Complex Emulsions as an Innovative Pharmaceutical Dosage form in Addressing the Issues of Multi-Drug Therapy and Polypharmacy Challenges

This review explores the intersection of microfluidic technology and complex emulsion development as a promising solution to the challenges of formulations in multi-drug therapy (MDT) and polypharmacy. The convergence of microfluidic technology and complex emulsion fabrication could herald a transformative era in multi-drug delivery systems, directly confronting the prevalent challenges of polypharmacy. Microfluidics, with its unparalleled precision in droplet formation, empowers the encapsulation of multiple drugs within singular emulsion particles. The ability to engineer emulsions with tailored properties-such as size, composition, and release kinetics-enables the creation of highly efficient drug delivery vehicles. Thus, this innovative approach not only simplifies medication regimens by significantly reducing the number of necessary doses but also minimizes the pill burden and associated treatment termination-issues associated with polypharmacy. It is important to bring forth the opportunities and challenges of this synergy between microfluidic-driven complex emulsions and multi-drug therapy poses. Together, they not only offer a sophisticated method for addressing the intricacies of delivering multiple drugs but also align with broader healthcare objectives of enhancing treatment outcomes, patient safety, and quality of life, underscoring the importance of dosage form innovations in tackling the multifaceted challenges of modern pharmacotherapy.

Demulsification of Silica Stabilized Pickering Emulsions Using Surface Freezing Transition of CTAC Adsorbed Films at the Tetradecane-Water Interface

The adsorbed film of cetyltrimethylammonium chloride (CTAC) at the tetradecane (C14) - water interface undergoes a first-order surface transition from two-dimensional liquid to solid states upon cooling. In this paper, we utilized this surface freezing transition to realize a spontaneous demulsification of Pickering emulsions stabilized by silica particles. In the temperature range above the surface freezing transition, the interfacial tension of silica laden oil-water interface was lower than CTAC adsorbed film, hence, stable Pickering emulsion was obtained by vortex mixing. However, the interfacial tension of CTAC adsorbed film decreased rapidly below the surface freezing temperature and became lower than the silica laden interface. The reversal of the interfacial tensions between silica laden and CTAC adsorbed films gave rise to Pickering emulsion demulsification by the desorption of silica particles from the oil-water interface. The exchange of silica particles and CTAC at the surface of emulsion droplets was also confirmed experimentally by using phase modulation ellipsometry at the oil-water interface.

Orthogonal Gelations to Synthesize Core-Shell Hydrogels Loaded with Nanoemulsion-Templated Drug Nanoparticles for Versatile Oral Drug Delivery

Hydrophobic active pharmaceutical ingredients (APIs) are ubiquitous in the drug development pipeline, but their poor bioavailability often prevents their translation into drug products. Industrial processes to formulate hydrophobic APIs are expensive, difficult to optimize, and not flexible enough to incorporate customizable drug release profiles into drug products. Here, a novel, dual-responsive gelation process that exploits orthogonal thermo-responsive and ion-responsive gelations is introduced. This one-step "dual gelation" synthesizes core-shell (methylcellulose-alginate) hydrogel particles and encapsulates drug-laden nanoemulsions in the hydrogel matrices. In situ crystallization templates drug nanocrystals inside the polymeric core, while a kinetically stable amorphous solid dispersion is templated in the shell. Drug release is explored as a function of particle geometry, and programmable release is demonstrated for various therapeutic applications including delayed pulsatile release and sequential release of a model fixed-dose combination drug product of ibuprofen and fenofibrate. Independent control over drug loading between the shell and the core is demonstrated. This formulation approach is shown to be a flexible process to develop drug products with biocompatible materials, facile synthesis, and precise drug release performance. This work suggests and applies a novel method to leverage orthogonal gel chemistries to generate functional core-shell hydrogel particles.

