Spray Drying for Pharmaceutical Raw Materials: A Systematic Review on Enhancing Bioavailability and Stability

source extracted confidence: high 2026-04-09
#biological-availability #drug-stability #spray-drying #humans #drug-delivery-systems

Spray Drying for Pharmaceutical Raw Materials: A Systematic Review on Enhancing Bioavailability and Stability

Swm et al., 2025 | Drug Des Devel Ther | Systematic Review

Citation

Swm Alyanis Mufid, Mita Soraya Ratnawulan, Husni Patihul. Spray Drying for Pharmaceutical Raw Materials: A Systematic Review on Enhancing Bioavailability and Stability. Drug Des Devel Ther. 2025;19:11433-11463. doi:10.2147/DDDT.S570027

Abstract

Spray drying is extensively utilized in pharmaceutical development because of its scalability, cost-effectiveness, and capacity to customize solid-state characteristics. This systematic review (PubMed and Scopus, 2021-2025) assesses the impact of spray drying on the bioavailability and stability of active pharmaceutical ingredients (API) and natural products within solid dispersions (SD), solid self-nanoemulsifying drug delivery systems (S-SNEDDS), and microencapsulation. A total of 27 qualifying studies were identified and offered quantitative comparisons with untreated controls. SDs yielded AUC enhancements of 9-20-fold (eg, oxyberberine approximately 9-fold, quercetin approximately 20-fold) and dissolution improvements of 2-6-fold. S-SNEDDS produced AUC enhancements of 4-9.9-fold (sorafenib approximately 4.6-fold, enzalutamide approximately 7-fold, niclosamide approximately 9.9-fold). Microencapsulation enhanced oxidative stability (eg, approximately 3-fold reduction in peroxide value pepper seed oil and encapsulation efficiency of pomegranate seed oil reaching 90%). Benefits were contingent upon the carrier, especially with PVP/PVPVA, HPMC/HPMCAS, soluplus, and maltodextrin with protein systems. Spray drying provides superior scalability and particle engineering control compared to freeze or vacuum drying, while it still poses hazards of thermal and oxidative stress. Ongoing deficiencies encompass inadequate carrier comparisons, insufficient mechanistic comprehension of drying kinetics, and issues related to scale-up and regulation. This review offers mechanistic insights and a standardized approach to facilitate future formulation development.

Key Findings

This review offers mechanistic insights and a standardized approach to facilitate future formulation development.

Outcomes Measured

  • Requires manual extraction

Population

Field Value
Population See abstract
Sample Size See abstract
Age Range See abstract
Condition stress

MeSH Terms

  • Biological Availability
  • Drug Stability
  • Spray Drying
  • Humans
  • Drug Delivery Systems
  • Drug Compounding
  • Pharmaceutical Preparations

Evidence Classification

  • Level: Systematic Review
  • Publication Types: Journal Article, Systematic Review
  • Vertical: quercetin

Provenance

Source extracted via PubMed E-utilities API on 2026-04-09