Efficient Synthesis of Submicrometer-Sized Active Pharmaceuticals by Laser Fragmentation in a Liquid-Jet Passage Reactor with Minimum Degradation

One challenge in the development of new drug formulations is overcoming their low solubility in relevant aqueous media. Reducing the particle size of drug powders to a few hundred nanometers is a well-known method that leads to an increase in solubility due to an elevated total surface area. However, state-of-the-art comminution techniques like cryo-milling suffer from degradation and contamination of the drugs, particularly when sub-micrometer diameters are aspired that require long processing times. In this work, picosecond-pulsed laser fragmentation in liquids (LFL) of dispersed drug particles in a liquid-jet passage reactor is used as a wear-free comminution technique using the hydrophobic oral model drugs naproxen, prednisolone, ketoconazole, and megestrol acetate. Particle size and morphology of the drug particles are characterized using scanning electron microscopy (SEM) and changes in particle size distributions upon irradiation are quantified using an analytical centrifuge. The findings highlight the superior fragmentation efficiency of the liquid-jet passage reactor setup, with a 100 times higher fraction of submicrometer particles (SMP) of the drugs compared to the batch control, which enhances solubility and goes along with minimal chemical degradation (<1%), determined by attenuated total reflection-Fourier transform infrared spectroscopy (ATR-FTIR), high-performance liquid chromatography (HPLC), and X-ray diffraction (XRD). Moreover, the underlying predominantly photo-mechanically induced laser fragmentation mechanisms of organic microparticles (MP) are discussed.