Spray Dried Biologics For Pulmonary Dosage Forms

By Dr. Richard Johnson, Chief Scientific Officer

Pulmonary delivery is emerging as a promising route for administering biologics, offering rapid absorption, needle‑free dosing, and the potential for both local and systemic therapies. However, the fragile nature of proteins, peptides, and other large molecules presents significant challenges in processing, stability, and delivery. Spray drying provides an effective solution by enabling precise particle engineering to create dry powders with the aerodynamic properties required for efficient lung deposition.

Through careful control of formulation parameters, spray drying produces particles typically within the optimal size range for deep lung delivery, while preserving the structural integrity and activity of sensitive biologics. The approach also enhances storage stability and supports scalable manufacturing from early development to commercial production. Combined with delivery systems such as dry powder inhalers, this technology enables consistent dosing and improved patient convenience. As a result, spray drying is becoming a key platform for advancing inhalable biologic therapies.