Nanoprecipitation in confined impinging jets mixers: Production, characterization and scale-up of pegylated nanospheres and nanocapsules for pharmaceutical use

Continuous Nanoprecipitation of Polycaprolactone in Additively Manufactured Micromixers

The polymeric ouzo effect is an energy-efficient and robust method to create nanoparticles with biologically degradable polymers. Usually, a discontinuous or semi-continuous process is employed due to its low technical effort and the fact that the amount of dispersions needed in a laboratory is relatively small. However, the number of particles produced in this method is not enough to make this process economically feasible. Therefore, it is necessary to improve the productivity of the process and create a controllable and robust continuous process with the potential to control parameters, such as the particle size or surface properties. In this study, nanoparticles were formulated from polycaprolactone (PCL) in a continuous process using additively manufactured micromixers. The main goal was to be able to exert control on the particle parameters in terms of size and zeta potential. The results showed that particle size could be adjusted in the range of 130 to 465 nm by using different flow rates of the organic and aqueous phase and varying concentrations of PCL dissolved in the organic phase. Particle surface charge was successfully shifted from a slightly negative potential of −14.1 mV to a negative, positive, or neutral value applying the appropriate surfactant. In summary, a continuous process of nanoprecipitation not only improves the cost of the method, but furthermore increases the control over the particle’s parameters.

Particle engineering principles and technologies for pharmaceutical biologics

The global market of pharmaceutical biologics has expanded significantly during the last few decades. Currently, pharmaceutical biologic products constitute an indispensable part of the modern medicines. Most pharmaceutical biologic products are injections either in the forms of solutions or lyophilized powders because of their low oral bioavailability. There are certain pharmaceutical biologic entities formulated into particulate delivery systems for the administration via non-invasive routes or to achieve prolonged pharmaceutical actions to reduce the frequency of injections. It has been well documented that the design of nano- and microparticles via various particle engineering technologies could render pharmaceutical biologics with certain benefits including improved stability, enhanced intracellular uptake, prolonged pharmacological effect, enhanced bioavailability, reduced side effects, and improved patient compliance. Herein, we review the principles of the particle engineering technologies based on bottom-up approach and present the important formulation and process parameters that influence the critical quality attributes with some mathematical models. Subsequently, various nano- and microparticle engineering technologies used to formulate or process pharmaceutical biologic entities are reviewed. Lastly, an array of commercialized products of pharmaceutical biologics accomplished based on various particle engineering technologies are presented and the challenges in the development of particulate delivery systems for pharmaceutical biologics are discussed.

Synthesis of polymer nanoparticles via electrohydrodynamic emulsification-mediated self-assembly

HYPOTHESIS

Electrospray can rapidly produce fine, organic solvent-in-water emulsions in the absence of surfactant via electrohydrodynamic emulsification (EE), a reverse configuration of traditional electrospray. This paper investigates whether EE can produce high-quality nanocomposites comprised of block co-polymers and organic nanoparticles (NPs) via the interfacial instability (IS) self-assembly method. Surfactant-free approaches may increase encapsulation efficiency and product uniformity, process speed, and ease of downstream product purification.

EXPERIMENTS

All particles were produced using EE-mediated self-assembly (SA) (EE-SA). Particles were produced using poly(lactic-co-glycolic acid) (PLGA) polymers as proof of concept. Then, block copolymer (BCP) micelles were synthesized from polystyrene-block-poly(ethylene oxide) (PS-b-PEO) (PS 9.5 kDa:PEO 18.0 kDa) in the presence and absence of superparamagnetic iron oxide nanoparticles (SPIONs) or quantum dots (QDs). Encapsulant concentration was varied, and the effect of encapsulant NP ligands on final particle size was investigated.

FINDINGS

EE-SA generated both pure polymer NPs and nanocomposites containing SPIONs and QDs. PLGA particles spanned from sub- to super-micron sizes. PS-b-PEO NPs and nanocomposites were highly monodisperse, and more highly loaded than those made via a conventional, surfactant-rich IS process. Free ligands decreased the size of pure BCP particles. Increasing encapsulant levels led to a morphological transition from spherical to worm-like to densely loaded structures.

