Ultrasonic atomisation into reduced pressure atmosphere—envisaging aseptic spray-drying for microencapsulation

Encapsulation of enzymes in food industry using spray drying: recent advances and process scale-ups

Enzymes are widely used in the food industry due to their ability in improving the functional, sensory, and nutritional properties of food products. However, their poor stability under harsh industrial conditions and their compromised shelf-lives during long-term storage limit their applications. This review introduces typical enzymes and their functionality in the food industry and demonstrates spray drying as a promising approach for enzyme encapsulation. Recent studies on encapsulation of enzymes in the food industry using spray drying and the key achievements are summarized. The latest developments including the novel design of spray drying chambers, nozzle atomizers and advanced spray drying techniques are also analyzed and discussed in depth. In addition, the scale-up pathways connecting laboratory scale trials and industrial scale productions are illustrated, as most of the current studies have been limited to lab-scales. Enzyme encapsulation using spray drying is a versatile strategy to improve enzyme stability in an economical and industrial viable way. Various nozzle atomizers and drying chambers have recently been developed to increase process efficiency and product quality. A comprehensive understanding of the complex droplet-to-particle transformations during the drying process would be beneficial for both process optimization and scale-up design.

Evaluation of Nano-Wall Material for Production of Novel Lyophilized-Probiotic Product

Lyophilization is one of the most used methods for bacterial preservation. In this process, the cryoprotectant not only largely decreases cellular damage but also plays an important part in the conservation of viability during freeze-drying. This study investigated using cryoprotectant and a mixture of the cryoprotectant to maintain probiotic activity. Seven probiotic strains were considered: (Limosilactobacillus reuteri KUKPS6103; Lacticaseibacillus rhamnosus KUKPS6007; Lacticaseibacillus paracasei KUKPS6201; Lactobacillus acidophilus KUKPS6107; Ligilactobacillus salivarius KUKPS6202; Bacillus coagulans KPSTF02; Saccharomyces cerevisiae subsp. boulardii KUKPS6005) for the production of a multi-strain probiotic and the complex medium for the lyophilized synbiotic production. Cholesterol removal, antioxidant activity, biofilm formation and gamma aminobutyric acid (GABA) production of the probiotic strains were analyzed. The most biofilm formation occurred in L. reuteri KUKPS6103 and the least in B. coagulans KPSTF02. The multi-strain probiotic had the highest cholesterol removal. All the probiotic strains had GABA production that matched the standard of γ-aminobutyric acid. The lyophilized synbiotic product containing complex medium as a cryoprotectant and wall material retained a high viability of 7.53 × 10⁸ CFU/g (8.89 log CFU/g) after 8 weeks of storage. We found that the survival rate of the multi-strain probiotic after freeze-drying was 15.37% in the presence of complex medium that was used as high performing wall material. Our findings provided a new type of wall material that is safer and more effective and, can be extensively applied in relevant food applications.

Oral Delivery of Encapsulated All-Trans Retinoic Acid Ameliorates Disease in Rodent Models of Colitis

BACKGROUND

All-trans retinoic acid (ATRA) is a biologically active isomer of retinoic acid (RA). Topical ATRA (retin-a, retin-a micro, atralin, renova, and avita) is the active pharmaceutical ingredient for FDA-approved treatments for acne and skin wrinkles. Oral formulations (Vesanoid) treat acute promyelocytic leukemia, but oral dosing can induce severe side effects. Despite benefits in various rodent models of inflammatory bowel disease (IBD), toxicity and controversial clinical observations have diminished enthusiasm for ATRA IBD clinical trials. To circumvent these issues and to use ATRA's key role in maintaining gut tolerance, we developed a poly(lactic-co-glycolic acid) (PLGA) microsphere (MS) encapsulated ATRA formulation aimed at directing ATRA delivery to immune structures of the gut, limiting systemic exposure. Initially, ATRA MS was developed as a component of a combinatorial product (TreXTAM) that also contained encapsulated transforming growth factor (TGF)-β and ATRA in a 1:2 w/w ratio. Although the combination was optimal, benefit was also observed when ATRA MS was given alone in the CD4+ CD25-T-cell adoptive transfer (ACT) colitis model.

METHODS

We used the ACT and DSS-induced murine models of colitis to expand on the dose-dependent effects of oral ATRA MS when given alone. The DSS model was also used to compare the efficacy of ATRA MS and soluble ATRA, while healthy animals were used to compare the pharmacokinetics of the two drugs.

RESULTS

In both the ACT and DSS-induced murine models of colitis, ATRA MS was observed to be effective in ameliorating disease. ATRA MS was also observed to be more effective than soluble ATRA in these models and displayed more favorable pharmacokinetics.

CONCLUSIONS

We suggest ATRA MS, as a standalone product, may attenuate IBD and perhaps limit fibrosis, while limiting systemic side effects.

