Spray drying formulation of hollow spherical aggregates of silica nanoparticles by experimental design

Highly Drug-Loaded Nanoaggregate Microparticles for Pulmonary Delivery of Cyclosporin A

Introduction

Nanoparticles have the advantages of improving the solubility of poorly water-soluble drugs, facilitating the drug across biological barriers, and reducing macrophage phagocytosis in pulmonary drug delivery. However, nanoparticles have a small aerodynamic particle size, which makes it difficult to achieve optimal deposition when delivered directly to the lungs. Therefore, delivering nanoparticles to the lungs effectively has become a popular research topic.

Methods

Nanoaggregate microparticles were used as a pulmonary drug delivery strategy for the improvement of the bioavailability of cyclosporine A (CsA). The nanoaggregate microparticles were prepared with polyvinyl pyrrolidone (PVP) as the excipient by combining the anti-solvent method and spray drying process. The physicochemical properties, aerodynamic properties, in vivo pharmacokinetics and inhalation toxicity of nanoaggregate microparticles were systematically evaluated.

Results

The optimal nanoparticles exhibited mainly spherical shapes with the particle size and zeta potential of 180.52 nm and -19.8 mV. The nanoaggregate microparticles exhibited irregular shapes with the particle sizes of less than 1.6 µm and drug loading (DL) values higher than 70%. Formulation NM-2 as the optimal nanoaggregate microparticles was suitable for pulmonary drug delivery and probably deposited in the bronchiole and alveolar region, with FPF and MMAD values of 89.62% and 1.74 μm. In addition, inhaled NM-2 had C max and AUC0-∞ values approximately 1.7-fold and 1.8-fold higher than oral cyclosporine soft capsules (Neoral®). The inhalation toxicity study suggested that pulmonary delivery of NM-2 did not result in lung function damage, inflammatory responses, or tissue lesions.

Conclusion

The novel nanoaggregate microparticles for pulmonary drug delivery could effectively enhance the relative bioavailability of CsA and had great potential for clinical application.

Data-Driven Modeling of the Spray Drying Process. Process Monitoring and Prediction of the Particle Size in Pharmaceutical Production

Spray drying is used in the pharmaceutical industry for particle engineering of amorphous solid dispersions (ASDs). The particle size of the spray-dried (SD) powders is one of their key attributes due to its impact on the downstream processes and the drug product's functional properties. Offline and inline laser diffraction methods can be used to estimate the product's particle size; however, the final release of these ASDs is based on offline instruments. This paper presents a novel data-driven modeling approach for predicting the particle size of SD products. The model-based characterization of the process and the product's particle size, as a critical quality attribute, follows the quality by design principles. The resulting model can be used for online process monitoring, reducing the risks of out-of-specifications products and supporting their real-time release. A Tucker3 model is trained to capture and factorize the deterministic variability of the process. Subsequently, a partial least-squares regression model is calibrated to model the impact that variability in the input material properties, the process parameters, and the spray nozzle have on the products' particle size. This strategy has been calibrated and validated using large scale production data for two intermediate drug products under high sparsity of particle size data. Despite the challenges, high accuracy was obtained in predicting the median particle size (dv50) for release. The 99% confidence interval results in an error of maximum 2.5 μm, which is less than 10% of the allowed range of variation.

Engineering Inhalable Therapeutic Particles: Conventional and Emerging Approaches

Respirable particles are integral to effective inhalable therapeutic ingredient delivery, demanding precise engineering for optimal lung deposition and therapeutic efficacy. This review describes different physicochemical properties and their role in determining the aerodynamic performance and therapeutic efficacy of dry powder formulations. Furthermore, advances in top-down and bottom-up techniques in particle preparation, highlighting their roles in tailoring particle properties and optimizing therapeutic outcomes, are also presented. Practices adopted for particle engineering during the past 100 years indicate a significant transition in research and commercial interest in the strategies used, with several innovative concepts coming into play in the past decade. Accordingly, this article highlights futuristic particle engineering approaches such as electrospraying, inkjet printing, thin film freeze drying, and supercritical processes, including their prospects and associated challenges. With such technologies, it is possible to reshape inhaled therapeutic ingredient delivery, optimizing therapeutic benefits and improving the quality of life for patients with respiratory diseases and beyond.

