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Updated: Mar 22, 2026

Flash NanoPrecipitation for the Encapsulation of Hydrophobic and Hydrophilic Compounds in Polymeric Nanoparticles

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NANEX: Process design and optimization.

Ramona Baumgartner¹, Josip Matić², Simone Schrank³

¹Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.

International Journal of Pharmaceutics

|April 20, 2016

Summary

The nano-extrusion (NANEX) process effectively incorporates high drug loadings into solid formulations by managing water content. This study optimizes NANEX for various polymers, enabling efficient water removal and high drug content in final products.

Keywords:

Devolatilization Mean residence time NANEX design and optimization One-step nano-extrusion process Screw configuration Water integration capacity

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Last Updated: Mar 22, 2026

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Area of Science:

Pharmaceutical Technology
Polymer Science
Chemical Engineering

Background:

The nano-extrusion (NANEX) process enables direct liquid-phase transfer of aqueous nano-suspensions into solid formulations.
Current limitations restrict drug content to 30% (w/w), necessitating higher water processing and deeper process understanding for increased drug loading.

Purpose of the Study:

To investigate the maximum water uptake/removal capacity of four different polymers (Kollidon® VA64, Eudragit® E PO, HPMCAS, PEG 20000) using the NANEX process.
To understand the impact of process parameters (throughput, screw speed) on mean residence time and filling degree during water management.
To model the interactions between screw geometry and process parameters for water addition/removal.

Main Methods:

Investigated water uptake/removal in four polymers with varying physicochemical properties.
Adapted process parameters like throughput and screw speed, monitoring mean residence time and filling degree.
Performed one-dimensional discretization modeling to analyze screw geometry and process parameter interactions.

Main Results:

Established that NANEX is suitable for polymers exhibiting specific water miscibility/solubility.
Identified that extended residence times in the extruder and low filling degrees in the degassing zone facilitate significant water addition/removal.
Achieved residual moisture content in extrudates comparable to those produced without water addition.

Conclusions:

The NANEX process can be optimized for various polymers to achieve high drug loadings by effectively managing water content.
Process parameters and polymer properties critically influence water handling during nano-extrusion.
NANEX offers a viable method for producing solid drug formulations with high drug content and controlled moisture levels.