Can SONICC quantify and image trace crystallinity inside a light-scattering organic powder, and what does it reveal about how cryomilling destroys crystallinity and how the milled material recrystallizes?
For griseofulvin, yes: SONICC tracked PXRD while PXRD still saw Bragg peaks and kept measuring to 0.04% after 180 min of milling, with an estimated detection limit of 4 ppm. Crystallinity fell first order (half-life 15 ± 1 min), the size distribution of the residual crystals did not visibly change, and cryomilled powder recrystallized 40-fold faster than melt-quenched powder at 50 °C. ····
For griseofulvin powders cryomilled for up to 180 min and sieved to 50–150 μm, SONICC crystallinity "compared favorably" with PXRD down to about 12% and continued to quantify residual crystallinity of 0.7, 0.2 and 0.04% after 90, 120 and 180 min, when the powder was already X-ray amorphous; the detection limit in powder was estimated at 4 ppm from the signal of one voxel, not demonstrated with a 4-ppm sample. ···· The loss of crystallinity followed first-order kinetics with a half-life of 15 ± 1 min, and the normalized size distribution of residual crystals between 320 and 3200 μm³ showed "no statistically significant change" from 90 to 180 min; the authors read both as "consistent with" a one-step process in which an intact microcrystal is rendered amorphous, rather than stepwise fragmentation. ··· DSC of the 3-h milled powder recovered −52 J/g against a theoretical −53.76 J/g, which the authors take to "strongly support" a crystal-to-glass transformation rather than nanocrystal formation. ··· At 50 °C the cryomilled powder recrystallized 40-fold faster than melt-quenched powder, uniformly and without visible nucleation sites; from this the authors "suggest" that the milled glass holds ordered domains larger than the critical nucleus but below SONICC detection, which nucleate without a barrier so that only growth limits the rate. ··· These domains were not detected by any measurement in the paper, and the study covers one compound, one mill and one recrystallization temperature. ···
01Why this study
Even trace residual crystallinity can shorten shelf life, and residual seeds can trigger crystallization of an amorphous solid and bias kinetic studies.
refs 6–8 ·
PXRD, Raman, IR and DSC average over the sample; about 0.2% crystallinity is reachable only with synchrotron X-rays.
Nunes 2005, ref 5 ·
An "X-ray amorphous" halo can mean a true glass or nanocrystals.
Bates 2006, ref 26; Crowley 2002, ref 37 ·
SONICC had detected API crystals in transparent films.
Wanapun 2010, ref 30; refs 27, 28 ·
More detail
What was already known. The introduction builds on these points:
- Why trace crystallinity matters. The solid form of an organic powder drives its chemical and physical properties; bioavailability depends on form, and even trace residual crystallinity can significantly affect shelf life. Accurate quantification below 1% crystallinity is a major unsolved difficulty. ·
- Seeds bias crystallization studies. Residual crystals left by incomplete vitrification can potentially induce and accelerate crystallization by heterogeneous nucleation (Fletcher 1963, ref 6; Carter 1993, ref 7), which can bias studies of crystallization kinetics and mechanism (Schmitt 1999, ref 8). Detecting crystallinity below 1% also helps screen conditions for crystallization control; preparation, formulation and storage temperature and humidity influence crystallization (refs 9–11).
- Current methods. Solid-state transformations in powders are studied by PXRD, Raman (Taylor 1998, ref 1; ref 2), infrared (ref 3) and DSC (ref 4). Detecting about 0.2% crystallinity by X-ray diffraction needed synchrotron radiation (Nunes 2005, ref 5), unsuitable for routine use, and all these methods average over the sample, giving no crystal size distributions or nucleation kinetics. ·
- Milling and crystallinity loss. Milling, sometimes at cryogenic temperature to limit heating, is used to reduce particle size and raise dissolution rate. It can cause crystallinity loss in inorganic (refs 16, 17) and organic materials (refs 18–21), typically through a higher-energy defective crystal that may then turn into a glass (refs 17, 22–24); the mechanism for organic systems remains open.
