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<p>Second harmonic generation (SHG) microscopy and Raman microscopy were used for qualitative and quantitative analysis of pharmaceutical materials. Prototype instruments and algorithms for sampling strategies and data analyses were developed to achieve pharmaceutical materials analysis with low limits of detection and short measurement times<br></p><p>Manufacturing an amorphous solid dispersion (ASD), in which an amorphous active pharmaceutical ingredient (API) within polymer matrix, is an effective approach to improve the solubility and bioavailability of a drug. However, since ASDs are generally metastable materials, they can often transform to produce crystalline API with higher thermodynamic stability. Analytical methods with low limits of detection for crystalline APIs were used to assess the stability of ASDs. With high selectivity to noncentrosymmetric crystals, SHG microscopy was demonstrated as an analytical tool, which exhibited a limit of detection of 10 ppm for ritonavir Form II crystals. SHG microscopy was employed for accelerated stability testing of ASDs, which provided a four-decade dynamic range of crystallinity for kinetic modeling. An established model was validated by investigating nucleation and crystal growth based on SHG images. To achieve <i>in situ</i> accelerated stability testing, controlled environment for in situstability testing (CEiST) was designed and built to provide elevated temperature and humidity, which is compatible with a commercial SHG microscope based on our research prototype. The combination of CEiST and SHG microscopy enabled assessment of individual crystal growth rates by single-particle tracking and nucleation rates for individual fields of view with low Poisson noise. In addition, SHG microscopy coupled with CEiST enabled the study of heterogeneity of crystallization kinetics within pharmaceutical materials.<br></p><p>Polymorphism of APIs plays an important role in drug formulation development. Different polymorphs of identical APIs may exhibit different physiochemical properties, e.g., solubility, stability, and bioavailability, due to their crystal structures. Moreover, polymorph transitions may take place during the manufacturing process and storage. Therefore, analytical methods with high speed for polymorph characterization, which can provide real-time feedback for the polymorphic transition, have broad applications in pharmaceutical materials characterization. Raman spectroscopy is able to determine the API polymorphism, but is hampered by the long measurement times. In this study, two analytical methods with high speed were developed to characterize API polymorphs. One is SHGmicroscopy-guided Raman spectroscopy, which achieved the speed of 10 ms/particle for clopidogrel bisulfate. Initial classification of two different polymorphs was based on SHG images, followed acquisition of Raman spectroscopyat the selected positions to determine the API crystal form. Another approach is implementing of dynamic sampling into confocal Raman microscopy to accelerate Raman image acquisition for 6-folds. Instead of raster scanning, dynamic sampling algorithm enabled acquiring Raman spectra at the most informative locations. The reconstructed Raman image of pharmaceutical materials has <0.5% loss of image quality with 15.8% sampling rate.<br></p>

Crystal engineering has advanced the strategies of design and synthesis of organic solids with the main focus being on improving the properties of the developed materials. Research in this area has a significant impact on large-scale manufacturing as industrial processes may give rise, at various stages, to stress-induced transformations and product modification. This thesis investigates the solid-state properties at play in the case of the surface and structural reorganization which results from the stress within a crystal during the drying of labile multicomponent organic solids. Chapter 1 introduces various concepts in solid-state chemistry and explores their application in the manufacture of solid pharmaceuticals. The significance of stress-induced transformations during the drying process is illustrated by reactions associated with crystal decomposition processes such as dehydration, desolvation and sublimation. The chapter also introduces carbamazepine (CBZ) multicomponent materials as models for the studies of stress-induced transformations. Chapter 2 presents the experimental section of the work and describes the materials, methods and equipment used for the study. Chapter 3 presents the analysis of the various crystal structures of CBZ. The crystal forms are classified with an emphasis on a comparison of intermolecular interactions, coformer arrangement, crystal packing and the geometric parameters of slip/cleavage planes within the crystals. Chapter 4 details the experimental methods for preparation of the samples. Cooling solution crystallization was the standard method which has been selected, and crystal habit and surface variations have been studied as a function of the solution concentration and the crystallization environment. Attention is given, in particular, to the preparation of carbamazepine dihydrate and the specific cocrystals carbamazepine cocrystals formed with benzoquinone and oxalic acid. Chapter 5 is devoted to the dehydration of carbamazepine dihydrate for samples prepared and examined in approximate 1-gram laboratory scale quantities. It explores the effect of vacuum, temperature, humidity and seeding on the surface and bulk properties of the products. Chapter 6 presents the solid-state characterization results obtained for samples crystallized at a much larger scale (ca. kilogram quantities) with a particular emphasis placed on their mechanical properties. It explores the comparison of large scaled batches with laboratory scale samples in order to obtain a greater understanding of how small-scale laboratory studies may be extrapolated to more commercial processes. Chapter 7 present results on the stress-induced transformations of carbamazepine solvates and cocrystals. It details the effect of thermal decomposition on the surface and bulk properties of the products, possible seeding effects, and the interconversion between carbamazepine dihydrate and carbamazepine benzoquinone cocrystal. Chapter 8 combines the research findings concerning the structural analyses of the materials in the context of current literature. Limitations related to the use of carbamazepine as a model and to the experimental set-up are also explored. In the final chapter conclusions are presented which correlate observations made on the crystallization and decomposition of multicomponent materials operating at small-scale to effects appropriate to manufacturing of pharmaceuticals at large scale.

The unique symmetry requirements of second harmonic generation (SHG) provide exquisite selectivity to chiral crystals, enabling independent quantitative modeling of the nucleation and crystal growth of active pharmaceutical ingredients (APIs) within amorphous solid dispersions (ASDs) during accelerated in situ stability testing, and in vitro dissolution testing. ASDs, in which an API is maintained in an amorphous state within a polymer matrix, are finding increasing use to address solubility limitations of small-molecule APIs. SHG microscopy yielded limits of detection for ritonavir crystals as low as 10 ppm, which is about two orders of magnitude lower than other methods currently available for crystallinity detection in ASDs. The quantitative capabilities of SHG analysis were substantially improved further while simultaneously dramatically reducing the total sample volume and storage burden through in situ analysis. Single particle tracking of crystal growth performed in situ enabled substantial improvements in the signal to noise ratio (SNR) for recovered crystal nucleation and growth rates by nonlinear optical microscopy. Upon dissolution, the presence of solubilizing additives in biorelevant media greatly affected the generation and stabilization of supersaturated solutions. SHG microscopy was found to enable the detection of crystals even in the highly turbid Ensure Plus® system. Analysis of the SHG micrographs clearly indicated that differences in the nucleation kinetics rather than growth rates dominated the overall trends in crystallinity. For weakly basic drugs, the fate of dissolution in fasted-state simulated intestinal fluid (FaSSIF, pH 6.5) varied with the ASDs drug loading, and was highly affected by the pre-exposure to the fasted-state simulated gastric fluid (FaSSGF, pH 1.6) medium, versus the dissolution in FaSSIF medium alone. The presence of crystals during the first stage of posaconazole ASDs dissolution in FaSSGF acted as nuclei for further crystallization in the later dissolution stage in FaSSIF. The results provide insights of better formulation prediction of poorly soluble drugs, as well as understanding origins of intraluminal absorption variability for such systems