Scale-up microreactor coupling binary surfactants for high-throughput preparation of flaky dasatinib nanocrystals

Background: Traditional methods for nanocrystal preparation often suffer from limitations such as poor control over particle size and morphology, low yield and instability. Methods: In this study, we developed a novel microreactor technique for the efficient preparation of dasatinib nanocrystals. The microreactor employed was equipped with a circular hole baffle to enhance mixing efficiency. The solvent-antisolvent process was optimized by systematically varying the solvent-to-antisolvent ratio, flow rate, and initial concentration of dasatinib. A binary surfactant system (SDBS/BS-12) was introduced in the anti-solvent phase to further improve the nanocrystal properties. Significant Findings: The optimized experimental conditions led to the successful preparation of dasatinib nanocrystals with exceptional properties. The nanocrystals exhibited an average particle size of 85 nm, a zeta potential of 47.5 mV, and a polydispersity index of 0.566, indicating superior dispersion and stability. Compared to conventional methods, the binary surfactant system resulted in a remarkable 6.5–12 times enhancement in nanocrystal shrinkage. The precise control over mixing dynamics within the microreactor enabled the production of high-quality nanocrystals with tailored properties. Furthermore, the simplicity, efficiency, and tunability of the proposed method suggests its potential for scale-up towards high-throughput nanoparticle preparation, broadening its application prospects in various fields.