in Antisolvent Membrane-Assisted Crystallization

Antisolvent crystallization is commonly used in the formation of heat-sensitive compounds as it is the case for most active pharmaceutical ingredients. Membranes have the ability to control the antisolvent mass transfer to the reaction medium, providing excellent mixing that inhibits the formation of local supersaturations responsible for the undesired properties of the resulting crystals. Still, optimization of the operating conditions is required. This work investigates the impact of solution velocity, the effect of antisolvent composition, the temperature and gravity, using glycine-water-ethanol as a model crystallization system, and polypropylene flat sheet membranes. Results proved that in any condition, membranes were consistent in providing a narrow crystal size distribution (CSD) with coefficient of variation (CV) in the range of 0.5-0.6 as opposed to 0.7 obtained by batch and drop-by-drop crystallization. The prism-like shape of glycine crystals was maintained as well, but slightly altered when operating at a temperature of 35 °C with the appearance of smoother crystal edges. Finally, the mean crystal size was within 23 to 40 µm and did not necessarily follow a clear correlation with the solution velocities or antisolvent composition, but increased with the application of higher temperature or gravity resistance. Besides, the monoclinic form of α-glycine was perfectly maintained in all conditions. The results at each condition correlated directly with the antisolvent transmembrane flux that ranged between 0.0002 and 0.001 kg/m². s. In conclusion, membrane antisolvent crystallization is a robust solution offering consistent crystal properties under optimal operating conditions.

Continuous synthesis of nano-drug particles by antisolvent crystallization using a porous hollow-fiber membrane module

The synthesis of nano-size drug particles by antisolvent crystallization using a porous hollow fiber membrane provides promising benefits such as the capability of continuous operation, low energy input, and ease of scale-up for a variety of industrial processes. Porous hollow fiber membranes have also been shown to produce more efficient mixing than conventional mixing equipment mostly because in mixing binary fluids, they provide sufficient mixing time, retention time, and a large contact interface for the drug solution and the antisolvent, allowing for the precise control of nucleation and crystal growth necessary to form nano-size particles. This study reports an experimental and numerical approach to obtain a further understanding of the fundamental principles of antisolvent crystallization using a porous hollow fiber membrane. This includes producing a particle size-controlled drug nanosuspension experimentally using a commercial microfiltration (MF) pencil scale module, and a numerical analysis of mixing behavior using a computational fluid dynamics (CFD) simulation. From the results obtained, a nanosuspension of a model drug, Indomethacin, with particles of average diameter 0.320 µm was prepared. Furthermore, this nanosuspension has higher stability and a much lower tendency to agglomerate as compared to simple mixing of the anti-solvent and drug solution. Results from the numerical simulation showed that micromixing is possible using the porous hollow fiber membrane even under the most compromising conditions.

Continuous production of polymer nanoparticles using a membrane-based flow cell

We demonstrate the surfactant-free production of polymer nanoparticles using a continuous membrane-based tangential flow cell. Co-current streams of water and polymethylmethacrylate (PMMA)/acetone/water solution were separated by a porous regenerated cellulose (RC) membrane. The water concentration in the PMMA solution was adjusted so that as additional water diffused through the RC membrane, the PMMA solution composition crossed the two phase boundary to precipitate PMMA nanoparticles. The size of these nanoparticles varied with the concentration of the PMMA feed and the amount of water diffusing across the membrane. The size distribution of PMMA particles produced in a continuous flow membrane cell was much narrower than those produced by drop-wise water addition or batch dialysis precipitation of PMMA particles. A continuous production of polymer nanoparticles of high purity and narrow polydispersity are important requirements for biomedical applications such as delivering therapeutics.

Particle engineering by optimization for the unseeded batch cooling crystallization of l-asparagine monohydrate

A model-based optimization approach is proposed to obtain temperature profiles to achieve the target CSD in a batch cooling crystallization process.

Continuous synthesis of polymer-coated drug particles by porous hollow fiber membrane-based antisolvent crystallization

Using porous hollow fiber membranes, this study illustrates a novel technique to continuously synthesize polymer-coated drug crystals by antisolvent crystallization. The synthesized polymer-coated drug crystals involve crystals of the drug Griseofulvin (GF) coated by a thin layer of the polymer Eudragit RL100. The process feed, an acetone solution of the drug GF containing the dissolved polymer, was passed through the shell side of a membrane module containing many porous hollow fibers of Nylon-6. Through the lumen of the hollow fibers, the antisolvent water was passed at a higher pressure to inject water jets through every pore in the fiber wall into the shell-side acetone feed solution, creating an extremely high level of supersaturation and immediate crystallization. It appears that the GF crystals are formed first and serve as nuclei for the precipitation of the polymer Eudragit, which forms a thin coating around the GF crystals. The polymer-coated drug crystals were collected by a filtration device at the shell-side outlet of the membrane module, and the surface morphology, particle size distribution, and the polymer coating thickness were then characterized by scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), laser diffraction spectroscopy (LDS), and thermogravimetric analysis (TGA). To study the properties of the coated drug crystals, X-ray diffraction (XRD), Raman spectroscopy, and dissolution tests were implemented. These results indicate that a polymer-coated, free-flowing product was successfully developed under appropriate conditions in this novel porous hollow fiber antisolvent crystallization (PHFAC) method. The coated drug particles can be potentially used for controlled release. The molecular and the crystal structures of GF were not affected by the PHFAC method, which may be easily scaled up.

Simple criterion for stability of aqueous suspensions of ultrafine particles of a poorly water soluble drug

In this work, a simple criterion is proposed for prediction of a long-term stability of aqueous suspensions of ultrafine particles of a poorly water soluble drug, curcumin. A new "stability parameter" (γ0ε/γε0) has been defined, which is a ratio of nondimensional mechanical (mainly ultrasonic) energy (ε/ε0) to nondimensional solid-liquid interfacial energy (γ/γ0). The stability of aqueous suspensions of curcumin particles over a period of 1 year and 9 months has been correlated with this parameter. In order to calculate this parameter, solid-liquid interfacial energies were first estimated, from nucleation rates, which in turn were calculated from size distributions of curcumin particles precipitated using water as antisolvent. The mechanical energy was then estimated from the intensity of ultrasound and mechanical agitation used during precipitation. It was found that precipitations carried out with higher values of γ0ε/γε0 (more than 100) result in aqueous suspensions with particle size less than 1 μm. It was further observed that these suspensions remain stable (i.e., no or negligible change in average particle size) for a period of 1 year and 9 months. On the other hand, the suspensions of particles precipitated at lower values of γ0ε/γε0 (less than 10) were found to be highly unstable (i.e., the average particle size changes drastically). These results suggest that γ0ε/γε0 can be used as a parameter to engineer stable aqueous suspensions of curcumin particles. Further, it was found that the use of the Mersmann equation to estimate solid-liquid interfacial surface tensions can help in making this criterion predictive.