Methods and apparatus for making particles using spray dryer and in-line jet mill

A method for making particles comprising:

• (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas;
• (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
• (c) flowing the feedstream through a particle concentration means to separate and remove between about 50 and 100 vol. % of the drying gas from the feedstream;
• and then
• (d) flowing the feedstream through a jet mill to deagglomerate or grind the particles.

A method for making particles comprising:

• (a) sprayer an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas;
• (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
• (c) flowing the feedstream through at least one secondary drying chamber in fluid communication with the discharge outlet of the primary drying chamber to evaporate a second portion of the solvent into the drying gas;
• and then
• (d) flowing the feedstream through a jet mill to deagglomerate or grind the particles.

A method for making particles comprising:

• (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas;
• (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
• and
• (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles, wherein the bulk material comprises a pharmaceutical agent.

A method for making particles comprising:

• (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas;
• (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
• and
• (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles, wherein the particles are microparticles.

A method for making particles comprising:

• (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas;
• (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
• and
• (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles,
• wherein the method further comprises adding to the feedstream an excipient material, a pharmaceutical agent, or both.

A method for making particles comprising:

• (a) spraying an emulsion, solution, or suspension, which comprises a solvent and a bulk material, through at least one atomizer and into a primary drying chamber having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to form droplets comprising the solvent and the bulk material, wherein the droplets are dispersed in the drying gas;
• (b) evaporating, in the primary drying chamber, at least a portion of the solvent into the drying gas to solidify the droplets and form particles dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
• and
• (c) flowing the particles of the feedstream through a jet mill to deagglomerate or grind the particles;
• wherein the method further comprises spraying a second emulsion, solution, or suspension through at least one additional atomizer and into the primary drying chamber.