Rapid Room-Temperature Aerosol Dehydration Versus Spray Drying: A Novel Paradigm in Biopharmaceutical Drying Technologies

Sadegh Poozesh, Maksim Mezhericher, Zehao Pan, Uzair Chaudhary, Prakash Manikwar, Howard A. Stone

Research output: Contribution to journalArticlepeer-review

1 Scopus citations


To ensure the high quality of biopharmaceutical products, it is imperative to implement specialized unit operations that effectively safeguard the structural integrity of large molecules. While lyophilization has long been a reliable process, spray drying has recently garnered attention for its particle engineering capabilities for the pulmonary route of administration. However, maintaining the integrity of biologics during spray drying remains a challenge. To address this issue, we explored a novel dehydration system based on aerosol-assisted room-temperature drying of biological formulations recently developed at Princeton University, called Rapid Room-Temperature Aerosol Dehydration. We compared the quality attributes of the bulk powder of biopharmaceutical products manufactured using this drying technology with that of traditional spray drying. For all the fragment antigen-binding formulations tested, in terms of protein degradation and aerosol performance, we were able to achieve a better product quality using this drying technology compared to the spray drying technique. We also highlight areas for improvement in future prototypes and prospective commercial versions of the system. Overall, the offered dehydration system holds potential for improving the quality and diversity of biopharmaceutical products and may pave the way for more efficient and effective production methods in the biopharma industry.

Original languageEnglish (US)
Pages (from-to)974-981
Number of pages8
JournalJournal of Pharmaceutical Sciences
Issue number4
StatePublished - Apr 2024

All Science Journal Classification (ASJC) codes

  • Pharmaceutical Science


  • Aerosol-assisted drying
  • Biopharmaceutical processing
  • Particle engineering
  • Protein degradation
  • Spray drying


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