Impact of formulation and operating parameters on particle size and grinding media wear in wet media milling of organic compounds – A case study for pyrene

Factors affecting the preparation of nanocrystals: characterization, surface modifications and toxicity aspects

INTRODUCTION

The fabrication of well-defined nanocrystals in size and form is the focus of much investigation. In this work, we have critically reviewed several recent instances from the literature that shows how the production procedure affects the physicochemical properties of the nanocrystals.

AREAS COVERED

Scopus, MedLine, PubMed, Web of Science, and Google Scholar were searched for peer-review articles published in the past few years using different key words. Authors chose relevant publications from their files for this review. This review focuses on the range of techniques available for producing nanocrystals. We draw attention to several recent instances demonstrating the impact of various process and formulation variables that affect the nanocrystals' physicochemical properties. Moreover, various developments in the characterization techniques explored for nanocrystals concerning their size, morphology, etc. have been discussed. Last but not least, recent applications, the effect of surface modifications, and the toxicological traits of nanocrystals have also been reviewed.

EXPERT OPINION

The selection of an appropriate production method for the formation of nanocrystals, together with a deep understanding of the relationship between the drug's physicochemical properties, unique features of the various formulation alternatives, and anticipated in-vivo performance, would significantly reduce the risk of failure during human clinical trials that are inadequate.

Abrasion-Induced Acceleration of Melt Crystallisation of Wet Comminuted Polybutylene Terephthalate (PBT)

Within this contribution, the effect of grinding media wear on the melt crystallisation of polybutylene terephthalate (PBT) is addressed. PBT was wet ground in a stirred media mill in ethanol using different grinding media beads (silica, chrome steel, cerium-stabilised and yttrium-stabilised zirconia) at comparable stress energies with the intention to use the obtained particles as feed materials for the production of feedstocks for laser powder bed fusion additive manufacturing (PBF-AM). In PBF‑AM, the feedstock’s optical, rheological and especially thermal properties—including melt crystallisation kinetics—strongly influence the processability and properties of the manufactured parts. The influence of process parameters and used grinding media during wet comminution on the optical properties, crystal structure, molar mass distribution, inorganic content (wear) and thermal properties of the obtained powders is discussed. A grinding media-dependent acceleration of the melt crystallisation could be attributed to wear particles serving as nuclei for heterogeneous crystallisation. Yttrium-stabilised zirconia grinding beads proved to be the most suitable for the production of polymer powders for the PBF process in terms of (fast) comminution kinetics, unchanged optical properties and the least accelerated crystallisation kinetics.

Conservative Finite Volume Schemes for Multidimensional Fragmentation Problems

In this article, a new numerical scheme for the solution of the multidimensional fragmentation problem is presented. It is the first that uses the conservative form of the multidimensional problem. The idea to apply the finite volume scheme for solving one-dimensional linear fragmentation problems is extended over a generalized multidimensional setup. The derivation is given in detail for two-dimensional and three-dimensional problems; an outline for the extension to higher dimensions is also presented. Additionally, the existing one-dimensional finite volume scheme for solving conservative one-dimensional multi-fragmentation equation is extended to solve multidimensional problems. The accuracy and efficiency of both proposed schemes is analyzed for several test problems.

Mechanistic Modeling of Wet Stirred Media Milling for Production of Drug Nanosuspensions

Drug nanocrystals have been used for a wide range of drug delivery platforms in the pharmaceutical industry, especially for bioavailability enhancement of poorly water-soluble drugs. Wet stirred media milling (WSMM) is the most widely used process for producing dense, stable suspensions of drug nanoparticles, also referred to as nanosuspensions. Despite a plethora of review papers on the production and applications of drug nanosuspensions, modeling of WSMM has not been thoroughly covered in any review paper before. The aim of this review paper is to briefly expose the pharmaceutical scientists and engineers to various modeling approaches, mostly mechanistic, including computational fluid dynamics (CFD), discrete element method (DEM), population balance modeling (PBM), coupled methods, the stress intensity-number model (SI-SN model), and the microhydrodynamic (MHD) model with a main focus on the MHD model for studying the WSMM process. A total of 71 studies, 30 on drugs and 41 on other materials, were reviewed. Analysis of the pharmaceutics literature reveals that WSMM modeling is largely based on empirical, statistically based modeling approaches, and mechanistic modeling could help pharmaceutical engineers develop a fundamental process understanding. After a review of the salient features and various pros-cons of each modeling approach, recent advances in microhydrodynamic modeling and process insights gained therefrom were highlighted. The SI-SN and MHD models were analyzed and critiqued objectively. Finally, the review points out potential research directions such as more mechanistic and accurate CFD-DEM-PBM simulations and the coupling of the MHD-PBM models with the CFD.

