The design and scale-up of spray dried particle delivery systems


INTRODUCTION: The rising demand for pharmaceutical particles with tailored physicochemical properties has opened new markets for spray drying especially for solubility enhancement, improving inhalation medicines and stabilization of biopharmaceuticals. Despite this, the spray drying literature is scattered and often does not address the principles underpinning robust development of pharmaceuticals. It is therefore necessary to present clearer picture of the field and highlight the factors influencing particle design and scale-up. Areas covered: The review presents a systematic analysis of the trends in development of particle delivery systems using spray drying. This is followed by exploring the mechanisms governing particle formation in the process stages. Particle design factors including those of equipment configurations and feed/process attributes were highlighted. Finally, the review summarises the current industrial approaches for upscaling pharmaceutical spray drying. Expert opinion: Spray drying provides the ability to design particles of the desired functionality. This greatly benefits the pharmaceutical sector especially as product specifications are becoming more encompassing and exacting. One of the biggest barriers to product translation remains one of scale-up/scale-down. A shift from trial and error approaches to model-based particle design helps to enhance control over product properties. To this end, process innovations and advanced manufacturing technologies are particularly welcomed.

Publication DOI:
Divisions: College of Health & Life Sciences > Aston Pharmacy School
College of Health & Life Sciences > Applied Health Research Group
Additional Information: This is an Accepted Manuscript of an article published by Taylor & Francis in Expert Opinion on Drug Delivery on 4/5/17, available online:
Uncontrolled Keywords: spray drying,particle design,drug delivery,scale-up,solubility,pulmonary,biopharmaceuticals,controlled-release
PURE Output Type: Article
Published Date: 2017-05-04
Published Online Date: 2017-05-04
Accepted Date: 2017-04-18
Submitted Date: 2016-12-23
Authors: Al-Khattawi, Ali (ORCID Profile 0000-0002-2498-2817)
Bayly, Andrew
Phillips, Andrew
Wilson, David



Version: Accepted Version

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