Inhalable Nanoparticle-based Dry Powder Formulations for Respiratory Diseases: Challenges and Strategies for Translational Research

The emergence of novel respiratory infections (e.g., COVID-19) and expeditious development of nanoparticle-based COVID-19 vaccines have recently reignited considerable interest in designing inhalable nanoparticle-based drug delivery systems as next-generation respiratory therapeutics. Among various available devices in aerosol delivery, dry powder inhalers (DPIs) are preferable for delivery of nanoparticles due to their simplicity of use, high portability, and superior long-term stability. Despite research efforts devoted to developing inhaled nanoparticle-based DPI formulations, no such formulations have been approved to date, implying a research gap between bench and bedside. This review aims to address this gap by highlighting important yet often overlooked issues during pre-clinical development. We start with an overview and update on formulation and particle engineering strategies for fabricating inhalable nanoparticle-based dry powder formulations. An important but neglected aspect in in vitro characterization methodologies for linking the powder performance with their bio-fate is then discussed. Finally, the major challenges and strategies in their clinical translation are highlighted. We anticipate that focused research onto the existing knowledge gaps presented in this review would accelerate clinical applications of inhalable nanoparticle-based dry powders from a far-fetched fantasy to a reality.

Soft Spray: An Emerging Technique for Metal-Organic Framework-Based Materials

As an emerging type of microporous inorganic-organic hybrid material, metal-organic frameworks (MOFs) have become more and more universal in various application fields. Preparing high-performance MOF materials by a simple method has always been the pursuit of synthetic chemists and materials scientists. Recently, a new technique of so-called "soft spray", where the atomized droplets of one reactant solution are sprayed onto the surface of the other reactant solution at a slow speed, has been developed to fabricate MOF-based materials, such as nanoparticles, thin films, and hybrids. This Perspective aims at summarizing the latest research progress of the preparation of MOF-based materials by the soft spray technique, discussing the possible mechanism, highlighting its powerful controllability in the morphological structure, and exhibiting great promise as a simple, efficient, and scalable technique.

Formation of polymorphs and pores in small nanocrystalline iron oxide particles

A novel chemical vapor synthesis reactor design is used to control the pore-particle mesostructure and investigate the pore formation mechanism through the variation of residence time in oxygen. This enables the exploitation of the Kirkendall effect at the nanoscale to generate ultrasmall pores in small nanocrystalline iron oxide particles. Detailed structural characterization and quantitative data analysis of complementary high resolution transmission electron microscopy images, X-ray diffractograms, nitrogen sorption isotherms and X-ray absorption spectra provide a consistent comprehensive picture of the hollow nanoparticles from the local to the microstructure. The pore formation mechanism seems to play a key role for β-Fe₂O₃ polymorph formation.

Metal-Organic Framework Photonic Balls: Single Object Analysis for Local Thermal Probing

Due to their high porosity and chemical versatility, metal-organic frameworks (MOFs) exhibit physical properties appealing for photonic-based applications. While several MOF photonic structures have been reported, examples of applications thereof are mainly limited to chemical sensing. Herein, the range of application of photonic MOFs is extended to local thermal and photothermal sensing by integrating them into a new architecture: MOF photonic balls. Micrometric-sized photonic balls are made of monodispersed MOFs colloids that are self-assembled via spray-drying, a low-cost, green, and high-throughput method. The versatility of the process allows tuning the morphology and the composition of photonic balls made of several MOFs and composites with tailored optical properties. X-ray nanotomography and environmental hyperspectral microscopy enable analysis of single objects and their evolution in controlled atmosphere and temperature. Notably, in presence of vapors, the MOF photonic balls act as local, label-free temperature probes. Importantly, compared to other thermal probes, the temperature detection range of these materials can be adjusted "on-demand." As proof of concept, the photonic balls are used to determine local temperature profiles around a concentrated laser beam. More broadly, this work is expected to stimulate new research on the physical properties of photonic MOFs providing new possibilities for device fabrication.