The effect of an ultrasonic spray nozzle on carbohydrate and protein-based coating materials for blueberry extract microencapsulation

BACKGROUND

An ultrasonic spray nozzle was evaluated for the production of powders and microcapsules, using blueberry extract, modified starch (HI-CAP 100), and whey protein isolate (WPI). The effects of ultrasonic power and the concentration of coating materials on the characteristics of the resulting samples - such as viscosity, particle size, microencapsulation efficiency, color, glass transition temperature, Fourier-transform infrared spectroscopy (FTIR), X-ray powder diffraction (XRD), and morphology - were also studied.

RESULTS

The apparent viscosity was primarily affected by the self-heating of the ultrasonic nozzle as the power increased. The largest mean particle size of samples was observed under conditions of 30% coating concentration at 10 W. Glass transition temperatures (T_g ) of the samples were affected by all atomization parameters significantly (P < 0.05) and the highest T_g values of all samples were determined when the coating concentration was maximum (30%) and power level was minimum (5 W). The FTIR and XRD results indicate that the power of the ultrasonic nozzle did not cause any change in WPI structure and led to only a small change in the structure of HI-CAP 100 at 10 W. The short atomization time preserved, to some extent, the properties of the coating materials and the blueberry extract. With regard to the morphological properties, it was observed that the samples obtained with WPI showed less shrinkage than HI-CAP 100.

CONCLUSION

The results indicated that an ultrasonic nozzle could be used successfully to prepare the blueberry microcapsule with HI-CAP 100 and WPI as coating materials. This study may contribute to the development of ultrasonic nozzle applications using different coatings for the microencapsulation of high-quality functional materials. © 2020 Society of Chemical Industry.

Oral encapsulated transforming growth factor β1 reduces endogenous levels: Effect on inflammatory bowel disease

BACKGROUND

TreXTAM^® is a combination of the key regulatory cytokine transforming growth factor beta (TGFβ) and all trans retinoic acid (ATRA) microencapsulated for oral delivery to immune structures of the gut. It is in development as a novel treatment for inflammatory bowel disease (IBD).

AIM

To measure TGFβ levels in blood and tissue after oral administration of encapsulated TGFβ.

METHODS

Animals were orally administered encapsulated TGFβ by gavage. Levels of drug substance in blood and in gut tissues at various times after administration were measured by ELISA.

RESULTS

We made the surprising discovery that oral administration of TreXTAM dramatically (approximately 50%) and significantly (P = 0.025) reduced TGFβ levels in colon, but not small intestine or mesenteric lymph nodes. Similarly, levels in rat serum after 25 d of thrice weekly dosing with either TreXTAM, or microencapsulated TGFβ alone (denoted as TPX6001) were significantly (P < 0.01) reduced from baseline levels. When tested in the SCID mouse CD4+CD25- adoptive cell transfer (ACT) model of IBD, oral TPX6001 alone provided only a transient benefit in terms of reduced weight loss.

CONCLUSION

These observations suggest a negative feedback mechanism in the gut whereby local delivery of TGFβ results in reduced local and systemic levels of the active form of TGFβ. Our findings suggest potential clinical implications for use of encapsulated TGFβ, perhaps in the context of IBD and/or other instances of fibrosis and/or pathological TGFβ signaling.

Development and Application of a Modified Method to Determine the Encapsulation Efficiency of Proteins in Polymer Matrices

A modified method to determine protein encapsulation efficiency in polymer matrices has been developed and applied to two proteins and two polymers to demonstrate its wide range of applicability. This study was pursued due to the wide variation in reported protein encapsulation efficiency of polymer-based microcapsules, even when the protein, the polymer, and the microcapsule manufacturing method were consistent. Hemoglobin (Hb) and bovine serum albumin (BSA) were chosen as model proteins and ethylcellulose and poly(lactic-co-glycolic acid) (PLGA) as model polymers. The polymer of the microcapsule was dissolved in dichloromethane/ethanol or dichloromethane/ethyl acetate for ethylcellulose or PLGA microcapsules, respectively. Liberated proteins were simultaneously precipitated, pelleted by centrifugation, isolated by decanting the polymer solution, redissolved in 10% w/v sodium dodecyl sulfate in 0.8 N sodium hydroxide, and quantified using a modified Lowry assay. Blank microcapsules and exogenously added proteins demonstrated ≥ 93.8% recovery of proteins. The mean encapsulation efficiency of ethylcellulose or PLGA microcapsules was 52.4 or 76.9% for Hb and 86.4 or 74.7% for BSA, respectively. This demonstrates the effective use of centrifugation and the importance of an appropriate cosolvent system in the measure of encapsulation efficiency where one solvent dissolves the polymer while the other solvent quantitatively precipitates the liberated protein. It is evident that an alkaline solution of sodium dodecyl sulfate is efficient at quantitatively dissolving precipitated proteins. Remediation of problems observed with current methods and high reproducibility suggest that this modified method is generally applicable to the measure of protein encapsulation efficiency of polymer microcapsules.

