Rapid on-Chip Assembly of Niosomes: Batch versus Continuous Flow Reactors.

Area of Science:

• Materials Science
• Nanotechnology
• Biotechnology

Background:

• Large-scale niosome production is hindered by batch process limitations like polydispersity and poor reproducibility.
• Traditional methods struggle to meet industrial demands for consistent niosome manufacturing.

Purpose of the Study:

• To develop a scalable and reproducible method for continuous niosome production using microfluidic reactors.
• To characterize the niosomes produced, including particle size, stability, morphology, and drug-carrying capacity.

Main Methods:

• Utilized commercially available microfluidic reactors for continuous niosome synthesis via thin film hydration and emulsification techniques.
• Employed high-resolution transmission electron microscopy (HR-STEM) for structural elucidation and morphology assessment.
• Assessed colloidal stability over six weeks and evaluated the encapsulation of hydrophilic and hydrophobic molecules using laser scanning confocal microscopy.

Main Results:

• Achieved homogeneous, large-scale niosome production (up to 120 mg/min) with improved batch-to-batch reproducibility.
• Demonstrated precise control over niosome particle size by adjusting synthesis temperature.
• Confirmed high cytocompatibility across three somatic cell lines and elucidated niosome multilamellar shell structure.

Conclusions:

• Microfluidic reactors offer a superior alternative to traditional batch methods for scalable niosome synthesis.
• The developed method allows for tunable particle size and demonstrates the potential of niosomes for dual-payload delivery.
• Niosomes produced via microfluidics exhibit excellent colloidal stability and cytocompatibility, paving the way for advanced therapeutic applications.