In an attempt to overcome problems of conventional high-energy preparation processes for colloidal drug carrier systems, premix membrane emulsification was investigated for the first time as an alternative low-energy input process for the preparation of pharmaceutical nanoemulsions and solid lipid nanoparticles. The effect of process parameters on dispersions based on nonpolar lipids (medium-chain triglycerides, soybean oil, and trimyristin) and different emulsifiers (sodium dodecyl sulfate, poloxamer 188, polyglyceryl-10-laurate, and sucrose laurate) was studied in a small-volume device and a larger scale-up approach. For emulsions and suspensions, mean particle sizes in a range from about 100 to 200 nm were observed for monomodal to monodisperse particle size distributions after 21 cycles of extrusion through polycarbonate membrane filters. As the mass ratio of matrix lipid to emulsifier (4:3, w/w concentrations) usually applied for the preparation of stable colloidal lipid particles was quite high, the amount of emulsifier in the dispersions was minimized. It was observed that the minimal concentration of emulsifier increased with decreasing membrane pore size. The possibility to prepare colloidal drug carrier systems with a high concentration of matrix lipid (up to 20%) by an optimized membrane extrusion process offers new opportunities for the processing of sensitive substances.
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