Crystallization Of Active Pharmaceutical Ingredients Research Articles

Effects of some polymeric additives on the cocrystallization of naproxen and nicotinamide via freeze drying

Crystallization of active pharmaceutical ingredients (APIs) has important implications for their bioavailability. Their dissolution behavior is affected by the phase, size, and dispersion of the crystal particles. Polymeric additives have served as effective modifiers of the API crystallization, and we tested their effects during the crystallization via freeze drying. Poly(vinylpyrrolidone), poly(vinylpyrrolidone-co-vinyl acetate), and poly(acrylic acid) were investigated for their effects on the cocrystallization of naproxen (API) and nicotinamide (coformer). We aimed to establish the types and concentrations of the polymers that modulated the size and dispersion of the particles without affecting the cocrystal phase. Poly(vinylpyrrolidone) (Mw 40000) and poly(vinylpyrrolidone-co-vinyl acetate) (Mw 45000–70000) at the concentration level of 3–5% were effective in this regard in increasing the initial and overall API dissolution, which was correlated with the microstructure of the freeze-dried solids. This study is intended to contribute to foundations for further research to apply crystal-modulating additives to the process of freeze drying.

Application of PAT in pharmaceutical manufacturing: model‐based control of particle size distribution in anti‐solvent aided crystallization

AbstractBACKGROUNDCrystallization plays a key role in determining the physiochemical properties of an active pharmaceutical solid, which are crucial for drug product performance as well as processibility in downstream operations. Precise control of crystallization parameters is hence necessary to maintain drug efficacy and consistency during active pharmaceutical ingredient (API) manufacturing. In our earlier work on crystallization of dexlansoprazole API, an empirical model was established with reactor temperature and addition time of anti‐solvent identified as critical process parameters (CPPs) and particle size distribution (PSD) as critical quality attribute (CQA). In this study we demonstrate model‐based control of particle size when disruptive incidences occur under a process analytical technology framework.RESULTSExperiments highlighted the deviation in PSD (CQA) on performing a planned disruption event in the form of temporary shutting down the anti‐solvent feeding dosing pump. Once the deviation had occurred due to process disruption, the desired set‐point of particle size was achieved by making the desired changes estimated from model equations for individual CPPs. The change was signaled to the temperature control system or the dosing pump, which then set the revised process conditions in real time during crystallization.CONCLUSIONThe study utilizes an empirical model to achieve the desired particle size by making suitable real‐time changes in CPP in view of process disruption. The case study aligns with the paradigm of quality by design, which expects manufacturers to understand their processes and their products and have in‐built controls to ensure that the resulting product consistently meets the approved specifications. © 2023 Society of Chemical Industry.

Metamorphosis of Topical Semisolid Products-Understanding the Role of Rheological Properties in Drug Permeation under the "in Use" Condition.

When developing topical semisolid products, it is crucial to consider the metamorphosis of the formulation under the "in use" condition. Numerous critical quality characteristics, including rheological properties, thermodynamic activity, particle size, globule size, and the rate/extent of drug release/permeation, can be altered during this process. This study aimed to use lidocaine as a model drug to establish a connection between the evaporation and change of rheological properties and the permeation of active pharmaceutical ingredients (APIs) in topical semisolid products under the "in use" condition. The evaporation rate of the lidocaine cream formulation was calculated by measuring the weight loss and heat flow of the sample using DSC/TGA. Changes in rheological properties due to metamorphosis were assessed and predicted using the Carreau-Yasuda model. The impact of solvent evaporation on a drug's permeability was studied by in vitro permeation testing (IVPT) using occluded and unconcluded cells. Overall, it was found that the viscosity and elastic modulus of prepared lidocaine cream gradually increased with the time of evaporation as a result of the aggregation of carbopol micelles and the crystallization of API after application. Compared to occluded cells, the permeability of lidocaine for formulation F1 (2.5% lidocaine) in unoccluded cells decreased by 32.4%. This was believed to be the result of increasing viscosity and crystallization of lidocaine instead of depletion of API from the applied dose, which was confirmed by formulation F2 with a higher content of API (5% lidocaine) showing a similar pattern, i.e., a 49.7% reduction of permeability after 4 h of study. To the best of our knowledge, this is the first study to simultaneously demonstrate the rheological change of a topical semisolid formulation during volatile solvent evaporation, resulting in a concurrent decrease in the permeability of API, which provides mathematical modelers with the necessary background to build complex models that incorporate evaporation, viscosity, and drug permeation in the simulation once at a time.