An Efficient, Lung-Targeted, Drug-Delivery System To Treat Asthma Via Microparticles

BACKGROUND

Chronic diseases such as diabetes, asthma, and heart disease are the leading causes of death in developing countries. Public health plays an important role in preventing such diseases to improve individuals' quality of life. Conventional dosage schemes used in public health to cure various diseases generally lead to undesirable side effects and renders the overall treatment ineffective. For example, a required concentration of drug cannot reach the lungs using conventional methods to cure asthma. Microspheres have emerged as a confirmed drug-delivery system to cure asthma.

METHOD

In this paper, a salbutamol-loaded poly lactic acid-co-glycolic acid-polyethylene glycol (PLGA-PEG) microsphere (SPP)-based formulation was prepared using a Buchi B-90 nanospray drier. Face-centered central composite design (CCD) was applied to optimize the spray-drying process.

RESULTS

The drug content and product yield were found to be 72%±0.8% and 86%±0.4%, respectively; drug release (91.1%) peaked for up to 12 hrs in vitro. Microspheres obtained from the spray dryer were found to be shriveled. The experiments were carried out and verified using various groups of rabbits. In our study, the particle size (8.24 µm) was observed to be an essential parameter for drug delivery. The in vivo results indicated that the targeting efficacy and drug concentration in the lung was higher with the salbutamol-loaded PLGA-PEG SPP formulation (1,410.1±10.11 µg/g, 15 mins), as compared to the conventional formulation (92±0.56 µg/g, 10 min). The final product was stable under 5°C±2°C, 25°C±2°C, and 40°C±2°C/75%±5% relative humidity. In addition, these co-polymers have a good safety profile, as determined by testing on human alveolar basal epithelium A549 cell lines.

CONCLUSION

Our results prove that microspheres are an alternative drug-delivery system for lung-targeted asthma treatments used in public health.

Recent Development of Optimization of Lyophilization Process

The objective of this review is to survey the development of the optimization of lyophilization. The optimization study of the lyophilizer has been roughly developing by the order of (i) trial-and-error approach, (ii) process modeling using mathematical models, (iii) scalability, and (iv) quality-by-design. From the conventional lyophilization studies based on the trial-and-error, the key parameters to optimize the operation of lyophilization were found out, i.e., critical material attributes (CMAs), critical process parameters (CPPs), and critical quality attributes (CQAs). The mathematical models using the key parameters mentioned above have been constructed from the viewpoints of the heat and mass transfer natures. In many cases, it is revealed that the control of the primary drying stage determines the outcome of the lyophilization of products, as compared with the freezing stage and the secondary drying stage. Thus, the understanding of the lyophilization process has proceeded. For the further improvement of the time and economical cost, the design space is a promising method to give the possible operation range for optimizing the lyophilization operation. This method is to search the optimized condition by reducing the number of key parameters of CMAs, CPPs, and CQAs. Alternatively, the transfer of lyophilization recipe among the lab-, pilot-, and production-scale lyophilizers (scale-up) has been examined. Notably, the scale-up of lyophilization requires the preservation of lyophilization dynamics between the two scales, i.e., the operation of lab- or pilot-scale lyophilizer under HEPA-filtrated airflow condition. The design space determined by focusing on the primary drying stage is large and involves the undesired variations in the quality of final products due to the heterogeneous size distribution of ice crystals. Accordingly, the control of the formation of the ice crystal with large size gave impact on the product quality and the productivity although the large water content in the final product should be improved. Therefore, the lyophilization should take into account the quality by design (QbD). The monitoring method of the quality of the product in lyophilization process is termed the “process analytical technology (PAT).” Recent PAT tools can reveal the lyophilization dynamics to some extent. A combination of PAT tools with a model/scale-up theory is expected to result in the QbD, i.e., a quality/risk management and an in situ optimization of lyophilization operation.

Scale-Up Procedure for Primary Drying Process in Lyophilizer by Using the Vial Heat Transfer and the Drying Resistance

The objective of this study is to design primary drying conditions in a production lyophilizer based on a pilot lyophilizer. Although the shelf temperature and the chamber pressure need to be designed to maintain the sublimation interface temperature of the formulation below the collapse temperature, it is difficult to utilize a production lyophilizer to optimize cycle parameters for manufacturing. In this report, we assumed that the water vapor transfer resistance (R_p) in the pilot lyophilizer can be used in the commercial lyophilizer without any correction, under the condition where both lyophilizers were operated in the high efficiency particulate air (HEPA)-filtrated airflow condition. The shelf temperature and the drying time for the commercial manufacturing were designed based on the maximum R_p value calculated from the pilot lyophilizer (1008 vials) under HEPA-filtrated airflow condition and from the vial heat transfer coefficient of the production lyophilizer (6000 vials). And, the cycle parameters were verified using the production lyophilizer of 60000 vials. It was therefore concluded that the operation of lab- or pilot-scale lyophilizer under HEPA-filtrated airflow condition was one of important factors for the scale-up.

