Search

A continuous manufacturing platform was developed for the synthesis of aqueous colloidal 10–20 nm gold nanoparticles (Au NPs) in a flow reactor using chloroauric acid, sodium citrate and citric acid at 95 oC and 2.3 bar(a) pressure. The use of a two-phase flow system – using heptane as the continuous phase – prevented fouling on the reactor walls, while improving the residence time distribution. Continuous syntheses for up to 2 h demonstrated its potential application for continuous manufacturing, while live quality control was established using online UV-Vis photospectrometry that monitored the particle size and process yield. The synthesis was stable and reproducible over time for gold precursor concentration above 0.23 mM (after mixing), resulting in average particle size between 12 and 15 nm. A hydrophobic membrane separator provided successful separation of the aqueous and organic phases and collection of colloidal Au NPs in flow. Process yield increased at higher inlet flow rates (from 70 % to almost 100 %), due to lower residence time of the colloidal solution in the separator resulting in less fouling in the PTFE membrane. This study addresses the challenges for the translation of the synthesis from batch to flow and provides tools for the development of a continuous manufacturing platform for gold nanoparticles.Graphical abstract

Among the unconventional approaches of supporting catalyst nanoparticles, the layer-by-layer assembly of polyelectrolyte multilayers for nanoparticle adsorption represents an easy and convenient method. It enables the deposition of singularly adsorbed nanoparticles and prevents them from aggregating. In this work, polydopamine was grafted onto the internal surface of a Teflon AF-2400 tubular membrane, known for its excellent permeability to light gases and inertness to chemicals. Poly(acrylic acid) and poly(allylamine hydrochloride) were sequentially adsorbed onto the modified surface of the membrane. Ex situ synthesized spherical, cubical, truncated octahedral palladium or dendritic platinum-palladium nanoparticles were then incorporated. The catalytic membranes were assembled in a tube-in-tube configuration and tested over 6 h of continuous nitrobenzene hydrogenation with molecular hydrogen. Stable conversion was observed for the truncated octahedral and dendritic nanoparticles, while a progressive deactivation occurred for the other nanoparticles. Due to their small size, the 3.7 nm spherical nanoparticles exhibited the highest reaction rate, 629molreactant/(molcatalyst⋅h), while the cubical nanoparticles showed the highest turnover frequency, ∼3000 h−1. The reactor concept developed in this work demonstrates how such a design can serve as a platform for conducting continuous multiphase catalytic reactions in flow using singularly adsorbed and finely tuned nanoparticles. The small volume of pressurized gas present in the tube-in-tube reactor offers improved process safety compared to a batch process, while the Teflon AF-2400 membrane provides control over the gas permeation during reaction.

Ionic gelation is commonly used to generate nanogels but often results in poor control over size and polydispersity. In this work we present a novel approach to the continuous manufacture of protein-loaded chitosan nanogels using microfluidics whereby we demonstrate high control and uniformity of the product characteristics. Specifically, a coaxial flow reactor (CFR) was employed to control the synthesis of the nanogels, comprising an inner microcapillary of internal diameter (ID) 0.595 mm and a larger outer glass tube of ID 1.6 mm. The CFR successfully facilitated the ionic gelation process via chitosan and lysozyme flowing through the inner microcapillary, while cross-linkers sodium tripolyphosphate (TPP) and 1-ethyl-2-(3-dimethylaminopropyl)-carbodiimide (EDC) flowed through the larger outer tube. In conjunction with the CFR, a four-factor three-level face-centered central composite design (CCD) was used to ascertain the relationship between various factors involved in nanogel production and their responses. Specifically, four factors including chitosan concentration, TPP concentration, flow ratio and lysozyme concentration were investigated for their effects on three responses (size, polydispersity index (PDI) and encapsulation efficiency (% EE)). A desirability function was applied to identify the optimum parameters to formulate nanogels in the CFR with ideal characteristics. Nanogels prepared using the optimal parameters were successfully produced in the nanoparticle range at 84 ± 4 nm, showing a high encapsulation efficiency of 94.6 ± 2.9% and a high monodispersity of 0.26 ± 0.01. The lysis activity of the protein lysozyme was significantly enhanced in the nanogels at 157.6% in comparison to lysozyme alone. Overall, the study has demonstrated that the CFR is a viable method for the synthesis of functional nanogels containing bioactive molecules.

