Preparation of Monodispersed Solid Lipid Microspheres Using a Microchannel Emulsification Technique

Monodisperse aqueous microspheres encapsulating high concentration of l-ascorbic acid: insights of preparation and stability evaluation from straight-through microchannel emulsification

Stabilization of l-ascorbic acid (l-AA) is a challenging task for food and pharmaceutical industries. The study was conducted to prepare monodisperse aqueous microspheres containing enhanced concentrations of l-AA by using microchannel emulsification (MCE). The asymmetric straight-through microchannel (MC) array used here constitutes 11 × 104 μm microslots connected to a 10 μm circular microholes. 5–30% (w/w) l-AA was added to a Milli-Q water solution containing 2% (w/w) sodium alginate and 1% (w/w) magnesium sulfate, while the continuous phase constitutes 5% (w/w) tetraglycerol condensed ricinoleate in water-saturated decane. Monodisperse aqueous microspheres with average diameters (dav) of 18.7–20.7 μm and coefficients of variation (CVs) below 6% were successfully prepared via MCE regardless of the l-AA concentrations applied. The collected microspheres were physically stable in terms of their dav and CV for >10 days of storage at 40°C. The aqueous microspheres exhibited l-AA encapsulation efficiency exceeding 70% during the storage.

A numerical study on the dynamics of droplet formation in a microfluidic double T-junction

In this study, droplet formations in microfluidic double T-junctions (MFDTD) are investigated based on a two-dimensional numerical model with volume of fluid method. Parametric ranges for generating alternating droplet formation (ADF) are identified. A physical background responsible for the ADF is suggested by analyzing the dynamical stability of flow system. Since the phase discrepancy between dispersed flows is mainly caused by non-symmetrical breaking of merging droplet, merging regime becomes the alternating regime at appropriate conditions. In addition, the effects of channel geometries on droplet formation are studied in terms of relative channel width. The predicted results show that the ADF region is shifted toward lower capillary numbers when channel width ratio is less than unity. The alternating droplet size increases with the increase of channel width ratio. When this ratio reaches unity, alternating droplets can be formed at very high water fraction (wf = 0.8). The droplet formation in MFDTD depends significantly on the viscosity ratio, and the droplet size in ADF decreases with the increase of the viscosity ratio. The understanding of underlying physics of the ADF phenomenon is useful for many applications, including nanoparticle synthesis with different concentrations, hydrogel bead generation, and cell transplantation in biomedical therapy.

Formulation characteristics of triacylglycerol oil-in-water emulsions loaded with ergocalciferol using microchannel emulsification

Food grade monodisperse O/W emulsions encapsulating ergocalciferol have been formulated using microchannel emulsification. The O/W emulsion droplets have an encapsulation efficiency of over 75% within the evaluated storage period.

Industrial lab-on-a-chip: design, applications and scale-up for drug discovery and delivery

Microfluidics is an emerging and promising interdisciplinary technology which offers powerful platforms for precise production of novel functional materials (e.g., emulsion droplets, microcapsules, and nanoparticles as drug delivery vehicles- and drug molecules) as well as high-throughput analyses (e.g., bioassays, detection, and diagnostics). In particular, multiphase microfluidics is a rapidly growing technology and has beneficial applications in various fields including biomedicals, chemicals, and foods. In this review, we first describe the fundamentals and latest developments in multiphase microfluidics for producing biocompatible materials that are precisely controlled in size, shape, internal morphology and composition. We next describe some microfluidic applications that synthesize drug molecules, handle biological substances and biological units, and imitate biological organs. We also highlight and discuss design, applications and scale up of droplet- and flow-based microfluidic devices used for drug discovery and delivery.

Dripping and jetting in microfluidic multiphase flows applied to particle and fiber synthesis

Dripping and jetting regimes in microfluidic multiphase flows have been investigated extensively, and this review summarizes the main observations and physical understandings in this field to date for three common device geometries: coaxial, flow-focusing and T-junction. The format of the presentation allows for simple and direct comparison of the different conditions for drop and jet formation, as well as the relative ease and utility of forming either drops or jets among the three geometries. The emphasis is on the use of drops and jets as templates for microparticle and microfiber syntheses, and a description is given of the more common methods of solidification and strategies for achieving complex multicomponent microparticles and microfibers.