Influence of an ultrasonic nozzle in spray-drying and storage on the properties of blueberry powder and microcapsules

BACKGROUND

Recently, ultrasonic nozzle technology has been applied in spray-drying because of its numerous advantages, including providing more uniform droplets and reducing damage observed in bioactive compounds. In this study, the production of blueberry powders and microcapsules by using an ultrasonic spray nozzle was investigated. Firstly, the important ultrasonic nozzle parameters were optimised by using response surface methodology and compared with a conventional nozzle (control). Secondly, powder and microcapsules obtained at the optimum point were stored at 22 °C and 35 °C at 0.32 water activity (aw ).

RESULTS

The optimum conditions were estimated as 125 °C inlet air temperature, 9 W ultrasonic power and 8% feed pump rate. There was significantly difference (P < 0.05) in the total phenolic content and antioxidant power of microcapsules produced by an ultrasonic nozzle and a conventional nozzle. Because the temperature affected the stability of powders negatively, the blueberry powder showed higher losses than microcapsules in the content of bioactive compounds. In addition, the ultrasonic nozzle showed a significantly greater protective effect on physico-chemical properties than did the conventional nozzle.

CONCLUSION

Results of the study point that the production of ultrasonic nozzle powders and microcapsules is feasible to use as a functional ingredient in food industry. © 2016 Society of Chemical Industry.

A simple derivation of the critical condition for the ultrasonic atomization of polymer solutions

A simple model is proposed for the ultrasonic atomization of polymer solutions. In this model, the atomization process is approximated as an equilibrium process. It is shown that the minimum attainable droplet size is determined by two parameters, the (Rayleigh) acoustic pressure acting on the surface of the liquid, and the surface tension of the liquid. Increasing the viscosity of the liquid suppresses the formation of small-sized droplets because of increased attenuation of the sound wave and thus decreased acoustic pressure. Lowering the surface tension of the liquid (e.g., by spreading a surfactant film on the liquid surface) has the opposite effect of enhancing the formation of smaller droplets. Also, there exists a maximum limit for the droplet size, because when the produced droplet is too large, the aspiration flow is unable to carry the droplet against sedimentation. These predictions are supported by experimental observations.

Effects of different rhBMP-2 release profiles in defect areas around dental implants on bone regeneration

This study was undertaken to evaluate the effects of different rhBMP-2 release profiles in defect areas around dental implants on osseointegration and bone regeneration. Four beagle dogs (13-15 kg) were used. The defect was 3 mm deep and there was a 1 mm gap around the implant. Each of the four implants was installed on the right and left mandibular alveolar ridges. After the implants were placed, experimental groups were applied to the surrounding defect area (n = 8 in each group, the control group was not treated). The inject group was injected with rhBMP-2 solution directly. In the gel group, rhBMP-2 mixed with a hydrogel matrix was applied. In the particle-gel group, rhBMP-2-embedded poly(lactic-co-glycolic acid)(PLGA) microparticles mixed with hydrogel matrix were applied to maintain consistent release. Sequential fluorescent labeling and histological analysis were performed to evaluate the new bone formation and osseointegration in the defect area. In the control group, larger marginal bone loss was detected as compared with the other groups (P  <  0.05). The gel group showed significantly higher levels of BIC in the buccal and lingual defect areas compared with the other groups (P  <  0.05). New-bone percentages in the inject and gel groups formed more new bone than in the particle-gel and control groups (P  <  0.05). Despite the limitations of this study, the use of only hydrogel, which allows early release of rhBMP-2 followed by consistent extended release, showed better bone formation and osseointegration than simple injection or PLGA microparticles with hydrogel matrix.

Entrapment of protein using electrosprayed poly(D,L-lactide-co-glycolide) microspheres with a porous structure for sustained release

The entrapment of a protein in porous poly(D,L-lactide-co-glycolide) (PLGA) microspheres is demonstrated through the closure of their outer surface pores for sustained delivery of the protein. The porous PLGA microspheres with less than 10 μm in size are prepared by electrospraying. Aqueous solutions containing fluorescein isothiocyanate-dextran or bovine serum albumin (BSA) are penetrated into the inner pores as a result of vacuum treatment, and the outer surface pores of the porous PLGA microspheres are then closed using a solvent (dimethyl sulfoxide) to ensure entrapment of the macromolecules. Confocal microscopy images confirm the presence of a large amount of the macromolecules inside the porous structure. Circular dichroism spectroscopy and release analysis reveal that BSA is entrapped without denaturation and released in a sustained manner for a period of over 2 months, respectively.

Multicenter clinical trial of leuprolide acetate depot (Luphere depot 3.75 mg) for efficacy and safety in girls with central precocious puberty

PURPOSE

We evaluated the efficacy, safety and psychological aspect of monthly administrations of the gonadotropin-releasing hormone agonists (GnRHa), leuprolide acetate depot (Luphere depot 3.75 mg), in patients with precocious puberty.

METHODS

A total of 54 girls with central precocious puberty were administered with leuprolide acetate (Luphere depot 3.75 mg) every four weeks over 24 weeks. We evaluated the percentage of children exhibiting a suppressed luteinizing hormone (LH) response to GnRH (LH peak≤3 IU/L), peak LH/follicle stimulating hormone (FSH) ratio of GnRH stimulation test less than 1, change in bone age/chronologic age ratio, change in the Tanner stage and change in eating habit and psychological aspect.

