Risk assessment of amorphous silicon dioxide nanoparticles in a glass cleaner formulation

Abstract

Since nanomaterials are a heterogeneous group of substances used in various applications, risk assessment needs to be done on a case-by-case basis. Here the authors assess the risk (hazard and exposure) of a glass cleaner with synthetic amorphous silicon dioxide (SAS) nanoparticles during production and consumer use (spray application). As the colloidal material used is similar to previously investigated SAS, the hazard profile was considered to be comparable. Overall, SAS has a low toxicity. Worker exposure was analysed to be well controlled. The particle size distribution indicated that the aerosol droplets were in a size range not expected to reach the alveoli. Predictive modelling was used to approximate external exposure concentrations. Consumer and environmental exposure were estimated conservatively and were not of concern. It was concluded based on the available weight-of-evidence that the production and application of the glass cleaner is safe for humans and the environment under intended use conditions.     

Deposition behavior of inhaled nanostructured TiO2 in rats: fractions of particle diameter below 100 nm (nanoscale) and the slicing bias of transmission electron microscopy

Context: In experimental studies with nanomaterials where translocation to secondary organs was observed, the particle sizes were smaller than 20?nm and were mostly produced by spark generators. Engineered nanostructured materials form microsize aggregates/agglomerates. Thus, it is unclear whether primary nanoparticles or their small aggregates/agglomerates occur in non-negligible concentrations after exposure to real-world materials in the lung. Objective: We dedicated an inhalation study with nanostructured TiO₂ to the following research question: Does the particle size distribution in the lung contain a relevant subdistribution of nanoparticles? Methods: Six rats were exposed to 88?mg/m³ TiO₂ over 5 days with 20% (count fraction) and <0.5% (mass fraction) of nanoscaled objects. Three animals were sacrificed after cessation of exposure (5 days), others after a recovery period of 14 days. Particle sizes were determined morphometrically by transmission electron microscopy (TEM) of ultra-thin lung slices. Since the particles visible are two-dimensional surrogates of three-dimensional structures we developed a model to estimate expected numbers of particle diameters below 100?nm due to the TEM slicing bias. Observed and expected numbers were contrasted in 2?×?2 tables by odds ratios. Results: Comparisons of observed and expected numbers did not present evidence in favor of the presence of nanoparticles in the rat lungs. In simultaneously exposed satellite animals agglomerates of nanostructured TiO₂ were observed in the mediastinal lymph nodes but not in secondary organs. Conclusions: For nanostructured TiO₂, the deposition of nanoscaled particles in the lung seem to play a negligible role.     

Generation and Characterization of Test Atmospheres with Nanomaterials

To ensure the product safety of nanomaterials, BASF has initiated an extensive program to study the potential inhalation toxicity of nanosize particles. As preparation work for upcoming inhalation studies, the following manufactured nanomaterials have been evaluated for their behavior in an exposure system designed for inhalation toxicity studies: titanium dioxide, carbon black, Aerosil R104, Aerosil R106, aluminum oxide, copper(II) oxide, amorphous silicon dioxide, zinc oxide, and zirconium(IV) oxide. As the physicochemical properties and the complex nature of ultrafine aerosols may substantially influence the toxic potential, the particle size, specific surface area, zeta potential, and morphology of each of the materials were determined. Aerosols of each material were generated using a dry powder aerosol generator and by nebulization of particle suspensions. The mass concentration of the particles in the inhalation atmosphere was determined gravimetrically and the particle size was determined using a cascade impactor, an optical particle counter, and a scanning mobility particle sizer. The dispersion techniques used generated fine aerosols with particle size distributions in the respiratory range. However, as a result of the significant agglomeration of nanoparticles in the test materials evaluated, no more than a few mass percent of the materials were present as single nanoparticles (i.e., < 100 nm). Considering the number, a greater percentage of nanoparticles was present. Based on the obtained results and experience with the equipment, a technical setup for inhalation studies with nanomaterials is proposed. Furthermore, a stepwise testing approach is recommended that also could reduce the number of animals used in testing.     

