Method and apparatus for formulating microspheres and microcapsules

A method of aseptically formulating a plurality of active agent containing polymer bodies comprising:

• a) providing a sterile suspension of active agent containing polymer bodies in a continuous phase in a process vessel;
• b) washing said active agent containing polymer bodies by replacing said continuous phase with water by moving said suspension through a filter adapted to eliminate continuous phase and returning said polymer bodies to a process vessel while maintaining said polymer bodies sterile and in suspension;
• c) while maintaining said polymer bodies sterile and in suspension, replacing said water with a formulating medium by moving said suspension through a filter adapted to remove continuous phase and return said polymer bodies to a process vessel;
• and,
• d) removing said suspension of active agent containing polymer bodies and formulating medium from said process vessel.

A method of making and formulating agent containing polymer bodies comprising:

• a) forming a dispersed phase comprising active agent;
• b) providing a continuous phase in which said dispersed phase will form an emulsion, at least one of said dispersed and continuous phases comprising polymer;
• c) introducing said dispersed and continuous phases into a reactor vessel, said reactor vessel including means for forming an emulsion, and forming an emulsion of said dispersed phase in said continuous phase;
• d) causing or allowing said polymer to form microspheres or microcapsules containing said agent;
• e) transporting said emulsion from said reactor vessel to a solvent removal vessel and removing solvent therein;
• f) formulating said polymer bodies by maintaining a suspension of said polymer bodies in said continuous phase;
• replacing said continuous phase with a formulating medium by moving said suspension through a filter adapted to remove continuous phase and return said polymer bodies to a process vessel while maintaining said to polymer bodies in suspension;
• and, removing said suspension of agent containing polymer bodies and formulating medium from said process vessel.

A method of making and formulating agent containing polymer bodies comprising:

• a) forming a dispersed phase comprising active agent;
• b) providing a continuous phase in which said dispersed phase will form an emulsion, at least one of said dispersed and continuous phases comprising polymer;
• c) introducing said dispersed and continuous phases into a reactor vessel, said reactor vessel including means for forming an emulsion, and forming an emulsion of said dispersed phase in said continuous phase;
• d) causing or allowing said polymer to form microspheres or microcapsules containing said agent;
• e) transporting said emulsion from said reactor vessel to a solvent removal vessel and removing solvent therein;
• f) formulating said polymer bodies by maintaining a suspension of said polymer bodies in said continuous phase;
• washing said agent containing polymer bodies by replacing said continuous phase with water by moving said suspension through a filter adapted to remove continuous phase and return said polymer bodies to a process vessel while maintaining said suspension;
• replacing said water with a formulating medium by moving said suspension through a filter adapted to eliminate said water and return said polymer bodies to a process vessel while maintaining said polymer bodies in suspension;
• and, removing said suspension of agent containing polymer bodies and formulating medium from said process vessel.