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In order to produce the desired final crystal form and achieve a high-purity yield, most pharmaceutical and fine chemical manufacturing processes include a series of crystallizations. Crystallization, especially batch crystallization, is still often regarded as "more an art than a science", because of nucleation timing differences, production of polymorphic crystal variants, etc. In 2004, the US Food and Drug Administration (FDA) proposed Process Analytical Technology (PAT)which is intended as a framework for innovative pharmaceutical development, manufacturing, and quality assurance. To apply PAT to ensure the quality of the pharmaceutical products produced using crystallization, JGC has been developing a simulator for the crystallization process. The simulator uses a temperature control loop based on information from in-situ and on-line measurements in combination with crystallization models and CFD. This technology could provide:
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- Conversion of chord length distribution (CLD) by Focused Beam Reflectance Measurement (FBRM) to Particle Size Distribution (PSD), using FBRM mapping matrix
- Conversion of FBRM count number to absolute particle number, using mass balance correction from a concentration meter
- Determination of primary and secondary nucleation parameters, respectively, from Kubota's theory, using the above information.
- Coupled crystallization and CFD simulation for risk-management associated with scale-up.
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