Drug nanoparticles by antisolvent precipitation: Mixing energy versus surfactant stabilization

Organic itraconazole (ITZ) solutions were mixed with aqueous solutions to precipitate sub-300 nm particles over a wide range of energy dissipation rates, even for drug loadings as high as 86% (ITZ weight/total weight). The small particle sizes were produced with the stabilizer poloxamer 407, which lowered the interfacial tension, increasing the nucleation rate while inhibiting growth by coagulation and condensation. The highest nucleation rates and slowest growth rates were found at temperatures below 20 C and increased with surfactant concentration and Reynolds number (Re). This increase in the time scale for growth reduced the Damkohler number (Da) (mixing time/precipitation time) to low values even for modest mixing energies. As the stabilizer concentration increased, the average particle size decreased and reached a threshold where Da may be considered to be unity. Da was maintained at a low value by compensating for a change in one variable away from optimum conditions (for small particles) by manipulating another variable. This tradeoff in compensation variables was demonstrated for organic flow rate vs Re, Re vs stabilizer concentration, stabilizer feed location (organic phase vs aqueous phase) vs stabilizer concentration, and stabilizer feed location vs Re. A decrease in the nucleation rate with particle density in the aqueous suspension indicated that secondary nucleation was minimal. A fundamental understanding of particle size control in antisolvent precipitation is beneficial for designing mixing systems and surfactant stabilizers for forming nanoparticles of poorly water soluble drugs with the potential for high dissolution rates.