Generation and characterization of test atmospheres with nanomaterials

To ensure the product safety of nanomaterials, BASF has initiated an extensive program to study the potential inhalation toxicity of nanosize particles. As preparation work for upcoming inhalation studies, the following manufactured nanomaterials have been evaluated for their behavior in an exposure system designed for inhalation toxicity studies: titanium dioxide, carbon black, Aerosil R104, Aerosil R106, aluminum oxide, copper(II) oxide, amorphous silicon dioxide, zinc oxide, and zirconium(IV) oxide. As the physicochemical properties and the complex nature of ultrafine aerosols may substantially influence the toxic potential, the particle size, specific surface area, zeta potential, and morphology of each of the materials were determined. Aerosols of each material were generated using a dry powder aerosol generator and by nebulization of particle suspensions. The mass concentration of the particles in the inhalation atmosphere was determined gravimetrically and the particle size was determined using a cascade impactor, an optical particle counter, and a scanning mobility particle sizer. The dispersion techniques used generated fine aerosols with particle size distributions in the respiratory range. However, as a result of the significant agglomeration of nanoparticles in the test materials evaluated, no more than a few mass percent of the materials were present as single nanoparticles (i.e., < 100 nm). Considering the number, a greater percentage of nanoparticles was present. Based on the obtained results and experience with the equipment, a technical setup for inhalation studies with nanomaterials is proposed. Furthermore, a stepwise testing approach is recommended that also could reduce the number of animals used in testing.     

Measurement of pharmaceutical particles using a time-of-flight particle sizer.

The Aerosizer is an instrument for time-of-flight measurement, which is widely used in particle size determinations. The results of various studies indicate that there are still some problems related to the optimization of the analysis conditions. In this study, the behaviour of a set of different kinds of pharmaceutical particles during Aerosizer measurements was studied. An Aerosizer LD equipment with an Aero-Disperser was validated with particle size standards. Volume particle size distributions of particles with different size and shape characteristics were determined (PVP, Celphere, lactose, a drug substance, PHB microparticles). The aim was to investigate the effects of the shear force and deagglomeration levels during the dispersion of the particles on the particle size distributions that were obtained. The results of this study indicate that the ability of the instrument to disperse particles is highly dependent on the properties of the materials. According to the validation measurements, the instrument gives accurate results for spherical, uncohesive particles. The capability of the dispersing unit to separate particles aerodynamically was well observed with PVP. Time-of-flight measurements were uncomplicated for relatively large particles, such as Celphere, which have little interaction with each other and with the instrument housing. For lactose, increasing shear force rates resulted in size distributions with larger particle sizes. In the case of the PHB microparticles the results indicated that the aggregates became smaller and particles were partly separated to primary particles with all shear force levels.     

Analysis of titanium dioxide and zinc oxide nanoparticles in cosmetics

There have been rapid increases in consumer products containing nanomaterials, raising concerns over the impact of nanoparticles (NPs) to humankind and the environment, but little information has been published about mineral filters in commercial sunscreens. It is urgent to develop methods to characterize the nanomaterials in products. Titanium dioxide (TiO₂) and zinc oxide (ZnO) NPs in unmodified commercial sunscreens were characterized by laser scanning confocal microscopy, atomic force microscopy, X-ray diffraction (XRD), and transmission electron microscopy (TEM). The results showed that laser scanning confocal microscopy evaluated primary particle aggregates and dispersions but could not size NPs because of the diffraction limited resolution of optical microscopy (200 nm). Atomic force microscopy measurements required a pretreatment of the sunscreens or further calibration in phase analysis, but could not provide their elemental composition of commercial sunscreens. While XRD gave particle size and crystal information without a pretreatment of sunscreen, TEM analysis required dilution and dispersion of the commercial sunscreens before imaging. When coupled with energy-dispersive X-ray spectroscopy, TEM afforded particle size information and compositional analysis. XRD characterization of six commercial sunscreens labeled as nanoparticles revealed that three samples contained TiO₂ NPs, among which two listed ZnO and TiO₂, and displayed average particle sizes of 15 nm, 21 nm, and 78 nm. However, no nanosized ZnO particles were found in any of the samples by XRD. In general, TEM can resolve nanomaterials that exhibit one or more dimensions between 1 nm and 100 nm, allowing the identification of ZnO and TiO₂ NPs in all six sunscreens and ZnO/TiO₂ mixtures in two of the samples. Overall, the combination of XRD and TEM was suitable for analyzing ZnO and TiO₂ NPs in commercial sunscreens.     

