The Challenges of Developing an API Crystallization Process for a Complex Polymorphic and Highly Solvating System. Part I

Developing a robust crystallization process for an active pharmaceutical ingredient (API) molecule with a complex polymorphic profile can present a significant challenge. The presented case illustrates an unusual crystallization development problem where a polymorphically complex API has the additional obstacles of poor solubility in standard crystallization solvents as well as a propensity for forming solvates. After early polymorph screening of this candidate highlighted the potential for a complex solid form profile, a variety of experimental approaches was utilized to determine the low-energy polymorph and characterize the various solvates formed. Characterization of the API crystallization process identified a critical solvent composition range for the transformation from a metastable solvate form to the desired polymorph. During subsequent crystallization process development studies, a new lower-energy polymorph was discovered. Examination of the crystal structures led to a rationale for the formation of solvates and the existence of a new lower-energy form.