Enabling technologies to increase spray drying throughput for brick dust compounds

August 01, 2025

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Over 70% of drug candidates today exhibit poor solubility in both water and organic solvents, posing a challenge for spray drying as a formulation strategy. To address this, three innovative approaches have emerged to enhance solubility and improve process efficiency. The first involves gently heating a drug slurry below the solvent’s boiling point to increase solubility without altering the standard process. The second, known as Temperature Shift technology, uses an in-line heat exchanger to rapidly raise the solution’s temperature just before atomization, allowing higher drug concentrations. The third technique adds small amounts of volatile processing aids—such as ammonia, acetic acid, or formic acid—to ionize the drug in methanol, boosting solubility and evaporating during drying. These methods not only enable spray drying of challenging “brick dust” compounds but also offer benefits in throughput, solvent reduction, and cost savings.