Spray Drying of Biologics, Proteins, & Peptides
Transform your liquid biologicals into stable, shelf-ready powders with APD’s proven Dynamic Atomization Technology.
With proprietary Dynamic Atomization Technology, Advanced Powder Dynamics (APD) transforms your temperature-sensitive proteins, peptides, and biomolecules into stable, high-performance powder formulations that retain biological activity and deliver reliable functionality. Whether working with therapeutic peptides or enzymes, APD ensures the resulting powder product meets the stability and performance criteria required in regulated biologic manufacturing. With spray drying of biologics, scalability, production capacity, and strict process control are paramount.
Scalable Spray Drying of Biologics
In biologics manufacturing, scalability requires consistent process parameters like shear force, residence time, and thermal profile to ensure preservation of complex molecular functionality. Even small process deviations can compromise sterility and homogeneity, leading to commercial as well as performance setbacks. APD’s scalable production capability bridges the critical gap between R&D and commercial-scale manufacturing, where precision and consistency are key.
Unmatched Production Capabilities
Our production lines include pilot dryers (DA-5, DA-50) for low-volume trial runs and a full-scale DA-500 dryer for commercial runs up to 80,000 lbs wet weight per campaign. The same core process parameters and controls are maintained across all scales, ensuring true scalability without the need for reformulation.
Our production capabilities include:
- Process temperatures below 100°C for heat-sensitive materials.
- In-process analytical monitoring for moisture, particle size, and bulk density.
- Compliance with cGMP, FDA, and global regulatory standards.
Advanced Encapsulation and Stabilization Technology
Protecting fragile biomolecules also depends on the right microencapsulation and formulation design. Proteins and peptides are prone to aggregation, denaturation, and oxidation, which compromise therapeutic efficacy.
APD’s stabilization and encapsulation technology isolates active compounds within protective matrices that minimize exposure to heat, oxygen, and mechanical stress during atomization and drying.
See APD in Action
Microbial Discovery Group partnered with APD to minimize product degradation during the drying process. Because microbes can degrade quickly with traditional drying methods, APD’s dynamic atomization process proved to be the perfect solution.
Cyclodextrin Microencapsulation
Using the CyLoc® cyclodextrin-based microencapsulation, APD encapsulates individual molecules within a stabilizing complex that enhances solubility, bioavailability, and shelf stability. Each process is supported by real-time analytical validation, ensuring molecular integrity, reproducibility, and regulatory compliance. This approach enables biologic materials to maintain their functionality even under ambient storage conditions.
This is a major advantage for enzyme preservation, as the extended stability and functionality help manufacturers reduce dependence on cold-chain storage and improve performance in dry formulations.
Engineered Process Control for Precision
Our Dynamic Atomization Technology (DAT) provides the highest level of precision through engineered process control.
Precise Atomization: We control droplet formation to prevent shear-induced denaturation and ensure uniform particle size.
Thermal Management: We maintain consistent airflow and temperature distribution to minimize heat exposure and oxidative stress.
Low-Stress Drying Environment: Our process prevents localized overheating, ensuring proteins, peptides, and biologics retain their structure.
Consistent Powder Quality: We produce uniform, reproducible powders with predictable solubility.
High Yield and Scalability: We optimize for process efficiency without compromising on molecular stability.
This engineered control enables APD to consistently produce biologic powders that maintain potency, structure, and performance throughout the shelf life.
Biopharmaceuticals Trust APD
At Advanced Powder Dynamics, we help biopharmaceutical innovators turn sensitive biological compounds into market-ready powder formulations. Our team has decades of experience handling over 300+ fragile compounds, from proteins and peptides to enzyme systems and bioactives.
Biomanufacturers can partner with APD for:
- Proven ability to maintain bioactivity and structural integrity in complex proteins.
- Expertise in particle engineering, ensuring flowability, solubility, and dose uniformity.
- Collaboration in product development projects from concept through commercialization.
From therapeutic peptides to enzyme-based actives, APD’s precision particle engineering expertise ensures your product performs as intended, functionally, and commercially.
To learn more about our services for spray drying of biologics, contact us or call (928) 492-4040.