RESULTS

(1) The percentage of children exhibiting a suppressed LH response to GnRH, defined as an LH peak≤3 IU/L at 24 weeks was 96.3 % (52/54). (2) The percentage of children exhibiting peak LH/FSH ratio<1 at 24 weeks of the study was 94.4 % (51/54). (3) The ratio of bone age and chronological age significantly declined from 1.27±0.07 to 1.24±0.01 after the 6 months of the study. (4) The mean Tanner stage manifested a significant change 2.3±0.48 at baseline, down to 1.70±0.61 at 24 weeks. (5) Based on the questionnaires, the score for eating habits showed a significant change from the baseline 34.0±6.8 to 31.3±6.8. (6) The psychological assessment did not exhibit a significant difference except with scores for sociability, problem behavior total score and other problems.

CONCLUSION

The leuprolide 3.75 mg (Luphere depot) is useful and safety for treating children with central precocious puberty.

Confinement of Acoustic Cavitation for the Synthesis of Protein-Shelled Nanobubbles for Diagnostics and Nucleic Acid Delivery

We report a novel flow-through sonication technique for synthesizing stable and monodispersed nano- and micrometer-sized bubbles that have potential applications in diagnostics and gene therapy. The size and size distribution of the bubbles are controlled by the active cavitation zone generated by ultrasound. These bubbles are shown to possess echogenic properties and can be used for loading oligonucleotides.

Evaluation of ultrasonic atomization as a new approach to prepare ionically cross-linked chitosan microparticles

Ultrasonic atomization was evaluated as a new approach for the preparation of ionically cross-linked controlled-release chitosan microparticles loaded with theophylline as the model drug, using tri-polyphosphate (TPP) as counter-ion. It was possible to nebulize both 2% and 3% (w/v) chitosan solutions as a function of their viscosity, usually not processed by employing the conventional nebulizer. The results of the chitosan molecular characterization using the SEC-MALS analysis revealed that ultrasonic atomization caused a certain depolymerization, probably due to the main chain scission of the 1,4-glycosidic bond; however, Fourier transform-infrared spectroscopy revealed the absence of other chemical modifications. The ultrasonic atomization allowed preparation of TPP cross-linked chitosan microparticles mostly ranging between 50 and 200 μm. As regards manufacturing parameters, the linking time and washing medium were found to affect the properties of the microparticles, while the stirring rate of the TPP solution did not show any influence. The evaluation of the formulation variables revealed that chitosan concentration strongly affected both the feasibility of the ultrasonic atomization and the drug release. All the microparticles showed an encapsulation efficiency of &gt; 50 % and, after an initial burst effect, a controlled release of drug for 48 h. In conclusion, the ultrasonic atomization could be proposed as a robust and innovative single-step procedure with scale-up potential to successfully prepare ionically cross-linked chitosan microparticles.

Nanomedicine in pulmonary delivery

The lung is an attractive target for drug delivery due to noninvasive administration via inhalation aerosols, avoidance of first-pass metabolism, direct delivery to the site of action for the treatment of respiratory diseases, and the availability of a huge surface area for local drug action and systemic absorption of drug. Colloidal carriers (ie, nanocarrier systems) in pulmonary drug delivery offer many advantages such as the potential to achieve relatively uniform distribution of drug dose among the alveoli, achievement of improved solubility of the drug from its own aqueous solubility, a sustained drug release which consequently reduces dosing frequency, improves patient compliance, decreases incidence of side effects, and the potential of drug internalization by cells. This review focuses on the current status and explores the potential of colloidal carriers (ie, nanocarrier systems) in pulmonary drug delivery with special attention to their pharmaceutical aspects. Manufacturing processes, in vitro/in vivo evaluation methods, and regulatory/toxicity issues of nanomedicines in pulmonary delivery are also discussed.

Preparation and characterization of hydroxyapatite-coated iron oxide particles by spray-drying technique

Magnetic particles of iron oxide have been increasingly used in medical diagnosis by magnetic resonance imaging and in cancer therapies involving targeted drug delivery and magnetic hyperthermia. In this study we report the preparation and characterization of iron oxide particles coated with bioceramic hydroxyapatite by spray-drying. The iron oxide magnetic particles (IOMP) were coated with hydroxyapatite (HAp) by spray-drying using two IOMP/HAp ratios (0.7 and 3.2). The magnetic particles were characterized by way of scanning electronic microscopy, energy dispersive X-ray, X-ray diffraction, Fourier transformed infrared spectroscopy, flame atomic absorption spectrometry,vibrating sample magnetometry and particle size distribution (laser diffraction). The surface morphology of the coated samples is different from that of the iron oxide due to formation of hydroxyapatite coating. From an EDX analysis, it was verified that the surface of the coated magnetic particles is composed only of HAp, while the interior containsiron oxide and a few layers of HAp as expected. The results showed that spray-drying technique is an efficient and relatively inexpensive method for forming spherical particles with a core/shell structure.