On the Mechanism and Kinetics of Synthesizing Polymer Nanogels by Ionizing Radiation-Induced Intramolecular Crosslinking of Macromolecules

Nanogels-internally crosslinked macromolecules-have a growing palette of potential applications, including as drug, gene or radioisotope nanocarriers and as in vivo signaling molecules in modern diagnostics and therapy. This has triggered considerable interest in developing new methods for their synthesis. The procedure based on intramolecular crosslinking of polymer radicals generated by pulses of ionizing radiation has many advantages. The substrates needed are usually simple biocompatible polymers and water. This eliminates the use of monomers, chemical crosslinking agents, initiators, surfactants, etc., thus limiting potential problems with the biocompatibility of products. This review summarizes the basics of this method, providing background information on relevant aspects of polymer solution thermodynamics, radiolysis of aqueous solutions, generation and reactions of polymer radicals, and the non-trivial kinetics and mechanism of crosslinking, focusing on the main factors influencing the outcomes of the radiation synthesis of nanogels: molecular weight of the starting polymer, its concentration, irradiation mode, absorbed dose of ionizing radiation and temperature. The most important techniques used to perform the synthesis, to study the kinetics and mechanism of the involved reactions, and to assess the physicochemical properties of the formed nanogels are presented. Two select important cases, the synthesis of nanogels based on polyvinylpyrrolidone (PVP) and/or poly(acrylic acid) (PAA), are discussed in more detail. Examples of recent application studies on radiation-synthesized PVP and PAA nanogels in transporting drugs across the blood-brain barrier and as targeted radioisotope carriers in nanoradiotherapy are briefly described.

Surface Freezing of Cetyltrimethylammonium Chloride-Hexadecanol Mixed Adsorbed Film at Dodecane-Water Interface

The surface freezing transition of a mixed adsorbed film containing cetyltrimethylammonium chloride (CTAC) and n-hexadecanol (C16OH) was utilized at the dodecane-water interface to control the stability of oil-in-water (O/W) emulsions. The corresponding surface frozen and surface liquid mixed adsorbed films were characterized using interfacial tensiometry and X-ray reflectometry. The emulsion samples prepared in the temperature range of the surface frozen and surface liquid phases showed a clear difference in their stability: the emulsion volume decreased continuously right after the emulsification in the surface liquid region, while it remained constant or decreased at a much slower rate in the surface frozen region. Compared to the previously examined CTAC-tetradecane mixed adsorbed film, the surface freezing temperature increased from 9.5 to 25.0 °C due to the better chain matching between CTAC and C16OH and higher surface activity of C16OH. This then renders such systems much more attractive for practical applications.

Nanoemulsion-Loaded Capsules for Controlled Delivery of Lipophilic Active Ingredients

Nanoemulsions have become ideal candidates for loading hydrophobic active ingredients and enhancing their bioavailability in the pharmaceutical, food, and cosmetic industries. However, the lack of versatile carrier platforms for nanoemulsions hinders advanced control over their release behavior. In this work, a method is developed to encapsulate nanoemulsions in alginate capsules for the controlled delivery of lipophilic active ingredients. Functional nanoemulsions loaded with active ingredients and calcium ions are first prepared, followed by encapsulation inside alginate shells. The intrinsically high viscosity of the nanoemulsions ensures the formation of spherical capsules and high encapsulation efficiency during the synthesis. Moreover, a facile approach is developed to measure the nanoemulsion release profile from capsules through UV-vis measurement without an additional extraction step. A quantitative analysis of the release profiles shows that the capsule systems possess a tunable, delayed-burst release. The encapsulation methodology is generalized to other active ingredients, oil phases, nanodroplet sizes, and chemically crosslinked inner hydrogel cores. Overall, the capsule systems provide promising platforms for various functional nanoemulsion formulations.