Shear-Thinning Effect of the Spinning Disc Mixer on Starch Nanoparticle Precipitation

Spinning disc technology is capable of achieving intensified micromixing within thin liquid films created through large shear rates, typically of the order of 103 s−1, generated by means of fast disc surface rotation. In this study the effect of the high shear on solvent–antisolvent mixing and starch nanoparticle precipitation is reported. Rheological studies of starch solutions at 2% w/v and 4% w/v have demonstrated their shear-thinning behaviour at the large shear rates experienced on the spinning disc surface. The effect of such high shear rate on starch nanoparticle precipitation is investigated alongside solute concentration and several other operating parameters such as flow rate, disc rotational speed, and solvent/antisolvent ratio. A reduction in nanoparticle size has been observed with an increase in starch concentration, although agglomeration was found to be more prevalent amongst these smaller particles particularly at larger flow rates and disc rotational speeds. Micromixing time, estimated on the basis of an engulfment mechanism, has been correlated against shear rate. With fast micromixing of the order of 1 ms observed at higher shear rates, and which are practically unaffected by the starch concentrations used, micromixing is not thought to be influential in determining the particle characteristics highlighted in this work.

Empirical Modelling of Hydrodynamic Effects on Starch Nanoparticles Precipitation in a Spinning Disc Reactor

Empirical correlations have been developed to relate experimentally determined starch nanoparticle size obtained in a solvent–antisolvent precipitation process with key hydrodynamic parameters of a spinning disc reactor (SDR). Three different combinations of dimensionless groups including a conventional Reynolds number (Re), rotational Reynolds number (Re_ω) and Rossby number (Ro) have been applied in individual models for two disc surfaces (smooth and grooved) to represent operating variables affecting film flow such as liquid flowrate and disc rotational speed, whilst initial supersaturation (S) has been included to represent varying antisolvent concentrations. Model 1 featuring a combination of Re, Re_ω and S shows good agreement with the experimental data for both the grooved and smooth discs. For the grooved disc, Re has a greater impact on particle size, whereas Re_ω is more influential on the smooth disc surface, the difference likely being due to the passive mixing induced by the grooves irrespective of the magnitude of the disc speed. Supersaturation has little impact on particle size within the limited initial supersaturation range studied. Model 2 which characterises both flow rate and disc rotational speed through Ro alone and combined with Re was less accurate in predicting particle size due to several inherent limitations.

Rapid and Controllable Synthesis of Nanocrystallized Nickel-Cobalt Boride Electrode Materials via a Mircoimpinging Stream Reaction for High Performance Supercapacitors

Nickel-cobalt borides (denoted as NCBs) have been considered as a promising candidate for aqueous supercapacitors due to their high capacitive performances. However, most reported NCBs are amorphous that results in slow electron transfer and even structure collapse during cycling. In this work, a nanocrystallized NCBs-based supercapacitor is successfully designed via a facile and practical microimpinging stream reactor (MISR) technique, composed of a nanocrystallized NCB core to facilitate the charge transfer, and a tightly contacted Ni-Co borates/metaborates (NCB_i ) shell which is helpful for OH^- adsorption. These merits endow NCB@NCB_i a large specific capacity of 966 C g^-1 (capacitance of 2415 F g^-1 ) at 1 A g^-1 and good rate capability (633.2 C g^-1 at 30 A g^-1 ), as well as a very high energy density of 74.3 Wh kg^-1 in an asymmetric supercapacitor device. More interestingly, it is found that a gradual in situ conversion of core NCBs to nanocrystallized Ni-Co (oxy)-hydroxides inwardly takes place during the cycles, which continuously offers large specific capacity due to more electron transfer in the redox reaction processes. Meanwhile, the electron deficient state of boron in metal-borates shells can make it easier to accept electrons and thus promote ionic conduction.

