Advanced particle technologies in the preparation of dry powders for inhalation--颗粒学报PARTICUOLOGY

a National Engineering Research Center for Industrial Crystallization Technology, School of Chemical Engineering and Technology, Tianjin University, Tianjin, 300072, China
b Collaborative Innovation Center of Chemical Science and Engineering (Tianjin), Tianjin, 300072, China
c Department of Chemical and Biological Engineering, The Hong Kong University of Science and Technology, Clear Water Bay, Hong Kong, China
d State Key Laboratory of Chemical Engineering, School of Chemical Engineering and Technology, Tianjin University, Tianjin, 300072, China

10.1016/j.partic.2025.04.007

Volume 102, July 2025, Pages 118-140

Received 11 February 2025, Revised 1 April 2025, Accepted 7 April 2025, Available online 18 April 2025, Version of Record 5 May 2025.

E-mail: r.lakerveld@ust.hk; x_huang@tju.edu.cn; hongxunhao@tju.edu.cn

Highlights

• Advanced methods like spray drying, crystallization, and milling were reviewed.

• Combined particle engineering techniques can address manufacturing challenges.

• Integration of AI and CFD can optimize drug properties and enhance delivery efficiency.

Abstract

Drug delivery via pulmonary inhalation can achieve targeted treatment by directly delivering the drugs to the area for treatment. The method is developing rapidly for the treatment of local and systemic diseases. However, dry powders for inhalation need to exhibit excellent aerodynamic performance. Particle size, morphology and density need to be tightly regulated to guarantee effective lung deposition and assure long-term chemical stability of the drug. In this work, the compositions and requirements of dry powders for inhalation are discussed. Furthermore, the state-of-art methods in particle technology for dry powders for inhalation, such as milling, droplet evaporation, direct crystallization, supercritical fluid and particle surface coating technologies, are reviewed. In addition, the application of process analytical techniques in the preparation of dry powders for inhalation, which can improve process capability and drug safety, is also discussed. Finally, current challenges in the field of dry powders for inhalation are discussed and some directional guidance is proposed to promote delivery efficiency, drug efficacy and process development.

Graphical abstract

Keywords

Dry powders for inhalation; Pulmonary drug delivery; Particle engineering; Micronization; Crystallization; Aerodynamic performance

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