This multiauthor review article aims to bring readers up to date with some of the current trends in the field of process analytical technology (PAT) by summarizing each aspect of the subject (sensor development, PAT based process monitoring and control methods) and presenting applications both in industrial laboratories and in manufacture e.g. at GSK, AstraZeneca and Roche. Furthermore, the paper discusses the PAT paradigm from the regulatory science perspective. Given the multidisciplinary nature of PAT, such an endeavour would be almost impossible for a single author, so the concept of a multiauthor review was born. Each section of the multiauthor review has been written by a single expert or group of experts with the aim to report on its own research results. This paper also serves as a comprehensive source of information on PAT topics for the novice reader.

The in situ measurement of solution supersaturation associated with the batch cooling crystallization of l-glutamic acid (LGA) at 500 mL and 20 L scale sizes is assessed via ATR-FTIR spectroscopy. A partial least squares chemometric calibration model was developed for the online prediction of LGA concentration from measured FTIR absorbance spectra overcoming some significant challenges related to the low sensitivity of LGA in the mid-IR frequency range, its low solubility in water, and its complex speciation chemistry. The solubility data of LGA in water over the temperature range from 40 to 80 °C, using ATR-FTIR, reveals excellent agreement with those obtained both from using a gravimetric method and literature data. The metastable zone width determined using the turbidimetric methods as a function of heating/cooling rates and solute concentration is found to increase with increasing cooling rate while it decreases with increasing solution concentration. Monitoring online crystallization via both spontaneous and seeded in 500 mL and 20 L crystallizers reveals good concentration predictions for seeded crystallization, while fouling of the ATR crystal prevents its routine use for unseeded crystallization studies. Higher supersaturation levels are found for the larger crystallizer scale-size consistent with enhancement of secondary nucleation at the smaller scale-size.

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When analyzing complex mixtures that exhibit sample-to-sample variability using spectroscopic instrumentation, the variation in the optical path length, resulting from the physical variations inherent within the individual samples, will result in significant multiplicative light scattering perturbations. Although a number of algorithms have been proposed to address the effect of multiplicative light scattering, each has associated with it a number of underlying assumptions, which necessitates additional information relating to the spectra being attained. This information is difficult to obtain in practice and frequently is not available. Thus, with a view to removing the need for the attainment of additional information, a new algorithm, optical path-length estimation and correction (OPLEC), is proposed. The methodology is applied to two near-infrared transmittance spectral data sets (powder mixture data and wheat kernel data), and the results are compared with the extended multiplicative signal correction (EMSC) and extended inverted signal correction (EISC) algorithms. Within the study, it is concluded that the EMSC algorithm cannot be applied to the wheat kernel data set due to core information for the implementation of the algorithm not being available, while the analysis of the powder mixture data using EISC resulted in incorrect conclusions being drawn and hence a calibration model whose performance was unacceptable. In contrast, OPLEC was observed to effectively mitigate the detrimental effects of physical light scattering and significantly improve the prediction accuracy of the calibration models for the two spectral data sets investigated without any additional information pertaining to the calibration samples being required.

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With a view to maintaining the validity of multivariate calibration models for chemical processes affected by temperature fluctuations, loading space standardization (LSS) is proposed. Through the application of LSS, multivariate calibration models built at temperatures other than those of the test samples can provide predictions with an accuracy comparable to the results obtained at a constant temperature. Compared with other methods, designed for the same purpose, such as continuous piecewise direct standardization, LSS has the advantages of straightforward implementation and good performance. The methodology was applied to shortwave NIR spectral data sets measured at different temperatures. The results showed that LSS can effectively remove the influence of temperature variations on the spectra and maintain the predictive abilities of the multivariate calibration models.

There is an increasing interest in using Raman spectroscopy to identify polymorphic forms and monitor phase changes in pharmaceutical products for quality control. Compared with other analytical techniques for the identification of polymorphs such as X-ray powder diffractometry and infrared spectroscopy, FT-Raman spectroscopy has the advantages of enabling fast, in situ, and nondestructive measurements of complex systems such as suspension samples. However, for suspension samples, Raman intensities depend on the analyte concentrations as well as the particle size, overall solid content, and homogeneity of the solid phase in the mixtures, which makes quantitative Raman analysis rather difficult. In this contribution, an advanced model has been derived to explicitly account for the confounding effects of a sample's physical properties on Raman intensities. On the basis of this model, a unique calibration strategy called multiplicative effects correction (MEC) was proposed to separate the Raman contributions due to changes in analyte concentration from those caused by the multiplicative confounding effects of the sample's physical properties. MEC has been applied to predict the anhydrate concentrations from in situ FT-Raman measurements made during the crystallization and phase transition processes of citric acid in water. The experimental results show that MEC can effectively correct for the confounding effects of the particle size and overall solid content of the solid phase on Raman intensities and, therefore, provide much more accurate in situ quantitative predictions of anhydrate concentration during crystallization and phase transition processes than traditional PLS calibration methods.