Thermodynamic Modeling of the Amorphous Solid Dispersion-Water Interfacial Layer and Its Impact on the Release Mechanism.

During the dissolution of amorphous solid dispersion (ASD) formulations, the gel layer that forms at the ASD/water interface strongly dictates the release of the active pharmaceutical ingredient (API) and, hence, the dissolution performance. Several studies have demonstrated that the switch of the gel layer from eroding to non-eroding behavior is API-specific and drug-load (DL)-dependent. This study systematically classifies the ASD release mechanisms and relates them to the phenomenon of the loss of release (LoR). The latter is thermodynamically explained and predicted via a modeled ternary phase diagram of API, polymer, and water, and is then used to describe the ASD/water interfacial layers (below and above the glass transition). To this end, the ternary phase behavior of the APIs, naproxen, and venetoclax with the polymer poly(vinylpyrrolidone-co-vinyl acetate) (PVPVA64) and water was modeled using the perturbed-chain statistical associating fluid theory (PC-SAFT). The glass transition was modeled using the Gordon-Taylor equation. The DL-dependent LoR was found to be caused by API crystallization or liquid-liquid phase separation (LLPS) at the ASD/water interface. If crystallization occurs, it was found that API and polymer release was impeded above a threshold DL at which the APIs crystallized directly at the ASD interface. If LLPS occurs, an API-rich phase and a polymer-rich phase are formed. Above a threshold DL, the less mobile and hydrophobic API-rich phase accumulates at the interface which prevents API release. LLPS is further influenced by the composition and glass transition temperature of the evolving phases and was investigated at 37 °C and 50 °C regarding impact of temperature of. The modeling results and LoR predictions were experimentally validated by means of dissolution experiments, microscopy, Raman spectroscopy, and size exclusion chromatography. The experimental results were found to be in very good agreement with the predicted release mechanisms deduced from the phase diagrams. Thus, this thermodynamic modeling approach represents a powerful mechanistic tool that can be applied to classify and quantitatively predict the DL-dependent LoR release mechanism of PVPVA64-based ASDs in water.

Kinetics of Water-Induced Amorphous Phase Separation in Amorphous Solid Dispersions via Raman Mapping.

The poor bioavailability of an active pharmaceutical ingredient (API) can be enhanced by dissolving it in a polymeric matrix. This formulation strategy is commonly known as amorphous solid dispersion (ASD). API crystallization and/or amorphous phase separation can be detrimental to the bioavailability. Our previous work (Pharmaceutics 2022, 14(9), 1904) provided analysis of the thermodynamics underpinning the collapse of ritonavir (RIT) release from RIT/poly(vinylpyrrolidone-co-vinyl acetate) (PVPVA) ASDs due to water-induced amorphous phase separation. This work aimed for the first time to quantify the kinetics of water-induced amorphous phase separation in ASDs and the compositions of the two evolving amorphous phases. Investigations were performed via confocal Raman spectroscopy, and spectra were evaluated using so-called Indirect Hard Modeling. The kinetics of amorphous phase separation were quantified for 20 wt% and 25 wt% drug load (DL) RIT/PVPVA ASDs at 25 °C and 94% relative humidity (RH). The in situ measured compositions of the evolving phases showed excellent agreement with the ternary phase diagram of the RIT/PVPVA/water system predicted by PC-SAFT in our previous study (Pharmaceutics 2022, 14(9), 1904).

Pervaporation-assisted crystallization of active pharmaceutical ingredients (APIs)

Crystallization of active pharmaceutical ingredients is essential in pharmaceutical production. Pervaporation, a thermally-driven membrane process, has not been explored in API crystallization. Here we demonstrated PV-assisted crystallization (PVaC) for simultaneous recovery of API ortho-aminobenzoic acid (o-ABA) and pure solvent. The PERVAP 4060 made of organophilic polymer was found suitable given the reasonable flux of ethanol of 3.69 ​kg/m2/h at 45 ​°C with saturated solution and 99.9% o-ABA rejection. A parametric study showed that the membrane permeance increased with feed flow rate and temperature, but decreased with supersaturation. In the sequential PVaC, the stable form I of o-ABA was obtained with 25 ​°C PV; while with 45 ​°C PV, only metastable form II crystallized. In the simultaneous PVaC, at 0 time lag pure form II was produced; by increasing time lag, form I increased significantly. The results indicated potential routes to control polymorph formation via PVaC, providing a promising alternative for API production.

