Continuous Crystallization

Crystal uniformity delivers exceptional product consistency

Continuous crystallization is the cornerstone of high-purity API production with Integrated Continuous Manufacturing (ICM). By maintaining steady-state supersaturation and precise thermal profiles in continuous crystallizers, we form crystals with uniform size, shape, and purity, thereby eliminating batch variability, reducing footprint, and enabling seamless integration with both upstream synthesis and downstream isolation.

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A Closer Look at Continuous Crystallization

In our continuous crystallization module, solutions feed into a series of Mixed Suspension Mixed Product Removal (MSMPR) crystallizers. Tight control over temperature, concentration, and residence time allows us to nucleate and grow crystals under optimal conditions. Inline PAT tools, such as focused beam reflectance measurement (FBRM) for particle sizing and Raman spectroscopy for polymorph detection, monitor every moment, accelerating process development. Additionally, the data can be fed into closed-loop control systems that instantly adjust parameters to maintain crystal quality. The result is a highly robust and scalable crystallization process that delivers consistent, in-spec material for downstream filtration and drying.

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Key Features of CONTINUUS’s Continuous Crystallizations

Steady-state operation produces uniform particle characteristics and eliminates batch-to-batch variation
Control and maintenance of low supersaturation throughout the crystallization process ensures high product purity and greatly reduced risk of encrustation
Equivalent yields to batch crystallization

Modes of Operation

Temperature-controlled crystallization
Antisolvent-controlled crystallization
Evaporation-driven crystallization
pH-controlled crystallization

Advanced Manufacturing Expertise to Guide Continuous Crystallization

We offer comprehensive process development and integration services for all continuous manufacturing unit operations.

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Continuous Crystallization Within an ICM Line

Integrated Continuous Manufacturing

Continuous crystallization produces intermediates and API of high purity and yield. When integrated with continuous filtration, the high purity crystallization and improved deliquoring and purging of impurities on the continuous filter often eliminates the need for recrystallization. This results in isolating product faster, at a higher quality, and at reduced cost in comparison to batch production.