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The low aqueous solubility and subsequently slow dissolution rate, as well as the poor bioavailability of several active pharmaceutical ingredients (APIs), are major challenges in the pharmaceutical industry. In this review, the particle engineering approaches using supercritical carbon dioxide (SC CO 2 ) as an antisolvent are critically reviewed. The different SC CO 2 -based antisolvent processes, such as the gas antisolvent process (GAS), supercritical antisolvent process (SAS), and a solution-enhanced dispersion system (SEDS), are described. The effect of process parameters such as temperature, pressure, solute concentration, nozzle diameter, SC CO 2 flow rate, solvent type, and solution flow rate on the average particle size, particle size distribution, and particle morphology is discussed from the fundamental perspective of the SAS process. The applications of the SAS process in different formulation approaches such as solid dispersion, polymorphs, cocrystallization, inclusion complexation, and encapsulation to enhance the dissolution rate, solubility, and bioavailability are critically reviewed. This review highlights some areas where the SAS process has not been adequately explored yet. This review will be helpful to researchers working in this area or planning to explore SAS process to particle engineering approaches to tackle the challenge of low solubility and subsequently slow dissolution rate and poor bioavailability., (© 2022. Controlled Release Society.)

The supercritical antisolvent (SAS) recrystallization process is one of the most promising recrystallization techniques for the particle formation of pharmaceutical compounds. In this process, a solution of active pharmaceutical ingredient (API) is sprayed into the supercritical carbon dioxide (SC CO2) environment. The mass transport of both the solvent and the antisolvent results in supersaturation followed by the crystallization of the API. In this work, a model is developed to estimate the supersaturation profile of solute in a droplet falling in the SC CO2 environment. The droplet consists of paracetamol as a solute and ethanol as a solvent. It moves down in the antisolvent (supercritical CO2) environment. Interestingly, the present model predicts a rise in supersaturation followed by a fall for a while and then a sharp increase. The competing phenomena of nucleation and growth mechanisms are used to justify this variation in the supersaturation. [ABSTRACT FROM AUTHOR]

[Display omitted] The novel particle generation processes of Active Pharmaceutical Ingredient (API)/drug have been extensively explored in recent decades due to their wide-range applications in the pharmaceutical industry. The Rapid Expansion of Supercritical Solutions (RESS) is one of the promising techniques to obtain the fine particles (micro to nano-size) of APIs with narrow particle size distribution (PSD). In RESS, supercritical carbon dioxide (SC CO 2) and API are used as solvent and solute respectively. In this literature survey, the application of RESS in the formation of fine particles is critically reviewed. Solubility of API in SC CO 2 and supersaturation are the key factors in tuning the particle size. The different approaches to model and predict the solubility of API in SC CO 2 are discussed. Then, the effect of process parameters on mean particle size and the particle size distribution are interpreted in the context of solubility and supersaturation. Furthermore, the less-explored applications of RESS in preparation of solid-lipid nanoparticles, liposome, polymorphic conversion, cocrystallization and inclusion complexation are compared with traditional processes. The solubility enhancement of API in SC CO 2 using co-solvent and its applications in particle generation are explored in published literature. The development and modifications in the conventional RESS process to overcome the limitations of RESS are presented. Finally, the perspective on RESS with special attention to its commercial operation is highlighted. [ABSTRACT FROM AUTHOR]