Molecular crystals often exhibit needle-like shapes, defined by an aspect ratio larger than 5, which can adversely impact dosing consistency, filtration efficiency, and production scalability. These needle-shaped crystals arise from complex factors such as solvent-solute interactions, local supersaturation, and chemical additives. Traditional mitigation methods include chemical additives and mechanical breakage. This talk explores an alternative approach through continuous crystallization, which enhances reproducibility and scalability but is often overlooked in addressing needle-shaped crystal issues. Examples of cooling, reaction, and anti-solvent crystallization in slug flow processes are discussed.
