Bridging Precision and Scale in Microparticle Drug Delivery Manufacturing

Producing uniform drug delivery particles at scale has long presented a challenge for pharmaceutical manufacturers. Techniques that offer tight control over particle size and structure often struggle with throughput, while traditional industrial methods deliver volume but less consistency. As advanced drug delivery systems become more important for long-acting therapies and targeted treatments, manufacturers are increasingly seeking production methods that can balance precision, scalability, and reproducibility. In this episode of Off Script, we spoke with Nathalie Pinkerton, PhD, assistant professor of the chemical and biomolecular engineering department at the NYU Tandon School of Engineering, about Sequential NanoPrecipitation (SNaP), a continuous flow technique designed to bring greater control to polymeric particle manufacturing. The conversation explores how separating particle formation into sequential mixing stages enables more predictable control over particle size and composition, the role of micromixer design in achieving consistent mixing and scale-up, and why encapsulation efficiency plays a critical role in manufacturing economics. Pinkerton also discusses the remaining steps needed to translate emerging particle manufacturing technologies from the lab into commercially viable pharmaceutical production platforms.