Investigation of the cytotoxicity of nanozeolites A and Y

Nanosized zeolite particles are important materials for many applications in the field of nanotechnology. The possible adverse effects of these nanomaterials on human health have been scarcely investigated and remain largely unknown. This study reports the synthesis of nanozeolites Y and A with particle sizes of 25-100 nm and adequate colloidal stability for in vitro cytotoxicity experiments. The cytotoxic response of macrophages, epithelial and endothelial cells to these nanocrystals was assessed by determining mitochondrial activity (MTT assay) and cell membrane integrity (LDH leakage assay). After 24 h of exposure, no significant cytotoxic activity was detected for nanozeolite doses up to 500 μg/ml. The addition of fetal calf serum to the cell culture medium during exposure did not significantly change this low response. The nanozeolites showed low toxicity compared with monodisperse amorphous silica nanoparticles of similar size (60 nm). These results may contribute to the application of safe nanozeolites for purposes such as medical imaging, sensing materials, low-k films and molecular separation processes.     

Simultaneous production and co-mixing of microparticles of nevirapine with excipients by supercritical antisolvent method for dissolution enhancement

Microparticles of a poorly water-soluble model drug, nevirapine (NEV) were prepared by supercritical antisolvent (SAS) method and simultaneously deposited on the surface of excipients such as lactose and microcrystalline cellulose in a single step to reduce drug–drug particle aggregation. In the proposed method, termed supercritical antisolvent-drug excipient mixing (SAS-DEM), drug particles were precipitated in supercritical CO₂ vessel containing excipient particles in suspended state. Drug/excipient mixtures were characterized for surface morphology, crystallinity, drug–excipient physico-chemical interactions, and molecular state of drug. In addition, the drug content uniformity and dissolution rate were determined. A highly ordered NEV–excipient mixture was produced. The SAS-DEM treatment was effective in overcoming drug–drug particle aggregation and did not affect the crystallinity or physico-chemical properties of NEV. The produced drug/excipient mixture has a significantly faster dissolution rate as compared to SAS drug microparticles alone or when physically mixed with the excipients.     

Rifampicin microparticles production by supercritical antisolvent precipitation

Semi-continuous supercritical antisolvent (SAS) precipitation has been used to produce Rifampicin micro- and nanoparticles with controlled particle size (PS) and particle size distribution (PSD). SAS experiments were performed using different liquid solvents. The best micronization results have been obtained using dimethyl sulfoxide (DMSO); using this solvent and operating at 40 degrees C, we obtained nanoparticles with mean diameters ranging from 0.4 to 1 microm at a pressure of 120 bar or more, and microparticles with mean diameters ranging from 2.5 to 5 microm at pressures between 90 and 110 bar. The morphology of Rifampicin precipitates was different too. Nanoparticles connected in small aggregates were obtained at pressures higher than 120 bar, whereas, spherical single microparticles were obtained operating at lower pressures. We also investigated the effect of the concentration of Rifampicin in the liquid solution on particles diameter: we observed that, increasing the liquid concentration, the mean PS increased and the PSD enlarged. XRD and HPLC analysis on treated Rifampicin showed that particles are amorphous and no degradation occurred as a consequence of supercritical processing. We attempted an explanation of the different morphologies observed considering the modification of the high pressure vapor-liquid equilibria of the ternary system Rifampicin-DMSO-CO(2) with respect to the behavior of the binary system DMSO-CO(2).     

Biodistribution of nanosilica particles in pregnant mice and the potential risk on the reproductive development

Nanomaterials acquire revolutionary functions such as anti-inflammatory and anti-viral effects by increasing surface area per unit weight, due to the reduction to nanosize. Such nanomaterials are rapidly put to practical use without safety evaluation. This is because it is widely assumed that nanomaterials are merely of the same molecular composition as existing materials of more than submicron size, and that nanomaterials cannot be absorbed from the digestive tract or skin as is the case with existing materials of more than submicron size. On the other hand, as was the case with thalidomide, evidence shows that fetuses and infants are affected more than adults by a variety of environmental toxins, because of physiological immaturity. Thus, placental or breast milk-mediated exposure to nanomaterials may possibly induce unexpected biological effects. To our knowledge, however, no studies have examined effects of pregnant animal exposure to nanomaterials on transitivity to placenta or infants, or on maintenance of pregnancy. Therefore, using nanosilica particles (nSPs) employed as additives in cosmetics and foods, we will report on the efficiency of transitivity of nSPs of various diameters to the circulation through the placental barrier after nanomaterial exposure and the risks of nSP exposure to pregnant mice. In this review, I will discuss the development of safety in nanomaterials and the maintenance of good health.     