Porous particles and novel carrier particles with enhanced penetration for efficient pulmonary delivery of antitubercular drugs

This study aimed to design dry powder inhaler formulations using a hydrophilic polymeric polysaccharide, phytoglycogen (PyG), as a multi-functional additive that increases the phagocytic activity of macrophage-like cells and enhances pulmonary delivery of drugs. The safety and usefulness of PyG were determined using in vitro cell-based studies. Dry powder inhaler formulations of an antitubercular drug, rifampicin, were fabricated by spray drying with PyG. The cytotoxicity, effects on phagocytosis, particle size, and morphology were evaluated. The aerosolization properties of the powder formulations were evaluated using an Andersen cascade impactor (ACI). Scanning electron microscope images of the particles on each ACI stage were captured to observe the deposition behavior. PyG showed no toxicity in A549, Calu-3, or RAW264.7 cell lines. At concentrations of 0.5 and 1 g/L, PyG facilitated the cellular uptake of latex beads and the expression of pro-inflammatory cytokine genes in RAW264.7 cells. Formulations with outstanding inhalation potential were produced. The fine particle fraction (aerodynamic size 2-7 µm) of the porous particle batch reached nearly 60%, whereas in the formulation containing wrinkled carrier particles, the extra-fine particle fraction (aerodynamic particle size < 2 μm) was 25.0% ± 1.7%. The deposition of porous and wrinkled particles on individual ACI stages was distinct. The inclusion of PyG dramatically improved the inhalation performance of porous and wrinkled powder formulations. These easily inhaled immunostimulatory carrier particles may advance the state of research by enhancing the therapeutic effect and alveolar delivery of antitubercular drugs.

Engineered mucoadhesive microparticles of formoterol/budesonide for pulmonary administration

In the present study, a multi-component system comprised of dipalmitylphospatidylcholine (DPPC), Chitosan, Lactose, and L-Leucine was developed for pulmonary delivery. Microparticles were engineered by the spray drying process and the selection of the critical parameters was performed by applying experimental design. The microcarriers with the appropriate size and yield were co-formulated with two active pharmaceutical ingredients (APIs), namely, Formoterol fumarate and Budesonide, and they were further investigated. All formulations exhibited spherical shape, appropriate aerodynamic performance, satisfying entrapment efficiency, and drug load. Their physicochemical properties were evaluated using Scanning Electron Microscopy (SEM), Fourier Transform Infrared Spectroscopy (FT-IR), and Differential Scanning Calorimetry (DSC). The aerodynamic particle size characterization was determined using an eight-stage Andersen cascade impactor, whereas the release of the actives was monitored in vitro in simulated lung fluid. Additional evaluation of the microparticles' mucoadhesive properties was performed by ζ-potential measurements and ex vivo mucoadhesion study applying a falling liquid film method using porcine lung tissue. Cytotoxicity and cellular uptake studies in Calu-3 lung epithelial cell line were conducted to further investigate the safety and efficacy of the developed formulations.

Hollow Silica Particles: A Novel Strategy for Cost Reduction

Thermal insulation materials are highly sought after for applications such as building envelopes, refrigerators, cryogenic fuel storage chambers, and water supply piping. However, current insulation materials either do not provide sufficient insulation or are costly. A new class of insulation materials, hollow silica particles, has attracted tremendous attention due to its potential to provide a very high degree of thermal insulation. However, current synthesis strategies provide hollow silica particles at very low yields and at high cost, thus, making the particles unsuitable for real-world applications. In the present work, a synthesis process that produces hollow silica particles at very high yields and at a lower cost is presented. The effect of an infrared heat absorber, carbon black, on the thermal conductivity of hollow silica particles is also investigated and it is inferred that a carbon black-hollow silica particle mixture can be a better insulating material than hollow silica particles alone.

