Process for making drug crystals of desired size distribution and morphology

A process for providing crystals of fluticasone propionate of desired size distribution and morphology, the process comprising:

• providing recrystallized columnar crystals of fluticasone propionate having aspect ratios of larger than 1 and less than 20, the aspect ratio of each recrystallized columnar crystal being the ratio of a longest dimension along a lengthwise axis relative to a shortest dimension of a transverse plane perpendicular to the lengthwise axis, wherein at least 90% by mass of the recrystallized columnar crystals have the shortest dimensions in the range of 50-250 microns;
• and
• sizing the recrystallized columnar crystals to provide a collection of sized crystals having target dimensions, wherein, no more than 10% of the collection of the sized crystals by mass are less than 30 microns, wherein the sizing includes segmenting at least a portion of the recrystallized columnar crystals along the respective lengthwise axes while retaining the dimensions of the transverse plane perpendicular to the lengthwise axis.