Preparation and comparison of spray dried and electrospun bioresorbable drug delivery systems

•Raman spectrometry as a potential process analytical technology tool for spray drying.•Spray dried and electrospun bioresorbable drug delivery systems.•Electrospun solid solution for smooth release of water soluble drug.

Two continuous processes, the spray drying method, producing microparticles in presence of hot gas flow, and the electrospinning technology, producing continuous polymer nanofibers at low temperature under high electric fields, were investigated and compared the first time. Both techniques were used to prepare slow release caffeine (as a model of rapidly water-soluble drug) using water-insoluble, biocompatible and bioresorbable PLGA and PLA as polymeric matrix. The structural characterization of the obtained samples was performed using SEM, XRD, DSC and at-line Raman mapping, while in vitro dissolution was detected by UV spectrophotometer. We found that the release profile of a highly water soluble drug can be adjusted to the requirements through the investigated continuous technologies. Solid molecular dispersion of caffeine at colloidal level could be prepared in PLA matrix using electrostatic spinning. Furthermore the continuous nonwoven structure of ultrafine fibers, produced this way, allows easer handling than that of independent fine particle’s. On the other hand continuous production of drug loaded microspheres with slightly less performance can be performed with the conventional technology of spray drying which is well known in the pharmaceutical industry.

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