Alloyed BiSb Nanoparticles Confined in Tremella-Like Carbon Microspheres for Ultralong-Life Potassium Ion Batteries

Bismuth-antimony alloy is considered as a promising potassium ion battery anode because of its combination of the high theoretical capacity of antimony and the excellent rate capacity of bismuth. However, the large volume change and sluggish reaction kinetic upon cycling have triggered severe capacity fading and poor rate performance. Herein, a nanoconfined BiSb in tremella-like carbon microspheres (BiSb@TCS) are delicately designed to address these issues. As-prepared BiSb@TCS renders an outstanding potassium-storage performance with a reversible capacity of 181 mAh g^-1 after ultralong 5700 cycles at a current density of 2 A g^-1 , and an excellent rate capacity of 119.3 mAh g^-1 at 6 A g^-1 . Such a superior performance can be ascribed to the delicate microstructure. The self-assembled carbon microspheres can strengthen integral structure and effectively accommodate the volume expansion of BiSb nanoparticles, and 2D carbon nanowalls in carbon microspheres can provide fast ion/electron diffusion dynamic. Theoretical calculation also suggests a thermodynamic feasibility of alloyed BiSb nanoparticles for storing potassium ion. Such a work shows that BiSb@TCS possesses a great potential to be a high-performance anode of potassium ion batteries. The rational designing of multiscaled structure would be instructive to the exploitation of other energy-storage materials.

Obtainment of the spray-dried extracts of Peperomia pellucida L. (H.B.K.) using different atomization temperatures: physicochemical characterization and technological development for pharmaceutical applications

Spray-dried extracts are prepared as powders or granules after solvent removal, which can be obtained in the presence or absence of pharmaceutical adjuvants. This work aimed to optimize the process of obtaining dried extracts of Peperomia pellucida L. (HBK) by spray drying. The characterization of the extract was performed by thermal analysis, specific surface area, particle size and high performance liquid chromatography (HPLC); then, capsules were developed for antimicrobial treatment, evaluating four bench lots by the determination of the angle of repose and time of flow, scanning electron microscopy, porosity and physicochemical quality control. There were no significant differences between the extracts obtained by spray drying at atomization temperatures of 140 °C, 160 °C and 180 °C, which was confirmed by thermal analysis. Specific surface area varied inversely with the mean particle size. Regarding the marker content by HPLC, no significant differences were found between the samples, although the flavonoid fraction was more stable at 160 °C. Bench lots (I to IV) were developed using the diluents Flowlac®, Starch® 1500, microcrystalline cellulose 250 and Cellactose® 80. Based on the results, the bench lot I, containing Flowlac®, was selected. The results of physicochemical quality control demonstrated that the selected formulation meets the pre-established parameters, and proving to be economically viable.

Spray drying as an advantageous strategy for enhancing pharmaceuticals bioavailability

Spray drying is an efficient technique that is used not only for rapid evaporation of the solvent from different systems but also for designing ultra-fine particles with various desirable characteristics. The obtained powders demonstrate reasonably narrow size distribution with a submicron-to-micron size range. It is one of the recent techniques applied to present acceptable solutions to enhance the absorption and bioavailability of some challenging drugs. In view of that, the purpose of this review is to shed some light on the wide variety of the recently developed fine particulate products that can be produced from spray-drying technique. This article reports the most outstanding advantages and challenges that could be overcome by exploiting the spray-drying technique for the production of different pharmaceuticals, including pure drug particles and drug-loaded polymeric carriers. The potential of this technique, whether used alone or in combination with other methods, in order to develop reproducible and scalable procedures for the best translation of bench-to-bedside innovation of pharmaceutical products is hereby discussed.

