Sustained release formulations using non-aqueous emulsions

A method for producing polymeric or polymer-coated microspheres comprising:

• combining
• (1) a dispersed phase comprising 1.0 to 30.0% w/w of total solid spray dried-protein suspended in a hydrocarbon solution, wherein the hydrocarbon solution comprises 5.0 to 35% w/v POE, into
• (2) a continuous phase to form emulsion droplets of the dispersed phase, wherein the continuous phase comprises a fluorocarbon solution comprising 0.1 to 5.0% w/v fluorosurfactant;
• hardening the emulsion droplets by removing the hydrocarbon liquids to form hardened polymer or polymer-coated microspheres.

A method for producing polymer or polymer-coated microparticles, comprising:

• combining a hydrocarbon solution comprising dissolved polymer and spray-dried protein powder to produce a dispersed phase;
• combining the dispersed phase with a continuous phase to produce emulsion droplets of the dispersed phase in the continuous phase, wherein the continuous phase comprises a fluorocarbon liquid and 0.1 to 5.0% w/v of a fluorosurfactant;
• and
• harvesting the polymer-coated microparticles.

A method for producing microparticles comprising:

• combining a first solution comprising a polymer in a hydrocarbon solvent with a second solution comprising a fluorocarbon solvent and a fluorosurfactant;
• agitating the combined solutions to produce an emulsion;
• removing the hydrocarbon solvent under vacuum while stirring the combined solutions to harden the microparticles;
• harvesting the microparticles;
• optionally washing the microparticles;
• and drying the microparticles.