Progesterone (PG)
is an essential sex hormone with a variety of
important biological functions, but its insolubility leads to low
bioavailability of most water-based formulations. What is more, the
commercial oil-based formulations often cause severe side effects
after long-term injection due to poor tissue absorption of oil. Herein,
we report an aseptic bottom-up method utilizing emulsion freeze-drying
technology that produces size-controllable, highly bioavailable, and
water-based PG nanocrystal injection. The key factors that can determine
the features of nanocrystals were investigated, including solvents,
water-to-oil ratio, drug concentrations, type of surfactants, temperature
in freeze-drying process, and lyoprotectants. Mechanisms of crystal
growth formation process for PG nanocrystals were also analyzed theoretically.
The prepared water-based PG nanocrystal suspension injection (PG/NSI)
not only showed quick dissolution behaviors but also had significantly
improved bioavailability in vivo. Therefore, this method can effectively
control the size of nanocrystals, enhance bioavailability of insoluble
drugs, and produce aseptic water-based nanocrystals that can be directly
used for injection. Moreover, this method can also be used to prepare
nanocrystals with the desired size under aseptic conditions for other
poorly water-soluble drugs.