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.