Influence mechanism of different organic solvents on API solvation behaviors: Molecular dynamics simulations

Solubilities of active pharmaceutical ingredients (APIs) in different solvents are important fundamental properties and are of particular interest in purification (e.g. crystallization) of APIs in industry. Therefore, the objective of this work is to investigate the solvation mechanisms of the poorly soluble API ibuprofen in various organic solvents, by using molecular dynamics (MD) simulations. It was found that the solvation performance of ibuprofen in protic solvents mainly depend on van der Waals interaction, while that in aprotic solvents mainly depend on the ability of forming hydrogen bond (H-bond) of the solvents. Wherein, the strength of H-bond between ibuprofen and protic solvents mainly depends on the hydrogen bond donor (HBD) of the solvent, while hydrogen bond acceptor (HBA) ability of solvents directly determines the strength of H-bond between ibuprofen and aprotic solvents. This difference nature in solvation mechanism was due to the structural properties of protic solvents and aprotic solvents. Among them, protic solvents containing hydroxyl group have strong HBD and HBA characteristics, whereas aprotic solvents only show the characteristics of HBA, because it does not contain active hydrogen protons. In general, the MD simulation results revealed that the better solvation performance of ibuprofen in organic solvents corresponds to the higher polarizability of protic solvents or the stronger HBA ability of aprotic solvents. This work is expected to provide theoretical guidance for choosing appropriate solvents during API preparation and development.

The Shelf Life of ASDs: 1. Measuring the Crystallization Kinetics at Humid Conditions.

Amorphous solid dispersions (ASDs), where an active pharmaceutical ingredient (API) is dissolved in a polymer, are a favored formulation technique to achieve sufficient bioavailability of poorly water-soluble APIs. The shelf life of such ASDs is often limited by API crystallization. Crystallization depends strongly on the storage conditions (relative humidity and temperature) and the polymer selected for generating the ASD. Determining the crystallization kinetics of ASDs under various conditions requires suitable analytical methods. In this work, two different analytical methods were compared and cross-validated: The first builds on water-sorption measurements combined with thermodynamic predictions ( Eur. J. Pharm. Biopharm. 2018, 127, 183-193, DOI: 10.1016/j.toxrep.2018.11.002), whereas the second applies Raman spectroscopy. Using the two independent methods, factors influencing the crystallization kinetics of ASDs containing the API griseofulvin were investigated quantitatively. It was found that crystallization kinetics increases with increasing temperature and relative humidity. Additionally, the influence of different polymers (poly(vinylpyrrolidone-co-vinyl acetate) and Soluplus) on crystallization kinetics were investigated. The experimentally obtained crystallization kinetics were described using the Johnson-Mehl-Avrami-Kolmogorov model and are the basis for future shelf life predictions at desired storage conditions.

Factors Influencing the Crystallization-Onset Time of Metastable ASDs.

In formulation development, amorphous solid dispersions (ASD) are considered to improve the bioavailability of poorly water-soluble active pharmaceutical ingredients (APIs). However, the crystallization of APIs often limits long-term stability and thus the shelf life of ASDs. It has already been shown earlier that the long-term stability of ASDs strongly depends on the storage conditions (relative humidity, temperature), the manufacturing methods, and the resulting particle sizes. In this work, ASDs composed of the model APIs Griseofulvin (GRI) or Itraconazole (ITR) and the polymers poly (vinylpyrrolidone-co-vinyl acetate) (PVPVA) or Soluplus® were manufactured via spray drying and hot-melt extrusion. Each API/polymer combination was manufactured using the two manufacturing methods with at least two different API loads and two particle-size distributions. It was a priori known that these ASDs were metastable and would crystallize over time, even in the dry stage. The amount of water absorbed by the ASD from humid air (40 °C/75% relative humidity), the solubility of the API in the ASD at humid conditions, and the resulting glass-transition temperature were predicted using the Perturbed-Chain Statistical Associating Fluid Theory (PC-SAFT) and the Gordon–Taylor approach, respectively. The onset of crystallization was determined via periodic powder X-ray diffraction (PXRD) measurements. It was shown that simple heuristics such as “larger particles always crystallize later than smaller particles” are correct within one manufacturing method but cannot be transferred from one manufacturing method to another. Moreover, amorphous phase separation in the ASDs was shown to also influence their crystallization kinetics. Counterintuitively, phase separation accelerated the crystallization time, which could be explained by the glass-transition temperatures of the evolving phases.

