Filling Syringes With Spray-Dried Powders - The How, The Why And The Benefits

For therapy developers, formulation challenges often stall progress when attempting to convert liquid drugs into stable powder forms. While the benefits of powder—enhanced stability and reduced cold chain reliance—are established, a common misconception remains that filling syringes directly with spray-dried powder is not feasible. This resource dismantles that myth, demonstrating how direct-to-syringe filling is not only possible but advantageous over traditional lyophilization.

By utilizing advanced nozzle technologies that dose deep into the syringe barrel, manufacturers can avoid seal contamination and bypass complex vial-to-syringe transfer steps. This approach resolves common issues associated with lyophilized "cake" collapse, foaming, and long freeze-drying times. Read the full application note to understand how replacing liquid formulations with spray-dried powder can ensure rapid reconstitution and unlock new efficiencies for clinical trials and patient delivery.