The disaster I never imagined having to worry about

Retonavir transformed into a more stable crystal form (polymorph two) that did not dissolve properly, halting production and making the drug ineffective. This change was initially unpredictable and hard to detect.

Chocolate's texture and snap depend on the specific crystal form of cocoa butter. Melting and cooling chocolate incorrectly can result in dull, unstable forms, similar to how Retonavir changed crystal structures.

Tin pest is a phenomenon where tin transforms into a different, less dense crystalline form at low temperatures, causing it to crumble and spread. This mirrors how the unstable Retonavir polymorph could 'seed' and transform entire batches.

The new stable form of Retonavir had a much deeper energy well, making it virtually impossible to revert to the original less stable form through heating or cooling, much like a ball rolling into a very deep valley.

The event highlighted the unpredictability of polymorphism, leading to increased regulatory and scientific focus on screening for different crystal forms, though complete prevention remains challenging.

Yes, over half of all known compounds are polymorphic, and it's possible for other drugs to undergo similar transformations. While rare, it poses a significant risk to drug availability and patient safety.