Hollow Silica Particles: Recent Progress and Future Perspectives

Hollow silica particles (or mesoporous hollow silica particles) are sought after for applications across several fields, including drug delivery, battery anodes, catalysis, thermal insulation, and functional coatings. Significant progress has been made in hollow silica particle synthesis and several new methods are being explored to use these particles in real-world applications. This review article presents a brief and critical discussion of synthesis strategies, characterization techniques, and current and possible future applications of these particles.

Spray Drying for the Preparation of Nanoparticle-Based Drug Formulations as Dry Powders for Inhalation

Nanoparticle-based therapeutics have been used in pulmonary formulations to enhance delivery of poorly water-soluble drugs, protect drugs against degradation and achieve modified release and drug targeting. This review focuses on the use of spray drying as a solidification technique to produce microparticles containing nanoparticles (i.e., nanoparticle (NP) agglomerates) with suitable properties as dry powders for inhalation. The review covers the general aspects of pulmonary drug delivery with emphasis on nanoparticle-based dry powders for inhalation and the principles of spray drying as a method for the conversion of nanosuspensions to microparticles. The production and therapeutic applications of the following types of NP agglomerates are presented: nanoporous microparticles, nanocrystalline agglomerates, lipid-based and polymeric formulations. The use of alternative spray-drying techniques, namely nano spray drying, and supercritical CO2-assisted spray drying is also discussed as a way to produce inhalable NP agglomerates.

Freeze-drying: A relevant unit operation in the manufacture of foods, nutritional products, and pharmaceuticals

Freeze-drying, a drying unit operation frequently used in food, pharmaceutical, and biopharmaceutical industries to prolong the shelf life of labile products, is an energy-intensive, time-consuming, and expensive process. Although all three steps (freezing, primary drying, and secondary drying) of freeze-drying are important, primary drying is the longest and most critical one. As sublimation during primary drying is mainly described in terms of heat and mass transfer, the present work provides extensive theoretical and experimental analyses of these processes. First, a detailed review of the current state-of-the art of freeze-drying, focusing on the drying stage, is given, which contributes to a fundamental understanding of the drying process. Second, a detailed experimental study of the drying section of the freeze-drying process is discussed, furnishing information on the relationship between input and output process parameters during the primary drying stage and thus aiding freeze-drying process design and optimization. In this regard, the influence of primary drying input parameters (i.e., shelf temperature and chamber pressure) and vial position on output parameters such as product temperature, sublimation rate, overall vial heat transfer coefficient, and resistance to mass transfer of the dried product are extensively discussed. For all combinations of shelf temperature and chamber pressure studied herein, the highest product temperature, sublimation rate, and overall vial heat transfer coefficient are observed in front edge vials, whereas the lowest values are observed in center vials. In general, the highest sublimation rate, at a given product temperature, is observed for low chamber pressure-high shelf temperature combinations.

Integration of Graphite and Silicon Anodes for the Commercialization of High-Energy Lithium-Ion Batteries

Silicon is considered a most promising anode material for overcoming the theoretical capacity limit of carbonaceous anodes. The use of nanomethods has led to significant progress being made with Si anodes to address the severe volume change during (de)lithiation. However, less progress has been made in the practical application of Si anodes in commercial lithium-ion batteries (LIBs). The drastic increase in the energy demands of diverse industries has led to the co-utilization of Si and graphite resurfacing as a commercially viable method for realizing high energy. Herein, we highlight the necessity for the co-utilization of graphite and Si for commercialization and discuss the development of graphite/Si anodes. Representative Si anodes used in graphite-blended electrodes are covered and a variety of strategies for building graphite/Si composites are organized according to their synthetic methods. The criteria for the co-utilization of graphite and Si are systematically presented. Finally, we provide suggestions for the commercialization of graphite/Si combinations.