- What a halo means. Loss of Bragg intensity with a diffuse halo marks disorder, but the halo can come from thermodynamic disordering (as in a melt quench) or kinetic disordering into nanocrystalline domains (Bates 2006, ref 26); "X-ray amorphous" is not necessarily fully disordered (refs 26, 37).
- SHG and SONICC. SHG converts 800 nm light into 400 nm light and is allowed in bulk only for crystals without an inversion centre, which covers most chiral crystals (all but point group O; Boyd 2003, ref 29). Racemic crystals and isotropic media such as liquids and glasses give no coherent SHG. SONICC was developed for protein crystals (Wampler 2008, ref 27; Kissick 2010, ref 28) and detected API crystals in transparent amorphous films down to about 90 nm (Wanapun 2010, ref 30). ·
What the paper set out to do. Optimize SONICC for powders, measure the relative crystallinity of a pharmaceutically relevant compound in strongly scattering powder, compare it with PXRD, and use the images of single crystallites to study how cryomilling removes crystallinity and how the milled material recrystallizes. ··
02How they approached it
One chiral drug, griseofulvin, was cryomilled for increasing times; the same sieved powders were measured by SONICC and PXRD, single crystallites in the SHG images gave the size distribution, DSC gave an energy balance, and melt-quenched glass served as the comparator for recrystallization. ····
What was done
Cryomill 15–180 min at 10 Hz in liquid nitrogen→sieve 50–150 μm.·
Melt 5 min→quench in liquid nitrogen→sieve 50–150 μm.
SONICC, 800 nm in, 400 nm out→mean SHG relative to crystalline powder.··
PXRD→crystallinity from peak and halo areas.·
log crystallinity vs milling time→first-order slope and half-life; detection limit from one voxel.··
3-D crystal counting→size distribution at 90, 120, 180 min.·
DSC of 3-h milled powder→recrystallization enthalpy vs theoretical value.·
SONICC time-lapse at 50 °C→cryomilled vs melt-quenched recrystallization.··
More detail
What was done
- Cryomilling. About 700 mg griseofulvin per sealed tube was cooled 5 min in liquid nitrogen, then milled at 10 Hz in cycles of 5 or 10 min with 1 min cooling between cycles, the tube kept submerged in liquid nitrogen; total milling times were 15, 30, 60, 90, 120 and 180 min. Samples were warmed to room temperature, moved to a dry nitrogen glovebox and sieved to 50–150 μm to keep particle size from affecting the X-ray and SHG signals. ·
- Melt quenching. Griseofulvin was held at its melting temperature for 5 min, quenched in liquid nitrogen, lightly ground in the glovebox and sieved to 50–150 μm.
- SONICC imaging. About 2 mg powder between slide and coverslip was scanned with a 100 fs, 80 MHz laser at 800 nm and 20 mW through a 10× (NA 0.3) objective; one frame took 25 s, z steps were 20 μm and one voxel was 4 × 4 × 20 μm³. The backward-scattered SHG at 400 nm was counted by photomultipliers. The low power kept the response linear from 100% crystallinity down. ·
- Crystallinity by SHG. The mean SHG over the field of view was divided by that of 100% crystalline griseofulvin, assuming randomly oriented crystals and a simple two-phase (crystal plus amorphous) system; no polymorph change was seen. ····
- Crystallinity by PXRD. Patterns from 5 to 35° 2θ were split into crystalline and amorphous areas; crystallinity = 100 × crystalline area / total area. ··
- Detection limit. The signal of a single voxel at S/B = 3 was divided by the signal of 100% crystalline powder, averaged over crystal orientations. ·
- Crystal size distribution. An ImageJ 3-D object counter counted adjacent voxels above about 140,000 counts/s as one crystal; histograms were normalized to the number of crystals and made only for milling times of 90 min or more, where crystals were sparse enough to separate. ·
- DSC. 2–4 mg of 3-h milled powder in a pinholed pan was heated at 10 °C/min from −50 °C past melting; the recrystallization exotherm was integrated and compared with the enthalpy expected for a fully amorphous sample, computed from literature heat of fusion and heat capacity. ·
- Recrystallization. 3-h cryomilled and melt-quenched powders were held at 50 °C and imaged by SONICC for up to 400 min; integrated SHG was plotted against time.