Impact of Solvent-Drug Interactions on the Desolvation of a Pharmaceutical Solvate.

In drug manufacturing, solvent-based methods are used for the crystallization of active pharmaceutical ingredients (APIs). Often, the solvent interacts with the API resulting in the formation of a new solid compound, the solvate. When desolvation occurs upon heating, it might result in the formation of new solid forms with significantly different physicochemical properties. Therefore, in this work, we study the desolvation kinetics by combining in situ powder X-ray diffraction (PXRD), all-atom molecular dynamics (MD) simulations, and macroscopic solid-state reaction kinetics modeling. The fluorobenzene (FB) solvate of Bruton's tyrosine kinase inhibitor Ibrutinib (IBR) was used as a model system. While the macroscopic solid-state modeling provides information about the desolvation kinetics, the MD simulations were used to trace individual FB molecules inside the crystal lattice. The activation energy of confined solvent diffusion, obtained by MD simulations, agrees well with results of the macroscopic solid-state reaction kinetics modeling. In addition, MD simulations provided detailed information about the IBR-FB interactions at the nanoscale. The mechanism revealed is that the solvent molecules diffusion, controlled by distinct open-close gating conformational changes of the drug, triggers the desolvation throughout the crystal lattice.

Hydrogel Microparticle-Templated Anti-Solvent Crystallization of Small-Molecule Drugs.

Conventional formulation strategies for hydrophobic small-molecule drug products frequently include mechanical milling to decrease active pharmaceutical ingredient (API) crystal size and subsequent granulation processes to produce an easily handled powder. A hydrogel-templated anti-solvent crystallization method is presented for the facile fabrication of microparticles containing dispersed nanocrystals of poorly soluble API. Direct crystallization within a porous hydrogel particle template yields core-shell structures in which the hydrogel core containing API nanocrystals is encased by a crystalline API shell. The process of controllable loading (up to 64% w/w) is demonstrated, and tailored dissolution profiles are achieved by simply altering the template particle size. API release is well described by a shrinking core model. Overall, the approach is a simple, scalable and potentially generalizable method that enables novel means of independently controlling both API crystallization and excipient characteristics, offering a "designer" drug particle system.

Membrane assisted crystallization of active pharmaceutical ingredients (APIs) by forward osmosis and its effect on crystal size and morphology

At present and in the past decade, forward osmosis (FO) membrane technology has grown as an emerging technology in various area specially desalination, waste and drinkable water treatment, pharmaceutical, and food processing industry. FO depends on the osmotic pressure difference generated between feed solution (FS) and that of draw solution (DS) which results the separation of selective liquid components possible. FO is energy intensive process creating concentration gradient between FS and DS, which is driving force for separation and concentration of saturated solutions. Membrane assisted crystallization (MAC) process; a combination of membrane technology with conventional crystallization processes is useful hybrid crystallization process recently developing mostly in pharmaceutical and food processing sectors. In this work, comprehensive study has been done on the membrane assisted FO process which utilizes various operation conditions which are necessities for development of hybrid MAC for the active pharmaceutical ingredients (APIs). Recently developed membranes have intrinsic characteristics of operational simplicity, high permeability, selectivity and efficiency. These characteristics make possible to develop a technology which satisfies the concept of various APIs production. The main objective of this present study is to compare the effect of various process parameters such as drug solution supersaturation, crystallization temperature, and time on crystal size and morphology of APIs by conventional crystallization and MAC.