Rapid production of protein-loaded biodegradable microparticles using surface acoustic waves

We present a straightforward and rapid surface acoustic wave (SAW) atomization-based technique for encapsulating proteins into 10 mum order particles composed of a biodegradable polymeric excipient, using bovine serum albumin (BSA) as an exemplar. Scans obtained from confocal microscopy provide qualitative proof of encapsulation and show the fluorescent conjugated protein to be distributed in a relatively uniform manner within the polymer shell. An ELISA assay of the collected particles demonstrates that the BSA survives the atomization, particle formation, and collection process with a yield of approximately 55%. The SAW atomization universally gave particles with a textured morphology, and increasing the frequency and polymer concentration generally gave smaller particles (to 3 mum average) with reduced porosity.

BSA-FITC-loaded microcapsules for in vivo delivery

Here we describe the preparation of BSA-FITC-loaded microcapsules as a model protein system for in vivo delivery. BSA-FITC-loaded microcapsules were prepared using a mono-axial nozzle ultrasonic atomizer, varying a number of parameters to determine optimal conditions. The preparation method chosen resulted in a BSA-FITC encapsulation efficiency of approximately 60% and a particle size of approximately 50 microm. An analysis of the microcapsules showed a BSA-FITC core surrounded by a poly(D,L-lactic-co-glycolic acid) (PLGA) shell. Injection of BSA-FITC-loaded microcapsules into rats resulted in a sustained release of BSA-FITC that maintained increased concentrations of BSA-FITC in plasma for up to 2 weeks. In contrast, the concentration of BSA-FITC in plasma after injection of BSA-FITC-only solution reached near-zero levels within 3 days. Fluorescence images of microcapsules removed at various times after implantation showed a gradual decrease of BSA-FITC in BSA-FITC-loaded microcapsules, confirming a sustained in vivo release of BSA-FITC. The duration of in vivo release and plasma concentration of BSA-FITC was correlated with the initial dose of BSA-FITC. BSA-FITC-loaded microcapsules maintained their structure for at least 4 weeks in the rat. The inflammatory response observed initially after injection declined over time. In conclusion, BSA-FITC-loaded microcapsules achieved sustained release of BSA-FITC, suggesting that microcapsules manufactured as described may be useful for in vivo delivery of pharmacologically active proteins.

Monodisperse structured multi-vesicle microencapsulation using flow-focusing and controlled disturbance

A method to produce monodisperse structured microcapsules in the diameter range from 10-100 microm is here presented. Flow-focusing is a well known technique whereby a steady capillary micro-jet is generated by the action of a highly accelerated co-flowing stream forced through a small orifice. The micro-jet breaks up owing to capillary instability, giving rise to droplets with a narrow size distribution. In the present study, flow-focusing gives rise not to simple but to compound capillary jets. At break-up, under suitable control parameters, such jets give rise to microcapsules where an outer liquid (shell liquid) surrounds a core liquid integrated by one or more vesicles. Furthermore, under adequate stimulation combining a sinusoidal signal with intermittent pulses, the jet break-up can be controlled. Highly monodisperse microcapsules are produced; fundamental geometric parameters (main diameter, shell thickness or number of cores) are reliably controlled. Rather than using a gas flow to focus the concentric stream of two immiscible liquids, this study has investigated in some detail the evolution of a concentric stream of three immiscible liquids forced through a small orifice. The selection of the surface tension coefficients between the three phases ensures the robust production of a microcapsule structure involving a plurality of vesicles homogeneously distributed in the capsule bulk, the number of cores being a freely chosen parameter. Such composite microcapsules find a broad field of technological applications in the pharmaceutical, food or biotechnology industries.

Electrospray encapsulation of water-soluble protein with polylactide. I. Effects of formulations and process on morphology and particle size

Bovine serum albumin (BSA) was encapsulated with poly (lactide) (PLA) using an electrospray technique in which a sufficiently strong electric field was applied to overcome the surface tension of a droplet and to produce small particles. The influences of PLA solvent type, PLA solution concentrations; the viscosity, electrical conductivity and surface tension of PLA solutions and PLA/BSA emulsions; and the applied voltage and flow rate on the morphology and size of the BSA-loaded PLA particles were examined. 1,2-dichloroethane (DCE) was a better solvent for PLA than dichloromethane. Spherical electrosprayed particles, with smooth surfaces, were observed with both solvents. The electrical conductivity increased and particle size decreased when acetone was mixed with DCE as PLA solvent. However, the particles were no longer spherical. The size of the particles increased and shape became spherical as PLA concentration was increased from 1-3%. Increasing the concentration to 4% resulted in the formation of a mixture of beads and fibres. Particle size decreased as applied voltage was increased from 10-15 kV and increased as flow rate was increased from 0.5-3 ml h(-1).