Cryo-milling with spherical crystalline cellulose beads: A contamination-free and safety conscious technology

Crystalline cellulose is a common inactive pharmaceutical additive. If this material can also be used to construct beads for the wet milling of pharmaceutical compounds, it could possibly address issues related to wear and contamination associated with zirconia and polyethylene beads. In this study, the model drug phenytoin was milled with spherical crystalline cellulose (SCC) in liquid nitrogen. The particle size of the milled product was found to be comparable to that obtained using zirconia beads, verifying the feasibility of using SCC beads for this purpose. Using a design of experiment approach, the bead amount, agitation speed, and milling time were all determined to have a significant effect on the milled particle size, giving a D50 value as low as 0.3 μm. No breakage of the SCC beads was observed during the milling process in durability tests under conditions that will degrade spherical D-mannitol beads, showing that this material exhibits sufficient durability. In addition, the variation in elastic modulus between beads was minimal. Because SCC is commercially available and easy to handle, the present wet milling technique is considered to have potential applications to the manufacture of pharmaceuticals on an industrial scale, as it shows sufficient milling capability and durability.

Cryo-milling using a spherical sugar: Contamination-free media milling technology

Milling beads experience wear upon repeated use. And milling beads made of material that is safe when ingested have not yet been developed. The present report describes the development and characteristics of spherical d-mannitol (SDM) beads, which would be safe when ingested. The model drug phenytoin was dispersed in liquid nitrogen along with SDM and the materials were agitated at high speed. The effects of the amount of beads, agitation speed, and milling time on phenytoin particle size, yield, and bead fractures were investigated using a central composite experimental design. The diameter of milled phenytoin particles decreased significantly as the amount of SDM beads and agitation speed increased. In contrast, no difference was found in the diameter with milling time. Although the fractured SDM ratio increased slightly at higher agitation speeds, the SDM was not broken and was durable enough for milling. This milling technique was applicable not only to phenytoin but also to other drug substances. Bead durability and applicability indicated that SDM can be used as wet milling beads that are considered safe for use if ingested.

Formation of long-term stable amorphous ibuprofen nanoparticles via antisolvent melt precipitation (AMP)

Antisolvent precipitation of poorly water-soluble drugs is a promising formulation technique to synthesize amorphous nanoparticles. The dissolution behavior of these nanoparticles is improved because of the high specific surface area and the amorphous state, leading to an enhanced bioavailability of the drug molecules. Nevertheless, stabilization of precipitated drug nanoparticles against agglomeration and recrystallization, which constitutes a key issue for further processing steps, has turned out to be a major challenge. For that reason, the present study presents a synthesis method to produce long-term stable amorphous ibuprofen nanoparticles via antisolvent precipitation. To reach this goal, a new precipitation method was developed: antisolvent melt precipitation (AMP). Formulation strategies (e.g. varying fraction of stabilizer) as well as process parameters (e.g. temperature) were under study to estimate their influence on particle size, size distribution, crystallinity, morphology and stability of synthesized drug nanoparticles.

Effects of decreasing activated carbon particle diameter from 30 μm to 140 nm on equilibrium adsorption capacity

The capacity of activated carbon particles with median diameters (D50s) of >∼1 μm for adsorption of hydrophobic micropollutants such as 2-methylisolborneol (MIB) increases with decreasing particle size because the pollutants are adsorbed mostly on the exterior (shell) of the particles owing to the limited diffusion penetration depth. However, particles with D50s of <1 μm have not been thoroughly investigated. Here, we prepared particles with D50s of ∼30 μm-∼140 nm and evaluated their adsorption capacities for MIB and several other environmentally relevant adsorbates. The adsorption capacities for low-molecular-weight adsorbates, including MIB, deceased with decreasing particle size for D50s of less than a few micrometers, whereas adsorption capacities increased with decreasing particle size for larger particles. The oxygen content of the particles increased substantially with decreasing particle size for D50s of less than a few micrometers, and oxygen content was negatively correlated with adsorption capacity. The decrease in adsorption capacity with decreasing particle size for the smaller particles was due to particle oxidation during the micromilling procedure used to decrease D50 to ∼140 nm. When oxidation was partially inhibited, the MIB adsorption capacity decrease was attenuated. For high-molecular-weight adsorbates, adsorption capacity increased with decreasing particle size over the entire range of tested particle sizes, even though particle oxygen content increased with decreasing particle size.

Novel strategies for the formulation and processing of poorly water-soluble drugs

Low aqueous solubility of active pharmaceutical ingredients presents a serious challenge in the development process of new drug products. This article provides an overview on some of the current approaches for the formulation of poorly water-soluble drugs with a special focus on strategies pursued at the Center of Pharmaceutical Engineering of the TU Braunschweig. These comprise formulation in lipid-based colloidal drug delivery systems and experimental as well as computational approaches towards the efficient identification of the most suitable carrier systems. For less lipophilic substances the preparation of drug nanoparticles by milling and precipitation is investigated for instance by means of microsystem-based manufacturing techniques and with special regard to the preparation of individualized dosage forms. Another option to overcome issues with poor drug solubility is the incorporation into nanospun fibers.