Contact
You are here: / / Spray Drying

Pharmaceutical Spray Drying

Engineered with pharmacists for pharmacists

Our spray drying solutions are developed together with pharmacists, delivering precise particle engineering under full GMP conditions. From early formulation development to commercial manufacturing, we enable safe processing of even highly potent APIs, seamless digital control and a clear, reproducible scale‑up from lab to production.

Benefits of Spray Drying:

  • Engineered with pharmacists for pharmacists
  • Flexible air distributor for different process gas flows
  • Full GMP design for pharmaceutical products
  • Dedicated particle collection for your application
  • Handling of high potent drugs up to OEB 5
  • The only lab spray dryer with Part 11–compliant, production-scale SCADA system as standard
  • Clear scale-up concept

Applications

Spray drying is particularly suitable in situations where solutions or suspensions need to be converted into stable solid products. For example, to improve the bioavailability of pharmaceutical active ingredients or to stabilize sensitive nutritional supplements. Formulations that can be processed via spray drying include, but are not limited to, amorphous solid dispersions, nanocrystals, and lipid‑based drug delivery systems (e.g., SEDDS, liposomes, etc.).

For you as a user, this means additional options in process design and more flexibility in particle design when existing methods reach their limits.

Oral Solid Dosage Forms

  • ASD (SSD)
  • Solidified LBDDS
  • Oral GLP-1
  • Direct Encapsulation

Inhalation & Nasal Application

  • Asthma, COPD
  • Antibiotics
  • CBD
  • Nose-To-Brain (CNS)

Micro-/Nanonization

  • Bioavailability Enhancement (BCS II/IV)
  • Dry Suspensions
  • Dry Emulsions

Microencapsulation

  • API Stabilization
  • Taste Masking
  • Controlled Release

Biopharmaceuticals & Biologics

  • Monoclonal Antibodies
  • Therapeutic Proteins
  • Vaccines (mRNA)
  • Aseptic Formulations

Special Features:

Atomizing methods: Precision where particle design matters

Selecting the right atomization method is a key design decision in spray dried particle engineering, as it directly influences drying efficiency, particle size distribution and product properties. Glatt offers a broad portfolio of atomization solutions to precisely meet the required particle design and product properties.

  • Top spray nozzle

    The two fluid top spray nozzle uses hot process gas to finely disperse the liquid feed into uniform droplets, delivering precise and gentle atomization. Ideal for heat sensitive and very fine powders, it supports a wide throughput range and ensures consistent product quality. A smart nozzle design with quick assembly and disassembly enables easy cleaning and efficient maintenance—perfect for demanding, regulated processes.

  • Pressure nozzle

    The pressure nozzle ensures reliable atomization by transforming pressure into finely dispersed droplets. With precise droplet size control and thereby narrow particle size distribution, it delivers consistent results, easy handling, and low maintenance for robust spray drying processes.

  • Two-fluid fountain spray nozzle

    The two‑fluid fountain spray nozzle uses opposing gas and liquid streams to create uniform droplets with precise particle size control. Ideal for spray congealing, it offers high process flexibility, robust performance, and fast assembly for easy cleaning—while not being suitable for heat‑sensitive products.

  • Rotary atomizer

    Rotary atomization uses a high‑speed rotating wheel to disperse the liquid feed by centrifugal force into the hot process gas. The particle design is controlled by adjusting the wheel speed. The system is ideal for high‑viscosity feeds, delivering high throughput, narrow particle size distribution and free‑flowing powders. A GMP‑compliant design with quick assembly and disassembly ensures easy cleaning and reliable operation in regulated environments.

Air distributor

The air distributor is responsible for introducing a homogeneous and well-defined airflow into the drying chamber. Glatt provides application-specific air distributors tailored to different atomization systems, ensuring optimal process conditions.

By precisely shaping and balancing the airflow, the air distributor enables stable spray patterns and efficient heat and mass transfer, resulting in consistent drying performance. Its design supports accurate adjustment of airflow rates

The result is reproducible particle formation, high process stability and precise control of critical parameters. Reduced temperature gradients protect sensitive products, while the GMP-compliant design supports reliable scale-up and efficient, automated operation.

Cyclone technology

Efficient, reliable powder separation is critical to spray drying performance. Glatt’s cyclone technology delivers consistently high separation efficiency while eliminating common issues such as powder settling, smearing, abrasion and milling effects.

Optimized airflow and smooth, hygienic geometries ensure high powder recovery – even for fine and low-density particles. The result: higher yields, reduced losses, and a more economical drying process.

Engineered for pharmaceutical applications, the Glatt cyclone technology meets the highest standards for GMP compliance, cleanability and process reliability.

Technical Data

Process gas rate
GSXLab90
GSX 1150
GSX 2380
GSX 3720
GSX 41800

Spray Drying Process

Solutions and Options

Cleaning

Glatt spray dryers are designed with a highly efficient and application‑oriented WIP (Wash‑in‑Place) cleaning concept, ensuring reliable cleanliness while minimizing manual effort, downtime, and operator exposure — fully aligned with GMP requirements.

Depending on product characteristics and regulatory requirements, different cleaning approaches can be implemented – precisely tailored to each application:

  • For simple applications, targeted manual rinsing of the drying chamber may be sufficient.
  • For more demanding products benefit from enhanced mechanical cleaning, such as the use of orbital cleaners instead of standard atomization devices. Strategically positioned CIP cleaning nozzles ensure effective wetting and cleaning of all surfaces in contact with product .

Glatt enables automated and reproducible WIP or CIP (Clean-in-Place) cleaning procedures with minimal disassembly efforts. This is supported by hygienic design features such as optimized chamber access, integrated cleaning nozzles and components specifically developed to minimize dead zones and product residues:

  • In the Glatt small‑scale spray dryers, ducts and main components are typically connected via clamp connections, allowing fast disassembly and efficient manual WIP cleaning.
  • In large-scale production systems with wider ducts, a semi-automatic or automatic cleaning is recommended. To increase cleaning efficiency and process robustness, the spray dryer can be segmented into defined cleaning zones, which are activated individually via the GlattView control system. This zoned WIP concept allows targeted cleaning of specific system sections, reducing unnecessary exposure of non‑critical areas. As a result, cleaning time, water and media consumption and operator intervention are significantly reduced, while a consistent, reproducible and fully GMP‑compliant cleaning outcome is maintained.

Media / Download

Download brochure