Processes for the production of polymorphic forms of rifaximin

1. A process for the production of rifaximin in polymorphic form α, comprising:

dissolving rifaximin in an alcoholic solvent at a temperature between approximately 45° C. and approximately 65° C.;

precipitating the rifaximin by adding water to the alcoholic solvent to form a suspension and by lowering the temperature of the suspension to between approximately 0° C. and approximately 50° C.; and

drying the rifaximin for a period of time between approximately 2 and approximately 72 hours to form rifaximin in polymorphic form α.

2. The process according to claim 1 , further comprising washing the rifaximin with water after precipitating.

3. The process according to claim 1 , wherein the alcoholic solvent is ethyl alcohol.

4. The process according to claim 1 , wherein said water added to precipitate the rifaximin is in a weight amount of between approximately 15% and approximately 70% with respect to the weight amount of alcoholic solvent used for the dissolution.

5. The process according to claim 1 , wherein after the addition of water, the temperature is lowered to between approximately 28° C. and approximately 32° C.

6. The process according to claim 1 , wherein the suspension is stirred at a temperature between approximately 40° C. and approximately 50° C. for a period of time between approximately 6 hours and approximately 24 hours.

7. The process according to claim 1 , where the temperature of the suspension is lowered to approximately 0° C. for a period of time between approximately 15 minutes and approximately one hour.

8. The process of claim 1 , wherein the drying step is conducted until the rifaximin has a water content of between approximately 2% and approximately 3%.

9. A process for the production of rifaximin in polymorphic form β, comprising:

dissolving rifaximin in an alcoholic solvent at a temperature between approximately 45° C. and approximately 65° C.;

precipitating the rifaximin by adding water to the alcoholic solvent to form a suspension and by lowering the temperature of the suspension to between approximately 0° C. and approximately 50° C.; and

drying the rifaximin for a period of time between approximately 2 and approximately 72 hours to form rifaximin in polymorphic form β.

10. The process according to claim 9 , wherein the alcoholic solvent is ethyl alcohol.

11. The process according to claim 9 , wherein after the addition of water, the temperature is lowered to between approximately 28° C. and approximately 32° C.

12. The process according to claim 9 , wherein the suspension is stirred at a temperature between approximately 40° C. and approximately 50° C. for a period of time between approximately 6 hours and approximately 24 hours.

13. The process according to claim 9 , where the temperature of the suspension is lowered to approximately 0° C. for a period of time between approximately 15 minutes and approximately one hour.

14. The process according to claim 9 , wherein the drying step is conducted until the rifaximin has a water content of between approximately 4.5% and approximately 6%.

15. A process for the production of rifaximin in polymorphic form γ, comprising:

dissolving rifaximin in an alcoholic solvent at a temperature between approximately 45° C. and approximately 65° C.;

precipitating the rifaximin by adding water to the alcoholic solvent to form a suspension and by lowering the temperature of the suspension to between approximately 0° C. and approximately 50° C.; and

drying the rifaximin for a period of time between approximately 2 and approximately 72 hours to form rifaximin in polymorphic form γ.

16. The process according to claim 15 , further comprising washing the rifaximin with water after precipitating prior to drying.

17. The process according to claim 15 , wherein the alcoholic solvent is ethyl alcohol.

18. The process according to claim 15 , wherein said water added to precipitate the rifaximin is in a weight amount of between approximately 15% and approximately 70% with respect to the weight amount of alcoholic solvent used for the dissolution.

19. The process according to claim 15 , wherein after the addition of water, the temperature is lowered to between approximately 28° C. and approximately 32° C.

20. The process according to claim 15 , wherein the suspension is stirred at a temperature between approximately 40° C. and approximately 50° C. for a period of time between approximately 6 hours and approximately 24 hours.

21. The process according to claim 15 , where the temperature of the suspension is lowered to approximately 0° C. for a period of time between approximately 15 minutes and approximately one hour.

22. The process of claim 15 , wherein the drying step is conducted until the rifaximin has a water content of between lower than approximately 2%.

23. A process for the production of rifaximin α, comprising:

suspending rifaximin γ in an alcohol/water solvent mixture;

heating the suspension for a period of time between approximately 6 and approximately 36 hours; and

drying the washed solid to form rifaximin α.

24. The process of claim 23 , wherein the drying step is conducted until the rifaximin has a water content of lower than approximately 3%.

