The Art of Precision: Designing Continuous Flow Crystallization Delivering Uniform Crystals
Strategies to Control Crystallite Size
Program Overview
- Strategies to control crystallite size, including rapid cooling and antisolvent addition
- Using PAT and inline imaging for real-process monitoring
- Steps to design a continuous flow crystallization system using batch crystallizations
Designing a crystallization process that consistently delivers materials with a uniform and reproducible particle size distribution (PSD) is critical for many applications. However, achieving this goal can be particularly challenging for materials that are inherently shock-sensitive. Implementing a continuous flow process can significantly mitigate the risks associated with such crystallizations, offering greater control and reliability.
To achieve precise control over crystallite size, the development of a finely tuned crystallizer incorporating various effective components is essential. This study began by conducting several batch-mode crystallization trials to identify key design elements and optimize process conditions. Strategies such as crystal attrition, rapid cooling crystallization, and reverse antisolvent addition were explored to minimize crystallite sizes. Additionally, cost-effective crystal growth inhibitors were investigated, leading to the discovery of highly effective options.
The application of process analytical technology (PAT) and inline imaging played a pivotal role in the success of this work. These tools provided real-time insights and enhanced process understanding, which will be discussed in detail during this webinar.
This webinar will delve into the fundamental steps for establishing suitable processing units and optimizing parameters essential for the successful operation of continuous flow crystallization that deliver high-quality materials with uniform crystallite size distribution.
Speakers
Majid Farahani
Sr. Research Scientist, Solid State R&D, Eurofins CDMO Alphora
Dr. Majid Farahani obtained his M.Sc. in Synthetic Organic Chemistry and his Ph.D. in Material Sciences (Chemistry). He completed a year-long postdoctoral fellowship at INRS under the supervision of Prof. Steven Laplante, focusing on high-throughput fragment-based drug discovery (FBDD) using NMR techniques in collaboration with Harvard Medical School. Majid then joined Western University as a postdoctoral fellow, where he studied the structural engineering of bio-based materials for versatile applications. In 2022, Majid joined Eurofins CDMO Alphora Inc. as a senior research scientist, specializing in solid-state characterization and crystallization process development for the manufacturing of Active Pharmaceutical Ingredients (APIs). Majid has published 23 peer-reviewed journal articles and has filed a patent application in the United States.