Characterisation of nanoparticulate systems by hydrodynamic chromatography

Particle size and particle size distribution can have a fundamental effect on the physical properties of colloidal dispersions. For many systems the measurement of average particle size is not sufficient, the presence of different size populations will have a strong influence on properties and could be related to the production process. Hydrodynamic chromatography (HDC) provides a method for the separation of polymers in solution or particles in suspension based on their size. In a packed column, the separation takes place in the inter-particle channels and the elution order is from large to small, analogous to gel permeation chromatography. The dynamic range of packed column HDC is from molecular size up to particles of greater than 1 microm. New instrumentation which can be used to determine the particle size distribution of a range of colloidal dispersions by packed column HDC is described. Data to support accuracy and precision of average particle size determination is presented as well as a number of case studies to illustrate the applicability of the technique to samples with polydisperse or multi-modal particle size distributions.     

Identification of physical-chemical variables affecting particle size following precipitation using a supercritical fluid

The physical-chemical processing variables affecting particle size following precipitation using the supercritical antisolvent (SAS) method were investigated by varying both the composition of the feed solvent and the structure of the solute, using a series of steroids. The key factor influencing particle size in these studies appears to be the solubility of the drug in the organic solvent/supercritical fluid mixture, where relatively high solubility causes a lower degree of supersaturation in the precipitation vessel, resulting in a relatively large particle size. Higher operating pressures result in larger particle sizes, probably through the effect of pressure on solubility. Physical properties of the carrier solvent, such as vapor pressure and dielectric constant, were not effective predictors of relative particle size of the precipitated powder, nor was solubility of the model drug in the carrier solvent. In limited studies of the physical state of the precipitated solid, higher apparent crystallinity was observed for powders with larger particle size. A precipitate of a different crystal form was observed when starting with hydrocortisone hemisuccinate monohydrate and may represent the loss of water of hydration. An amorphous solid was precipitated when starting with yttrium acetate dihydrate. Broad guidelines for effective particle size reduction using this technique are presented.     

Identification of Physical-Chemical Variables Affecting Particle Size Following Precipitation Using a Supercritical Fluid

The physical-chemical processing variables affecting particle size following precipitation using the supercritical antisolvent (SAS) method were investigated by varying both the composition of the feed solvent and the structure of the solute, using a series of steroids. The key factor influencing particle size in these studies appears to be the solubility of the drug in the organic solvent/supercritical fluid mixture, where relatively high solubility causes a lower degree of supersaturation in the precipitation vessel, resulting in a relatively large particle size. Higher operating pressures result in larger particle sizes, probably through the effect of pressure on solubility. Physical properties of the carrier solvent, such as vapor pressure and dielectric constant, were not effective predictors of relative particle size of the precipitated powder, nor was solubility of the model drug in the carrier solvent. In limited studies of the physical state of the precipitated solid, higher apparent crystallinity was observed for powders with larger particle size. A precipitate of a different crystal form was observed when starting with hydrocortisone hemisuccinate monohydrate and may represent the loss of water of hydration. An amorphous solid was precipitated when starting with yttrium acetate dihydrate. Broad guidelines for effective particle size reduction using this technique are presented.     

Risk assessment strategies for nanoscale and fine-sized titanium dioxide particles: Recognizing hazard and exposure issues

The basic tenets for assessing health risks posed by nanoparticles (NP) requires documentation of hazards and the corresponding exposures that may occur. Accordingly, this review describes the range and types of potential human exposures that may result from interactions with titanium dioxide (TiO₂) particles or NP – either in the occupational/workplace environment, or in consumer products, including food materials and cosmetics. Each of those applications has a predominant route of exposure. Very little is known about the human impact potential from environmental exposures to NP – thus this particular issue will not be discussed further. In the workplace or occupational setting inhalation exposure predominates. Experimental toxicity studies demonstrate low hazards in particle-exposed rats. Only at chronic overload exposures do rats develop forms of lung pathology. These findings are not supported by multiple epidemiology studies in heavily-exposed TiO₂ workers which demonstrate a lack of correlation between chronic particle exposures and adverse health outcomes including lung cancer and noncancerous chronic respiratory effects. Cosmetics and sunscreens represent the major application of dermal exposures to TiO₂ particles. Experimental dermal studies indicate a lack of penetration of particles beyond the epidermis with no consequent health risks. Oral exposures to ingested TiO₂ particles in food occur via passage through the gastrointestinal tract (GIT), with studies indicating negligible uptake of particles into the bloodstream of humans or rats with subsequent excretion through the feces. In addition, standardized guideline-mandated subchronic oral toxicity studies in rats demonstrate very low toxicity effects with NOAELs of >1000 mg/kg bw/day. Additional issues which are summarized in detail in this review are: 1) Methodologies for implementing the Nano Risk Framework – a process for ensuring the responsible development of products containing nanoscale materials; and 2) Safe-handling of nanomaterials in the laboratory.     

