Sonication-assisted emulsification has emerged as a powerful technique for the preparation of microparticles in various fields, including pharmaceuticals, cosmetics, and food science. This study aims to investigate the impact of different polymers in an aqueous system on the preparation of microparticles by the double emulsion technique. By understanding the factors that affect emulsification and stability, we can optimize the production of microparticles with desired characteristics. This study discusses the mechanism behind sonication-assisted emulsification, the various polymers used, and the analysis of particle size, morphology, and stability. The microparticle were prepared with a water-in-oil-in-water (W/O/W) solvent evaporation method, for various polymers (including EC 4 cp, Eudragit® RS 100, Eudragit® RL 100, PLGA (RG503H) and PCL) that solvent used dichloromethane. The particle size/distribution of the emulsion droplets/hardened microparticles was monitored using FBRM. The morphology of polymeric microparticles was characterized using scanning electron microscopy (SEM). The transformation of the emulsion droplets into solid microparticles occured within the first 11.5, 20, 26, 30.5 and 56 min when EC 4 cp, Eudragit® RS 100, Eudragit® RL 100, PLGA (RG503H) and PCL were used respectively. The square weighted mean chord length of PCL microparticles was smallest, but the chord count was not the highest. The chord length distribution (CLD) measured by FBRM showed that a larger mean particle size gave longer CLD and a lower peak of particle number. SEM data revealed that the morphology of microparticles was influenced by the type of polymer. Sonicator helped in emulsification of polymeric system in aquous. FBRM can be employed for online monitoring of the shift in the microparticle CLD and detect transformation of emulsion droplets into solid microparticles during the solvent evaporation process. The microparticle CLD and transformation process were strongly influenced by polymer type.