Process considerations related to the microencapsulation of plasmid DNA via ultrasonic atomization

An effective means of facilitating DNA vaccine delivery to antigen presenting cells is through biodegradable microspheres. Microspheres offer distinct advantages over other delivery technologies by providing release of DNA vaccine in its bioactive form in a controlled fashion. In this study, biodegradable poly(D,L-lactide-co-glycolide) (PLGA) microspheres containing polyethylenimine (PEI) condensed plasmid DNA (pDNA) were prepared using a 40 kHz ultrasonic atomization system. Process synthesis parameters, which are important to the scale-up of microspheres that are suitable for nasal delivery (i.e., less than 20 microm), were studied. These parameters include polymer concentration; feed flowrate; volumetric ratio of polymer and pDNA-PEI (plasmid DNA-polyethylenimine) complexes; and nitrogen to phosphorous (N/P) ratio. PDNA encapsulation efficiencies were predominantly in the range 82-96%, and the mean sizes of the particle were between 6 and 15 microm. The ultrasonic synthesis method was shown to have excellent reproducibility. PEI affected morphology of the microspheres, as it induced the formation of porous particles that accelerate the release rate of pDNA. The PLGA microspheres displayed an in vitro release of pDNA of 95-99% within 30 days and demonstrated zero order release kinetics without an initial spike of pDNA. Agarose electrophoresis confirmed conservation of the supercoiled form of pDNA throughout the synthesis and in vitro release stages. It was concluded that ultrasonic atomization is an efficient technique to overcome the key obstacles in scaling-up the manufacture of encapsulated vaccine for clinical trials and ultimately, commercial applications.

Encapsulation of indomethacin using coaxial ultrasonic atomization followed by solvent evaporation

We have encapsulated indomethacin into poly (lactide-co-glycolide) (PLGA) using coaxial ultrasonic atomization technique. The specific aims of this study were to evaluate the effect of drug loading and a change in relative concentration of polymer in the inner and outer layers of coflowing spray liquids on the physicochemical characteristics of the particles. Indomethacin, a non steroidal anti-inflammatory drug, was selected as a model compound. The micro/nanocapsules prepared using a drug free PLGA solution as an outer layer showed higher encapsulation efficiency. Thermal analysis of the formulations indicated that indomethacin was dissolved within the PLGA matrix. The formulations prepared with 25 mg indomethacin showed relatively smaller particle size compared with the formulations prepared with 50 mg indomethacin. The particles, in general, showed bi- and tri-modal distribution. Irrespective of the compositions of the liquids 1 and 2, all the particles were smooth and spherical. A cross-section view of the particles revealed the presence of three different internal morphologies. These formulations were a mixture of hollow or solid spheres, and single or multiple spheres encapsulated into a larger sphere. To the best of our knowledge, this is the first study revealing the cross-sectional view of particles prepared with coaxial ultrasonic atomization technique.

Kinetics of solvent extraction/evaporation process for PLGA microparticle fabrication

Organic solvent extraction/evaporation from an o/w-dispersion has been widely used for the fabrication of PLGA microparticles. The purpose of this work was to elucidate the kinetics of the solvent extraction/evaporation process. A mathematical diffusion model was developed and applied to predict the duration of the solvent extraction. As the diffusion coefficient, D(p), plays a major role in the modeled process, a new and experimentally simple method for estimating D(p) was developed. Both the experimental method and the mathematical model were validated through PLGA microparticle fabrication experiments. For microparticles of mode diameters of 2 and 20 microm, the solvent was extracted in approximately 10 s. Sufficient hardening of the microparticles required, however, the evaporation of solvent from the extraction phase. Residual solvent in extraction phase exerted a strong effect on the morphology of the final product as demonstrated by scanning electron microscopy. Only if most solvent was removed from the aqueous extraction phase, a powdery product of individual microparticles was obtained. At residual organic solvent concentration of above 0.2% in the extraction phase, the microparticles strongly aggregated during collection on a membrane filter and final drying. The presented methods may be useful for better controlling microparticle fabrication processes by solvent extraction/evaporation.

Pharmaceutical particle engineering via spray drying

This review covers recent developments in the area of particle engineering via spray drying. The last decade has seen a shift from empirical formulation efforts to an engineering approach based on a better understanding of particle formation in the spray drying process. Microparticles with nanoscale substructures can now be designed and their functionality has contributed significantly to stability and efficacy of the particulate dosage form. The review provides concepts and a theoretical framework for particle design calculations. It reviews experimental research into parameters that influence particle formation. A classification based on dimensionless numbers is presented that can be used to estimate how excipient properties in combination with process parameters influence the morphology of the engineered particles. A wide range of pharmaceutical application examples—low density particles, composite particles, microencapsulation, and glass stabilization—is discussed, with specific emphasis on the underlying particle formation mechanisms and design concepts.

Particle Engineering for Pulmonary Drug Delivery

With the rapidly growing popularity and sophistication of inhalation therapy, there is an increasing demand for tailor-made inhalable drug particles capable of affording the most efficient delivery to the lungs and the most optimal therapeutic outcomes. To cope with this formulation demand, a wide variety of novel particle technologies have emerged over the past decade. The present review is intended to provide a critical account of the current goals and technologies of particle engineering for the development of pulmonary drug delivery systems. These technologies cover traditional micronization and powder blending, controlled solvent crystallization, spray drying, spray freeze drying, particle formation from liquid dispersion systems, supercritical fluid processing and particle coating. The merits and limitations of these technologies are discussed with reference to their applications to specific drug and/or excipient materials. The regulatory requirements applicable to particulate inhalation products are also reviewed briefly.

