Advancing Nanoparticle Production: Scaling Up Techniques, Challenges, and Future Perspectives in Pharmaceutical Applications
Abdelmonem, R., Ayman, M., lofty, S., Ezzat, Y., Nabeah, J., Mohamed, H., safwat, M., Abdelzaher, A., AboAlfa, A., Abdelkhalek, M., ali, R., samy, S., Fathy, M., Abdelati, A., Abdellatif, M., Eltahan, M. (2025). Advancing Nanoparticle Production: Scaling Up Techniques, Challenges, and Future Perspectives in Pharmaceutical Applications. EKB Journal Management System, 2(2), 26-39. doi: 10.21608/jpsdm.2025.374728.1031
Rehab Abdelmonem; MennaAllah Ayman; Sara Emad lofty; Yara Ezzat; Jaklin momtaz Nabeah; Hager Mohamed; Mohamed safwat; Abdelrahman Abdelzaher; alaa AboAlfa; Mohamed Abdelkhalek; Roaa mohamed ali; Salma samy; Mai Hany Fathy; Aliaa Abdelati; Menna Abdellatif; Mahmoud Eltahan. "Advancing Nanoparticle Production: Scaling Up Techniques, Challenges, and Future Perspectives in Pharmaceutical Applications". EKB Journal Management System, 2, 2, 2025, 26-39. doi: 10.21608/jpsdm.2025.374728.1031
Abdelmonem, R., Ayman, M., lofty, S., Ezzat, Y., Nabeah, J., Mohamed, H., safwat, M., Abdelzaher, A., AboAlfa, A., Abdelkhalek, M., ali, R., samy, S., Fathy, M., Abdelati, A., Abdellatif, M., Eltahan, M. (2025). 'Advancing Nanoparticle Production: Scaling Up Techniques, Challenges, and Future Perspectives in Pharmaceutical Applications', EKB Journal Management System, 2(2), pp. 26-39. doi: 10.21608/jpsdm.2025.374728.1031
Abdelmonem, R., Ayman, M., lofty, S., Ezzat, Y., Nabeah, J., Mohamed, H., safwat, M., Abdelzaher, A., AboAlfa, A., Abdelkhalek, M., ali, R., samy, S., Fathy, M., Abdelati, A., Abdellatif, M., Eltahan, M. Advancing Nanoparticle Production: Scaling Up Techniques, Challenges, and Future Perspectives in Pharmaceutical Applications. EKB Journal Management System, 2025; 2(2): 26-39. doi: 10.21608/jpsdm.2025.374728.1031

Advancing Nanoparticle Production: Scaling Up Techniques, Challenges, and Future Perspectives in Pharmaceutical Applications

Journal of Pharmaceutical Sciences and Drug Manufacturing-Misr University for Science and Technology
Volume 2, Issue 2 - Serial Number 20225, June 2025, Page 26-39  XML PDF (931.32 K)
Document Type: Review Articles.
DOI: 10.21608/jpsdm.2025.374728.1031
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Authors
Rehab Abdelmonemorcid 1; MennaAllah Ayman2; Sara Emad lofty2; Yara Ezzat2; Jaklin momtaz Nabeah2; Hager Mohamed2; Mohamed safwat2; Abdelrahman Abdelzaher2; alaa AboAlfa2; Mohamed Abdelkhalek2; Roaa mohamed ali2; Salma samy2; Mai Hany Fathy2; Aliaa Abdelati2; Menna Abdellatif1; Mahmoud Eltahan email 1
1Department of Industrial Pharmacy, College of Pharmaceutical Sciences and Drug Manufacturing, Misr University for Science and Technology (MUST), P.O. Box 77, Giza, Egypt.
2College of Pharmaceutical Sciences and Drug Manufacturing, Misr University for Sciences and Technology, 6th October City, Egypt.
Abstract
Abstract
Background: Nanoparticles (NPs) have transformed pharmaceutical sciences by enhancing drug delivery, solubility, and absorption. However, scaling up NP production from laboratory settings to industrial capacities is facing immense challenges due to process difficulties, consistency issues, and high costs.
Objectives: This review discusses recent progress, challenges, and critical process parameters (CPPs) in scaling up different NP preparation methods. It highlights sustainable strategies, process limitations, and future opportunities in pharmaceutical nanoparticle production.
Methods: A systematic review was conducted using international databases such as (Scopus, PubMed, Web of Science, Google Scholar) between 2012 and 2024. The keywords used in the primary search included scale-up, challenges, limitations, critical process parameters, and nanoparticles. This study considered conventional and novel methods for preparing nanoparticles, including thin film hydration, ethanol injection, ultrasonication, spray drying, and high-pressure homogenization.
Results: This review outlines and discusses critical process parameters such as mixing speed, temperature control, choice of solvent, and flow rate that impact NP size, morphology, and stability during scale-up. Advanced techniques such as microfluidics and ethanol injection allow one to control the characteristics of nanoparticles with precision, while high-pressure homogenization ensures particle-size consistency. More importantly, environmentally friendly synthesis approaches are a useful route toward sustainable production practices.
Conclusions: Scaling up NP production requires optimization of process parameters, equipment design, and a focus on reproducibility and cost-efficiency. While challenges persist, adopting green synthesis methods and developing regulatory frameworks will enhance clinical translation and commercial viability of NP-based drug delivery systems.
Keywords
Nanoparticles; Scaling-Up Techniques; High-Pressure Homogenization; Ethanol Injection Method; Critical Process Parameters
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