“Efficient process development and quality control for continuous nanomanufacturing:
An impingement jet mixing case study.”

Customer Case Study

A continuous impingement jet mixing line was combined with inline NanoFlowSizer monitoring to support faster process development and real-time quality control of nanoemulsions.

Using SR-DLS, droplet size was measured inline under flow and used to guide an automated design of experiments. This enabled identification of operating conditions that produced a narrow target distribution around 85 nm, while also allowing automatic diversion of out-of-spec material.

The study shows how real-time particle size insight can accelerate development and support GMP-aligned continuous nanomanufacturing.

Key take aways:

• Real-time inline particle size monitoring enabled direct droplet size measurement under flow, without relying only on offline testing.
• Faster process development was achieved by combining inline size data with an automated DoE workflow.
• Optimized nanoemulsions below 100 nm were produced, with the final target distribution reaching a mean of 84.8 nm and a standard deviation of 34.3 nm.
• Real-time quality control made it possible to detect deviations from the target particle size distribution during production.
• Automatic diversion of out-of-spec material helped maintain consistent product quality throughout the run.
• Supports continuous and GMP-aligned manufacturing, with reduced reliance on manual sampling and offline analysis.

The NanoFlowSizer