Flow physics and mixing quality in a confined impinging jet mixer

Due to their ability to provide efficient mixing at small scales, confined impinging jet mixers (CIJMs) are employed widely in nanoparticle assembly processes such as flash nanoprecipitation and flash nanocomplexation, which require rapid mixing. In this mixing device, two jets from opposite directions impinge directly on each other forming a thin shear layer that breaks down rapidly into small flow structures. This enables effective mixing of the species transported by each jet by drastically reducing the diffusion distance. In the present study, the mixing performance of a commonly used cylindrical CIJM is examined by direct numerical simulations. Analysis of the simulation results indicates that the interaction of the shear layer with the inner walls of the CIJM is critical in inducing a range of instabilities in the impinging jet flow. By examining flow structures, statistical quantities, and metrics, we have characterized and quantified the mixing quality of a binary mixture in the CIJM. Product uniformity in processes such as precipitation and complexation is expected to depend on the residence time of the constituents, and this quantity is also calculated and compared for the cases with different jet Reynolds numbers. The jet Reynolds numbers of Re = 200, 600, and 1000 are considered, and the simulation results show that the CIJM achieves very good mixing for the Re = 600 and Re = 1000 cases. It is also found that the Re = 600 case performs slightly better than the other cases in terms of uniformity of the residence time. These quantitative analyses offer useful insights into the mechanism of nanoparticle size control and uniformity afforded by the unique flow physics and mixing characteristics in the CIJMs.

Overcoming the Limits of Flash Nanoprecipitation: Effective Loading of Hydrophilic Drug into Polymeric Nanoparticles with Controlled Structure

Flash nanoprecipitation (FNP) is a widely used technique to prepare particulate carriers based on various polymers, and it was proven to be a promising technology for the industrial production of drug loaded nanoparticles. However, up to now, only its application to hydrophobic compounds has been deeply studied and the encapsulation of some strongly hydrophilic compounds, such as caffeine, remains a challenge. Caffeine loaded poly-ε-caprolactone (PCL) nanoparticles were produced in a confined impinging jet mixer using acetone as the solvent and water as the antisolvent. Caffeine was dissolved either in acetone or in water to assess the effects of two different process conditions. Nanoparticles properties were assessed in terms of loading capacity (LC%), encapsulation efficiency (EE%), and in vitro release kinetics. Samples were further characterized by dynamic light scattering, scanning electron microscopy, X-ray photo electron spectroscopy, and infrared spectroscopy to determine the size, morphology, and structure of nanoparticles. FNP was proved an effective technique for entrapping caffeine in PCL and to control its release behavior. The solvent used to solubilize caffeine influences the final structure of the obtained particles. It was observed that the active principle was preferentially adsorbed at the surface when using acetone, while with water, it was embedded in the matrix structure. The present research highlights the possibility of extending the range of applications of FNP to hydrophilic molecules.

Current developments and applications of microfluidic technology toward clinical translation of nanomedicines

Nanoparticulate drug delivery systems hold great potential for the therapy of many diseases, especially cancer. However, the translation of nanoparticulate drug delivery systems from academic research to industrial and clinical practice has been slow. This slow translation can be ascribed to the high batch-to-batch variations and insufficient production rate of the conventional preparation methods, and the lack of technologies for rapid screening of nanoparticulate drug delivery systems with high correlation to the in vivo tests. These issues can be addressed by the microfluidic technologies. For example, microfluidics can not only produce nanoparticles in a well-controlled, reproducible, and high-throughput manner, but also create 3D environments with continuous flow to mimic the physiological and/or pathological processes. This review provides an overview of the microfluidic devices developed to prepare nanoparticulate drug delivery systems, including drug nanosuspensions, polymer nanoparticles, polyplexes, structured nanoparticles and theranostic nanoparticles. We also highlight the recent advances of microfluidic systems in fabricating the increasingly realistic models of the in vivo milieu for rapid screening of nanoparticles. Overall, the microfluidic technologies offer a promise approach to accelerate the clinical translation of nanoparticulate drug delivery systems.

