Innovating patient care with aseptic spray drying

Despite the challenges inherent in pioneering a new technology, we are confident that aseptic spray drying will soon become the industry standard for producing high-quality pharmaceutical products. Aseptic spray drying is a sophisticated process that stands apart from traditional spray drying and freeze-drying methods. This technique offers numerous advantages, including lower capital and operating costs, a smaller equipment footprint and a faster drying process for many applications. It operates continuously, making it ideal for bulk drying and scaling up production. The controlled particle size distribution it provides is crucial for maintaining product consistency, and it offers unique options for the creation of a more effective product.

In the pharmaceutical industry, spray drying is a versatile process that enhances the stability, shelf life and usability of various drug forms, including vaccines, inhalable medicines, biopharmaceuticals and customized medicines. As David Costes, GEA Sales Manager for pharmaceutical spray dryers, notes, "Prospective clients already see the economic advantages and the quality of the powder produced, but it takes time to shift perceptions in a very conservative industry."

Transformative applications and benefits

Aseptic spray drying offers numerous disruptive benefits for the pharmaceutical industry, particularly in terms of improving patient outcomes and safety. Traditional freeze-drying methods often involve salts to maintain product structure, but this method is susceptible to an excess of residue, reconstitution problems or other chemical or physical issues. Instead, aseptic spray drying creates a unique, non-frozen structure. This can lead to better bioavailability of the active pharmaceutical ingredient (API), allowing for lower dosages with the same or better effectiveness and consequently fewer side effects for patients.

Spray drying has provided numerous benefits across various industries by improving the stability, usability and shelf life of products. Whether in food, nutraceuticals, agriculture, cosmetics or chemicals, spray drying helps create high-quality, uniform powders that meet specific product requirements. This versatility makes spray drying a valuable technology for both enhancing product performance and consumer experience. Several pharmaceutical products are already on the market, demonstrating this shift.

A commitment to innovation

GEA's leadership in aseptic spray drying is rooted in over two decades of expertise. Our experience with closed-cycle spray drying naturally extends to aseptic processes, underscoring our commitment to innovation and reliability. We have invested heavily in ensuring compliance and quality, driven by our belief in the transformative potential of this technology. Our state-of-the-art testing facilities offer customers the chance to conduct proof-of-concept trials, helping them validate their products' performance.

We understand that integrating new technologies like aseptic spray drying into established pharmaceutical processes can be daunting. That's why we prioritize strong partnerships with our clients. Our approach is highly collaborative. This ensures that each solution meets specific requirements and delivers the best possible results for patients. We engage in deep dialogues with our clients, co-developing parameters and adjusting along the way to ensure optimal outcomes.

We additionally ensure a smooth transition by working closely with regulatory bodies to meet all compliance requirements and update standard operating procedures (SOPs). Our phased validation plan, starting with small-scale pilot studies, guarantees consistent product quality. We also provide comprehensive training for staff to ensure they are proficient with the new equipment. 

Embracing the future of pharmaceutical manufacturing

We foresee aseptic spray drying following a similar trajectory to traditional spray drying, which has become the preferred drying method for several industries over the past two decades. As more products receive regulatory approval, we expect aseptic spray drying to gain wider acceptance, becoming the obvious choice for many companies. To meet these future demands, GEA has assembled a team of specialists focused on advancing aseptic spray drying.

Our vision includes greater production capacities and more widespread adoption of aseptic spray drying across the pharmaceutical industry. We believe that as the technology continues to prove its value, it will become the standard method for producing high-quality sterile pharmaceutical products, ensuring better outcomes for patients.