The quantitative analysis of nanomaterials synthesis kinetics is valuable both for understanding the synthesis and for development of manufacturing processes, and it usually requires the use of syn...

The advancement of analytical methods for nanoparticle measurements is critical both for the growing industrial exploitation of engineered nanoparticles and for developing robust strategies to understand and control the concentration of nanomaterials in humans and the environment. For high value nanoparticles, the measurement of nanoparticle number concentration in a liquid directly impacts the ability to assess the scale and reproducibility of the production process, it allows optimisation of efficiency and supports regulatory compliance. This measurement is also useful to monitor and control the intentional or accidental release of engineered nanoparticles into the environment at the production plant, as well as by end-users., peer-reviewed

Thiolate-gold nanoclusters have various applications. However, most of the synthesis methods require prolonged synthesis times from several hours to days. In the present study, we report a rapid synthesis method for [Au25(Cys)18] nanoclusters and their application for photobactericidal enhancement. For [Au25(Cys)18] synthesis, we employed a tube-in-tube membrane reactor using CO as a reducing agent at elevated temperatures. This approach allows continuous generation of high-quality [Au25(Cys)18] within 3 min. Photobactericidal tests against Staphylococcus aureus showed that crystal violet-treated polymer did not have photobactericidal activity, but addition of [Au25(Cys)18] in the treated polymer demonstrated a potent photobactericidal activity at a low white light flux, resulting in >4.29 log reduction in viable bacteria numbers. Steady-state and time-resolved photoluminescence spectroscopies demonstrated that after light irradiation, photoexcited electrons in crystal violet flowed to [Au25(Cys)18] in the silicone, suggesting that redox reaction from [Au25(Cys)18] enhanced the photobactericidal activity. Stability tests revealed that leaching of crystal violet and [Au25(Cys)18] from the treated silicone was negligible and cyclic testing showed that the silicone maintained a strong photobactericidal activity after repeated use.

The development of new bio-based coating materials to be applied on cellulosic and plastic based substrates, with improved performances compared to currently available products and at the same time with improved sustainable end of life options, is a challenge of our times. Enabling cellulose or bioplastics with proper functional coatings, based on biopolymer and functional materials deriving from agro-food waste streams, will improve their performance, allowing them to effectively replace fossil products in the personal care, tableware and food packaging sectors. To achieve these challenging objectives some molecules can be used in wet or solid coating formulations, e.g., cutin as a hydrophobic water- and grease-repellent coating, polysaccharides such as chitosan-chitin as an antimicrobial coating, and proteins as a gas barrier. This review collects the available knowledge on functional coatings with a focus on the raw materials used and methods of dispersion/application. It considers, in addition, the correlation with the desired final properties of the applied coatings, thus discussing their potential.

Small iron oxide nanoparticles (IONPs) were synthesised in water via co-precipitation by quenching particle growth after the desired magnetic iron oxide phase formed. This was achieved in a millifluidic multistage flow reactor by precisely timed addition of an acidic solution. IONPs (≤5 nm), a suitable size for positive T1 magnetic resonance imaging (MRI) contrast agents, were obtained and stabilised continuously. This novel flow chemistry approach facilitates a reproducible and scalable production, which is a crucial paradigm shift to utilise IONPs as contrast agents and replace currently used Gd complexes. Acid addition had to be timed carefully, as the inverse spinel structure formed within seconds after initiating the co-precipitation. Late quenching allowed IONPs to grow larger than 5 nm, whereas premature acid addition yielded undesired oxide phases. Use of a flow reactor was not only essential for scalability, but also to synthesise monodisperse and non-agglomerated small IONPs as (i) co-precipitation and acid addition occurred at homogenous environment due to accurate temperature control and rapid mixing and (ii) quenching of particle growth was possible at the optimum time, i.e., a few seconds after initiating co-precipitation. In addition to the timing of growth quenching, the effect of temperature and dextran present during co-precipitation on the final particle size was investigated. This approach differs from small IONP syntheses in batch utilising either growth inhibitors (which likely leads to impurities) or high temperature methods in organic solvents. Furthermore, this continuous synthesis enables the low-cost (£10 per g) and large-scale production of highly stable small IONPs without the use of toxic reagents. The flow-synthesised small IONPs showed high T1 contrast enhancement, with transversal relaxivity (r2) reduced to 20.5 mM-1 s-1 and longitudinal relaxivity (r1) higher than 10 mM-1 s-1, which is among the highest values reported for water-based IONP synthesis.

