Synthesis of drug-loaded microparticles with precise control over size distribution and shape is crucial for achieving desired drug distribution in the microparticles and tuning drug release profiles. Common large-scale production techniques produce microparticles with a broad particle size distribution and require challenging operating conditions. In this study, the spinning disk atomization (SDA) technique for microdroplet production is coupled with the solvent-antisolvent precipitation method to generate drug-loaded polymeric microparticles with a narrow size distribution. The design criteria and fabrication of an equipment with a non-contact seal system that integrates spinning disk atomization and precipitation methods for conducting laboratory drug particle production experiments that involve volatile hydrocarbons is discussed. Production of itraconazole drug-loaded microparticles using the SDA setup by considering the system's operation, maintenance, and safety aspects is discussed, and the system's efficiency evaluated through material balance is shown. This laboratory equipment is capable of producing drug-loaded microparticles with a narrow size distribution under moderate operating conditions and can be scaled up suitably to meet high production requirements. The applications of this equipment can be explored in various fields, such as the production of drug particles, conversion of waste polymers into microparticles, and microencapsulation of food ingredients.

Recent methods employing microfluidics have enabled the production of microparticles with a uniform size distribution. However, microparticle production methods using PDMS microfluidic devices and glass chips containing microchannels can handle only fluids with a limited range of physical and chemical properties and are faced with a variety of operation problems such as clogging, high operating pressures and offer only limited scope for reuse and modifications. Further, fabrication cost of these devices is very high. There are microfluidic devices for particle production fabricated using glass capillaries, but most of these are joined using adhesives which are not compatible with many hydrocarbon solvents and will not sustain long term operation. In this work, a microfluidic device for microparticle production with removable capillaries that addresses these drawbacks is presented. This device can handle a variety of hydrocarbon solvents, allows easy replacement of capillaries, permits repeated use of the device over long term, facilitates removal of air bubbles, impurities, coagulated droplets, and solid particles. Further, it can be easily fabricated manually using readily available components such as glass vials and capillaries at a very low cost in a glass blowing facility. The experimental setup, chemical system and procedures to produce drug encapsulated microparticles using this device are also briefly discussed. Results of these experiments show that the device can produce drug encapsulated particles with a narrow size distribution.