Dry Powder Inhalation (DPI)
Integrated DPI Development & Manufacturing from Formulation Through Commercial
With historic expertise in powders and scalable Harro Höfliger technologies, Experic helps developers address complex interactions among formulation, powder properties, filling processes, and device performance from the earliest stages of development.
Precision Micro-Dosing & Capsule Filling via Harro Höfliger Platforms
Experic achieves ultra-low dose precision filling down to sub-milligram levels (<1 mg up to 50+ mg) using state-of-the-art Harro Höfliger automated systems, guaranteeing 100% in-line weight verification for size 00 to 3 HPMC and gelatin capsules, alongside unit-dose and multi-dose blister formats.
Our non-destructive powder filling technologies adapt to complex product characteristics, cohesive APIs, and aggressive throughput requirements while maintaining aerodynamic integrity.
- Early DPI development for single-dose units
- Formulation development and optimization
- Particle engineering for inhaled delivery
- Lactose-based and spray-dried formulations
- Low-shear and high-shear blending
- Aerodynamic Particle Size Distribution (APSD) testing
- Delivered Dose Uniformity (DDU) and Unit Dose Uniformity (UDU) testing
- Filling feasibility and processability studies
Dry Powder Dosing & Filling Capability Matrix
| Parameter | Technical Specification & Capability | |
|---|---|---|
 | Dose Mass Target Range | <1 mg (sub-milligram) up to 50+ mg (single-dose); up to 5 g (reservoir devices) |
 | Dosing & Filling Mechanisms | Harro Höfliger Vacuum-Drum Dosing (Omnidose), Vacuum-Assisted Membrane, Auger Filling, MicroVibe |
 | Manufacturing Equipment | Harro Höfliger Drum Lab, Modu-C LS IPK (with drum), Modu-C MS, MicroVibe TT, SDM |
 | Primary Device Formats | Size 00, 0, 1, 2, and 3 HPMC & Gelatin DPI capsules; unit-dose / multi-dose thermo-formed and cold-formed foil blisters |
 | Weight Verification | 100% in-line gravimetric and acoustic mass verification controls |
 | Environmental Controls | Ultra-low humidity cGMP manufacturing suites (<10% to 20% RH) |
Advanced DPI Formulation Architecture & Particle Engineering
Experic engineers bespoke pulmonary delivery formulations by mapping and optimizing particle-particle interactions for both traditional carrier-based blends and advanced carrier-free engineered particles. Our formulation optimization mitigates agglomeration, minimizes bridging, and engineers flowability specifically tailored for deep lung pulmonary delivery.
Blended APIs
Specialized low-shear and high-shear blending of APIs (balancing coarse and fine fractions) to optimize detachment energies and aerodynamic fine particle fraction (FPF) during patient inhalation.
Spray-Dried APIs
Advanced handling of spray-dried particles, maximizing delivery efficiency for high-payload or structurally sensitive biologic molecules.
Streamlined Clinical Manufacturing to Commercial Supply
From early-stage DPI prototype optimization to cGMP clinical manufacturing and commercial scale-up, our Cranbury, NJ facility integrates process development, analytical validation, and primary packaging into a single cohesive CDMO workflow.
Phase-Appropriate Scale-Up
We utilize phase-specific development processes, transitioning seamlessly from manual/semi-automated Harro Höfliger Drum Lab prototypes to fully automated Modu-C MS high-speed manufacturing lines without altering fundamental dosing mechanics.
Integrated Packaging & Logistics
Complete secondary packaging services, specialized DPI device assembly, customized blister packing, labeling, clinical storage, and global trial logistics.
Frequently Asked Questions
Dry Powder Inhalation
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Experic provides integrated DPI development and manufacturing services including formulation development, particle engineering, process development, blending, filling feasibility, precision capsule filling, analytical testing, clinical manufacturing, scale-up, packaging, and clinical supply support.
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Experic supports lactose-based blends, spray-dried formulations, cohesive powders, and pure APIs. Development strategies are tailored to each powder’s characteristics and account for factors including particle size, aerosolization, cohesiveness, flowability, clumping, bridging, and manufacturability.
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Experic supports capsule sizes 3 through 00 and powder doses ranging from 1 mg to 50 mg, as well as reservoir device filling up to 5 g. Its filling technologies can accommodate different powder characteristics, dose requirements, and production scales.
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Experic provides specialized inhalation testing including Aerodynamic Particle Size Distribution (APSD), Delivered Dose Uniformity (DDU), and Unit Dose Uniformity (UDU), supported by broader analytical method development, validation, stability, in-process, and release testing capabilities.
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Yes. Experic uses phase-appropriate Harro Höfliger filling technologies and integrated process development to support DPI programs as they progress from development and clinical manufacturing toward commercial production. Its equipment portfolio provides scalable filling capabilities while helping maintain process knowledge and manufacturing continuity across development stages.