The tendency for crystallization
during storage and administration
is the most considerable hurdle for poorly water-soluble drugs formulated
in the amorphous form. There is a need to better detect often subtle
and complex surface crystallization phenomena and understand their
influence on the critical quality attribute of dissolution. In this
study, the interplay between surface crystallization of the amorphous
form during storage and dissolution testing, and its influence on
dissolution behavior, is analyzed for the first time with multimodal
nonlinear optical imaging (coherent anti-Stokes Raman scattering (CARS)
and sum frequency generation (SFG)). Complementary analyses are provided
with scanning electron microscopy, X-ray diffraction and infrared
and Raman spectroscopies. Amorphous indomethacin tablets were prepared
and subjected to two different storage conditions (30 °C/23%
RH and 30 °C/75% RH) for various durations and then dissolution
testing using a channel flow-through device. Trace levels of surface
crystallinity previously imaged with nonlinear optics after 1 or 2
days of storage did not significantly decrease dissolution and supersaturation
compared to the freshly prepared amorphous tablets while more extensive
crystallization after longer storage times did. Multimodal nonlinear
optical imaging of the tablet surfaces after 15 min of dissolution
revealed complex crystallization behavior that was affected by both
storage condition and time, with up to four crystalline polymorphs
simultaneously observed. In addition to the well-known α- and
γ-forms, the less reported metastable ε- and η-forms
were also observed, with the ε-form being widely observed in
samples that had retained significant surface amorphousness during
storage. This form was also prepared in the pure form and further
characterized. Overall, this study demonstrates the potential value
of nonlinear optical imaging, together with more established solid-state
analysis methods, to understand complex surface crystallization behavior
and its influence on drug dissolution during the development of amorphous
drugs and dosage forms.