Granular biodurable nanomaterials: No convincing evidence for systemic toxicity

Nanomaterials are usually defined by primary particle diameters ranging from 1 to 100 nm. The scope of this review is an evaluation of experimental animal studies dealing with the systemic levels and putative systemic effects induced by nanoparticles which can be characterized as being granular biodurable particles without known specific toxicity (GBP). Relevant examples of such materials comprise nanosized titanium dioxide (TiO₂) and carbon black. The question was raised whether GBP nanomaterials systemically accumulate and may possess a relevant systemic toxicity. With few exceptions, the 56 publications reviewed were not performed using established standard protocols, for example, OECD guidelines but used non-standard study designs. The studies including kinetic investigations indicated that GBP nanomaterials were absorbed and systemically distributed to rather low portions only. There was no valid indication that GPB nanomaterials possess novel toxicological hazard properties. In addition, no convincing evidence for a relevant specific systemic toxicity of GBP nanomaterials could be identified. The minority of the papers reviewed (15/56) investigated both nanosized and microsized GBP materials in parallel. A relevant different translocation of GBP nanomaterials in contrast to GBP micromaterials was not observed in these studies. There was no evidence that GPB nanomaterials possess toxicological properties other than their micromaterial counterparts.     

Improved physicochemical characteristics of felodipine solid dispersion particles by supercritical anti-solvent precipitation process

Solid dispersions of felodipine were formulated with HPMC and surfactants by the conventional solvent evaporation (CSE) and supercritical anti-solvent precipitation (SAS) methods. The solid dispersion particles were characterized by particle size, zeta potential, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), powder X-ray diffraction (XRD), solubility and dissolution studies. The effects of the drug/polymer ratio and surfactants on the solubility of felodipine were also studied. The mean particle size of the solid dispersions was 200-250 nm; these had a relatively regular spherical shape with a narrow size distribution. The particle size of the solid dispersions from the CSE method increased at 1 h after dispersed in distilled water. However, the particle sizes of solid dispersions from the SAS process were maintained for 6 h due to the increased solubility of felodipine. The physical state of felodipine changed from crystalline to amorphous during the CSE and SAS processes, confirmed by DSC/XRD data. The equilibrium solubility of the felodipine solid dispersion prepared by the SAS process was 1.5-20 microg/ml, while the maximum solubility was 35-110 microg/ml. Moreover, the solubility of felodipine increased with decreasing drug/polymer ratio or increasing HCO-60 content. The solid dispersions from the SAS process showed a high dissolution rate of over 90% within 2 h. The SAS process system may be used to enhance solubility or to produce oral dosage forms with high dissolution rate.     

Physicochemical determinants in the cellular responses to nanostructured amorphous silicas

Amorphous silicas, opposite to crystalline polymorphs, have been regarded so far as nonpathogenic, but few studies have addressed the toxicity of the wide array of amorphous silica forms. With the advent of nanotoxicology, there has been a rising concern about the safety of silica nanoparticles to be used in nanomedicine. Here, we report a study on the toxicity of amorphous nanostructured silicas obtained with two different preparation procedures (pyrolysis vs. precipitation), the pyrogenic in two very different particle sizes, in order to assess the role of size and origin on surface properties and on the cell damage, oxidative stress, and inflammatory response elicited in murine alveolar macrophages. A quartz dust was employed as positive control and monodispersed silica spheres as negative control. Pyrogenic silicas were remarkably more active than the precipitated one as to cytotoxicity, reactive oxygen species production, lipid peroxidation, nitric oxide synthesis, and production of tumor necrosis factor-α, when compared both per mass and per unit surface. Between the two pyrogenic silicas, the larger one was the more active. Silanols density is the major difference in surface composition among the three silicas, being much larger than the precipitated one as indicated by joint calorimetric and infrared spectroscopy analysis. We assume here that full hydroxylation of a silica surface, with consequent stable coverage by water molecules, reduces/inhibits toxic behavior. The preparation route appears thus determinant in yielding potentially toxic materials, although the smallest size does not always correspond to an increased toxicity.     

