Microencapsulation of bioactive principles with an airless spray-gun suitable for processing high viscous solutions

Area of Science:

• Chemical Engineering
• Materials Science
• Pharmaceutical Technology

Background:

• Producing microparticles (MPs) from highly viscous feed solutions (FSs) presents significant manufacturing challenges.
• Existing methods may not be optimized for high-viscosity materials, limiting scalability and efficiency.

Purpose of the Study:

• To design, assemble, and test a novel production plant prototype for manufacturing MPs from viscous FSs.
• To evaluate the prototype's performance and suitability for large-scale production.

Main Methods:

• The prototype integrated components like an air compressor, piston pump, spray-gun, and filtration system.
• Parameter optimization involved nozzle selection, nebulization timing, and CaCl2 concentration.
• MP characterization included size, distribution, flow properties, swelling, encapsulation efficiency, and release.

Main Results:

• The prototype successfully processed FSs up to 3% alginate concentration, yielding high throughput from 2 L.
• Optimal CaCl2 concentration was identified as 15% w/v.
• Characterized MPs exhibited irregular morphology, good flowability, gastro-resistance, and potential for prolonged release.

Conclusions:

• The developed prototype is suitable for processing large volumes (≥2 L) of high-viscosity FSs.
• The produced MPs are viable for bioactive principle delivery applications.
• The system demonstrates potential for efficient and scalable microparticle production.