Microgels of silylated HPMC as a multimodal system for drug co-encapsulation

Combined therapy is a global strategy developed to prevent drug resistance in cancer and infectious diseases. In this field, there is a need of multifunctional drug delivery systems able to co-encapsulate small drug molecules, peptides, proteins, associated to targeting functions, nanoparticles. Silylated hydrogels are alkoxysilane hybrid polymers that can be engaged in a sol-gel process, providing chemical cross linking in physiological conditions, and functionalized biocompatible hybrid materials. In the present work, microgels were prepared with silylated (hydroxypropyl)methyl cellulose (Si-HPMC) that was chemically cross linked in soft conditions of pH and temperature. They were prepared by an emulsion templating process, water in oil (W/O), as microreactors where the condensation reaction took place. The ability to functionalize the microgels, so-called FMGs, in a one-pot process, was evaluated by grafting a silylated hydrophilic model drug, fluorescein (Si-Fluor), using the same reaction of condensation. Biphasic microgels (BPMGs) were prepared to evaluate their potential to encapsulate lipophilic model drug (Nile red). They were composed of two separate compartments, one oily phase (sesame oil) trapped in the cross linked Si-HPMC hydrophilic phase. The FMGs and BPMGs were characterized by different microscopic techniques (optic, epi-fluorescence, Confocal Laser Scanning Microscopy and scanning electronic microscopy), the mechanical properties were monitored using nano indentation by Atomic Force Microscopy (AFM), and different preliminary tests were performed to evaluate their chemical and physical stability. Finally, it was demonstrated that it is possible to co-encapsulate both hydrophilic and hydrophobic drugs, in silylated microgels, that were physically and chemically stable. They were obtained by chemical cross linking in soft conditions, and without surfactant addition during the emulsification process. The amount of drug loaded was in favor of further biological activity. Mechanical stimulations should be necessary to trigger drug release.

Microfluidic-assisted fabrication of carriers for controlled drug delivery

The microfluidic technique has brought unique opportunities toward the full control over the production processes for drug delivery carriers, owing to the miniaturisation of the fluidic environment. In comparison to the conventional batch methods, the microfluidic setup provides a range of advantages, including the improved controllability of material characteristics, as well as the precisely controlled release profiles of payloads. This review gives an overview of different fluidic principles used in the literature to produce either polymeric microparticles or nanoparticles, focusing on the materials that could have an impact on drug delivery. We also discuss the relations between the particle size and size distribution of the obtained carriers, and the design and configuration of the microfluidic setups. Overall, the use of microfluidic technologies brings exciting opportunities to expand the body of knowledge in the field of controlled drug delivery and great potential to clinical translation of drug delivery systems.

Oil-in-microgel strategy for enzymatic-triggered release of hydrophobic drugs

Polymer microgels have received considerable attention due to their great potential in the biomedical field as drug delivery systems. Hyaluronic acid (HA) is a naturally occurring glycosaminoglycan composed of N-acetyl-d-glucosamine and d-glucuronic acid. This polymer is biodegradable, nontoxic, and can be chemically modified. In this work, a co-flow microfluidic strategy for the preparation of biodegradable HA microgels encapsulating hydrophobic drugs is presented. The approach relies on: (i) generation of a primary oil-in-water (O/W) nanoemulsion by the ultrasonication method, (ii) formation of a double oil-in-water-in-oil emulsion (O/W/O) using microfluidics, and (iii) cross-linking of microgels by photopolymerization of HA precursors modified with methacrylate groups (HA-MA) present in the aqueous phase of the droplets. The procedure is used for the encapsulation and controlled release of progesterone. Degradability and encapsulation/release studies in PBS buffer at 37°C in presence of different concentrations of hyaluronidase are performed. It is demonstrated that enzymatic degradation can be used to trigger the release of progesterone from microgels. This method provides precise control of the release system and can be applied for the encapsulation and controlled release of different types of hydrophobic drugs.

Multifunctional microspherical magnetic and pH responsive carriers for combination anticancer therapy engineered by droplet-based microfluidics

Drug loaded luminescent porous silicon diatoms and magnetic bacterial nanowires were encapsulated within pH sensitive polymer forming biodegradable microcapsules using droplet-based microfluidics for targeting colorectal cancer.