Key equations
The crystalline peak area A_c over the total area, crystalline plus amorphous halo A_a, gives percent crystallinity, assuming each area is proportional to its phase. The SHG crystallinity is defined in words only: mean SHG of the sample over the field of view divided by that of fully crystalline griseofulvin.··
The enthalpy released when a fully amorphous sample crystallizes at T is the heat of fusion corrected by the heat capacity difference between the melting point and T; the paper uses it to obtain −53.76 J/g.··
Terms used on this page
- SHG: a nonlinear optical process that turns two photons of 800 nm into one of 400 nm; it needs an ordered, non-centrosymmetric structure, so glasses and liquids give none.
- Voxel: the smallest 3-D image element, here 4 × 4 × 20 μm³ = 320 μm³.
- X-ray amorphous: no Bragg peaks in PXRD, only a halo; the material can still contain crystals too small or too few for PXRD.
- Critical nucleus: the smallest ordered cluster that grows rather than dissolves; a domain larger than it can grow without a nucleation barrier.
- Induction time: the delay before the first crystals appear.
- One-step vs multistep amorphization: whole crystals turning amorphous at once, versus crystals being broken into ever smaller crystals.
03Main findings
SONICC tracks PXRD and keeps measuring after PXRD goes blind
At 60 min SONICC gave 6% and PXRD 12%; after 90, 120 and 180 min, when the powder was X-ray amorphous, SONICC still measured 0.7, 0.2 and 0.04%. ·
More detail
Crystallinity fell with milling time by both methods, and the two agreed at 15 and 30 min (SONICC about 38 and 19%, PXRD about 32 and 22%, read from Fig. 1c). PXRD saw Bragg peaks up to 60 min (about 12%); from 90 min its patterns showed only a halo, and after 180 min the pattern looked like that of melt-quenched glass. SONICC quantified 0.7, 0.2 and 0.04% after 90, 120 and 180 min "with high signal-to-noise". ··· At 60 min the methods differed (SONICC 6%, PXRD 12%), which the authors call significant and say "may arise" from the high halo background and small Bragg peaks in PXRD. · The paper describes the gain in range as three decades (abstract and conclusions) and four decades (results); the measured span, 100% to 0.04%, is about 3.4 decades. · The 120-min value is printed as 0.2% but plotted at about 0.15%.
Estimated detection limit: 4 ppm in powder
One voxel at signal-to-background 3, relative to fully crystalline powder, corresponds to 4 × 10⁻⁴ % crystallinity (4 ppm).
More detail
The detection limit was estimated, not measured with a 4-ppm sample: the signal of a single 4 × 4 × 20 μm³ voxel at S/B = 3, averaged over orientations, was divided by the signal of 100% crystalline powder. ·· It is far higher than the about 10⁻⁹ % (about 10 parts per trillion) reported earlier for uniform amorphous griseofulvin films, which the authors attribute "largely" to a weak background from surface SHG in powder. · Raising the laser power should lower it, since SHG grows with the square of the incident intensity; power was kept at 20 mW to stay linear at high crystallinity. ·
Crystallinity falls first order with a half-life of 15 min
log crystallinity fell linearly with milling time, slope −0.020 ± 0.002 min⁻¹, half-life 15 ± 1 min.
