Abstract: Systems and methods are provided for vacuum spray drying. In one example, a method for spray drying includes estimating an outlet temperature to achieve a minimum drying rate at atmospheric pressure based on a selected liquid feed and a selected liquid to gas ratio, calculating a predicted dryer pressure at which the minimum drying rate can be reached at a reduced outlet temperature, and spray drying the selected liquid feed at the selected liquid to gas ratio, the predicted dryer pressure and the reduced outlet temperature. The reduced outlet temperature is less than a maximum temperature and the predicted dryer pressure includes an approximation for droplet solidification.

Abstract: A formulation is provided for a spray dried lipid nanoparticle matrix particles, including lipid nanoparticles, a buffer system, and a barrier matrix stabilizer, wherein the barrier matrix stabilizer is included in a solid weight percent based on a maximum osmolarity and a maximum acceptable injectable volume of an injectable formulation comprising the spray dried lipid nanoparticle matrix particles.

Abstract: Systems and methods are provided for vacuum spray drying. In one example, a method for spray drying includes estimating an outlet temperature to achieve a minimum drying rate at atmospheric pressure based on a selected liquid feed and a selected liquid to gas ratio, calculating a predicted dryer pressure at which the minimum drying rate can be reached at a reduced outlet temperature, and spray drying the selected liquid feed at the selected liquid to gas ratio, the predicted dryer pressure and the reduced outlet temperature. The reduced outlet temperature is less than a maximum temperature and the predicted dryer pressure includes an approximation for droplet solidification.