Spray drying: From a traditional technology to modern biotechnological applications

Area of Science:

• Pharmaceutical Technology
• Biotechnology
• Nanomedicine

Background:

• Spray drying, patented in the 19th century, is a key method for converting liquids into powders.
• It offers control over particle properties and is used in food, chemical, and pharmaceutical sectors.
• Recent advancements focus on biopharmaceuticals, vaccines, and nanomedicine applications.

Purpose of the Study:

• To review the fundamental principles of spray drying.
• To examine formulation impacts and scale-up challenges.
• To explore emerging applications in biopharmaceuticals, nanomedicine, and aseptic processing.

Main Methods:

• Review of spray drying principles and applications.
• Analysis of formulation components and their effects.
• Discussion of scale-up, industrial implementation, and Quality by Design (QbD).

Main Results:

• Spray drying enables precise control over particle size, morphology, and moisture content.
• It is successfully applied in pharmaceutical formulations like inhalable powders and amorphous solid dispersions.
• Emerging applications include stabilizing biopharmaceuticals and vaccines, and nano-into-micro strategies in nanomedicine.

Conclusions:

• Spray drying is evolving into a platform technology for modern biotechnology and pharmaceutical applications.
• Aseptic spray drying is crucial for sterile parenteral formulations and vaccines.
• The technology enhances shelf life and reduces cold chain dependency for sensitive biologics.