Effects of Spray Drying Temperature on Dry Emulsion Properties and Aceclofenac Entrapment Efficiency

Introduction: Aceclofenac (ACE), a BCS class II non-steroidal anti-inflammatory drug, has limited bioavailability due to poor aqueous solubility. Objective: To investigate the effects of spray drying temperature on the physicochemical properties and entrapment efficiency of ACE in dry emulsions. Methods: Dry emulsions were prepared by spray drying an oil-in-water emulsion containing maltodextrin, HPMC E6, and Aerosil 200 at temperatures ranging from 110°C to 160°C. The powders were characterized for moisture content and water activity using a rapid moisture analyzer and a water activity meter, respectively. Powder yield, bulk density, and particle size were determined using standard gravimetric and sizing methods. Aceclofenac entrapment efficiency was assessed by UV spectrophotometry. FTIR spectroscopy was used to evaluate drug-excipient interactions, and in vitro drug release was assessed using the USP 24 paddle method. Results: The dry emulsion powder formed at 130°C had a high yield (53.5%), good particle integrity, and small powder particle size. With the spray drying temperature increasing from 110°C to 160°C, the entrapment efficiency of ACE in dry emulsion powder decreased from 78.09% to 70.52%. Conclusions: Spray drying temperature has a significant impact on the physicochemical properties and entrapment efficiency of aceclofenac in dry emulsions. Higher temperatures led to decreased entrapment efficiency. The formulation dried at 130°C showed optimal yield, particle integrity, and size. Thus, 130°C is the most suitable temperature for producing effective aceclofenac-loaded dry emulsion powders.