Spray Drying
Advanced Particle Engineering from Formulation Development Through GMP Manufacturing
Experic provides integrated pharmaceutical spray drying services for the development and manufacture of high-performance powder formulations to optimize particle size, morphology, stability, solubility, and bioavailability.
Pharmaceutical Spray Drying & Particle Engineering
Experic supports spray-drying programs designed to control key attributes during development. Precise control of formulation composition and process parameters allows developers to engineer critical powder characteristics for the intended route of administration and product performance.
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Optimize particle dimensions and distribution for dissolution, bioavailability, aerosolization, and targeted delivery.
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Engineer particle structure and physical properties to support downstream processing and product performance.
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Improve dissolution of poorly soluble APIs through approaches including amorphous solid dispersions (ASDs).
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Convert solution-based formulations into dry powders to reduce water activity and support product stability.
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Optimize powder behavior to support consistent downstream filling and delivery.
Spray Drying Development& Optimization Matrix
| Development Stage | Key Considerations | Development Objective | |
|---|---|---|---|
 | Formulation Development |
| Develop a stable, homogeneous formulation suitable for spray drying |
 | Atomization |
| Control particle size distribution and morphology |
 | Drying |
| Optimize drying efficiency while minimizing product degradation |
 | Particle Engineering |
| Achieve powder characteristics appropriate for the intended application |
 | Downstream Processing |
| Maintain engineered powder performance through final dosage-form manufacturing |
 | Scale Up |
| Establish a robust and reproducible path toward GMP manufacturing |
Spray Drying for Dry Powder
Inhalation & Nasal Drug Delivery
Experic combines spray drying with deep expertise in powder handling, encapsulation, and dry powder inhalation. Through a collaboration with Flurry Powders, Experic further integrates formulation and particle engineering, aerosol performance characterization, and device considerations to support a total systems approach to inhaled and nasal product development.
The collaboration provides an integrated development pathway encompassing:
- Formulation and particle engineering
- Spray drying and solid-state optimization
- Aerosol performance characterization
- Device selection and engineering aligned with the target product profile
- Clinic-ready GMP and GMP-aligned manufacturing and scale-up
Experic operates a GMP spray dryer configured to Flurry Powders’ proprietary PSD-1 specifications, supporting efficient process transfer from R&D into GMP manufacturing.
Integrated Spray Drying, Encapsulation & Downstream Manufacturing
Experic connects spray-drying development with powder handling and filling feasibility to help ensure that an optimized particle can also be reliably converted into the intended drug product. For inhalation programs in particular, incorporating filling studies during development can help identify potential challenges before later-stage scale-up.
- Powder characterization and analytical testing
- Filling feasibility studies
- Low-dose and precision powder filling
- Blending and encapsulation
- Dry powder inhalation product development
- Clinical manufacturing
- Packaging and clinical supply support
Frequently Asked Questions
Pharmaceutical Spray Drying
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Pharmaceutical spray drying converts a liquid formulation into a dry powder by atomizing the liquid into droplets and rapidly evaporating the solvent in a controlled drying environment. The process can be used to engineer particle size, morphology, density, stability, solubility, and other properties important to drug product performance.
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Spray drying can support a range of pharmaceutical applications, including dry powder inhalation and nasal products as well as formulations requiring improved solubility or stability. It can be particularly useful for poorly aqueous-soluble APIs, challenging molecules, and formulations requiring tightly controlled particle characteristics.
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Experic integrates spray drying with formulation and process development, particle engineering, analytical testing, powder handling, encapsulation, and GMP manufacturing. Through its strategic collaboration with Flurry Powders, clients can also access specialized formulation, aerosol characterization, and device expertise for inhaled and nasal drug development.
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A QbD approach evaluates how critical material attributes and critical process parameters influence the critical quality attributes of the spray-dried powder. Experic can use risk analysis and Design of Experiments to build process understanding, optimize parameters, and establish a more robust strategy for scale-up and manufacturing.
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Yes. Experic supports an integrated pathway encompassing formulation and process development, spray drying, analytical testing, downstream powder filling, and clinical manufacturing. Its collaboration with Flurry Powders is designed to facilitate transfer from specialized R&D spray-drying development into GMP manufacturing.