See also Fig. 1
More detail
The SONICC points fall on a straight line in a plot of log relative crystallinity against milling time, with slope −0.020 ± 0.002 min⁻¹ (8% RSD) and half-life 15 ± 1 min. The log base is not printed; by the extractor's check the half-life matches the slope only for base-10 logs, so the natural-log rate constant would be about 0.046 min⁻¹. ·· The points at 90 and 120 min lie below the line and the 180-min point above it. · The authors read first-order kinetics as each crystallite having "a finite statistical chance" of turning amorphous per unit milling time (the paper writes "suggests"). · Extending the line suggests about 5 h of milling for 1 ppm residual crystallinity. ·
Residual crystallinity sits in a few localized crystals whose size distribution does not change
After milling, SHG came only from isolated crystallites; between 90 and 180 min the normalized size distribution stayed about the same (about 0.6 of crystals in the smallest 320-μm³ bin) while crystallinity fell about 16-fold. ··
More detail
Crystalline powder gave SHG across the whole field; a 0.2% milled powder gave SHG only at isolated spots although powder covered the whole field. The authors conclude that the residual crystallinity comes from a few well-localized crystallites, not from many weakly ordered regions ("suggest"). · The CSD, counted only at 90, 120 and 180 min, was dominated by the smallest bin (320 μm³: about 0.63, 0.57 and 0.62 of crystals for 180, 120 and 90 min) and fell off steeply with size up to 3200 μm³ (read from Fig. 3). The authors see "no statistically significant change", which is "consistent with" a one-step process in which whole microcrystals of 320–3200 μm³ (8–18 μm) turn amorphous; a stepwise breakdown would shift the distribution toward small crystals. They also infer that the crystals reached their "fracture limit" before 90 min. ·· No statistical test, crystal counts or replicates are given, and the smallest bin equals one voxel. ·
DSC recovers nearly all the crystallization enthalpy
The 3-h milled powder released −52 J/g on recrystallization against −53.76 J/g expected for fully amorphous material. ·
See also Fig. 4
More detail
The DSC trace showed no glass transition, a two-part exotherm (a broad one peaking near 90 °C and a sharp one near 110 °C, read from Fig. 4c) and melting near 217 °C. The authors take the two exotherms as surface and bulk crystallization, following an earlier study. The released −52 J/g did not differ significantly, within DSC uncertainty, from the theoretical −53.76 J/g. Close to 100% of the excess enthalpy was thus recovered, "confirming" that the residual crystallinity is a small mass fraction. · A nanocrystalline product would return only about 40% of the heat of fusion, so the data "strongly support" a crystal-to-glass change. · The measured value is a single number without uncertainty, and the inputs of the theoretical value are not printed.
Cryomilled powder recrystallizes 40-fold faster than melt-quenched powder
At 50 °C SHG of the 3-h milled powder rose uniformly across the field within about 60 min; melt-quenched powder formed separate crystals slowly (induction 20 min). ··
More detail
In the cryomilled powder SHG appeared over the whole field by 20 min, was widespread by 60 min and covered most of the field by 120 min; no single nucleation sites could be seen. Integrated SHG reached about 140 × 10⁵ counts/s at 200 min and about 178 × 10⁵ at 400 min. The melt-quenched powder nucleated stochastically after an induction time of 20 min, and separate crystals grew in number from 120 to 400 min; its curve is labelled "40×". · The authors call the overall rate of the milled powder 40-fold higher. · They "suggest" that the milled powder holds many ordered domains, beyond the residual crystals seen in Fig. 2, that are larger than the critical nucleus but below SONICC detection, and that these remove the nucleation barrier so that only growth sets the rate; calorimetry places them at a low mass fraction. ·· SONICC cannot distinguish a true glass from domains smaller than about 90 nm. How the 40-fold factor was obtained is not stated.
04Further observations
- PXRD peaks did not broaden with milling.