25. The process according to claim 23 , wherein the drying water content is between approximately 2% and approximately 3.0%.

26. The process according to claim 23 , wherein the solvent mixture comprises ethyl alcohol.

27. A process for the production of rifaximin β, comprising:

suspending rifaximin γ in an alcohol/water solvent mixture;

heating the suspension for a period of time between approximately 6 and approximately 36 hours; and

drying the washed solid to form rifaximin β.

28. The process according to claim 27 , further comprising washing the rifaximin with water prior to drying.

29. The process according to claim 27 , wherein the drying step is conducted until the rifaximin has a water content between approximately 5.0% and approximately 6.0%.

30. The process according to claim 27 , wherein the solvent mixture comprises ethyl alcohol.

31. A process for the production of rifaximin α comprising, drying β under vacuum at about +30° C. for 8 or more hours to obtain α.

32. A process for the production of rifaximin β comprising, maintaining α in an atmosphere containing a about 56% relative humidity until β is obtained.

33. A process for the production of rifaximin γ comprising heating α in ethyl alcohol until dissolution of the solid, adding water to the mixture, cooling the mixture, washing the mixture with water, and drying in a vacuum to obtain γ.

34. A process for the production of one or more of a Form α, Form β, or Form γ polymorph of rifaximin, comprising:

reacting an amount of rifamycin O with an excess of 2-amino-4-methylpyridine in a solvent mixture comprising water and ethyl alcohol in volumetric ratios between about 1:1 and about 2:1 for a time between about 2 and about 8 hours;

treating the reaction mixture at room temperature with a solution of ascorbic acid in a mixture of water, ethyl alcohol and concentrated aqueous hydrochloric acid;

adjusting the pH of the solution to about 2.0 with hydrochloric acid concentrated aqueous solution,

filtering and washing the resulting raw rifaximin solid with the water/ethyl alcohol solvent mixture;

purifying the raw rifaximin by dissolution in ethyl alcohol;

precipitating rifaximin by addition of water, with between about 15% to about 70% to the weight amount of ethyl alcohol used for the dissolution at a temperature of from between about 50° C. to about 0° C. under stirring for between about 4 to about 36 hours;

filtering and washing a resulting solid with water; and

drying the rifaximin at a temperature of from between about room temperature to about 105° C.,

wherein the rifaximin Form α when free from other polymorphic forms of rifaximin has x-ray powder diffraction pattern peaks at about 7.4°; 19.7°; 21.0° and 22.1° 2-θ,

wherein the rifaximin Form β when free from other polymorphic forms of rifaximin has x-ray powder diffraction pattern peaks at about 5.4°; 9.0°; and 20.9° 2-θ, and

wherein the rifaximin Form γ when free from other polymorphic forms of rifaximin has x-ray powder diffraction pattern peaks at about 5.0°, 7.1°, and 8.4° 2-θ.

35. The process of claim 34 , wherein the drying is for between about 2 hours and about 72 hours; wherein the reacting of rifamycin O with an excess of 2-amino-4-methylpyridine is at a temperature of from between about 40° C. to about 60° C.;

wherein the purifying the raw rifaximin by dissolution in ethyl alcohol is at a temperature of from between about 45° C. to about 65° C.;

wherein the rifamycin O is reacted with between about 2.0 to about 3.5 molar equivalents of 2-amino-4-methylpyridine;

wherein the precipitating step further comprises lowering the temperature to between about 28° C. to about 32° C. to start crystallization and form a suspension; or

wherein the resulting suspension is kept at a temperature of from between about 40° C. to about 50° C. under stifling for a time from between about 6 to about 24 hours.

36. The process of claim 35 , further comprising,

cooling the suspension to about 0° C. for from between about 15 minutes and about one hour;

filtering the resulting solid; and

drying the solid to a water content of from between 0% and about 3.0% water to form rifaximin Form α.

37. The process of claim 34 , wherein the precipitating step further comprises:

cooling the solution to a temperature of from between about 28° C. to about 32° C.;

maintaining the solution at from between about 40° C. and about 50° C. under stifling for between about 6 to about 24 hours;

cooling the solution to about 0° C. for between about 15 minutes to about one hour;

filtering a resulting solid;

drying the solid from between about 4.5 to about 100% water content to form rifaximin Form β.