The interaction of methylene blue and crystal violet dyes with a range of gold nanoparticles (AuNPs), gold nanoclusters and gold/silver nanoclusters is reported. It is found that 20 nm citrate-capped AuNPs have strong interactions with these two dyes that result in red-shifted absorption peaks in their electronic absorption spectra. Transmission electron microscopy and dynamic light scattering measurements show that this can be attributed to these AuNPs combining into large agglomerates. Eventually, precipitation is observed. The agglomeration process is triggered when the dye reaches or exceeds a threshold concentration and then does not stop until all the AuNPs have agglomerated into large particles and precipitated. Calculations suggest that the threshold concentration corresponds to having sufficient dye molecules to form a monolayer on the surface of AuNPs. We also observe similar red-shifting in the absorption peaks of the electronic absorption spectra of 11–50 nm citrate-capped AuNPs formed by both single step and seeded growth methods. No such interactions were observed in the UV-vis spectra of the dyes with Tris-capped AuNPs, gold nanoclusters or gold/silver nanoclusters.

A microfluidic reactor was developed to enhance the speed (reaction time

Small iron oxide nanoparticles (IONPs) were synthesised in water via co-precipitation by quenching particle growth after the desired magnetic iron oxide phase formed. This was achieved in a millifluidic multistage flow reactor by precisely timed addition of an acidic solution. IONPs (≤5 nm), a suitable size for positive T1 magnetic resonance imaging (MRI) contrast agents, were obtained and stabilised continuously. This novel flow chemistry approach facilitates a reproducible and scalable production, which is a crucial paradigm shift to utilise IONPs as contrast agents and replace currently used Gd complexes. Acid addition had to be timed carefully, as the inverse spinel structure formed within seconds after initiating the co-precipitation. Late quenching allowed IONPs to grow larger than 5 nm, whereas premature acid addition yielded undesired oxide phases. Use of a flow reactor was not only essential for scalability, but also to synthesise monodisperse and non-agglomerated small IONPs as (i) co-precipitation and acid addition occurred at homogenous environment due to accurate temperature control and rapid mixing and (ii) quenching of particle growth was possible at the optimum time, i.e., a few seconds after initiating co-precipitation. In addition to the timing of growth quenching, the effect of temperature and dextran present during co-precipitation on the final particle size was investigated. This approach differs from small IONP syntheses in batch utilising either growth inhibitors (which likely leads to impurities) or high temperature methods in organic solvents. Furthermore, this continuous synthesis enables the low-cost (

A stable water-based suspension containing chitin nanofibrils (CN), chitin nanofibrils complexed with nanolignin and the latter containing Vitamin E was prepared starting from CN nanosuspension and nanostructured powders. The water-based coating was deposited by a spray technique on three different renewable and biodegradable films consisting of biodegradable polyesters and starch to prepare possible beauty mask prototypes. After drying, the films were extracted with water to control their potential release on the wet skin and different amounts of released materials were obtained. The results were discussed considering the composition and morphology of the adopted substrates and their interactions with the coating. The eco-compatibility of these films is related to the absence of preservatives and their easy biodegradability in several environmental conditions, decreasing their burden on solid waste management with respect to fossil-based versions.

