Crystallization
Optimize production with fast, reliable insights into particle size, shape, and morphology
Challenges
in Crystallization Processes
Crystallization is a complex process influenced by factors such as temperature, supersaturation, mixing conditions, and impurities. Without proper monitoring and optimization, it often results in inconsistent purification and suboptimal product properties.Common operational challenges include:
Variations in crystal size that lead to problems in downstream processes like filtration, drying, and packaging
Non-uniform shapes or malformed crystals that affect solubility, dissolution rates, and overall product quality
Variability in crystallization conditions that result in poor reproducibility and low yield, leading to overall production inefficiencies
Inconsistent crystallization conditions (e.g., cooling rate, supersaturation) resulting in product variability
Secondary nucleation that leads to the formation of fines, resulting in inconsistent crystal sizes and reduction of yield
Formation of crystal conglomerates that affect the product's morphology, solubility, purity, and dissolution rate
Conservative cooling/evaporation rates/anti-solvent addition profiles (often employed to mitigate secondary nucleation) leading to lower throughput and inefficient crystallization processes
Variability of seed slurry consistency, leading to fluctuations in the final size and distribution of resulting crystals
How ParticleTech
Helps
Application
Areas
Throughput Optimization
Use real-time data to fine-tune cooling and evaporation rates, increasing throughput without sacrificing quality
Yield Improvement
Use precise measurement data to minimize wastage and maximize yield by optimizing crystallization conditions
Conglomerate Control
Detect conglomerate formation and adjust process parameters to maintain crystal purity and mitigate subsequent challenges related to filtration and drying
Process Optimization
Adjust key crystallization parameters such as cooling/evaporation/anti-solvent addition rates based on real-time particle data to enhance crystal quality and process robustness
Quality Control
Monitor and ensure consistent crystal size, shape, and morphology throughout the production process, improving product quality and reducing batch variability
Seed Slurry Monitoring
Analyze seed slurries to ensure uniform size and concentration of crystals per volume, ensuring optimal seeding for consistent final crystal size and morphology
WorkFlow
of a Practical Analysis
Minimal sample preparation
Analyze crystal slurries directly from the crystallization process with ParticleTech Sample Unit. There is no need for washing and drying the crystal slurries before the analysis
No calibration or cleaning required
Ensuring seamless operation
Analysis time under two minutes
Allowing for real-time process monitoring and optimization
Compatible with High-Viscosity Samples
Can also analyze high-viscosity crystal slurry samples, where samples are placed in standard titer-plate formats, ensuring flexibility across various sample types
Seed Slurry Analysis
Easily analyze seed slurries (size distribution and crystal concentration) by transferring a drop of diluted seed slurry to a ParticleTech CombiCell
Business Benefits
of using ParticleTech for Pigment Analysis
Quickly assesses particle size, shape, morphology, and defects with high precision, allowing for faster decision-making
Provides immediate insights into crystallization conditions, enabling faster adjustments and reducing process variations
Unlike traditional microscopy-based methods, ParticleTech’s system offers objective, repeatable results
By optimizing crystallization processes and detecting defects early, ParticleTech ensures higher product yield and quality
Useful for optimizing crystallization in pharmaceuticals, food production, chemicals, and more