Rational Design and Development of a Soluble Mesoporous Carrier for the Solidification of a Preconcentrated Self-Nanoemulsion Formulation

[Image: see text] The solidification of self-preconcentrated nanoemulsion without changes in nanodroplet formation gains particular consideration due to the interaction between solidified carriers. This work aimed to develop mannitol mesoporous as a soluble carrier for supersaturated self-nanoemulsion (SSNE) using a design of experiment (DoE) approach. The mesoporous carrier was prepared by a spray-drying technique. The type of templating agent (TA) used to form a porous system, the amount of TA, and solid loading in the spray-drying process were studied. Several characterizations were performed for mannitol mesoporous formation, namely, powder X-ray diffraction, thermal analysis, scanning electron microscopy, and surface area analyzer. Solidification of SSNE incorporated into the mesoporous mannitol was carried out, followed by compaction behavior, flowability, and nanodroplet formation. The results revealed several process parameters for preparing the mesoporous mannitol, notably TA, which gained more significant consideration. Solid loading in the mesoporous preparation system reduced the surface area and pore size and did not affect solid SSNE flowability. The amount of TA increased the pore size and volume dramatically as well as the compactibility and flowability. Ammonium carbonate was the preferable TA for preparing the mesoporous carrier, particularly for the nanodroplet formulation process. In addition, synergistic and antagonistic interactions between factors were also observed. The optimized mesoporous carrier was applied for solidification, and there was no difference between SSNE and solid SSNE in the performance of nanodroplet formation.