Uniform polymer microspheres: monodispersity criteria, methods of formation and applications

For many applications, polymer microspheres (MS) should possess a monodisperse size distribution. With such uniformity they are able to deliver precise amounts of drug per MS, optimize the release kinetics of an encapsulated drug, obtain repeatable in vivo biodistributions to different organs and tissues, and obtain the maximum protection of (protein) drugs from degradation. This review classifies monodisperse polymer MS according to their methods of production and gives examples of the formation of uniform MS and their applications in the medical field. In the literature, the term ‘monodisperse’ is often used inaccurately, and this article attempts to rectify this by clearly defining monodispersity in terms of the coefficient of variation and the polydispersity index, the two statistical quantities most frequently used to describe the size distribution of MS.

Microfluidics for food, agriculture and biosystems industries

Microfluidics, a rapidly emerging enabling technology has the potential to revolutionize food, agriculture and biosystems industries. Examples of potential applications of microfluidics in food industry include nano-particle encapsulation of fish oil, monitoring pathogens and toxins in food and water supplies, micro-nano-filtration for improving food quality, detection of antibiotics in dairy food products, and generation of novel food structures. In addition, microfluidics enables applications in agriculture and animal sciences such as nutrients monitoring and plant cells sorting for improving crop quality and production, effective delivery of biopesticides, simplified in vitro fertilization for animal breeding, animal health monitoring, vaccination and therapeutics. Lastly, microfluidics provides new approaches for bioenergy research. This paper synthesizes information of selected microfluidics-based applications for food, agriculture and biosystems industries.

Preparation of uniform-sized multiple emulsions and micro/nano particulates for drug delivery by membrane emulsification

Much attention has in recent years been paid to fine applications of drug delivery systems, such as multiple emulsions, micro/nano solid lipid and polymer particles (spheres or capsules). Precise control of particle size and size distribution is especially important in such fine applications. Membrane emulsification can be used to prepare uniform-sized multiple emulsions and micro/nano particulates for drug delivery. It is a promising technique because of the better control of size and size distribution, the mildness of the process, the low energy consumption, easy operation and simple equipment, and amendable for large scale production. This review describes the state of the art of membrane emulsification in the preparation of monodisperse multiple emulsions and micro/nano particulates for drug delivery in recent years. The principles, influence of process parameters, advantages and disadvantages, and applications in preparing different types of drug delivery systems are reviewed. It can be concluded that the membrane emulsification technique in preparing emulsion/particulate products for drug delivery will further expand in the near future in conjunction with more basic investigations on this technique.

Parallelized edge-based droplet generation (EDGE) devices

We here report on three parallelized designs of the new edge-based droplet generation mechanism, which, unlike existing mechanisms, produces many equally sized droplets simultaneously at a single droplet formation unit. Operation of the scaled-out systems is straight forward; only the oil inlet pressure has to be controlled to let all the units produce oil droplets, given certain basic design constraints. For systems with a typical nozzle depth of 1.2 microm, the mean droplet diameter is 7.5 microm and the coefficient of variation is below 10%. The number of droplets that is formed per unit can easily be increased by increasing the length of the unit. The stable pressure range in which monodisperse droplets are formed can be extended by small adjustments to the design. Overall, the EDGE devices are simple in design and robust in use, making them suitable for massive outscaling.

Tuning curvature in flow lithography: a new class of concave/convex particles

Polymeric particles of complex shapes and chemistry have been used for a wide variety of applications in the materials and bioengineering fields. An interesting means of introducing complexity is through curvature. In this work, stop-flow lithography is used to generate concave/convex particles at high throughputs of 3x10(4) particles/h. These particles have finely tuned curvature in the plane orthogonal to the plane of projection of light. The shape in the plane of projection of light is determined by the mask shape. The chemical programmability of this technique is further demonstrated by creating multifunctional particles, i.e., patchy and capped particles. The directed assembly of these particles can find potential application in a variety of fields like biology, photonics, and liquid crystals.