Architecture and Preparation of Hollow Catalytic Devices

Since pioneering work done in the late 1990s, synthesis of functional hollow materials has experienced a rapid growth over the past two decades while their applications have been proven to be advantageous across many technological fields. In the field of heterogeneous catalysis, the development of micro- and nanoscale hollow materials as catalytic devices has also yielded promising results, because of their higher activity, stability, and selectivity. Herein, the architecture and preparation of these catalysts with tailorable composition and morphology are reviewed. First, synthesis of hollow materials is introduced according to the classification of template mediated, template free, and combined approaches. Second, different architectural designs of hollow catalytic devices, such as those without functionalization, with active components supported onto hollow materials, with active components incorporated within porous shells, and with active components confined within interior cavities, are evaluated respectively. The observed catalytic performances of this new class of catalysts are correlated to structural merits of individual configuration. Examples that demonstrate synthetic approaches and architected configurations are provided. Lastly, possible future directions are proposed to advance this type of hollow catalytic devices on the basis of our personal perspectives.

Global Sensitivity Analysis of a Spray Drying Process

Spray drying is a key unit operation used to achieve particulate products of required properties. Despite its widespread use, the product and process design, as well as the process control remain highly empirical and depend on trial and error experiments. Studying the effect of operational parameters experimentally is tedious, time consuming, and expensive. In this paper, we carry out a model-based global sensitivity analysis (GSA) of the process. Such an exercise allows us to quantify the impact of different process parameters, many of which interact with each other, on the product properties and conditions that have an impact on the functionality of the final drug product. Moreover, classical sensitivity analysis using the Sobol-based sensitivity indices was supplemented by a polynomial chaos-based sensitivity analysis, which proved to be an efficient method to reduce the computational cost of the GSA. The results obtained demonstrate the different response dependencies of the studied variables, which helps to identify possible control strategies that can result in major robustness for the spray drying process.

Synthesis and Characterization of Nanoscale Tungsten Particles with Hollow Superstructure Using Spray Drying Combined with Calcination Process

Nanoscale tungsten (W) powder is used in some special materials. In this study, a hollow superstructure W powder consisting of nanoparticles was synthesized by spray drying combined with two-step calcination from commercial (NH₄)₆W₇O₂₄·6H₂O. The high-pressure gas (HPG) was the significant factor in spray drying process, which affect the BET surface area and average particles size of the spray-dried powders. The detailed influences of calcined steps and calcination temperature in the microstructure and average particles size of final W particles were investigated. The size distribution of as-synthesized nanoscale W particles with hollow superstructure was from 40 to 200 nm, and the average size was about 100 nm. The as-synthesized W powder shows good sintering properties. It should be noted that the powder technology in this study can be used to synthesize other powders with high-performance requirements. .

Fabrication of MOF Thin Films at Miscible Liquid-Liquid Interface by Spray Method

Metal-organic frameworks (MOFs) are an intriguing class of porous crystalline inorganic-organic hybrid materials. The fabrication of oriented, crystalline thin film of MOFs is expected to open novel avenues to traditional applications and to serve myriad advanced technologies. Here, a facile spray-assisted miscible liquid-liquid interface (MLLI) synthetic strategy is carried out and reported under mild condition that utilizes miscible interface for the rapid and controllable fabrication of large-area free-standing MOF thin films. The methodology can employ various metal nodes and organic ligands to yield various high quality lamellar/granulous MOF thin films at MLLI, which indicates the universality of the MLLI strategy.