Detection and Analysis of Drug Crystals in Medical Transdermal Patches by Using X-ray Diffraction Measurement

The crystallization of active pharmaceutical ingredients (APIs) in matrix-type transdermal patches has implications for the rate of drug absorption through the skin and patch adhesion strength. Therefore, the presence or absence and the degree of API crystallinity must be controlled to guarantee the quality of patches. In this study, the utility of laboratory-level X-ray diffractometers for the detection and analysis of crystalline APIs in transdermal patches was investigated using medical patches of tulobuterol and isosorbide dinitrate. Several matrix-type patches employ a controlled drug delivery system containing intentionally crystallized API. Both benchtop and high-resolution laboratory X-ray diffractometers can detect several characteristic peaks of the APIs in these patches even if the patches are wrapped in an outer bag, although a benchtop model provides peak heights one-seventh to one-fifth that of a high-resolution instrument. An isosorbide dinitrate patch containing an unintentionally crystallized spot was wrapped in an outer bag, followed by measurements using both X-ray diffractometers. For both instruments, several isosorbide dinitrate-derived peaks were detected only at the crystallized spot, although the signal-to-noise ratio was poorer for the benchtop model. These results show that a high-resolution X-ray diffractometer is advantageous for high-detection sensitivity and offers a high degree of freedom of the measurement position on the sample. It was concluded that a laboratory-level high-resolution X-ray diffractometer can be used to examine the crystalline state of APIs in patches inside an unopened outer bag.

The Crystallization of Active Pharmaceutical Ingredients with Low Melting Points in the Presence of Liquid–Liquid Phase Separation

Liquid–liquid phase separation (LLPS) during the crystallization of active pharmaceutical ingredients (APIs) often causes agglomeration and other quality issues in crystal products; thus, it should be avoided if possible. However, LLPS in the crystallization of APIs with low melting points cannot be circumvented in some cases due to yield considerations. The crystallization of ibuprofen in an ethanol/water mixture was studied to explore methods to reduce agglomeration in the presence of LLPS. It was found that unseeded crystallization produced agglomerates when LLPS took place. The two liquid phases resulting from LLPS underwent LLPS again when they were cooled separately, indicating the dynamic nature of LLPS. Seeding and seed ageing at a low supersaturation were very effective in mitigating agglomeration. The effects of two widely used surfactants, i.e., Tween 80 and hydroxypropyl methylcellulose (HPMC), on LLPS and crystallization were confirmed preliminarily. More work needs to be conducted to explore their usefulness in LLPS handling. The findings and techniques presented in this study may be applicable to the crystallization of other APIs with low melting points.

Process development in the QbD paradigm: Implementing design of experiments (DoE) in anti-solvent crystallization for production of pharmaceuticals

Developing an understanding of critical process parameters and their impact on product quality attributes is crucial for implementing quality-by-design (QbD) in a pharmaceutical crystallization process. Use of statistical design of experiments (DoE) is widely accepted to be a more efficient experimental strategy for gaining the required process understanding than the traditional one-variable-at-a-time approach. In recent years, crystallization of active pharmaceutical ingredients (APIs) has been explored to generate crystals with desirable physical characteristics. Many problems in downstream processes can be attributed to poor particle characteristics established during the crystallization step. This paper presents the implementation of a DoE driven QbD approach for the anti-solvent crystallization of Dexlansoprazole API. Focused beam reflectance measurements were used to obtain crystal morphology data. Minitab19 statistical software was utilized for experimentation design and analysis. The empirical model thus created was statistically relevant. The model has been further used to design a control strategy to enable in-process control of the crystal size distribution during crystallization, as expected in the QbD paradigm. We expect that the proposed approach may benefit those wishing to achieve consistency in product quality during API crystallization.

Design of Spherical Crystallization of Active Pharmaceutical Ingredients via a Highly Efficient Strategy: From Screening to Preparation

Design of Spherical Crystallization of Active Pharmaceutical Ingredients via a Highly Efficient Strategy: From Screening to Preparation

Discrimination of ranitidine hydrochloride crystals using X-ray micro-computed tomography for the evaluation of three-dimensional spatial distribution in solid dosage forms

A non-destructive discrimination method for crystals in solid dosage drug forms was first developed using a combination of Raman spectroscopy and X-ray micro-computed tomography (X-ray CT). Identification of the crystal form of an active pharmaceutical ingredient (API) at the appropriate pharmaceutical dosage is crucial, as the crystal form is a determinant of the quality and performance of the final formulation. To develop a non-destructive analytical methodology for the discrimination of solid API crystals in a solid dosage form, we utilized a combination of Raman spectroscopy and X-ray CT to differentiate between ranitidine crystal polymorphs (forms 1 and 2) in tablet formulations containing three excipients. The difference in electron density correlated with the true density between ranitidine polymorphs, thereby enabling the discrimination of crystal forms and visualization of their three-dimensional spatial localization inside the tablets through X-ray CT imaging. Furthermore, X-ray CT imaging revealed that the crystal particles were of varying densities, sizes, and shapes within the same batch. These findings suggest that X-ray CT is not only an imaging tool but also a unique method for quantitative physicochemical characterization to study crystal polymorphs and solid dosage forms.

