R&D


nanoSaar works very closely with customers to develop proprietary (nano)solutions. Generally, per CDA (confidential disclosure agreement), we receive a briefing for a proposal that then becomes a joint development agreement.

In an initial rapid prototyping project, we develop particulated, emulsified or encapsulated systems to demonstrate proof of principle. Based on analytical tests and stability results, we then optimize the prototype products.

The final step consists of transfer to production—including production processes, quality control, quality assurance, and regulatory tasks.

Development Process

Project planning

  •  Physical and chemical characteristics of the substance
  •  Current applications
  •  Possible application routes
  •  Identification of problems and limiting properties
  •  Aims and advantages
  •  Possible formulation strategies
  •  Compatibility with excipients
  •  Costs, timelines

Rapid prototyping

  • Selection of encapsulation materials, precursors, emulsifiers, and solvents
  • Lab-scale production of different formulations
  • Characterization of formulations
  • Particle-size distribution determined by DLS and LS (intensity, number, volume) 
  • Polydispersity index
  • Zeta potential
  • Substance loading efficiency

Formulation selection

  • Short-term/Long-term stability studies regarding sedimentation, ageing, aggregation, agglomeration, and disintegration

Product optimization

  • Effects of process parameters with design of experiments
  • Effects of formulation composition with design of experiments (main effects, interactions)
  • Particle size, polydispersity index
  • Zeta potential
  • Loading efficiency
  • Increase in concentration (centrifugation, X-Flow filtration, dialysis)

Scale-up/Incrementing

  • Determination of critical parameters
  • Determination of QC/QA parameters
  • MicroJet Reactor set-up for specific product
  • Production of trial batches
  • QC of trial batches

Transfer or manufacturing

  • Installation of MJR® production units
  • Training of technical staff
  • Use of MJR® production capacities
 
 

R&D Management


 
 
 

Hermann Schirra

Managing Director of nanoSaar Lab GmbH.

More than 20 years of nanotechnology experience.

R&D positions at Leibniz Institute for New Materials (INM) in Saarbrücken, Germany—and other companies.

Founder of Sarastro GmbH.

Focus on product development for industrial, medical, medical-device, pharmaceutical, and food & beverage applications.

Mr. Schirra has received several awards.

 
 

MJR® Technology


MicroJet Reactor technology has continuously been advanced the past 25 years. It is widely used in the chemical, cosmetic and food industries. This technology produces micro/nano particles, emulsions, and encapsulations for customers in different industries.

 

 
 
 
 

In a specialized MicroJet Reactor (MJR®), two reactants collide as impinging liquid jets. The hydrodynamic pressure is converted to kinetic energy. During this process, the reactants mix completely in a spherical lens and form the micro/nano particles, emulsions, and encapsulations in less than 0.1 milliseconds. A gas flow regulates this continuous mixing process. Micro/nano particles, emulsions, and encapsulations thus form in one or more manufacturing steps. The end product—an emulsion or dispersion—is highly homogenous. The MicroJet Reactor is set up such that all parameters can easily be adjusted to produce high-precision particles or droplets that comply with EFSA and REACH regulations. Last but not least, this process allows for great flexibility.

 
 

Key Applications


The MJR® process is ideal for the following applications:

 
 

Emulsions: improvement of color, texture, and uniformity with micron and submicron emulsions (e.g., flavor & fragrance oils, waxes).

 

Nanoparticles for filling materials, additives, and chemicals (e.g., insoluble metal salts, biocides, metal oxides).

 

Encapsulation: ingredient stability, taste masking, dispersibility via micro/nano encapsulations (e.g., pigments, vitamins, omega-3, fragrances, pesticides).

 
 

Precise Nanoparticles with the MJR® Reactor


Parameters are highly controllable and reproducible thanks to MJR® technology. Chemical parameters include the concentration of raw materials, stoichiometry, and solvent composition; physical parameters range from raw-material flow rates and flow rate ratio to carrier-gas pressure and nozzle sizes. The end material thus exhibits well-defined properties such as particle size, particle-size distribution, droplet size, and droplet-size distribution. Product-development and regulatory considerations alike are consequently handled with great efficiency.

 
 

 Precise Particles

 
 

Fine Nanoemulsions with the MJR® Reactor


 

 
 

Fine Nanoemulsions

 
 

Simple Particle and Complex Shell Systems


We can serialize our MJR® reactors and design complex cascade processes. As shown in the figure, cascading results in multilayer particle systems or coated nanoemulsions of liquid ingredients. Even complex syntheses are driven continuously without sacrificing the high-speed characteristics of the MJR® process. Typical application for such multi step MJR® processes include production of surface-modified core-shell particles based on inorganic salts or (hydr)oxides as well as formation of multi-encapsulated fragrances or omega-3 fatty acids.