Microfluidic generation of microgels from synthetic and natural polymers

In this tutorial review we discuss recent advances in the application of microfluidics for the generation of microgels from synthetic and biological polymers. We summarize advantages and drawbacks of the current methods used in microfluidic synthesis and assembly of polymer microgels. Continuous microfluidic encapsulation of cells is discussed as an exemplary application of the microgels. The article is finalized with a perspective on future research in the field. The article will be of interest to chemists, cell biologists, pharmacologists, and medicinal chemists.

Characterization of emulsification at flat microchannel Y junctions

Y junctions with a large width-to-depth ratio were used for the emulsification of hexadecane in various ethanol-water mixtures with different static interfacial tension and viscosity. The resulting droplets were monodisperse. To describe droplet size a force-balance model was derived and was found to apply well. The model shows that the droplet size scales with the channel depth, and with the square root of the inverse capillary number (Ca-1/2) based on the continuous phase, the disperse-phase flow rate was found to be unimportant.

Gas-liquid two-phase flow patterns in rectangular polymeric microchannels: effect of surface wetting properties

Here we map gas-liquid two-phase flow regimes observed in polymeric microchannels with different wetting properties. We utilized video and confocal microscopy to examine two-phase flow patterns produced by parallel injection of air and water through a Y-shaped junction into a rectangular microchannel made of poly(dimethylsiloxane) (PDMS). We observed seven flow regimes in microchannels with hydrophobic walls, whereas only two flow patterns were identified in hydrophilic microchannels. Our study demonstrates that surface wettability has a profound influence on the spatial distribution of air and water moving in microchannels.

Microchannel emulsification: from computational fluid dynamics to predictive analytical model

Emulsion droplet formation was investigated in terrace-based microchannel systems that generate droplets through spontaneous Laplace pressure driven snap-off. The droplet formation mechanism was investigated through high-speed imaging and computational fluid dynamics (CFD) simulation, and we found good agreement in the overall shape of the phases during droplet formation. An analytical model was derived from the insights that were gained from the CFD simulations, which describes the droplet diameter as a function of applied pressure. The analytical model covers the influence of both process parameters and geometry of the terrace well and can be used for fast optimization and evaluation studies.

Continuous and size-dependent sorting of emulsion droplets using hydrodynamics in pinched microchannels

In this report, a microfluidic system is presented for continuous and size-dependent separation of droplets utilizing microscale hydrodynamics. The separation scheme is based on laminar-flow focusing and spreading in a pinched microchannel, referred to as "pinched flow fractionation (PFF)", which was previously developed for the size-dependent separation of solid particles, such as polymer microparticles or cells. By simply introducing emulsion and the continuous phase into a microchannel, continuous separation could be achieved without using complicated operations or devices. We first examined whether this scheme could be applied for droplets, by using a pinched microchannel with one outlet, and observed the behaviors of monodisperse droplets generated at the upstream T-junction. Analysis via high-speed imaging revealed that the length of the pinched segment is critical for precise separation of droplets. Then, separation of a polydisperse oil-in-water emulsion that was prepared previously was demonstrated using a microfluidic device equipped with multiple outlets. These results showed the ability of the presented system to sort or select specific-sized droplets easily and accurately, which would be difficult to achieve using normal-scale schemes, such as centrifugation or filtration.

Stop-flow lithography in a microfluidic device

Polymeric particles in custom designed geometries and with tunable chemical anisotropy are expected to enable a variety of new technologies in diverse areas such as photonics, diagnostics and functional materials. We present a simple, high throughput and high resolution microfluidic method to synthesize such polymeric particles. Building off earlier work that we have done on continuous flow lithography (CFL) (D. Dendukuri, D. C. Pregibon, J. Collins, T. A. Hatton, P. S. Doyle, Nat. Mater., 2006, 5, 365-369; ref. 1), we have devised and implemented a new setup that uses compressed air driven flows in preference to syringe pumps to synthesize particles using a technique that we call stop-flow lithography (SFL). A flowing stream of oligomer is stopped before polymerizing an array of particles into it, providing for much improved resolution over particles synthesized in flow. The formed particles are then flushed out at high flow rates before the cycle of stop-polymerize-flow is repeated. The high flow rates enable orders-of-magnitude improvements in particle throughput over CFL. However, the deformation of the PDMS elastomer due to the imposed pressure restricts how quickly the flow can be stopped before each polymerization event. We have developed a simple model that captures the dependence of the time required to stop the flow on geometric parameters such as the height, length and width of the microchannel, as well as on the externally imposed pressure. Further, we show that SFL proves to be superior to CFL even for the synthesis of chemically anisotropic particles with sharp interfaces between distinct sections.

