The influence of customized geometries and process parameters on nanoemulsion and solid lipid nanoparticle production in microsystems

In many fields of research and technology, nanodisperse formulations are applied. Especially in pharmaceutical applications, it is necessary to facilitate the processing of small educt batches for formulation screening of new active pharmaceutical ingredient in high quality. In this study, the design of microsystems for high-pressure homogenization is systematically studied and variations of design parameters are evaluated. The designs primarily produced in silicon are successfully transferred to stainless steel to facilitate higher pressure drops over the homogenizing structure at elevated temperature required for solid lipid nanoparticle (SLN) processing. Different groups of geometric principles are applied and can be ranked by droplet breakup efficiency: straight channel < z-channel < orifice ∼ y-channel. Changes within a geometric principle alter the droplet breakup efficiency as well. Conclusively, nanoemulsion (NE) and SLN can be produced in the customized microchannels presented. Especially multiple orifice systems and y-channels with rounded inlet structures prove most efficient.

► Production of nanoemulsion and solid lipid nanoparticle in customized microchannels.
► Systematical evaluation of various microchannel geometries.
► Orifice and Y-shaped microchannels prove most efficient.
► Facilitation of continuous production (only one cycle needed).