When two different substances are mixed in a solution and then freeze-dried, some physical changes can affect the crystallographic characteristics of the final product.2,3) Pikal et al. have reported the mutual inhibition of crystallization of mannitol and glycine during lyophilization.3) However, there are not many articles which study the effect of a crystalline active substance on the physical state of mannitol forms.Mannitol is an excipient broadly used in the freeze-drying process, [4][5][6][7][8] and its crystalline and amorphous forms have been extensively studied. 4,[6][7][8] The freeze-drying process can produce a partially amorphous and partially crystalline material 6) ; the crystallization of mannitol during this process can lead to different anhydrous polymorphs (a, b, and d). The existence of crystalline mannitol hydrate obtained during the freeze-drying process has been confirmed by Yu et al.
7)As a result of these changes to the crystal form of mannitol during freeze-drying there is a difference in the physical and chemical stability of the freeze-dried solid, which can induce adverse effects. Therefore, by studying the physical chemistry of freeze-dried mannitol containing formulations one can anticipate these changes and prevent adverse effects.During the freeze-drying process, samples are subject to different cycles of freeze and vacuum drying. These processes can lead to modifications of the initial crystalline form of the drug. 4,5,8,9) The effects of freezing rate, temperature and mannitol concentration may also induce crystallographic changes producing a previously known mannitol form.6,7) Yu et al. have shown that mixtures of d (major) and b (minor) polymorphs were produced by freeze-drying a 4% w/v pure mannitol solution.7) Nevertheless, other authors when employing a fast freezing process favored the formation of b form when 5% (w/v) mannitol solution was freezedried.6) The difficulties which arise when attending to control these variables (as temperature and cooling rate) during the freeze-drying process are shown by Yu et al.,7) who identify several factors that can contribute to the vial-to-vial variation in the amount and stability of the mannitol hydrate.In the current study, acetylsalicylic acid (AAS) is used as model crystalline drug. Possible changes in crystallinity of AAS can be easily detected because its crystallographic characteristics are well known. 10,11) Therefore, the objectives of this study are to (1) Identify and measure the different crystalline mannitol forms obtained when a second crystallizing solute is present. (2) Determine the effect of a similar to industrial scale freeze-drying process conditions on the physical state of freeze-dried mannitol present as a single component.
ExperimentalMaterials AAS USP 23 (Merck, Darmstadt, Germany). b Mannitol NF (ICI Americas Inc., U.S.A.). d-mannitol was obtained using a procedure described by Kim et al. 6) All other ingredients were of reagent grade or better (Merck).Methods. Powder Samples Physical Mixtures: Samples ...