Electrokinetic flow in an elliptic microchannel covered by ion-penetrable membrane

The electrokinetic flow of an electrolyte solution in an elliptical microchannel covered by an ion-penetrable, charged membrane layer is examined theoretically. The present analysis extends previous results in that a two-dimensional problem is considered, and the system under consideration simulates the flow of a fluid, for example, in a microchannel of biological nature such as vein. The electroosmostic volumetric flow rate, the total electric current, the streaming potential, and the electroviscous effect of the system under consideration are evaluated. We show that, for a constant hydraulic diameter, the variations of these quantities as a function of the aspect ratio of a microchannel may have a local minimum or a local maximum at a medium level of ionic strength, which depends on the thickness of the membrane layer. For a constant cross-sectional area, the electroosmostic volumetric flow rate, the total electric current, and the streaming potential increase monotonically with the increase in the aspect ratio, but the reverse is true for the electroviscous effect.

Multiphase microfluidics: from flow characteristics to chemical and materials synthesis

We review transport characteristics of pressure-driven, multiphase flows through microchannel networks tens of nanometres to several hundred of micrometres wide with emphasis on conditions resulting in enhanced mixing and reduced axial dispersion. Dimensionless scaling parameters useful in characterizing multiphase flows are summarized along with experimental flow visualization techniques. Static and dynamic stability considerations are also included along with methods for stabilizing multiphase flows through surface modifications. Observed gas-liquid and immiscible liquid-liquid flows are summarized in terms of flow regime diagrams and the different flows are related to applications in chemistry and materials synthesis. Means to completely separate multiphase flows on the microscale and guidelines for design of scalable multiphase systems are also discussed.

Reactions in droplets in microfluidic channels

Fundamental and applied research in chemistry and biology benefits from opportunities provided by droplet-based microfluidic systems. These systems enable the miniaturization of reactions by compartmentalizing reactions in droplets of femoliter to microliter volumes. Compartmentalization in droplets provides rapid mixing of reagents, control of the timing of reactions on timescales from milliseconds to months, control of interfacial properties, and the ability to synthesize and transport solid reagents and products. Droplet-based microfluidics can help to enhance and accelerate chemical and biochemical screening, protein crystallization, enzymatic kinetics, and assays. Moreover, the control provided by droplets in microfluidic devices can lead to new scientific methods and insights.

Continuous-flow lithography for high-throughput microparticle synthesis

Precisely shaped polymeric particles and structures are widely used for applications in photonic materials, MEMS, biomaterials and self-assembly. Current approaches for particle synthesis are either batch processes or flow-through microfluidic schemes that are based on two-phase systems, limiting the throughput, shape and functionality of the particles. We report a one-phase method that combines the advantages of microscope projection photolithography and microfluidics to continuously form morphologically complex or multifunctional particles down to the colloidal length scale. Exploiting the inhibition of free-radical polymerization near PDMS surfaces, we are able to repeatedly pattern and flow rows of particles in less than 0.1 s, affording a throughput of near 100 particles per second using the simplest of device designs. Polymerization was also carried out across laminar, co-flowing streams to generate Janus particles containing different chemistries, whose relative proportions could be easily tuned. This new high-throughput technique offers unprecedented control over particle size, shape and anisotropy.

Lattice Boltzmann simulations of droplet formation in a T-shaped microchannel

We investigated the formation of a droplet from a single pore in a glass chip, which is a model system for droplet formation in membrane emulsification. Droplet formation was simulated with the lattice Boltzmann method, a method suitable for modeling on the mesoscale. We validated the lattice Boltzmann code with several benchmarks such as the flow profile in a rectangular channel, droplet deformation between two shearing plates, and a sessile drop on a plate with different wetting conditions. In all cases, the modeling results were in good agreement with the benchmark. A comparison of experimental droplet formation in a microchannel glass chip showed good quantitative agreement with the modeling results. With this code, droplet formation simulations with various interfacial tensions and various flow rates were performed. All resulting droplet sizes could be correlated quantitatively with the capillary number and the fluxes in the system.