Thiolate-gold nanoclusters have various applications. However, most of the synthesis methods require prolonged synthesis times from several hours to days. In the present study, we report a rapid synthesis method for [Au

Reproducibility in the synthesis of nanomaterials is a crucial aspect for their real-life applications. It is particularly pertinent in the context of gold nanoparticles, where a plethora of seeded-growth methods are being developed to control particle morphology and size. The translation of such methods to manufacturing can be hindered by poor reproducibility of the seed production step. This study focuses on the development of a highly reproducible platform for the synthesis of gold nanoparticles, as potential substrates for glucose sensing. A flow reactor was designed, starting from a detailed study of the synthesis in batch. The well-established Turkevich synthesis was investigated via in situ time-resolved UV-vis spectroscopy. In order to enhance the reproducibility of the synthesis the effect of passivating the gold precursor stock before its use in the synthesis was investigated. It is shown that starting from a pre-passivated precursor provided improved control over the initial reaction stage, at the expense of a small increase in the reaction time. At the optimal reaction conditions, the proposed modified Turkevich method allowed for the synthesis in batch of ∼12 nm monodisperse (RSD ∼10%) particles, with a variability from batch to batch of only ∼5%. The information gathered from the batch study, in particular the reaction time, was used to translate the synthesis from batch to flow. The system utilized for the flow synthesis consisted of a segmented flow reactor, where an organic stream was employed to segment the reactive aqueous stream to avoid reactor fouling and improve monodispersity. The use of segmented flow enables treating each droplet as a “travelling batch”, hence allowing the direct use of the kinetic data obtained in batch to design the flow reactor, leading to the rapid identification of the minimum residence time to allow for reaction completion. The flow reactor enabled the synthesis of ∼11 nm monodisperse (RSD ∼10%) particles, with full precursor conversion and reproducibility between reactor runs higher than that obtained in batch (variability of ∼2%). The flow-produced gold nanoparticles were tested for glucose sensing, exploiting their glucose oxidase-mimicking behaviour and demonstrated satisfactory glucose detection in the range of 1–10 mM.

Co-precipitation is by far the most common synthesis for magnetic iron oxide nanoparticles (IONPs), as cheap and environmentally friendly precursors and simple experimental procedures facilitate IONP production in many labs. Optimising co-precipitation syntheses remains challenging however, as particle formation mechanisms are not well understood. This is partly due to the rapid particle formation (within seconds) providing insufficient time to characterise initial precipitates. To overcome this limitation, a flow chemistry approach has been developed using steady-state operation to “freeze” transient reaction states locally. This allowed for the first time a comprehensive analysis of the early stages of co-precipitation syntheses via in-situ Small Angle X-ray Scattering and in-situ synchrotron X-Ray Diffraction. These studies revealed that after mixing the ferrous/ferric chloride precursor with the NaOH base solution, the most magnetic iron oxide phase forms within 5 s, the particle size changes only marginally afterwards, and co-precipitation and agglomeration occur simultaneously. As these agglomerates were too large to achieve colloidal stability via subsequent stabiliser addition, co-precipitated IONPs had to be de-agglomerated. This was achieved by adding the appropriate quantity of a citric acid solution which yielded within minutes colloidally stable IONP solutions around a neutral pH value. The new insights into the particle formation and the novel stabilisation procedure (not requiring any ultra-sonication or washing step) allowed to design a multistage flow reactor to synthesise and stabilise IONPs continuously with a residence time of less than 5 min. This reactor was robust against fouling and produced stable IONP solutions (of ~1.5 mg particles per ml) reproducibly via fast mixing ( 500 ml/h) for low materials cost.

Seeded-growth synthetic protocols enable precise control of particle size and shape, crucial for many sensing applications. However, scaling-up these syntheses in a reproducible way is challenging, as minimal variation in process parameters such as seed size, concentration or reaction temperature can significantly alter the final product. Flow reactors enable tight control in the process parameters and high reproducibility of the synthesis, representing a potential technology to perform seeded-growth syntheses in large scale. This work reports the design of a flow platform for the controlled synthesis of spherical gold nanoparticles with size up to 150 n m through a seeded-growth approach, and their use in Surface Enhanced Raman Scattering (SERS) and Photoinduced Enhanced Raman Spectroscopy (PIERS). The particle growth kinetics were studied via in situ time-resolved UV–Vis spectroscopy. The spectroscopic data were fitted with a kinetic model, which was subsequently used for the design of the reactor. The kinetics-based design approach enabled fast translation of the growth synthesis in flow, eventually allowing the on demand flow synthesis of particles with controllable size, ranging from 50 to 150 n m , with high reproducibility and full precursor conversion. The particles were tested for SERS and PIERS for different substrates, including warfare agents and biomolecules, with enhancement factors between 10 3 and 10 8 depending on the analyte, demonstrating their potential for detection of various analytes.

