Sub-100-micron calcium-alginate microspheres: Preparation by nitrogen flow focusing, dependence of spherical shape on gas streams and a drug carrier using acetaminophen as a model drug

We developed a miniature gas-liquid coaxial flow device using glass capillaries, aiming to produce sub-100-μm Ca-alginate microspheres. Depending on collecting distance and the flow rates of nitrogen gas and alginate solution, however, Ca-alginate microparticles of different shapes were obtained. Spherical, monodisperse microparticles (microspheres) could only be obtained at certain gas flow rates and within a corresponding range of collecting distance. The result suggests that, for particles of this size, the gas flow rate and collecting distance are crucial for the formation of the spherical shape. We evaluated, as an example of its applications, the microsphere as a drug carrier using acetaminophen as a model drug. Large (~150 μm) and small (~70 μm) drug-loaded microspheres were prepared using two respective devices. Specifically, the drug-loaded microspheres were complexed with chitosan of different molecular weights. The dependence of in vitro drug release on the microsphere size and the chitosan molecular weight was examined. Alginic acid sodium salt (PubChem CID: 5102882); Chitosan (PubChem CID: 71853); Calcium chloride (PubChem CID: 5284359); Sodium chloride (PubChem CID: 5234); Acetaminophen (PubChem CID: 1983); Polydimethylsiloxane (PubChem CID: 24771); n-Octadecyltrimethoxysilane (PubChem CID: 76486). [Display omitted] •A miniature gas-liquid coaxial flow capillary device was developed.•The coaxial alignment of capillaries was ensured by a special clamping mechanism.•Monodisperse sub-100-μm Ca-alginate microspheres were produced at particular operating conditions.•The gas stream providing the droplets additional kinetic energy was important for the formation of the spherical shape.•The size of the polyelectrolyte complex microspheres was found to be important for retarding the initial burst release of drug.