- No glass transition was visible in DSC of milled powder; a two-part exotherm took its place. ·
- The crystal counter merged neighbouring crystals at high density (one "crystal" of 2.3 × 10⁷ μm³ at 60 min). ·
- SONICC located crystals inside powder that looks opaque in brightfield. ·
More detail
- No peak broadening. PXRD Bragg peaks kept their width as milling went on; the authors cite peak broadening as the sign of nanostructure formation. ·
- DSC. No Tg was visible because an exotherm falls in the same temperature range, as reported before; the exotherm was bimodal, described earlier as surface (lower temperature) followed by bulk (higher temperature) crystallization. ·
- Counting artefact. At 60 min the algorithm reported a largest crystal of 2.3 × 10⁷ μm³, 25% of the total imaged volume and larger than the starting crystals, so it overestimates size when crystals touch; counts were therefore restricted to 90 min and longer. ·
- Imaging through scatter. In griseofulvin dispersed in viscous nitrocellulose, the SHG signal matched the positions of powder seen in brightfield (Fig. S1). The authors credit SHG selectivity, infrared excitation and, mainly, the insensitivity of nonlinear signals to scatter: only unscattered (ballistic) light at the focus generates SHG, so scatter lowers intensity but not resolution. ·
- No polymorph change was seen in these studies, which allowed a two-phase model. ·
- Extrapolation. Extending the first-order line beyond the measured range gives about 5 h of milling for 1 ppm residual crystallinity. ·
- Speed. One frame took 25 s here; the conclusions mention frame rates of a few seconds and possible video-rate imaging, against minutes to hours for Raman mapping or solid-state NMR. ··
05How the authors connect the findings
More detail
- First-order kinetics means the rate of disordering is proportional to the remaining crystalline material, read by the authors as each crystallite having "a finite statistical chance" of being rendered amorphous per unit milling time (citing ref 40). At the microscopic level, a microcrystal has a finite probability of meeting local shear high enough to deform its lattice and become amorphous. ·
- Two mechanisms were weighed: one-step amorphization of intact microcrystals (ref 26) and multistep breakdown into ever smaller crystals. Only the second predicts a growing share of small crystals; the measured CSD did not change from 90 to 180 min while crystallinity fell about 16-fold, which the authors find "consistent with" the one-step process for crystals of 320–3200 μm³. ··
- DSC: −52 J/g released against −53.76 J/g expected, so close to 100% of the excess enthalpy is recovered; a nanocrystalline product would return about 40% of the heat of fusion. Hence a crystal-to-glass transformation ("strongly support"). ··
Melt-quenched powder. Recrystallization at 50 °C showed stochastic nucleation with a 20-min induction time and growth of separate crystals. ·
Cryomilled powder. Recrystallization was uniform, with no visible nucleation sites, no induction time on the SONICC time scale and a rate 40-fold higher. Since residual crystals can seed secondary or heterogeneous nucleation (ref 37), the authors "suggest" ordered domains larger than the critical nucleus but below the detection limit, at low mass fraction; by removing the nucleation barrier they make the overall rate depend only on growth. ····
What sets the switch point. The presence of sub-detection ordered domains in the milled glass, absent from melt-quenched glass; SONICC cannot see domains much smaller than about 90 nm. ·
Conclusion drawn. Abstract: the cryomilled disordered state "appears to contain ordered domains" larger than the critical nucleus; conclusions: their presence "provides a barrier-less nucleation source". ·
06What it means for formulation
- SONICC can quantify trace crystallinity in API powders quickly and at the scale where crystallization starts. ·
- It needs chiral crystals and cannot easily tell analyte crystals from other chiral crystals in mixtures or tablets.
- An "X-ray amorphous" milled drug is not equivalent to a melt-quenched glass: here it crystallized 40-fold faster.
More detail
- SONICC "has the potential" to address questions on crystallization in powders, giving macroscopic and microscopic information quickly; its probe volume is comparable to that of early crystallization events, unlike bulk PXRD, solid-state NMR or Raman. ·
- Residual crystallinity after incomplete vitrification can seed crystallization and bias kinetic studies; detecting it below 1% helps screen conditions for crystallization control.
- The detection limit can be improved by raising laser power.
- The analyte must crystallize in a chiral unit cell, and other chiral crystalline components in the probe volume "may complicate" multicomponent powders and tablets.
- PXRD amorphousness is not a stability guarantee: the 3-h milled powder still held about 0.04% detectable crystals, and its recrystallization at 50 °C was far faster than that of the melt-quenched glass.
