Novel multi-nozzle spray coating technology for the continuous production and isolation of drug nanoparticles

Different strategies have been employed to improve the bioavailability of poorly soluble drug candidates, including nanomaterials like polymeric and raw-drug nanoparticles. A multitude of top-down and bottom-up approaches have been reported in the literature to date to produce such products, but the adoption of bottom-up methods in industry is still limited due to technical challenges like low yields, particle aggregation, and inadequate rheological properties. This work presents a novel technology termed multi-nozzle supercritical enhanced nano-coating (MUSENC) for the simultaneous production and isolation of drug nanoparticles. Using multiple spraying nozzles, nanoparticles of celecoxib (263 ± 59 nm) were coated onto micron-sized carrier particles, enhancing yield (61 ± 4 %) and isolation efficiency (drug loading of 6.1 ± 0.4 %). Computational fluid dynamics simulations provided insights into the interactions of the spraying jets, aiding in process optimization. All formulations exhibited good flowability and mechanical strength, demonstrating the effectiveness of this continuous single-step manufacturing process.