Efficient
downstream processing of active pharmaceutical ingredients
(APIs) can depend strongly on their particulate properties, such as
size and shape distributions. Especially in drug products with high
API content, needle-like crystal habit of an API may show compromised
flowability and tabletability, creating significant processability
difficulties on a production scale. However, such a habit can be adapted
to the needs of downstream processing. To this end, we modified the
needle-like crystal habit of the model API 5-aminosalicylic acid (5-ASA).
This study reports processability assessment of six representative
crystal habits of 5-ASA (needles, plates, rectangular bars, rhombohedrals,
elongated hexagons, and spheroids) in the context of direct compression
using ring shear tester, flow rate analyzer, and instrumented tablet
press. As expected, needles were very cohesive, had low flow rate
(1.0 ± 0.08 mg/s), and low bulk density (0.14 ± 0.01 g/mL)
but showed better tabletability, whereas the opposite was observed
with more isotropic crystal habits. For instance, spheroids, elongated
hexagons, and rhombohedrals were easy/free-flowing and had high bulk
densities (≥0.5 g/mL), but final tablets had lower tensile
strength than that of needles. Of the six crystal habits, the plates
showed a good compromise considering both flowability and tabletability.