Acceleration of Final Residual Solvent Extraction From Poly(lactide-co-glycolide) Microparticles

PURPOSE

The removal of the residual solvent dichloromethane from biodegradable poly(D,L-lactic-co-glycolic acid) (PLGA) microparticles was investigated by aqueous or alcoholic wet extraction or vacuum-drying.

METHODS

Microparticles were prepared by the O/W solvent extraction/evaporation method. The solidified microparticles were separated by filtration and the effect of subsequent drying and wet extraction methods were investigated. The residual solvent content was analysed with gas chromatography (organic solvents) and Karl Fischer titration (water). The effect of extraction conditions on microparticle aggregation, surface morphology and encapsulation of the drugs dexamethasone and risperidone was investigated.

RESULTS

Residual dichloromethane was reduced to 2.43% (w/w) (20 °C) or 0.03% (w/w) (35 °C) by aqueous wet extraction. With vacuum-drying, residual dichloromethane only decreased from about 5% (w/w) to 4.34% (w/w) (20 °C) or 3.20% (w/w) (35 °C) due to the lack of the plasticizing effect of water. Redispersion of filtered, wet microparticles in alcoholic media significantly improved the extraction due to an increased PLGA plasticization. The potential of different extractants was explained with the Gordon-Taylor equation and Hansen solubility parameters. Extraction in methanol: or ethanol:water mixtures reduced residual dichloromethane from 4 - 7% (w/w) to 0.5 - 2.3% (w/w) within 1 h and 0.08 - 0.18% (w/w) within 6 h. Higher alcohol contents and higher temperature resulted in aggregation of microparticles and lower drug loadings.

CONCLUSION

The final removal of residual dichloromethane was more efficient with alcoholic wet extraction followed by aqueous wet extraction at elevated temperature and vacuum drying of the microparticles.

Precise Control of the Surface and Internal Morphologies of Porous Particles Prepared Using a Spontaneous Emulsification Method

Porous particles with controllable surface and internal morphologies were successfully prepared by a "one-step mechanical emulsification" technique via the control of spontaneous emulsification where self-emulsification is followed by mechanical emulsification. The morphological changes in the porous particles were determined not by the preparation conditions of the water-in-oil-in-water (w/o/w) emulsion but by the proportion of solvents that favors the stabilization of the spontaneously prepared water-in-oil (w/o) emulsion droplets acting as porogens. The proposed method for controlling the morphology of the porous particles could be applied to all particle-preparation systems based on emulsion-solvent evaporation using organic solvents. The methodology for the morphological control of porous particles independent of the concentration or composition of the polymer is considered valuable for future investigations into the aerodynamic performance and drug-release behavior of biomedical porous particles with complex shapes.