Spray Drying: The Key To Maximize Drug Solubility And Bioavailability

By Rui C. Silva + Michael Levis, Senior Spray Drying Expert + Head Process Technologies, Principle Scientist Particle Technologies

Poor solubility remains one of the most significant formulation challenges in pharmaceutical development, affecting a large proportion of new drug candidates and limiting their bioavailability. As developers seek effective ways to improve drug performance, spray drying has emerged as a versatile technology that can transform challenging molecules into viable therapies.

By converting crystalline APIs into amorphous solid dispersions, spray drying can enhance dissolution rates, improve bioavailability, and maintain stability throughout a product’s shelf life. The technology also offers exceptional control over particle characteristics, enabling formulators to tailor powders for specific delivery routes, including oral solid dosage forms and inhaled therapies. Beyond small molecules, spray drying is increasingly being explored as an alternative to freeze drying for sensitive biologics, offering faster processing and improved powder handling characteristics.

See how advances in particle engineering, process development, and scale-up strategies are helping developers overcome solubility challenges while supporting efficient progression from early-stage development through commercial manufacturing.