Core-Shell Composite Hydrogels for Controlled Nanocrystal Formation and Release of Hydrophobic Active Pharmaceutical Ingredients

Although roughly 40% of pharmaceuticals being developed are poorly water soluble, this class of drugs lacks a formulation strategy capable of producing high loads, fast dissolution kinetics, and low energy input. In this work, a novel bottom-up approach is developed for producing and formulating nanocrystals of poorly water-soluble active pharmaceutical ingredients (APIs) using core-shell composite hydrogel beads. Organic phase nanoemulsion droplets stabilized by polyvinyl alcohol (PVA) and containing a model hydrophobic API (fenofibrate) are embedded in the alginate hydrogel matrix and subsequently act as crystallization reactors. Controlled evaporation of this composite material produces core-shell structured alginate-PVA hydrogels with drug nanocrystals (500-650 nm) embedded within the core. Adjustable loading of API nanocrystals up to 83% by weight is achieved with dissolution (of 80% of the drug) occurring in as little as 30 min. A quantitative model is also developed and experimentally validated that the drug release patterns of the fenofibrate nanocrystals can be modulated by controlling the thickness of the PVA shell and drug loading. Thus, these composite materials offer a "designer" drug delivery system. Overall, our approach enables a novel means of simultaneous controlled crystallization and formulation of hydrophobic drugs that circumvents energy intensive top-down processes in traditional manufacturing.

Blending of reactive prepolymers to control the morphology and polarity of polyglycidol based microgels

The compartmentalization of microgels is a challenging task for synthetic polymer chemistry. Although the complexation with low molecular weight compounds or the use of microfluidic techniques offer attractive possibilities for other length scales, it is difficult to implement compartments in the mesoscale range of 10-100 nm. Herein we show how simple blending of reactive prepolymers is suitable to design new microgel morphologies with tailored compartments. We use poly(EEGE)-block-poly(AGE) as crosslinkable, pro-hydrophilic prepolymer in blends with varying amounts of crosslinkable, yet hydrophobic poly(THF-stat-AllylEHO) or inert and hydrophobic polystyrene, and crosslink the allyl functional prepolymer(s) in a thiol-ene click-type reaction after miniemulsification. Our strategy shows how arrested versus free nanophase separation can be used to control easily the morphology and polarity of microgel particles.

Microfluidics for Advanced Drug Delivery Systems

Considerable efforts have been devoted towards developing effective drug delivery methods. Microfluidic systems, with their capability for precise handling and transport of small liquid quantities, have emerged as a promising platform for designing advanced drug delivery systems. Thus, microfluidic systems have been increasingly used for fabrication of drug carriers or direct drug delivery to a targeted tissue. In this review, the recent advances in these areas are critically reviewed and the shortcomings and opportunities are discussed. In addition, we highlight the efforts towards developing smart drug delivery platforms with integrated sensing and drug delivery components.

Stimulus-responsive polymers and other functional polymer surfaces as components in glass microfluidic channels

The integration of smart stimulus-responsive polymers as functional elements within microfluidic devices has greatly improved the performance capabilities of controlled fluid delivery. For their use as actuators in microfluidic systems, reversible expansion and shrinking are unique mechanisms which can be utilized as both passive and active fluid control elements to establish gate and valve functions (passive) and pumping elements (active). Various constituents in microfluidic glass channels based on stimulus-responsive elements have been reported based on pH-responsive, thermoresponsive and photoresponsive coatings. Fluid control and robust performance have been demonstrated in microfluidic devices in a number of studies. Here we give a brief overview of selected examples from the literature reporting on the use of stimulus response polymers as active or passive elements for fluid control in microfluidic devices, with specific emphasis on glass-based devices. The remaining challenges include improving switching times and achieving local addressability of the responsive constituent. We envisage tackling these challenges by utilizing redox-responsive polymers which offer fast and reversible switching and local addressability in combination with nanofabricated electrodes.

