Analysis of process parameters affecting spray-dried oily core nanocapsules using factorial design

Area of Science:

• Pharmaceutical Technology
• Materials Science
• Chemical Engineering

Background:

• Optimizing nanocapsule production is crucial for effective drug delivery.
• Spray drying is a common method for producing nanocapsules, but requires precise parameter control.
• Oily core nanocapsules offer unique properties for encapsulating lipophilic drugs.

Purpose of the Study:

• To optimize process parameters for spray-dried oily core nanocapsules (NCs) production.
• To achieve targeted size and high drug yield using a fractional factorial experimental design (FFED).
• To characterize the physical and morphological properties of the produced NCs.

Main Methods:

• A two-level four-factor fractional factorial experimental design (FFED) was employed.
• Process parameters included inlet temperature, feed flow rate, atomizing air flow, and aspiration rate.
• Nanocapsules were characterized for size (dynamic light scattering), yield, morphology (electron microscopy), and powder flowability (Carr's index, Hausner ratio).

Main Results:

• Mean nanocapsule size ranged from 129.5 to 444.8 nm, with yields from 14.1% to 31.1%.
• Statistical analysis confirmed the model's ability to predict yield based on process parameters.
• Optimal conditions predicted a maximum yield of 30.8%, producing spherical NCs with an oily core and sizes under 200 nm.

Conclusions:

• The FFED is an effective method for optimizing spray-dried nanocapsule production.
• Specific process parameters were identified to control nanocapsule size and maximize drug yield.
• Successfully produced spray-dried oily core NCs with targeted characteristics for potential pharmaceutical applications.