38. The process of claim 34 , wherein the precipitating step further comprises:

cooling the solution to a temperature of from between about 28° C. to about 32° C.;

cooling the solution to about 0° C., under stirring, for between about 6 to about 24 hours;

filtering a resulting solid; and

drying the solid to a water content of between about 1.0% and about 2.0% to form rifaximin Form γ.

39. The process of claim 34 , wherein the rifaximin Form α has a water content of less than 4.5%.

40. The process of claim 34 , wherein the rifaximin Form β has a water content of greater than or equal to 4.5%.

41. The method of claim 34 , wherein the rifaximin Form γ has a water content from about 0% to about 2%.

42. A process for the production of rifaximin O, comprising:

reacting an amount of rifamycin O with an excess of 2-amino-4-methylpyridine in a solvent mixture comprising water and ethyl alcohol to form a reaction mixture;

treating the reaction mixture with a solution of a weak acid, water, and alcohol to lower the pH of the solution to form a suspension;

filtering the suspension and washing the resulting solid with a water, alcohol, and solvent mixture to form raw rifaximin;

purifying the raw rifaximin by dissolution in an alcohol at a temperature between about 45° C. and about 65° C.;

precipitating the raw rifaximin by the addition of water;

lowering of the temperature of the suspension to between about 50° C. to about 0° C. under stirring to form a second suspension;

filtering the second suspension; and

washing a resulting solid with water and drying to obtain rifaximin O.

43. The process of claim 42 , wherein the rifamycin O is reacted with between about 2.0 to about 3.5 molar equivalents of 2-amino-4-methylpyridine;

wherein the reacting a solvent mixture comprising water and ethyl alcohol is in volumetric ratios from between about 1:1 to about 2:1; wherein the alcohol is one or more of ethyl alcohol, menthol, propanol, or 2-butanol; wherein the reacting a solvent mixture comprising water and ethyl alcohol is for a time from between about 2 to about 8 hours;

wherein the reacting a solvent mixture comprising water and alcohol is at a temperature from between about 40° C. to about 60° C.;

wherein the treating the reaction mixture is at about room temperature;

wherein the solution to treat the reaction mixture comprises a weak reducing agent in a mixture of water, alcohol and a strong acid;

wherein the weak acid is ascorbic acid;

wherein the strong acid is hydrochloric acid;

wherein when treating the reaction mixture the pH is lowered to about 2.0;

wherein the drying is by one or more of under vacuum, under conditions of normal pressure, or in the presence of a drying agent;

wherein the drying is at a temperature between about room temperature to about 105° C.;

wherein the drying is for a time from between about 2 to about 72 hours;

wherein the precipitating the rifaximin is by the addition of water in weight amounts of from between about 15% to about 70% of the weight amount of ethyl alcohol used for the reacting; or

wherein the second suspension is formed under stifling for a time from between about 4 to about 36 hours.

44. The process of claim 42 , wherein after the precipitation of raw rifaximin the method further comprises:

lowering the temperature to between about 28° C. to about 32° C.;

maintaining the temperature at between about 40° C. to about 50° C. under stirring for between about 6 to about 24 hours;

cooling to about 0° C. for between about 15 minutes to about one hour;

filtering a resulting solid; and

drying the resulting solid to a water content from between about 3.0% to 0% to form rifaximin Form α, wherein the rifaximin Form α has x-ray powder diffraction pattern peaks at about 7.4°; 19.7°; 21.0° and 22.1° 2-θ.

45. The process of claim 42 , wherein after the precipitation of raw rifaximin the method further comprises:

lowering the temperature to between about 28° C. to about 32° C.;

maintaining the temperature at between about 40° C. to about 50° C. under stifling for between about 6 to about 24 hours;

cooling to about 0° C. for between about 15 minutes and about one hour;

filtering a resulting solid; and

drying the solid to a water content greater than or equal to about 4.5% to form rifaximin Form β, wherein the rifaximin Form β has x-ray powder diffraction pattern peaks at about 5.4°; 9.0°; and 20.9° 2-θ.

46. The process of claim 42 , wherein after the precipitation of raw rifaximin the method further comprises:

lowering the temperature to between about 28° C. to about 32° C.;

cooling the temperature to about 0° C. under stifling for between about 6 to about 24 hours;

filtering a resulting solid; and

drying the solid to a water content of between about 1.0% to about 2.0% to form rifaximin Form γ, wherein the rifaximin Form γ has x-ray powder diffraction pattern peaks at about 5.0°, 7.1°, and 8.4° 2-θ.