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Spray Dried Biologics

Spray drying biologics can enhance delivery, improve bioavailability and open up new delivery routes for biologics.

Spray Dried Biologics

Unlocking New Possibilities for Biologic Drug Development

Biologic therapies are transforming the treatment landscape across a wide range of diseases, but their development often comes with significant formulation and stability challenges.

Many proteins, peptides, antibodies and emerging biologic modalities are inherently sensitive, requiring careful handling throughout development, manufacturing and distribution to maintain their integrity and therapeutic performance.

Spray drying has emerged as a powerful formulation technology that can help address these challenges. By converting biologic molecules into carefully engineered dry powders, spray drying can improve stability, support alternative routes of administration and create opportunities for more patient-friendly therapies.

At Upperton, we apply our expertise in complex molecule development, formulation science and particle engineering to support the development of spray-dried biologics from early feasibility through to clinical supply manufacture. Working closely with our clients, we design formulation strategies that protect sensitive molecules while delivering the particle characteristics needed to achieve the desired therapeutic outcome.

Protecting Complex Biologics

Stabilising Biologics Through Spray Drying

Biologic molecules can be highly sensitive to environmental and processing conditions, creating challenges when developing stable, practical drug products. Spray drying can transform liquid biologic formulations into dry, stabilised powders while offering opportunities to optimise particle characteristics, formulation composition and product performance. This can support the development of robust biologic drug products designed for alternative routes of administration.

Enabling Alternative Delivery

From Liquid Biologics to Dry Powder Delivery

Spray-dried biologics can enable the development of dry powder formulations for applications including pulmonary and other non-invasive delivery approaches. By combining formulation science with controlled spray drying and particle engineering, Upperton can help explore new opportunities for biologics beyond conventional liquid formulations, supporting more convenient and flexible treatment options.

Improve the stability of your biologic

Why Spray Dry Biologics?

For many biologic drug developers, formulation stability remains one of the biggest barriers to successful product development. Traditional liquid formulations can be vulnerable to degradation, aggregation and environmental stresses during storage and transport.

Converting a biologic into a dry powder format can help overcome these limitations by placing the molecule into a more stable physical state. Beyond improving stability, spray drying allows scientists to engineer particles with highly specific characteristics. Particle size, density, morphology and moisture content can all be optimised to support the intended delivery route, whether that is pulmonary, nasal, oral or injectable following reconstitution.

This capability has made spray drying an increasingly attractive option for developers seeking to create differentiated biologic products with improved shelf life, enhanced performance and greater flexibility throughout the supply chain.