Functionalization of Cotton Fabrics with Polycaprolactone Nanoparticles for Transdermal Release of Melatonin

Drug delivery by means of transdermal patches raised great interest as a non-invasive and sustained therapy. The present research aimed to design a patch for transdermal delivery of melatonin, which was encapsulated in polycaprolactone (PCL) nanoparticles (NPs) by employing flash nanoprecipitation (FNP) technique. Melatonin-loaded PCL nanoparticles were successfully prepared with precise control of the particle size by effectively tuning process parameters. The effect of process parameters on the particle size was assessed by dynamic light scattering for producing particles with suitable size for transdermal applications. Quantification of encapsulated melatonin was performed by mean of UV spectrophotometry, obtaining the estimation of encapsulation efficiency (EE%) and loading capacity (LC%). An EE% higher than 80% was obtained. Differential scanning calorimetry (DSC) analysis of NPs was performed to confirm effective encapsulation in the solid phase. Cotton fabrics, functionalized by imbibition with the nano-suspension, were analyzed by scanning electron microscopy to check morphology, adhesion and distribution of the NPs on the surface; melatonin transdermal release from the functionalized fabric was performed via Franz’s cells by using a synthetic membrane. NPs were uniformly distributed on cotton fibres, as confirmed by SEM observations; the release test showed a continuous and controlled release whose kinetics were satisfactorily described by Baker–Lonsdale model.

Synthesis and Nanoprecipitation of HEMA-CLn Based Polymers for the Production of Biodegradable Nanoparticles

The control over the size distribution and stability of polymeric nanoparticles (NPs) is crucial in many of their applications, especially in the biomedical field. These characteristics are typically influenced by the production method and the nature of the starting material. To investigate these aspects, the controlled radical polymerization of functionalized methacrylates constituted by 2-hydroxyethyl methacrylate (HEMA) functionalized with a controlled number of ε-caprolactone (CL) units (HEMA-CL_n), was carried out via reversible addition–fragmentation chain transfer polymerization (RAFT) in solution. The living reaction allows for good control over the molar mass of the final polymer with a low molar mass dispersity. The obtained polymer solutions were nanoprecipitated in order to produce NPs suitable for drug delivery applications with narrow particle size distribution and a wide size range (from 60 to 250 nm). The NP synthesis has been performed using a mixing device, in order to control the parameters involved in the nanoprecipitation process. As already seen for similar systems, the size of the produced NPs is a function of the polymer concentration during the nanoprecipitation process. Nevertheless, when the polymer concentration is kept constant, the NP size is influenced by the chemical structure of the polymer used, in terms of the presence of PEG (poly(ethylene glycol)), the degree of RAFT polymerization, and the length of the caprolactone side chain. These characteristics were also found to influence the stability and degradation properties of the produced NPs.

Poly-epsilon-caprolactone nanoparticles enhance ursolic acid in vivo efficacy against Trypanosoma cruzi infection

Despite affecting millions of people worldwide, Chagas disease is still neglected by the academia and industry and the therapeutic option available, benznidazole, presents limited efficacy and side effects. Within this context, ursolic acid may serve as an option for treatment, however has low bioavailability, which can be enhanced through the encapsulation in polymeric nanoparticles. Therefore, herein we developed ursolic acid-loaded nanoparticles with poly-ε-caprolactone by the nanoprecipitation method and characterized them for particle size, zeta potential, polydispersity, encapsulation efficiency, morphology by scanning electron microscopy and thermal behavior by differential scanning calorimetry. Results indicated that an appropriate ratio of organic phase/aqueous phase and polymer/drug is necessary to produce smaller particles, with low polydispersity, negative zeta potential and high drug encapsulation efficiency. In vitro studies indicated the safety of the formulation against fibroblast culture and its efficacy in killing T. cruzi. Very importantly, the in vivo study revealed that the ursolic acid-loaded nanoparticle is as potent as the benznidazole group to control parasitemia, which could be attributed to improved bioavailability of the encapsulated drug. Finally, the toxicity evaluation showed that while benznidazole group caused liver toxicity, the nanoparticles were safe, indicating that this formulation is promising for future evaluation.

