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Updated: Dec 23, 2025

Capillary-based Centrifugal Microfluidic Device for Size-controllable Formation of Monodisperse Microdroplets

Capillary-based Centrifugal Microfluidic Device for Size-controllable Formation of Monodisperse Microdroplets

Published on: February 22, 2016

Seeded droplet microfluidic system for small molecule crystallization.

N Garg¹, R Tona, P Martin

¹Advanced Manufacturing Technologies, GlaxoSmithKline, 709 Swedeland Road, King of Prussia, PA, USA. david.x.lai@gsk.com.

|April 24, 2020

Summary

This summary is machine-generated.

Microfluidic seeded crystallization controls polymorphism and particle size distribution for abacavir hemisulfate. This droplet reactor method enables precise control over crystal growth for pharmaceutical manufacturing.

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Area of Science:

Pharmaceutical Science
Chemical Engineering
Materials Science

Background:

Controlling polymorphism and particle size distribution is crucial for active pharmaceutical ingredient (API) development.
Traditional crystallization methods often struggle with precise control over these parameters.
Abacavir hemisulfate, a key antiviral drug, requires specific crystalline forms for efficacy.

Purpose of the Study:

To demonstrate a microfluidic approach for seeded crystallization of abacavir hemisulfate.
To control polymorphism and achieve a narrow particle size distribution (PSD).
To develop a scalable method for continuous pharmaceutical manufacturing.

Main Methods:

Utilized droplet reactors for seeded crystallization, employing two distinct techniques.
Technique 1: Emulsion system with a dispersed phase (API and seeds) and a continuous phase for solvent extraction.
Technique 2: In-flow combination of seed suspension and supersaturated API streams, emulsified in an insoluble continuous phase, followed by temperature-controlled incubation.

Main Results:

Achieved crystallization of abacavir hemisulfate into spherical agglomerates.
Demonstrated control over crystal number and size by adjusting seed concentration and utilizing temperature cycling.
Showcased enhanced control over particle size distribution (PSD) through monodispersed droplet reactors and controlled mass availability per seed.

Conclusions:

Microfluidic seeded crystallization in droplet reactors offers precise control over polymorphism and PSD.
The demonstrated techniques are scalable for continuous manufacturing of pharmaceutical particles.
This approach provides a foundation for advanced control over crystal properties in drug development.