Technological considerations related to the up-scaling of protein microencapsulation by spray-drying

Research and development of therapeutics and vaccines based on biodegradable polymers are intensive and one of the most promising fields in controlled drug delivery. However, new applications necessitate successful technology transfer and industrial scale-ups. In an endeavour to produce clinical samples of a single-administration tetanus vaccine based on poly(lactide-co-glycolide) microspheres, we report on technological parameters that are of importance in the up-scaling of the spray-drying process. The results show that an up-scaling of the encapsulation of protein vaccines or drug by spray-drying is feasible, but that additives, the type of polymer solvent, the polymer concentration, the w/o ratio and the product collection method influence process and product quality.