Processing of heat-sensitive active agents

A method of melt processing an active agent comprising:

• forming a first mixture of an active agent, a first polymer material and a first solvent S1, wherein said first solvent comprises an organic solvent and said first polymer is present in said first solvent at 1% to 20% by volume and said active agent is a nanoparticulate having a largest linear dimension of less than or equal to 500 nanometers and a degradation temperature of less than 200° C.;
• adding said first mixture to a second solvent and forming a second mixture including a dispersed phase of said first mixture in said second solvent, wherein said second solvent comprises a hydrocarbon;
• removing said first solvent from said second mixture;
• encapsulating said active agent in said first polymer material exhibiting a first processing temperature T1, wherein said active agent forms domains within a matrix of said first polymer, wherein said domains are discrete, and forming a plurality of capsules including said active agent;
• and
• melt processing said capsules with a second polymer material by injection molding, blow molding, extrusion, twin screw extrusion, compression molding, or transfer molding, wherein said second polymer exhibits a second processing temperature T2, wherein T1>T2, wherein said plurality of capsules are dispersed within a matrix of said second polymer and wherein said encapsulating of said active agent in the first polymer is conducted at a relatively lower temperature than said melt processing with said second polymer;
• and
• wherein said first polymer exhibits a processing temperature T1 in the range of 120° C. to 400° C., and said second polymer exhibits a processing temperature T2 in the range of less than 200° C.