Droplet microfluidics for producing functional microparticles

Isotropic microparticles prepared from a suspension that undergoes polymerization have long been used for a variety of applications. Bulk emulsification procedures produce polydisperse emulsion droplets that are transformed into spherical microparticles through chemical or physical consolidation. Recent advances in droplet microfluidics have enabled the production of monodisperse emulsions that yield highly uniform microparticles, albeit only on a drop-by-drop basis. In addition, microfluidic devices have provided a variety of means for particle functionalization through shaping, compartmentalizing, and microstructuring. These functionalized particles have significant potential for practical applications as a new class of colloidal materials. This feature article describes the current state of the art in the microfluidic-based synthesis of monodisperse functional microparticles. The three main sections of this feature article discuss the formation of isotropic microparticles, engineered microparticles, and hybrid microparticles. The complexities of the shape, compartment, and microstructure of these microparticles increase systematically from the isotropic to the hybrid types. Each section discusses the key idea underlying the design of the particles, their functionalities, and their applications. Finally, we outline the current limitations and future perspectives on microfluidic techniques used to produce microparticles.

Synthesis of biomimetic oxygen-carrying compartmentalized microparticles using flow lithography

We report a microfluidic approach for lithographically photo-patterning compartmentalized microparticles with any 2D-extruded shape, down to the cellular length scale (~10 microns). The prepolymer solution consists of a UV crosslinkable perfluorodecalin-in-water nanoemulsion stabilized by Pluronic(®) F-68. The nanoemulsions are generated using high-pressure homogenization and are osmotically stabilized by the trapped species method. The presence of PFC droplets increases the solubility and diffusivity of oxygen in the prepolymer solution, thereby enhancing the rate of O2 inhibition during microparticle synthesis. We develop a simple model that successfully predicts the augmented O2 mass transport, which agrees well with experimental data. Informed by our analytical results, cell-sized composite microgels are generated by controlling the oxygen environment around the polydimethylsiloxane (PDMS) microfluidic synthesis device. These nanoemulsion composites are functionally similar to red blood cells as oxygen carriers. Such bio-inspired polymeric particles with controlled physical properties are promising vehicles for drug delivery and clinical diagnostics.

Composite hydrogels as a vehicle for releasing drugs with a wide range of hydrophobicities

Many vitamins, bioactive lipids and over 40% of newly developed drugs are hydrophobic, and their poor water solubility limits their delivery using conventional formulations. In this work we investigated a composite gel system formulated from microemulsions embedded in alginate hydrogels, and showed that it is capable of loading several hydrophobic compounds with a wide range of aqueous solubility. All gels were clear, with no precipitations, indicating the solubility of the drugs in the gels. The release behavior was similar for different microemulsion formulations, various drugs and increasing concentrations of a drug. These findings indicate that our system could potentially act as a generic system, where the properties of the release do not depend on the drug but rather on the attributes of the gel. The structure of composite gels was investigated using small-angle scattering of X-rays and neutrons (SAXS and SANS, respectively). SANS showed more sensitivity to the structure of the microemulsion in the composite gel than SAXS did. SAXS and SANS plots of the composite gels show that both the droplets and the gel network preserve their structure when mixed together.

Multiphase flow microfluidics for the production of single or multiple emulsions for drug delivery

Considerable effort has been directed towards developing novel drug delivery systems. Microfluidics, capable of generating monodisperse single and multiple emulsion droplets, executing precise control and operations on these droplets, is a powerful tool for fabricating complex systems (microparticles, microcapsules, microgels) with uniform size, narrow size distribution and desired properties, which have great potential in drug delivery applications. This review presents an overview of the state-of-the-art multiphase flow microfluidics for the production of single emulsions or multiple emulsions for drug delivery. The review starts with a brief introduction of the approaches for making single and multiple emulsions, followed by presentation of some potential drug delivery systems (microparticles, microcapsules and microgels) fabricated in microfluidic devices using single or multiple emulsions as templates. The design principles, manufacturing processes and properties of these drug delivery systems are also discussed and compared. Furthermore, drug encapsulation and drug release (including passive and active controlled release) are provided and compared highlighting some key findings and insights. Finally, site-targeting delivery using multiphase flow microfluidics is also briefly introduced.

