Production of dry-state ketoprofen-encapsulated PMMA NPs by coupling micromixer-assisted nanoprecipitation and spray drying.

We present a two-step process to produce dry-state Ketoprofen-loaded poly(methyl methacrylate) nanoparticles (NPs) with controllable size and tunable drug release profile. A colloidal suspension of drug-loaded nanoparticles was first obtained from a nanoprecipitation process and then transferred into a commercial spray dryer. Three micromixers of different designs and mixing principles (molecular diffusion and impact mixing) were tested. After the first step, highly monomodal NPs in the size range 100 to 210 nm were obtained as seen by the low polydispersity index value (ca. PDI ∼ 0.2) returned by a dynamic light scattering detector. Physicochemical properties, encapsulation efficiency/ratio and drug release kinetics of NPs before and after drying were determined. For similar operating conditions, the best micromixer tested (impact mixing) allowed concluding that the NPs size was not significantly affected by the spray drying while encapsulation parameters and drug release rate were slightly decreased compared to the non spray-dried NPs. A sustained drug release was observed over 6 h and the drug release rate (up to 70%) was found to vary with the size of the NPs which in turn was a function of the flow rate ratio between the polymer solution and the non-solvent solution.