Theory and practice of electrospray crystallization in particle size reduction

Nowdays, one of the most challenges for the researchers is the formulation of poorly water soluble drugs. Reduction of particle size of active agents to submicron range could result in a faster dissolution rate and higher bioavailability. Integration as crystallization process is an often used particle size decreasing technique. The aim of this study was to show the theoretical background and practical application of the electros pray crystallization as an innovative particle size decreasing technique. Our model drug was the niflumic acid (NIF), which belongs to the BCS Class II. After the optimization of the process parameters, the physico-chemical properties of the samples were characterized. Particle size and shape were visualized by scanning electron microscopy (SEM). Crystalline state of NIF and the samples were investigated using differential scanning calorimetry (DSC) and X-ray powder diffraction. Physico-chemical properties were determined using dissolution test from simulated media. The electrospray crytallization resulted in particle size reduction but the aggregation of nanonized NIF crystals (NIF-nano) could not avoid without excipient. Aggregates with poor secondary forces are suitable for production of the interactive physical mixture. It was found that NIF-nano could be well distributed on the surface of the mannitol as carrier and the Poloxamer R protected the NIF-nano crystals (320 nm)from aggregation. Consequently, the physical mixture resulted in product with higher polarity, better wettability and faster dissolution rate of NIF as raw NIF or NIF-nano.