Cotton fabric functionalisation with menthol/PCL micro- and nano-capsules for comfort improvement

OBJECTIVE

Cotton functionalisation with poly-ɛ-caprolactone (PCL) micro- and nano-capsules containing menthol was carried out with the aim of introducing a long-lasting refreshing sensation.

MATERIALS AND METHODS

The preparation of the polymer micro- and nano-capsules was carried out by solvent displacement technique. A confined impinging jets mixer was used in order to ensure fast mixing and generate a homogeneous environment where PCL and menthol can self-assemble.

RESULTS

The micro- and nano-capsules and the functionalised fabrics were characterised by means of DSC, FT-IR spectroscopy and SEM imaging. Micro- and nano-capsules of different size, from about 200 to about 1200 nm, were obtained varying menthol to PCL ratio (from 0.76 to 8), overall concentration and flow rate (i.e. mixing conditions). The inclusion of menthol was confirmed by DSC analysis.

DISCUSSION AND CONCLUSION

A patch test was carried out by 10 volunteers. Micro-capsules were found to be effective in conferring the fabric a refreshing sensation without altering skin physiology.

Microfluidic preparation of polymer nanospheres

In this work, solid polymer nanospheres with their surface tailored for drug adhesion were prepared using a V-shaped microfluidic junction. The biocompatible polymer solutions were infused using two channels of the microfluidic junction which was also simultaneously fed with a volatile liquid, perfluorohexane using the other channel. The mechanism by which the nanospheres are generated is explained using high speed camera imaging. The polymer concentration (5-50 wt%) and flow rates of the feeds (50-300 µl min^-1) were important parameters in controlling the nanosphere diameter. The diameter of the polymer nanospheres was found to be in the range of 80-920 nm with a polydispersity index of 11-19 %. The interior structure and surfaces of the nanospheres prepared were studied using advanced microscopy and showed the presence of fine pores and cracks on surface which can be used as drug entrapment locations.

Dynamic light scattering and X-ray photoelectron spectroscopy characterization of PEGylated polymer nanocarriers: internal structure and surface properties

In this work, nanospheres and nanocapsules are precipitated in confined impinging jet mixers through solvent displacement and characterized. Acetone and water are used as the solvent and antisolvent, respectively, together with polymethoxypolyethylene glycol cyanoacrylate-co-hexadecylcyanoacrylate and Miglyol as the copolymer and oil, respectively. Characterization is performed with dynamic light scattering, with electrophoretic measurements, and for the first time with X-ray photoelectron spectroscopy. Results show that the presence of polyethylene glycol chains seems to be more pronounced on the surface of nanospheres than on that of nanocapsules. The thickness of the copolymer layer in nanocapsules ranges from 1 to 10 nm, depending on the value of the oil:copolymer mass ratio. Fast dilution is confirmed to have a positive effect in suppressing aggregation but can induce further copolymer precipitation.

Modified nanoprecipitation method for polysulfone nanoparticles preparation

Towards developing a more universal and productive nanoprecipitation processes, we focus on the preparation of polysulfone (PSF) nanoparticles through instantaneous solvent displacement in a metal membrane contactor between dimethylformamide (DMF) and water. In the original nanoprecipitation process, cubic nuclei can form instantaneously, but slow growth and aggregation have intensive interactions. Moreover, the reservation of DMF may enhance the adhesive effect between polymeric particles, causing severe particle aggregation. To overcome this difficulty, a modified nanoprecipitation method appending a quenching step was proposed. The well-dispersed PSF nanoparticles are successfully obtained when ethyl acetate is introduced. In this way, DMF can be extracted from water solution, thus facilitating the precipitating of PSF. Furthermore, selecting water as the continuous fluid, the particle size can be adjusted simply by tuning the operating parameters, including the PSF concentration in the dispersed fluid and the ratio of two feeds. Compared with previous reports on the continuous nanoprecipitation process for polymeric nanoparticles preparation, this work shows advantages including expanding the adaptability to more functional polymers, providing better flexibility on process or product development independent of the use of surfactant, and presenting a high throughput and easy-to-scale-up equipment platform.