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ORIGINAL RESEARCH article
Front. Chem. Eng.
Sec. Computational Methods in Chemical Engineering
Volume 7 - 2025 | doi: 10.3389/fceng.2025.1565916
Model-aided Process Development for Scalable Spray Drying of Sticky Substances
Provisionally accepted- 1Veranova, Devens, United States
- 2Veranova, Cambridge, United Kingdom
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Spray drying efficiently generates fine, dried powders used in the pharmaceutical, food, and chemical industries. However, industry-wide challenges in optimization and scale-up of spray drying processes require further research due to the large number of interacting parameters that impact product yield and particle characteristics. The work presented herein demonstrates a novel, model-aided workflow to optimize yield and transfer the spray-drying process to different equipment and scales that would otherwise demand large experimental costs. This study achieves a comprehensive understanding of spray drying dynamics through a hybrid modeling approach that utilizes a commercial mechanistic model (gFormulate®) to capture critical process parameters and integrates it with modified open-source computational fluid dynamics software (OpenFOAM © ). Modelling the age of droplets using OpenFoam® provided deeper insights into residence time, and wall interactions. This study highlights the significance of droplet age modelling on
Keywords: Spray drying, bioavailability, Amorphous solid dispersion, mechanistic modeling, Computational Fluid Dynamics (CFD), Scale-up, tech transfer, Wall agglomeration
Received: 23 Jan 2025; Accepted: 07 Apr 2025.
Copyright: © 2025 Kapil, Wombwell, Kegel and Hamlin. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
* Correspondence: Ankur Kapil, Veranova, Devens, United States
Disclaimer: All claims expressed in this article are solely those of the authors and do not necessarily represent those of their affiliated organizations, or those of the publisher, the editors and the reviewers. Any product that may be evaluated in this article or claim that may be made by its manufacturer is not guaranteed or endorsed by the publisher.