Minimizing agglomeration, aeration, and preserving the coating of pharmaceutical compositions comprising ibuprofen

A method of preparing a pharmaceutical composition comprising:

• forming a pharmaceutical suspension comprising:
• 30-50% w/w a coated API, wherein the API coating comprises a first coating material and 0.5-5% w/w silica surrounding, partially embedded in, and/or embedded in the first coating material;
• 50-70% w/w a matrix solution or suspension comprising:
• 1-5% w/w a matrix former;
• 0.5-4% w/w a structure former;
• 0.01-0.1% w/w a viscosity modifier;
• 0.1-1% w/w an anti-aerating agent;
• and
• a solvent;
• dosing the pharmaceutical suspension into a mold;
• freezing the pharmaceutical suspension in the mold;
• and
• freeze drying the dosed pharmaceutical suspension in the mold to form the pharmaceutical composition.