Isothermal Crystallization and Time-Temperature Transformation of Amorphous Nifedipine: A Case of Polymorphism Formation and Conversion.

Crystallization of active pharmaceutical ingredients (APIs) from the supercooled liquid state is an important issue in determining the stability of amorphous pharmaceutical dispersions. In the present study, the isothermal crystallization from the supercooled liquid state of the pharmaceutical compound nifedipine was investigated by both rheological and differential scanning calorimetry (DSC) measurements, and the crystallization kinetics was fitted to the Johnson-Mehl-Avrami (JMA) equation. Both the crystallization induction time and completion time from the two methods were used to construct the time-temperature-transformation (TTT) diagram for nifedipine. A model based on a modification of classical homogeneous nucleation and crystal growth theory was employed to fit the induction and completion time curves. Both DSC and rheological methods give similar results for the crystallization kinetics of the nifedipine. From the crystallization kinetics modeling, the solid-liquid interfacial surface tension σSL of nifedipine was estimated and the value was found to be consistent with prior results obtained from melting point depression measurements as a function of crystal size. Evidence is shown that for temperatures below 110 °C, at the early stage of nucleation, NIF first nucleates into the metastable β'-form and later converts into the stable α-form during the isothermal crystallization. We are also able to report the heat of fusion of the γ'-NIF based on the calorimetric experiments.

Crystallization Risk Assessment of Amorphous Solid Dispersions by Physical Shelf-Life Modeling: A Practical Approach.

Amorphous solid dispersions (ASDs) of a poorly water-soluble active pharmaceutical ingredient (API) in a polymer matrix can enhance the water solubility and therefore generally improve the bioavailability of the API. Although examples of long-term stability are emerging in the literature, many ASD products are kinetically stabilized, and inhibition of crystallization of a drug substance within and beyond shelf life is still a matter of debate, since, in some cases, the formation of crystals may impact bioavailability. In this study, a risk assessment of API crystallization in packaged ASD drug products and a mitigation strategy are outlined. The risk of shelf-life crystallization and the respective mitigation steps are assigned for different drug product development scenarios and the scientific principles of each step are discussed. Ultimately, the physical stability of ASD drug products during shelf-life storage is modeled. The methodology is based on the quantification of crystal growth kinetics by transmission Raman spectroscopy (TRS), modeling the impact of water sorption on the glass-transition temperature of the ASD, and the prediction of moisture uptake by the packaged ASD drug product during storage. This approach is applied to an ASD of fenofibrate that features both fast API crystallization under accelerated storage conditions and long-term stability in a suitable protective packaging under conventional storage conditions.

Computer Aided Design of Solvent Blends for Hybrid Cooling and Antisolvent Crystallization of Active Pharmaceutical Ingredients.

Choosing a solvent and an antisolvent for a new crystallization process is challenging due to the sheer number of possible solvent mixtures and the impact of solvent composition and crystallization temperature on process performance. To facilitate this choice, we present a general computer aided mixture/blend design (CAMbD) formulation for the design of optimal solvent mixtures for the crystallization of pharmaceutical products. The proposed methodology enables the simultaneous identification of the optimal process temperature, solvent, antisolvent, and composition of solvent mixture. The SAFT-γ Mie group-contribution approach is used in the design of crystallization solvents; based on an equilibrium model, both the crystal yield and solvent consumption are considered. The design formulation is implemented in gPROMS and applied to the crystallization of lovastatin and ibuprofen, where a hybrid approach combining cooling and antisolvent crystallization is compared to each method alone. For lovastatin, the use of a hybrid approach leads to an increase in crystal yield compared to antisolvent crystallization or cooling crystallization. Furthermore, it is seen that using less volatile but powerful crystallization solvents at lower temperatures can lead to better performance. When considering ibuprofen, the hybrid and antisolvent crystallization techniques provide a similar performance, but the use of solvent mixtures throughout the crystallization is critical in maximizing crystal yields and minimizing solvent consumption. We show that our more general approach to rational design of solvent blends brings significant benefits for the design of crystallization processes in pharmaceutical and chemical manufacturing.