RECENT ADVANCES AND EMERGING APPLICATIONS OF SPRAY DRYING IN DRUG DELIVERY AND BIOPHARMACEUTICAL FORMULATION

Abstract

More than a century after the first patent describing a rudimentary atomization and drying apparatus, spray drying remains an indispensable technology in the pharmaceutical industry. Recent advances have transformed spray drying from a simple particle-generation process into a sophisticated platform capable of producing powders from solutions, suspensions, and emulsions while enabling precise control over particle size, morphology, and physicochemical properties. Since its early adoption in the dairy industry, spray drying has evolved to support a wide range of pharmaceutical applications owing to its advantages as a single-step, continuous, cost-effective, and scalable manufacturing process. Initially employed primarily for the production of microparticles, modern spray-drying technologies now facilitate the precise engineering of nanoparticles and other advanced drug delivery systems. Furthermore, technological innovations have expanded its applicability to heat-sensitive materials, including proteins, peptides, and other biologics, without compromising their stability or functionality. Spray drying also enables versatile particle surface modifications, allowing targeted delivery to specific tissues and organs. Consequently, spray-dried formulations have been investigated for administration through multiple routes, including local, intravenous, and pulmonary delivery. Rather than providing an exhaustive overview of all pharmaceutical applications of spray drying, this review highlights recent technological advances and emerging applications that are redefining its role in modern drug development and manufacturing. By examining current trends and innovations, the review aims to provide insights into the expanding potential of spray drying as a versatile platform for pharmaceutical product design and delivery.