Electrohydrodynamic atomization and spray-drying for the production of pure drug nanocrystals and co-crystals

In recent years, nanotechnology has offered attractive opportunities to overcome the (bio)pharmaceutical drawbacks of most drugs such as low aqueous solubility and bioavailability. Among the numerous methodologies that have been applied to improve drug performance, a special emphasis has been made on those that increase the dissolution rate and the saturation solubility by the reduction of the particle size of pure drugs to the nanoscale and the associated increase of the specific surface area. Different top-down and bottom-up methods have been implemented, each one with its own pros and cons. Over the last years, the latter that rely on the dissolution of the drug in a proper solvent and its crystallization or co-crystallization by precipitation in an anti-solvent or, conversely, by solvent evaporation have gained remarkable impulse owing to the ability to adjust features such as size, size distribution, morphology and to control the amorphous/crystalline nature of the product. In this framework, electrohydrodynamic atomization (also called electrospraying) and spray-drying excel due to their simplicity and potential scalability. Moreover, they do not necessarily require suspension stabilizers and dry products are often produced during the formation of the nanoparticles what ensures physicochemical stability for longer times than liquid products. This review overviews the potential of these two technologies for the production of pure drug nanocrystals and co-crystals and discusses the recent technological advances and challenges for their implementation in pharmaceutical research and development.

Micelle-template synthesis of hollow silica spheres for improving water vapor permeability of waterborne polyurethane membrane

Hollow silica spheres (HSS) with special interior spaces, high specific surface area and excellent adsorption and permeability performance were synthesized via micelle-template method using cetyl trimethyl ammonium bromide (CTAB) micelles as soft template and tetraethoxysilane (TEOS) as silica precursor. SEM, TEM, FT-IR, XRD, DLS and BET-BJH were carried out to characterize the morphology and structure of as-obtained samples. The results demonstrated that the samples were amorphous with a hollow structure and huge specific surface area. The growth of HSS was an inward-growth mechanism along template. Notably, we have provided a new and interesting fundamental principle for HSS materials by precisely controlling the ethanol-to-water volume ratio. In addition, the as-obtained HSS were mixed with waterborne polyurethane (WPU) to prepare WPU/HSS composite membrane. Various characterizations (SEM, TEM, FT-IR and TGA) revealed the morphology, polydispersity and adherence between HSS and WPU. Performance tests showed that the introduction of HSS can improve the water vapor permeability of composite membrane, promoting its water resistance and mechanical performance at the same time.

Fabrication of Metal-Organic Framework and Infinite Coordination Polymer Nanosheets by the Spray Technique

We have developed a rapid and convenient method for fabricating metal-organic framework (MOF) and infinite coordination polymer (ICP) nanosheets by spraying the atomized solution of metal ions onto the organic ligand solution. Nanosheet formation could be attributed to the anisotropic diffusion of metal ions in the ligand solution, which may give rise to a lateral interface of metal ions and organic ligands, where the crystals tend to grow laterally in the form of nanosheets. Three kinds of Zn- and Cu-based MOF nanosheets and two kinds of Co-based ICP nanosheets have been successfully obtained by spraying under mild conditions. The two-dimensional structures of nanosheets with a nanometer thickness and a homogeneous size can be evidenced by scanning electron microscopy, atomic force microscopy, X-ray diffraction, Brunauer-Emmett-Teller, and Fourier transform infrared spectroscopy measurements. Furthermore, the fabricated ICP nanosheets have exhibited efficient catalytic performance for the conversion of CO₂ to high-value-added chemicals. This spray technique simplifies the nanosheet production process by industrialized means and enhances its controllability by the fast liquid-liquid interfacial fabrication, thus allowing access to the industrialized fabrication of MOF and ICP nanosheets.