Cellulosic board-based packaging is very widely used in commercial products, especially in the food and personal care sectors. The use of biomolecules with antimicrobial properties can improve the shelf life of the packed perishable product and ensure a greater product safety. Chitin and chitosan are polysaccharides derived from natural resources with antimicrobial properties that are suitable also for food contact applications. In this paper the preparation of chitosan and chitin-based treatments were studied to treat board. Different mixtures, mainly based on chitin or on chitosan, were used to prepare films by solvent casting analysing the effect of the solvent, drying temperature and the addition of a plasticizer onto tensile properties. The study allowed selecting suitable compositions for board treatments. Results of bending stiffness tests and water absorptiveness indicated that the treatment based on chitin was the most promising, because of its better capacity of not modifying the board properties and thickness ascribed to its good capability of linking to cellulosic fibres. These treatments resulted effective in reducing the growth of bacteria and moulds on the boards; therefore, they reduced the number of bacteria present in starch-based food packed in treated board, thus showing the possibility of effectively improve the shelf life of perishable products.

Plasticized poly(lactic acid) (PLA)/poly(butylene succinate) (PBS) blend-based films containing chitin nanofibrils (CN) and calcium carbonate were prepared by extrusion and compression molding. On the basis of previous studies, processability was controlled by the use of a few percent of a commercial acrylic copolymer acting as melt strength enhancer and calcium carbonate. Furthermore, acetyl n-tributyl citrate (ATBC), a renewable and biodegradable plasticizer (notoriously adopted in PLA based products) was added to facilitate not only the processability but also to increase the mechanical flexibility and toughness. However, during the storage of these films, a partial loss of plasticizer was observed. The consequence of this is not only correlated to the change of the mechanical properties making the films more rigid but also to the crystallization and development of surficial oiliness. The effect of the addition of calcium carbonate (nanometric and micrometric) and natural nanofibers (chitin nanofibrils) to reduce/control the plasticizer migration was investigated. The prediction of plasticizer migration from the films&rsquo, core to the external surface was carried out and the diffusion coefficients, obtained by regression of the experimental migration data plotted as the square root of time, were evaluated for different blends compositions. The results of the diffusion coefficients, obtained thanks to migration tests, showed that the CN can slow the plasticizer migration. However, the best result was achieved with micrometric calcium carbonate while nanometric calcium carbonate results were less effective due to favoring of some bio polyesters&rsquo, chain scission. The use of both micrometric calcium carbonate and CN was counterproductive due to the agglomeration phenomena that were observed.

Gold nanomaterials have diverse applications ranging from healthcare and nanomedicine to analytical sciences and catalysis. Microfluidic and millifluidic reactors offer multiple advantages for their synthesis and manufacturing, including controlled or fast mixing, accurate reaction time control and excellent heat transfer. These advantages are demonstrated by reviewing gold nanoparticle synthesis strategies in flow devices. However, there are still challenges to be resolved, such as reactor fouling, particularly if robust manufacturing processes are to be developed to achieve the desired targets in terms of nanoparticle size, size distribution, surface properties, process throughput and robustness. Solutions to these challenges are more effective through a coordinated approach from chemists, engineers and physicists, which has at its core a qualitative and quantitative understanding of the synthesis processes and reactor operation. This is important as nanoparticle synthesis is complex, encompassing multiple phenomena interacting with each other, often taking place at short timescales. The proposed methodology for the development of reactors and processes is generic and contains various interconnected considerations. It aims to be a starting point towards rigorous design procedures for the robust and reproducible continuous flow synthesis of gold nanoparticles. Graphical Abstract

