Spray Drying Process Screening and Scale-Up

We process solutions, suspensions, and emulsions of small molecules, biologics, probiotics, and nucleic acids dissolved or dispersed in water or volatile organic solvents. The feed must be pumpable and stable under process conditions. A preliminary compatibility test is recommended for novel formulations.

Typical lab‑scale runs require a few grams of active ingredient per condition, depending on the evaporative capacity and target particle size. Exact minimum quantities are confirmed during the scoping phase to ensure meaningful results with your available material.

Yes, our pilot‑scale spray dryer can be operated in closed‑loop mode with nitrogen as the drying gas. This is recommended for oxygen‑sensitive APIs or when using flammable organic solvents. The bag filter collection system maintains containment.

We apply thermodynamic scaling rules (constant drying potential / constant atomization energy) to maintain product quality attributes across lab, pilot, and production scales. Key parameters such as droplet size and drying temperature profile are validated by sampling at each stage.

Yes, we provide a complete analytical package including X‑ray diffraction, differential scanning calorimetry, scanning electron microscopy, particle size distribution, residual solvent analysis, and moisture content. Additional assays can be included per project scope.

Low‑temperature spray drying is available with controlled inlet temperatures down to ambient levels. We also use glass‑forming excipients that protect the active during drying and storage. Compatibility and stability are evaluated in the pre‑formulation phase.

We provide a comprehensive scale‑up report including process parameters, performance data, and risk assessment to facilitate technology transfer. The specific support level is defined in the project SOW.