The effect of tertiary
butyl alcohol (TBA) as a cosolvent on the
phase behavior of mannitol in frozen and freeze-dried systems was
characterized using differential scanning calorimetry (DSC) and X-ray
diffractometry (XRD; laboratory and synchrotron sources). Solutions
of mannitol (2 and 5% w/w) in TBA–water systems of different
compositions (5 to 30% w/w TBA) were characterized, both during cooling
and warming using DSC and XRD. At and below the TBA–water eutectic
composition (22.5% w/w TBA), mannitol crystallization was completely
inhibited in the frozen state, while it crystallized as anhydrous
δ-mannitol in the final lyophile. The presence of mannitol did
not affect the phase behavior of TBA. The ability of mannitol to serve
as a cryoprotectant in frozen solutions, and as a bulking agent in
final lyophile was evaluated using human serum albumin (HSA) as a
model protein. When HSA in a TBA (5% w/w)–water solution containing
mannitol (2% w/w) was freeze–thawed or freeze-dried, there
was no evidence of HSA aggregation. Thus, when TBA was used as a cosolvent,
mannitol exhibited dual functionality, serving as a cryoprotectant
in frozen solutions and as a bulking agent in the final lyophile.