Building functional materials for health care and pharmacy from microfluidic principles and Flow Focusing

In this review, we aim at establishing a relationship between the fundamentals of the microfluidics technologies used in the Pharmacy field, and the achievements accomplished by those technologies. We describe the main methods for manufacturing micrometer drops, bubbles, and capsules, as well as the corresponding underlying physical mechanisms. In this regard, the review is intended to show non-specialist readers the dynamical processes which determine the success of microfluidics techniques. Flow focusing (FF) is a droplet-based method widely used to produce different types of fluid entities on a continuous basis by applying an extensional co-flow. We take this technique as an example to illustrate how microfluidics technologies for drug delivery are progressing from a deep understanding of the physics of fluids involved. Specifically, we describe the limitations of FF, and review novel methods which enhance its stability and robustness. In the last part of this paper, we review some of the accomplishments of microfluidics when it comes to drug manufacturing and delivery. Special attention is paid to the production of the microencapsulated form because this fluidic structure gathers the main functionalities sought for in Pharmacy. We also show how FF has been adapted to satisfy an ample variety of pharmaceutical requirements to date.

A dual enzyme microgel with high antioxidant ability based on engineered seleno-ferritin and artificial superoxide dismutase

An antioxidant microgel with both glutathione peroxidase (GPx) and superoxide dismutase (SOD) activities is reported. Using computational design and genetic engineering methods, the main catalytic components of GPx are fabricated onto the surface of ferritin. The resulting seleno-ferritin (Se-Fn) monomers can self-assemble into nanocomposites that exhibit remarkable GPx activity due to the well organized multi-GPx catalytic centers. Subsequently, a porphyrin derivative is synthesized as an SOD mimic, and is employed to construct a synergistic dual enzyme system by crosslinking Se-Fn nanocomposites into a microgel. Significantly, this dual enzyme microgel is demonstrated to display better antioxidant ability than single GPx or SOD mimics in protecting cells from oxidative damage.

Advanced materials and processing for drug delivery: the past and the future

Design and synthesis of efficient drug delivery systems are of vital importance for medicine and healthcare. Materials innovation and nanotechnology have synergistically fueled the advancement of drug delivery. Innovation in material chemistry allows the generation of biodegradable, biocompatible, environment-responsive, and targeted delivery systems. Nanotechnology enables control over size, shape and multi-functionality of particulate drug delivery systems. In this review, we focus on the materials innovation and processing of drug delivery systems and how these advances have shaped the past and may influence the future of drug delivery.

Microgel capsules tailored by droplet-based microfluidics

Microgel capsules are micrometer-sized particles that consist of a cross-linked, solvent-swollen polymer network complexed with additives. These particles have various applications, such as drug delivery, catalysis, and analytics. To optimize the performance of microgel capsules, it is crucial to control their size, shape, and content of encapsulated additives with high precision. There are two classes of microgel-capsule structures. One class comprises bulk microcapsules that consist of a polymer network spanning the entire particle and entrapping the additive within its meshes. The other class comprises core-shell structures; in this case, the microgel polymer network just forms the shell of the particles, whereas their interior is hollow and hosts the encapsulated payload. Both types of structures can be produced with exquisite control by droplet-based microfluidic templating followed by subsequent droplet gelation. This article highlights some early and recent achievements in the use of this technique to tailor soft microgel capsules; it also discusses applications of these particles. A special focus is on the encapsulation of living cells, which are very sensitive and complex but also very useful additives for immobilization within microgel particles.

Controlled enzyme-catalyzed degradation of polymeric capsules templated on CaCO₃: influence of the number of LbL layers, conditions of degradation, and disassembly of multicompartments

Enzyme-catalyzed degradation of CaCO₃-templated capsules is presented. We investigate a) biodegradable, b) mixed biodegradable/synthetic, and c) multicompartment polyelectrolyte multilayer capsules with different numbers of polymer layers. Using confocal laser scanning microscopy we observed the kinetics of the non-specific protease Pronase-induced degradation of capsules is slowed down on the order of hours by either increasing the number of layers in the wall of biodegradable capsules, or by inserting synthetic polyelectrolyte multilayers into the shell comprised of biodegradable polymers. The degradation rate increases with the concentration of Pronase. Controlled detachment of subcompartments of multicompartment capsules, with potential for intracellular delivery or in-vivo applications, is also shown.