Utilizing Hot-Melt Extrusion and Spray Drying Techniques for Preparation of Liquid and Solid Cannabidiol Nano-Structured Lipid Carriers Formulations

Nanostructured lipid carriers (NLCs) have attracted considerable interest as drug delivery systems capable of enhancing the solubility and oral bioavailability of poorly water-soluble drugs. In our previous work, cannabidiol (CBD)-loaded NLCs prepared by hot homogenization demonstrated improved dissolution and oral bioavailability. In the present study, hot-melt extrusion (HME) was investigated as a rapid and easily scalable alternative method for the preparation of CBD NLCs. Additionally, spray drying was used to convert the prepared CBD NLCs into a solid dosage form. CBD NLCs were prepared using HME at different screw speeds (100, 200, and 300 rpm), followed by probe sonication, and characterized for particle size, entrapment efficiency (EE), and drug release. Spray drying was performed with different carriers (D-lactose, Kollidon® VA 64, maltodextrin 12, and Soluplus®) to evaluate their compatibility and performance. The results showed that the screw speed has an impact on the properties of the NLCs, while probe sonication further reduced particle size, resulting in enhanced entrapment efficiency, and drug release of all formulations. Although NLC produced at a screw speed of 300 rpm was the most stable in both 4 °C and 25 °C. Among the carriers tested for spray drying, maltodextrin achieved nearly complete CBD release, while Soluplus® led to increased particle size and reduced release. Overall, HME combined with probe sonication proved to be a robust approach for the preparation of CBD NLCs, which were successfully converted into solid powder formulations by spray drying, offering a promising strategy for scalable production of CBD NLCs.