- The route to the amorphous state matters for physical stability: milling-derived amorphous drug may carry sub-detection order that removes the nucleation step, whereas melt-quenched glass must nucleate first.
- For screening amorphous products of chiral APIs, SHG imaging can count residual seeds well below PXRD limits; the paper shows this for one neat drug, not for dispersions with polymer.
07Open questions
- SONICC cannot distinguish a true glass from domains much smaller than about 90 nm.
- How well does it work in multicomponent powders and tablets with other chiral crystals?
- The ordered sub-detection domains were inferred, not observed.
- The constant size distribution has no statistics behind it.
More detail
- Domains of griseofulvin smaller than about 90 nm approach the SONICC detection limit, so a true glass and a material with much smaller crystalline domains look the same. ·
- Discrimination of analyte crystals from other chiral crystalline media in mixtures and tablets.
- Detection limit at higher laser power, given the quadratic signal dependence.
- No measurement detects the sub-detection ordered domains; their existence rests on the kinetics. ·
- The CSD comparison gives no test statistic, crystal counts or replicates, the smallest bin is one voxel, and the size measure is the number of voxels above an intensity threshold, which also depends on crystal brightness. ·
- How the 40-fold rate factor was derived is not stated; the melt-quenched curve carries a "40×" label.
- Only one compound, one mill, one sieve fraction and one recrystallization temperature (50 °C) were studied; no polymer was present.
- The first-order line has systematic residuals, and the 5-h estimate extends it past the data.
08How solid
AI assessment, not a statement made in the paperThe crystallinity measurements and the recrystallization contrast are direct and large. The mechanisms (one-step amorphization, sub-detection seeds) are inferences from unreplicated images and kinetics. ···
More detail
- SONICC and PXRD agree at high crystallinity, and SONICC extends the measured range to 0.04%.
- Crystalline powder lights up everywhere while milled powder shows isolated crystallites, also in scattering powder. ·
- The recrystallization difference between milled and melt-quenched powder is large and visible in the images. ·
- The DSC enthalpy agrees with the theoretical value within a few percent. ·
- The "rate constant" is a base-10 slope; the line has systematic residuals and the extrapolation goes beyond the data. ·
- The CSD comparison has no statistics and resolves only crystals of one voxel or more. ·
- The detection limit is calculated, not demonstrated, and the dynamic range is stated as three and as four decades. ·
- The 40-fold rate factor and the 20-min induction time are not traceable in the figures. ·
- The DSC comparison rests on one measurement and on literature inputs that are not printed.
- No replicates are given for any crystallinity value except the slope uncertainty. ·
09Figure guide
Every figure and table of the paper, what it is there for, and what to check on the original. Key figures are shown with the story.
| Figure | What it does in the paper | Supports | Check (AI note) |
|---|---|---|---|
| Graphical abstract (p.4745) | Shows the 3-D SHG image of a 0.2% powder and the optical layout. | header | A schematic, not data. |
| Fig. 1 (p.4747)key figure | The core comparison: SHG depth profiles, PXRD patterns and log crystallinity vs milling time with the first-order line.··· | F1, F3, K1, K3 | log base not printed; 120-min point plotted at ≈0.15%, printed 0.2%; systematic residuals.·· |
| Fig. 2 (p.4748)key figure | Shows where residual crystallinity sits: isolated crystallites in milled powder. | F4 | |
| Fig. 3 (p.4748)key figure | Tests one-step vs multistep amorphization through the normalized CSD at 90–180 min. | F4, K4 | No statistics; smallest bin is one voxel.· |
| Fig. 4 (p.4749)key figure | Recrystallization of milled vs melt-quenched powder at 50 °C, and DSC of milled powder.·· | F5, F6, K5, K6 | "40×" label and 40-fold factor not explained; no frame shows the 20-min induction.· |
More detail
| Figure | What it does in the paper | Supports | Check (AI note) |
|---|---|---|---|
| Fig. S1 (SI p.S1)key figure | SHG signal coincides with the powder in brightfield in a scattering medium. | 0.4 |