Pharmaceutical Spray Drying

Containment in pharmaceutical spray drying

In pharmaceutical spray drying, containment is not an option – it is a requirement. When handling highly potent or solvent‑based formulations, reliable containment concepts are essential to ensure operator safety, product integrity and full regulatory compliance.

Our pharmaceutical spray dryers are therefore designed as closed systems that enable safe processing from feeding to powder discharge. Continuous containment across all critical process steps minimizes exposure risks while ensuring reproducible product quality in regulated GMP environments.

Closed processes – engineered for high‑potency APIs

Our Pharma spray drying technology with integrated containment follow a fully closed process design. Product feeding, atomization, drying, powder separation and discharge are performed without open interfaces. High‑efficiency cyclones, secondary filters and defined pressure regimes ensure secure separation of particles while preventing product release into the surrounding area.

The use of inert process gases such as nitrogen further enhances safety when processing solvent‑containing or oxygen‑sensitive products. Continuous monitoring of oxygen levels and system pressure guarantees stable and controlled operating conditions throughout the entire spray drying process.

Integrated containment across the entire system

Reliable containment in spray drying cannot be achieved by individual components alone. It requires a holistic system concept:

• Gas‑tight connections between all process modules
• Defined filtration concepts for exhaust and recirculation air
• Dust‑tight discharge solutions for powders and residues
• Containment‑oriented design of sampling, cleaning and maintenance interfaces

This integrated approach ensures that containment performance is maintained not only during production, but also during cleaning, product changeover and service operations – critical moments for operator exposure.

Cleaning concepts that support containment

Cleaning is an integral part of any pharmaceutical spray drying process – and a critical phase from a containment perspective. Closed pre‑wash concepts reduce product residues before system opening, thereby significantly lowering exposure risks for operators.

Design principles focused on cleanability, accessibility and reproducibility enable safe manual or automated cleaning procedures in line with GMP requirements. This supports fast product changeovers, validated cleaning results and long‑term operational safety.

Designed for GMP environments

Containment‑ready spray drying systems are developed for installation in controlled pharmaceutical environments with defined air exchange rates, pressure cascades and monitoring concepts. Combined with validated containment performance, this ensures:

• Protection of personnel when handling potent substances
• Prevention of cross‑contamination between products
• Full compliance with GMP and occupational safety regulations

The result is a spray drying solution that combines high process performance with maximum safety – from early development to commercial production.

Process Analytical Technology (PAT) in pharmaceutical spray drying

In pharmaceutical spray drying, not only the final result matters – but how reliably and controllably it is achieved. Process Analytical Technology (PAT) brings transparency to the entire process. By continuously collecting, analyzing, and interpreting critical process data, PAT delivers deep insight into key process parameters in real time and during operation.

Real-time monitoring instead of offline analysis

Unlike conventional offline testing, PAT enables immediate monitoring of critical quality attributes such as particle size, moisture content, and temperature profiles during spray drying.
Deviations are detected early, control loops respond instantly – long before product quality or process stability are compromised.

Reproducible quality across all scales

PAT provides the foundation for robust and scalable processes, from early development to commercial production. By systematically linking process parameters with product properties, PAT significantly simplifies scale-up and technology transfer. Processes can be compared, validated, and optimized based on reliable data.

Enabling QbD, automation and GMP compliance

As an integral part of modern spray drying systems, PAT strongly supports Quality by Design (QbD) strategies.
Combined with advanced control and automation solutions, it enables validated, GMP-compliant processes with full data traceability – a key advantage when processing complex or sensitive APIs.

From process knowledge to process control

PAT makes pharmaceutical spray drying predictable and controllable.
It transforms process data into actionable knowledge – enabling higher yields, reduced waste and a safe, sustainable pharmaceutical manufacturing process.