A Novel Preparation Method for Microspheres of Water Soluble Polymers Using Polypropyleneglycol as the Dispersion Medium

Polypropyleneglycol (PPG) was used as a dispersion medium for the preparation of microspheres (MS) consisting of starch, gelatin, whey protein or dextran. Aqueous solutions of the polymers were dispersed in PPG at various initial temperatures and then the systems were cooled to 0.5 degrees C to allow water in the dispersed phase to dissolve in PPG. The particle size of the starch-MS was dependent on the initial temperature of PPG in the preparation process. There were two different processes for particle generation in the procedure. One of them was via the formation of a temporary emulsion during the early phase of dispersion of the aqueous polymer solution into PPG. The other was via the stable emulsion in which the aqueous polymer solution was dispersed in water-saturated PPG. The particle size generated in the former process was dependent on the initial temperature: a high temperature gave large particles but a low temperature gave small particles, while that in the latter process was temperature-independent. This preparation method for MS will be useful for the formulation of heat-sensitive material, such as protein-containing drugs.

Encapsulation of proteins in biodegradable polymeric microparticles using electrospray in the Taylor cone-jet mode

Solvent extraction (or evaporation from a W(1)/O/W(2)-dispersion), coacervation, and spray drying methods are commonly employed to encapsulate protein drugs in polymeric microparticles for sustained delivery applications. To overcome the limitations of these methods, a novel electrospray method was developed to encapsulate a model protein drug-bovine serum albumin (BSA) in biodegradable polymeric microparticles and examine the feasibility of the process in not denaturing the protein. Microparticles of approximately 20 microm diameter with corrugated surfaces and smooth surfaces were observed by scanning electron microscope. Confocal laser scanning microscope images showed that BSA was distributed evenly in microparticles. Sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) was employed to investigate the protein integrity of BSA released from the polymer matrix after 38 days. No protein degradation was observed during the 38 days release. The secondary structure of released BSA was characterized by Fourier transform infrared (FTIR) and circular dichroism (CD), which suggested that the released BSA was almost identical to native BSA. The encapsulation efficiency could reach 76% by adjusting the amount of the additive Pluronic F127 and processing parameters. The release profile could be tailored by the fabrication process and the sustained release of BSA could endure for more than 1 month. More than 80% of the bioactivity of BSA (evaluated by BSA ELISA kit) could be maintained after releasing from polymer matrix. Findings of the present study demonstrate that this novel electrospray method is a promising approach to encapsulate bioactive materials such as proteins, enzymes, antibiotics, and DNA fragments in biodegradable polymeric particles.

Continuous contact- and contamination-free ultrasonic emulsification-a useful tool for pharmaceutical development and production

A novel concept was developed here for the continuous, contact- and contamination-free treatment of fluid mixtures with ultrasound. It is based on exciting a steel jacket with an ultrasonic transducer, which transmitted the sound waves via pressurised water to a glass tube installed inside the jacket. Thus, no metallic particles can be emitted into the sonicated fluid, which is a common problem when a sonotrode and a fluid are in direct contact. Moreover, contamination of the fluid from the environment can be avoided, making the novel ultrasonic flow-through cell highly suitable for aseptic production of pharmaceutical preparations. As a model system, vegetable oil-in-water emulsions, fed into the cell as coarse pre-emulsions, were studied. The mean droplet diameter was decreased by two orders of magnitude yielding Sauter diameters of 0.5 microm and below with good repeatability. Increasing the residence time in the ultrasonic field and the sonication power both decreased the emulsion mean diameter. Furthermore, the ultrasonic flow-through cell was found to be well suited for the production of nanoparticles of biodegradable polymers by the emulsion-solvent extraction/ evaporation method. Here, perfectly spherical particles of a volume mean diameter of less than 0.5 microm could be prepared. In conclusion, this novel technology offers a pharmaceutically interesting platform for nanodroplet and nanoparticle production and is well suited for aseptic continuous processing.

Microspheres for Drug Delivery

With advances in biotechnology, genomics, and combinatorial chemistry, a wide variety of new, more potent and specific therapeutics are being created. Because of common problems such as low solubility, high potency, and/or poor stability of many of these new drugs, the means of drug delivery can impact efficacy and potential for commercialization as much as the nature of the drug itself. Thus, there is a corresponding need for safer and more effective methods and devices for drug delivery. Indeed, drug delivery systems—designed to provide a therapeutic agent in the needed amount, at the right time, to the proper location in the body, in a manner that optimizes efficacy, increases compliance and minimizes side effects—were responsible for $47 billion in sales in 2002, and the drug delivery market is expected to grow to $67 billion by 2006.