Steering a crystallization process to reduce crystal polydispersity; case study of insulin crystallization

The use of the classical nucleation-growth-separation principle (NGSP) was restricted hitherto to nucleation kinetics studies only. A novel application of the NGSP is proposed. To reduce crystal polydispersity internal seeding of equally-sized crystals is suggested, the advantage being avoidance of crystal grinding, sieving and any introduction of impurities. In the present study, size distributions of grown insulin crystals are interpreted retrospectively to select the proper nucleation stage parameters. The conclusion is that when steering a crystallization process aimed at reducing crystal polydispersity, the shortest possible nucleation stage duration has to be chosen because it renders the closest size distribution of the nucleated crystal seeds. Causes of inherent propensity to increasing crystal polydispersity during prolonged growth are also explored. Step sources of increased activity, present in some crystals while absent in others, are pointed as the major polydispersity cause. Insulin crystal morphology is also considered since it determines the dissolution rate of a crystalline medicine.