Overcoming challenges in compounding analgesic medications

Compounded analgesics play a vital role in personalised pain management. From customised topical creams and gels to nasal sprays and troches, these formulations are tailored to meet specific patient needs when commercial medications fall short. However, preparing compounded analgesics is far from straightforward. Pharmacists face several technical and operational challenges that can impact the safety, efficacy, and consistency of the final product. 

This article explores the most common issues encountered in the compounding of analgesics and the innovations available to address them. 

1. Why are some analgesic topicals gritty or uneven?

A common challenge in topical analgesic compounding is the presence of coarse or gritty textures caused by poorly incorporated active pharmaceutical ingredients (APIs). This issue is especially prevalent when working with crystalline or granular APIs that are difficult to solubilise or disperse evenly into the base.

Traditional solution:
Pharmacies often rely on mechanical ointment mills to refine the texture and break down particulates. However, this adds time, requires additional cleaning, and increases the risk of cross-contamination and product loss.

2. How does air entrapment impact analgesic formulations?

High-shear mixing devices can unintentionally introduce air into the formulation. In topical or mucosal dosage forms, this air can cause inconsistencies in volume or weight-based dosing, which in turn affects therapeutic accuracy. Entrapped air can also reduce the product’s shelf stability and alter its appearance or feel.

Traditional solution:
To remove air, compounding pharmacists may transfer products between devices like unguators and ointment mills, or manually de-aerate using spatulas or syringes, which is a labour-intensive and imprecise process.

3. What are the challenges with insoluble active ingredients?

Some analgesic APIs are poorly soluble in water or oil, requiring additional processing to ensure even distribution. This typically involves steps that extend compounding time and increase the potential for error, like grinding, levigation, or trituration.

Traditional solution:
Particle size reduction is often achieved through pre-processing with a mortar and pestle or the use of auxiliary milling equipment. However, these steps may not be adequate for all formulations and can result in material waste or inconsistent results.

4. Why is achieving a homogeneous mix difficult in multi-API formulations?

Many analgesic formulations include multiple active ingredients—such as lidocaine, ketoprofen, and gabapentin—each with different physical properties. Achieving a homogeneous final product is essential to ensure accurate dosing and therapeutic effect, yet difficult to accomplish using basic mixing tools.

Traditional solution:
Pharmacists often resort to combining several mixing and processing techniques to ensure full dispersion. This can be time-consuming and demands a high level of skill and attention to detail.

The future of analgesic compounding in Australian pharmacies

The growing demand for personalised pain relief continues to place pressure on Australian compounding pharmacies to produce high-quality analgesic formulations efficiently and consistently. To meet these expectations, many are now turning to integrated mixing technologies that combine multiple functions—such as solubilization, emulsification, milling, and de-aeration—into a single, closed system. 

One such solution is the MAZ® mixer, which utilises planetary mixing and milling media to streamline the compounding process. By combining key steps like particle size reduction, air removal, and homogenisation into a single workflow, the MAZ offers a modern approach to compounding analgesics with improved precision, reduced processing time, and minimised product loss. 

As Australian pharmacies adapt to increasing compounding demands and regulatory expectations, advanced tools like the MAZ® mixer offer a practical, future-proof way to improve patient outcomes and pharmacy efficiency with customised analgesic therapies that are safe, reliable, and effective.  

👉 Speak with an expert today to discuss how MAZ can streamline your analgesic compounding workflow.