The present invention provides methods for producing composite particles
using supercritical fluid as a plasticizing and extracting agent,
composite particles formed in accordance with the methods and an
apparatus for carrying out the methods. In accordance with the methods of
the invention, a polymer, a wax and/or a lipid that is a solid at
standard temperature and pressure is contacted with a supercritical fluid
to form a melt, either before or after the polymer, wax and/or lipid has
been contacted with a solution comprising a solute dissolved in a
solvent. The supercritical fluid plasticizes the polymer, wax and/or lip
and extracts the solvent from the solution, resulting in the formation of
a two-fraction system including a first melt-rich fraction that includes
the plasticized melt and fine particles of precipitated solute that are
dispersed in the melt, and a second fraction that includes the
supercritical fluid and the solvent. Expansion of the first fraction
across a pressure drop results in the formation of composite particles
that include the polymer, wax and/or lipid and the solute.