What the Project Is
Hovione is a Contract Development and Manufacturing Company dedicated to helping Pharmaceutical Customers bring new and off-patent drugs to market. The company’s unique approach focuses on doing well what is difficult – delivering solutions that customers cannot find elsewhere. With nearly two decades of extensive expertise, Hovione leverages advanced techniques to tackle complex challenges in drug formulation and manufacturing. The project centers on harnessing the power of spray drying – a continuous process that has been refined over the last 19 years for the production of solid dispersions. This approach, which appears almost like magic when it comes to overcoming traditional solubility issues in oral drugs, is also highly relevant for inhalable particles, specialty excipients, and the isolation of thermally labile products… the benefits speak for themselves.
Main Benefit
Key advantages of this project include:
- Committed support for pharmaceutical customers bringing innovative and off-patent drugs to market
- Utilization of continuous spray drying – a state-of-the-art process that rapidly produces particle formations
- Over 19 years of experience making solid dispersions, ensuring cutting-edge application and formulation expertise
- Efficient atomization of a feed (solution, emulsion, or suspension) into hot nitrogen, leading to flash drying that produces uniform and high-quality particles
- Tailored production of inhaled powders, resulting in controlled particle size and morphology that positively impacts Fine Particle Fraction (FPF) and lung deposition
Spray Drying Technology
The backbone of this project is the spray drying technology, a continuous process celebrated for its versatility and speed. Over nearly two decades, this method has evolved into the fastest growing platform designed to overcome the solubility issues related to oral drugs. Taking a feed – which could be a solution, an emulsion, or a suspension – and atomizing it into hot nitrogen results in flash, rapid drying. This process not only forms the particles swiftly but also starts a series of steps that ensure the production of high-quality materials for a range of pharmaceutical applications. The natural flow of production, from atomization to cyclone separation, showcases a seamless integration of science and manufacturing.
Continuous Process Advantages
The process begins when the feed is atomized, creating tiny droplets that instantly encounter hot nitrogen, triggering a flash drying effect. This rapid flash drying results in solid particle formation that is then efficiently separated using a cyclone or filter bag. The continuous nature of this technology dramatically improves production efficiency. The inherent advantages of the continuous process are not only technical but also economic, significantly reducing production times while ensuring that the final products maintain robust quality and consistency. It feels almost as if the ingredients are dancing together in the air before settling perfectly into place.
Diverse Applications
The versatility behind spray drying is a key element that opens up several innovative applications. One prominent application is the creation of solid dispersions; these dispersions are amorphous materials composed of a drug and a polymer that work hand in hand to overcome solubility limitations inherent in BCS class 2 and 4 drugs. Another distinct application involves microencapsulated particles, where a crystalline drug is neatly encapsulated with a coating polymer, preserving stability with a kind of protective layer. When it comes to inhaled powders, there is a significant focus on the ability to control particle size, morphology, and other critical properties that dictate performance in terms of Fine Particle Fraction (FPF) and effective lung deposition. Furthermore, due to the gentle nature of the process, this method can isolate thermally labile materials – products that would normally degrade in conventional processes – with outstanding efficiency and care.
Project Impact
- SDG 3: Good Health and Well-being – By enabling the development of improved pharmaceutical solutions that address challenging solubility issues, this project contributes to better healthcare outcomes.
- SDG 9: Industry, Innovation, and Infrastructure – The continuous spray drying technology drives innovation in production processes and supports robust pharmaceutical manufacturing infrastructures.
- SDG 12: Responsible Consumption and Production – The efficient, continuous nature of the spray drying technique reduces waste and optimizes resource use, echoing responsible production practices.
Exploring Further Possibilities
The comprehensive impact of this project extends beyond solving immediate production challenges. There is also an emphasis on knowledge sharing and continuous improvement, as shown by the detailed three-part webinar series, “Amorphous Solid Dispersions by Spray Drying: From Early Formulation to Commercial Lifecycle Management.” This series connects technical expertise with practical applications, offering a deep dive into the nuances of spray drying technology and its manifold benefits in the pharmaceutical domain. It demonstrates that in addition to serving as a robust manufacturing solution, the method acts as a catalyst for innovation and informed decision-making in drug development. The capacity to produce high-integrity solid dispersions and other novel formulations illustrates the potential of spray drying technology to redefine pharmaceutical manufacturing practices in a rapidly evolving industry.