Biodegradable polymers are promising materials for films and sheets used in many widely diffused applications like packaging, personal care products and sanitary products, where the synergy of high biocompatibility and reduced environmental impact can be particularly significant. Plasticized poly(lactic acid) (PLA)/poly(butylene succinate) (PBS) blend-based films, showing high cytocompatibility and improved flexibility than pure PLA, were prepared by laboratory extrusion and their processability was controlled by the use of a few percent of a commercial melt strength enhancer, based on acrylic copolymers and micro-calcium carbonate. The melt strength enhancer was also found effective in reducing the crystallinity of the films. The process was upscaled by producing flat die extruded films in which elongation at break and tear resistance were improved than pure PLA. The in vitro biocompatibility, investigated through the contact of flat die extruded films with cells, namely, keratinocytes and mesenchymal stromal cells, resulted improved with respect to low density polyethylene (LDPE). Moreover, the PLA-based materials were able to affect immunomodulatory behavior of cells and showed a slight indirect anti-microbial effect. These properties could be exploited in several applications, where the contact with skin and body is relevant.

A mathematical model for the liquid-phase synthesis of spherical nanoparticles in continuous flow micro- and milli-reactors was developed, accounting for residence time distributions (RTD). These distributions were derived for the reactants and the particles involved in the synthesis. The kinetic parameters needed to describe the reactions were calculated from experimental data available in the literature from batch reactors, with the aid of population balance modelling. They were subsequently used, without further modification, to simulate the synthesis in flow reactors via population balance modelling, averaging the nanoparticle properties at the reactor outlet using the reactor RTDs. The model was employed to describe the synthesis of silica nanoparticles as a case study, and validated against flow reactor results from the literature. The results demonstrate direct RTD effects and indirect diffusion-induced effects on the evolution of the particle size distribution during the flow synthesis. The former are created by the inherent widening of the RTDs, due to the different residence time experienced by each fluid element, leading to a broadening of the particle size distribution. The latter are induced by the difference in diffusivity between nanoparticles and liquid reactants, which leads to different dispersion processes in the reactor for the different components of the reaction mixture. These effects appear as the major cause of particle size distribution difference between (single phase) flow and batch syntheses.

An innovative set-up of synchrotron radiation soft X-ray Fluorescence was applied at the TwinMic beamline (Elettra Sincrotrone Trieste) to test the potential of the method in investigating the interaction between protectives and consolidants with sandstone substrates. To this purpose, products developed in the framework of the EU-funded Nano-Cathedral Project (grant agreement No 646178) were studied through chemical mapping of sandstone cross sections with the aim of inspecting the distribution and the adhesion/cohesion ability of the products. The paper illustrates the obtained results, also in combination with SEM-EDS imaging, paying special attention to the experimental challenges encountered in the use of the TwinMic set-up. Even though the TwinMic microscope normally works in transmission mode to focus the microprobe on the sample, we successfully managed to scan thick (1 mm) samples in reflection mode, thus showing the potential of this technique for the investigation of samples that cannot be easily prepared as thin (≤1 μm) cross sections.

The consolidation of degraded carbonate stone used in ancient monuments is an important topic for European cultural heritage conservation. The products most frequently used as consolidants are based on tetraalkoxy- or alkylalkoxy-silanes (in particular tetraethyl-orthosilicate, TEOS), resulting in the formation of relatively stable amorphous silica or alkylated (hydrophobic) silica inside the stone pores. However, silica is not chemically compatible with carbonate stones; in this respect, nanocalcite may be a suitable alternative. The present work concerns the preparation of water suspensions of calcite nanoparticles (CCNPs) by controlled carbonation of slaked lime using a pilot-scale reactor. A simplified design of experiment was adopted for product optimization. Calcite nanoparticles of narrow size distribution averaging about 30 nm were successfully obtained, the concentration of the interfacial agent and the size of CaO being the most critical parameters. Primary nanoparticle aggregation causing flocculation could be substantially prevented by the addition of polymeric dispersants. Copolymer-based dispersants were produced in situ by controlled heterophase polymerisation mediated by an amphiphilic macro-RAFT (reversible addition-fragmentation transfer) agent. The stabilized CCNP aqueous dispersions were then applied on carbonate and silicate substrates; Scanning Electron Microscopy (SEM)analysis of cross-sections allowed the evaluation of pore penetration, interfacial binding, and bridging (gap-filling) properties of these novel consolidants.