Scale Up Considerations for Dry Powder Inhaler Manufacturing by Spray Drying

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Webinar Date/Time: Thu, Sep 28, 2023 11:00 AM EDT

Explore the complexities of upscaling the process from laboratory to clinical and commercial scales, while addressing the unique hurdles tied to producing ultra-fine particles (1-5µm) for effective lung delivery.

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Event Overview:

Spray drying is a versatile particle-engineering tool used to produce respirable dry powders of small molecule APIs and biologics. Production of very small particle sizes (1-5µm), is required for delivery to the deep lung, but also leads to significant challenges in scaling the process from lab-scale dryers to clinical or commercial scale dryers. This webinar addresses the scale-up challenges facing pulmonary dry powders produced by spray drying.

Key Learning Objectives

  • Identify the unique ways in which pulmonary dry powder manufacturing by spray drying is challenging, compared with other processes
  • Understand the key attributes of a pulmonary dry powder processed by spray drying
  • Learn about process innovations which can help address challenging scale-up problems

Who Should Attend

  • Pharmaceutical-industry directors
  • Principal Investigators/CMC Leads
  • Manufacturing and development engineers


Kim Shepard
Associate Director, Principal Engineer, R&D
Lonza Small Molecules

Kim Shepard is a Principal Engineer in the Research group at Lonza's site in Bend, Oregon, USA, where she has worked since 2015. She leads projects focused on developing new technologies for bioavailability enhancement and inhalation delivery. Kim’s areas of expertise include the formulation and manufacturing of spray-dried dispersions for inhalation and oral delivery, as well as the physics of polymers and amorphous materials. She received her Bachelor and Master's degrees in Chemical Engineering from Stevens Institute of Technology and her Ph.D. in Chemical Engineering from Princeton University.

Cody Prather
Sr. Engineer, Research & Development
Lonza Small Molecules

Cody Prather is a Sr. Engineer in the R&D group at Lonza at the Bend, Oregon site, having worked there since 2015. He obtained his Master’s degree in Mechanical Engineering at Montana State University. His focus has been on generating innovative solutions in engineering design and atomization technologies as related to some of Lonza’s key platforms: bioavailability enhancement, multiparticulates, and inhalation. He currently leads the engineering endeavors of the R&D inhalation platform.

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