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.