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Microfluidic generation of nanoparticles using standing wave induced ultrasonic spray drying
Holger Bolze1,2, Keiran Mc Carogher1, Simon Kuhn1
1KU Leuven, Department of Chemical Engineering Celestijnenlaan 200F 3001 Leuven Belgium simon.kuhn@kuleuven.be.
Nanoscale Advances
|March 17, 2025
Summary
A novel plug flow method enhances spray drying atomization using ultrasound, creating uniform 7.24 μm droplets. This energy-efficient process successfully produces 140 nm pharmaceutical lipid nanoparticles.
Area of Science:
- Chemical Engineering
- Materials Science
- Pharmaceutical Technology
Background:
- Spray drying is vital for pharmaceutical particle generation.
- Droplet size in atomization directly impacts final particle characteristics.
- Conventional ultrasound atomization can be energy-intensive.
Purpose of the Study:
- To investigate a novel plug flow-induced surface atomization method for microfluidic applications.
- To evaluate its efficacy for producing pharmaceutical carrier particles and nanoparticles.
- To assess the energy efficiency and droplet characteristics of this new atomization technique.
Main Methods:
- Utilizing plug flow within a microfluidic device to generate resonating plugs.
- Applying ultrasound frequency to trigger surface atomization and droplet formation.
- Characterizing droplet size, polydispersity index (PDI), and nanoparticle generation.
Main Results:
- Achieved monodisperse droplets with an average size of 7.24 μm and a PDI of 0.18.
- Demonstrated an energy-efficient pulsed atomization process (<1 W power).
- Successfully generated lipid nanoparticles with an average size of 140 nm.
Conclusions:
- The plug flow-induced surface atomization is a viable and energy-efficient method for microfluidic spray drying.
- This technique shows significant potential for controlled nanoparticle production, particularly for pharmaceutical applications.
- The discrete burst events offer precise control over particle generation.
