Spray drying is a technology that transforms a liquid formulation — solution, suspension, or oil-in-water emulsion — into a dry, free-flowing powder through a continuous, single-step process. The liquid feed is atomized into a chamber, where small droplets contact a stream of hot air, inducing instantaneous solvent evaporation and yielding solid microparticles of controlled shape, size, and morphology.
Across pharmaceutical, nutraceutical, food, and cosmetic applications, spray drying can be an effective solution to improve the aqueous solubility of poorly water-soluble molecules, enhance the stability of sensitive compounds, and engineer microparticulate systems with tailored release profiles and applications. Our process development approach uses DoE, ensuring reproducibility from feasibility through scale-up. For highly potent APIs (HPAPIs), we operate within a fully closed isolator system, guaranteeing operator safety and environmental containment without compromising product quality.
Every project begins with a thorough assessment of the feed formulation: homogeneity, stability, and viscosity must be optimized before processing. We systematically define the process parameters (inlet temperature, feed rate, nozzle diameter and atomizer configuration) to achieve the target particle size distribution (PSD) and the required product quality attributes for each specific application.
