Freezing step controls the mannitol phase composition heterogeneity

Freeze-dried samples were prepared from D-mannitol solution by selected freezing conditions. Crystalline structures of prepared samples were determined by XRD analysis, and distributions of the various crystal structures of mannitol were obtained for each sample. It was found that the amount of each polymorph was quite well correlated to the freezing conditions, namely the ice crystal nucleation temperature and the cooling rate. In case of samples prepared at fast cooling rates, the samples where the ice crystals nucleated at higher temperature contained much more stable form than the samples nucleated at lower temperature. Besides, the samples prepared at slow cooling rates predominantly contained stable crystalline forms despite of the variation of nucleation temperatures. Moreover, the experimental results also indicated that the various polymorphs were also distributed vertically through the sample along the direction of the heat flux during freezing. The tendency of the polymorph distribution through the freeze-dried cake was also elucidated by using the simulated temperature profiles during freezing. Thus, the profiles of mannitol polymorphs after the freezing derived from the temperature distributions could predict the global tendency of polymorphism behaviour, and, consequently, would be useful to achieve quality control of freeze-dried formulations.