Advantages and challenges of the spray-drying technology for the production of pure drug particles and drug-loaded polymeric carriers

Spray-drying is a rapid, continuous, cost-effective, reproducible and scalable process for the production of dry powders from a fluid material by atomization through an atomizer into a hot drying gas medium, usually air. Often spray-drying is considered only a dehydration process, though it also can be used for the encapsulation of hydrophilic and hydrophobic active compounds within different carriers without substantial thermal degradation, even of heat-sensitive substances due to fast drying (seconds or milliseconds) and relatively short exposure time to heat. The solid particles obtained present relatively narrow size distribution at the submicron-to-micron scale. Generally, the yield% of spray-drying at laboratory scale with conventional spray-dryers is not optimal (20-70%) due to the loss of product in the walls of the drying chamber and the low capacity of the cyclone to separate fine particles (<2 μm). Aiming to overcome this crucial drawback in early development stages, new devices that enable the production of submicron particles with high yield, even for small sample amounts, have been introduced into the market. This review describes the most outstanding advantages and challenges of the spray-drying method for the production of pure drug particles and drug-loaded polymeric particles and discusses the potential of this technique and the more advanced equipment to pave the way toward reproducible and scalable processes that are critical to the bench-to-bedside translation of innovative pharmaceutical products.

Formation of Highly Ordered Spherical Aggregates from Drying Microdroplets of Colloidal Suspension

The formation of highly ordered spherical aggregates of silica nanoparticles by the evaporation of single droplets of an aqueous colloidal suspension levitated (confined) in the electrodynamic quadrupole trap is reported. The transient and final structures formed during droplet evaporation have been deposited on a silicon substrate and then studied with SEM. Various successive stages of the evaporation-driven aggregation of nanoparticles have been identified: formation of the surface layer of nanoparticles, formation of the highly ordered spherical structure, collapse of the spherical surface layer leading to the formation of densely packed spherical aggregates, and rearrangement of the aggregate into the final structure of a stable 3D quasi-crystal. The evaporation-driven aggregation of submicrometer particles in spherical symmetry leads to sizes and morphologies of the transient and final structures significantly different than in the case of aggregation on a substrate. The numerical model presented in the article allows us to predict and visualize the observed aggregation stages and their dynamics and the final aggregates observed with SEM.

Tailored Crumpling and Unfolding of Spray-Dried Pristine Graphene and Graphene Oxide Sheets

For the first time, pristine graphene can be controllably crumpled and unfolded. The mechanism for graphene is radically different than that observed for graphene oxide; a multifaced crumpled, dimpled particle morphology is seen for pristine graphene in contrast to the wrinkled, compressed surface of graphene oxide particles, showing that surface chemistry dictates nanosheet interactions during the crumpling process. The process demonstrated here utilizes a spray-drying technique to produce droplets of aqueous graphene dispersions and induce crumpling through rapid droplet evaporation. For the first time, the gradual dimensional transition of 2D graphene nanosheets to a 3D crumpled morphology in droplets is directly observed; this is imaged by a novel sample collection device inside the spray dryer itself. The degree of folding can be tailored by altering the capillary forces on the dispersed sheets during evaporation. It is also shown that the morphology of redispersed crumpled graphene powder can be controlled by solvent selection. This process is scalable, with the ability to rapidly process graphene dispersions into powders suitable for a variety of engineering applications.

Preparation of porous carbon microspheres anode materials from fine needle coke powders for lithium-ion batteries

Fine carbon particles are granulated to porous carbon microspheres which show improved electrochemical properties as anode materials for lithium ion batteries.

Development of Budesonide Loaded Biopolymer Based Dry Powder Inhaler: Optimization, In Vitro Deposition, and Cytotoxicity Study

The progress in the development of DPI technology has boosted the use of sensitive drug molecules for lung diseases. However, delivery of these molecules from conventional DPI to the active site still poses a challenge with respect to deposition efficiency in the lung. At same time, serious systemic side effects of drugs have become a cause for concern. The developed budesonide loaded biopolymer based controlled release DPI had shown maximum in vitro lung deposition with least toxicity. The subject of present study, lactose-free budesonide loaded biopolymer based DPI, further corroborates the great potential of antiasthmatic drugs. This technology is expected to revolutionize the approaches towards enhanced therapeutic delivery of prospective drugs.