Sustained release delivery systems. III. Preparation and in vitro dissolution of surface-reacted dapsone particles

The use of low solubility materials as coating agents to prepare sustained release particles is well known. Distinct from this physical process, the present work was undertaken to assess the feasibility of chemically forming a low solubility derivative, or derivatives, on the surface of a drug particle. Accordingly, the surface reaction of solid dapsone (DDS) particles exposed to acetic anhydride vapor was studied as a function of time, temperature, particle size, and particle type (compressed and precipitated). The in vitro dissolution of these particles was also studied. Over time, DDS was converted to monacetyldapsone (MADDS) and diacetyldapsone (DADDS). The temperature-controlled reaction studies were carried out using a small rotating basket that contained the DDS powder while being permeable to acetic anhydride vapor. The extent of conversion as a function of time was determined by removing samples at known time intervals and assaying for DDS, MADDS and DADDS using HPLC. At any one time, the fraction of DDS acetylated decreased with increasing particle size. The time course of the reaction for compressed particles was different from that for precipitated particles. Temperature studies suggested that the conversion reaction of the precipitated particles was under chemical control while that for compressed particles was under diffusion control. In either case, it appeared that conversion proceeded in accordance with the so-called “shrinking unreacted core” model, which resulted in the formation of an external layer of MADDS and DADDS that increased in thickness with time, while the diameter of the unreacted core decreased. That such a low solubility layer had an influence on the release of the unreacted drug core was confirmed by in vitro dissolution studies. As the content of DADDS in the reacted layers increased, the rate of dissolution of DDS from the core decreased markedly.     

Nanotechnology, cosmetics and the skin: is there a health risk?

Cosmetic formulations may contain nano-emulsions and microscopic vesicles consisting of traditional cosmetic materials, although it is uncertain whether they should be qualified as actual nanomaterials. Vesicle materials do not penetrate into living human skin. Vesicle formulations may enhance or reduce skin absorption of ingredients, albeit at a limited scale. Sunscreens contain TiO2 or ZnO nanoparticles (NP), which are efficient UV filters. A number of studies suggest that insoluble NP do not penetrate into or through human skin. The results of in vivo toxicity tests showed that TiO2 and ZnO NP are non-toxic. In vitro and in vivo cytotoxicity, genotoxicity, photogenotoxicity, acute toxicity, sensitisation and ecotoxicology studies on TiO2 NP found no difference in the safety profile of micro- or nano-sized materials, all of which were non-toxic. Although some in vitro investigations on TiO2 particles reported cell uptake, oxidative cell damage or genotoxicity, these results may be secondary to phagocytosis of cells exposed to excessive particle concentrations. Studies on wear debris nano- and microparticles support the traditional view that toxicity of small particles is related to their chemistry, rather than their particle size. There is little evidence supporting a general rule that adverse effects of particles on the skin or other tissues increase with smaller particle size, or produce novel toxicities relative to those of larger particles. Overall, the current evidence suggests that nano-sized cosmetic or sunscreen ingredients pose no potential risk to human health, whereas their use in sunscreens has large benefits, such as the protection of human skin against skin cancer.     

Generation of Fine Powders of Recombinant Human Deoxyribonuclease Using the Aerosol Solvent Extraction System

PURPOSE: To investigate the feasibility of using the Aerosol Solvent Extraction System (ASES) to produce fine powders of recombinant human deoxyribonuclease (rhDNase), lysozyme-lactose and rhDNase-lactose powders from aqueous based solutions. METHODS: The ASES technique using high pressure carbon dioxide modified with ethanol or ethanol and triethylamine was used for the generation of rhDNase powders and protein-lactose powders from aqueous based solutions. Particle size, morphology, size distributions, crystallinity, and powder aerosol performance were measured. The biochemical integrity of the processed rhDNase was assessed by testing the monomer content and the degree of deamidation. RESULTS: RhDNase precipitated as spherical particles in the size range between 50 and 500 nm. The primary nano-sized particles were agglomerated to micron-sized clumps of particles during the precipitation process. The median particle size and the fine particle fraction were functions of the operating temperature and the nozzle system used. RhDNase was substantially denatured in the ASES process using carbon dioxide modified with ethanol as anti-solvent. However almost complete recovery of the monomer was achieved using carbon dioxide modified with ethanol-triethylamine as an anti-solvent. Lysozyme-lactose and rhDNase-lactose powders were also precipitated as agglomerated spheres using the ASES process. The powders were amorphous except for those with lactose content higher than 45%. CONCLUSIONS: Micron-sized particles of rhDNase suitable for inhalation delivery were generated from aqueous based solutions using the modified ASES technique. The biochemical integrity of the rhDNase powder is a function of the antisolvent and the operating temperature.